Laser Pattern Transfer Printing With Moveable Substrate Pitch Control
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Solution Overview
Problem
Existing pattern transfer printing methods for high viscosity paste in solar PV and electronics industries are limited by the need for contact between the source and receiving substrates, which restricts pattern flexibility and throughput.
Innovation Solution
A dynamic pattern transfer printing system using a laser scanner to illuminate a source substrate with trenches arranged in a first pattern, releasing printing paste onto a receiving substrate, which is moved to create a second pattern with a different pitch, allowing for non-contact printing and pattern adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screen printing or stationary pattern transfer printing is used, then the printing process is simple and reliable, but the deposited paste pattern cannot be changed during printing, leading to inflexibility in adapting to changing target locations and varying substrate widths
Solution Approach 1:
The patent applies dynamics by making the receiving substrate moveable during the printing process. The receiving substrate can be moved in real-time to change the deposited pattern, allowing adaptation to different target locations and substrate widths. This transforms the previously static printing system into a dynamic one where the pattern can be modified during deposition without requiring multiple screens or complex reconfiguration.
Solution Approach 2:
The patent introduces a moveable stage as an intermediary component between the stationary source substrate and the receiving substrate. This moveable stage enables controlled movement of the receiving substrate during printing, serving as a mediator that allows pattern modification without directly complicating the source substrate or printing mechanism. The moveable stage acts as the intermediary that translates control signals into physical displacement, achieving adaptability with manageable complexity.
2Productivity
If stationary substrates are used in pattern transfer printing, then the printing process is stable and easy to control, but the throughput is limited and cannot accommodate varying substrate widths efficiently
Solution Approach 1:
The moveable receiving substrate enables continuous printing across varying substrate widths by allowing real-time adjustment of the deposition area. This dynamic capability increases throughput by eliminating the need to stop and reconfigure for different substrate sizes, while the controlled movement maintains operational simplicity through automated positioning.
Solution Approach 2:
The moveable receiving substrate provides multi-functionality by accommodating various substrate widths and patterns within a single printing system. Instead of requiring different printing setups for different applications, the universal moveable platform allows one system to handle multiple substrate types and patterns, thereby increasing productivity without sacrificing ease of operation.
3Adaptability or versatility
If the receiving substrate is moved during printing, then different patterns and pitches can be achieved, but the system complexity increases due to additional movement control mechanisms
Solution Approach 1:
The moveable stage serves as an intermediary that simplifies the control architecture by providing a dedicated, isolated mechanism for substrate movement. This separates the movement control function from the printing mechanism itself, allowing pattern variation through simple stage displacement without complicating the overall system. The intermediary stage absorbs the complexity of movement control, leaving the printing process itself relatively simple.
Solution Approach 2:
The dynamic moveable receiving substrate enables pattern variation through controlled displacement during deposition. By making the substrate moveable rather than changing the source pattern, the system achieves versatility with minimal added complexity. The dynamic adjustment of substrate position during printing creates different patterns and pitches without requiring complex reconfiguration of the printing apparatus.
4Reliability
If screen printing is used for high viscosity paste, then the printing method is simple and reliable, but the mesh screen contacts the receiving substrate causing pattern inflexibility and potential substrate damage
Solution Approach 1:
The patent introduces a non-contact pattern transfer mechanism as an intermediary between the source substrate and receiving substrate. Instead of direct contact printing through a mesh screen, the invention uses a moveable stage to enable contactless deposition. This intermediary approach maintains the reliability of paste transfer while eliminating the pattern inflexibility and substrate damage issues associated with mesh screen contact.
Solution Approach 2:
The invention replaces the mechanical mesh screen contact system with a non-contact deposition method using a moveable receiving substrate. By substituting the mechanical screen-paste-substrate contact mechanism with a controlled movement system, the patent maintains reliable paste transfer while achieving pattern flexibility. The mechanical substitution eliminates the constraints of screen geometry and contact-related substrate damage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables flexible pattern transfer with reduced pitch, improving adaptability to changing target locations and increasing throughput by decoupling the source and receiving substrate movements.
Implementation Method 1
radiating light towards the front surface of the source substrate, to remove at least one piece of the coating material from the source substrate and deposit said removed at least one piece onto the receiving substrate
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
Dynamic pattern transfer printing systems and method are provided, which decouple the design of the trench patterns on a source substrate for pattern transfer printing, from the resulting metallic paste lines patterns transferred to a receiving substrate, such as PV cells. The receiving substrate may be moved forward (along the scanning direction of the laser illumination used to transfer the paste from the trenches onto the receiving substrate) to reduce the pattern pitch with respect to the source substrate, and/or the receiving substrate may be moved backward (against the scanning direction) to increase the pattern pitch with respect to the source substrate. For example, dynamic pattern transfer printing may be used to accommodate different widths of the substrates for more effective pattern transfer, and/or to enable one-to-many pattern transfer technologies with high wafer throughput. Also, pattern transfer sheet with separate multiple groups of trenches are provided.