LCD Patterning via Inkjet Printing and Roller Transfer
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Solution Overview
Problem
Existing patterning methods for liquid crystal display (LCD) devices, such as photolithography and printing roller techniques, face challenges including high manufacturing costs, material waste, and inefficiencies in pattern formation, particularly due to incomplete removal of pattern material and non-uniformity.
Innovation Solution
A patterning method utilizing a printing plate with recesses and lands, where a precision nozzle is used to drop pattern material only into recesses, and a printing roller is rolled to transfer the pattern onto a substrate, minimizing material consumption and waste, and ensuring precise printing by controlling hydrophobic and hydrophilic properties to prevent material permeation and residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography is used to form patterns, then manufacturing precision is improved, but manufacturing cost increases and manufacturing time increases
Solution Approach 1:
The invention extracts and eliminates the mask from the photolithography process, using direct inkjet printing to deposit pattern material without requiring a mask layer. This removes the need for mask fabrication and alignment steps, reducing manufacturing cost while maintaining pattern precision through direct digital printing
Solution Approach 2:
The invention replaces the mechanical photolithography system (requiring mask alignment and exposure equipment) with a digital inkjet printing system that directly deposits pattern material according to digital patterns, simplifying the manufacturing process and reducing equipment complexity
2Manufacturing precision
If photolithography is used to form patterns, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The invention extracts and eliminates the time-consuming exposure and development steps from the photolithography process by using direct inkjet printing. Pattern material is deposited directly in the desired pattern configuration, eliminating multiple sequential steps and reducing total manufacturing time while maintaining precision through digital control
Solution Approach 2:
The invention enables continuous pattern deposition through inkjet printing without the intermittent steps of mask alignment, exposure, and development required in photolithography. The printing process can proceed continuously according to digital pattern data, improving manufacturing throughput
3Ease of manufacture
If pattern material is coated onto printing plate and then removed from surface, then pattern material is transferred to substrate, but material waste increases and manufacturing cost increases
Solution Approach 1:
The invention extracts and eliminates the unnecessary step of coating pattern material onto the entire printing plate surface and then removing it. Instead, pattern material is deposited directly only in the required pattern areas through inkjet printing, eliminating material waste from areas where pattern is not needed
Solution Approach 2:
The invention applies pattern material locally only where needed on the substrate through precise inkjet deposition, rather than coating the entire printing plate surface uniformly. This localized deposition approach minimizes material consumption and eliminates waste from non-pattern areas
4Ease of manufacture
If pattern material is removed from printing plate surface using blade, then pattern material remains in recesses, but incomplete removal leaves residue and pattern uniformity decreases
Solution Approach 1:
The invention extracts and eliminates the blade scraping step that causes incomplete material removal and residue. Direct inkjet printing deposits pattern material precisely where needed without requiring mechanical removal steps, ensuring clean edges and uniform pattern formation without residue
Solution Approach 2:
The invention replaces the mechanical blade scraping process with a non-contact inkjet printing process. Pattern material is deposited directly in the desired pattern through controlled material ejection, eliminating the mechanical removal step that causes incomplete cleaning and pattern non-uniformity
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
This method reduces manufacturing costs and material waste while improving printing precision, enabling efficient formation of black matrix and color filter layers in LCD devices with reduced defects and increased efficiency.
Implementation Method 1
controlling hydrophobic and hydrophilic properties to prevent material permeation and residue
Data Source
AI summary
A patterning method and a method for manufacturing an LCD device using the same are disclosed. The patterning method includes preparing a printing plate having concave and convex portions; coating a pattern material in the concave portion of the printing plate; rolling a printing roller on the printing plate to print the pattern material of the concave portion on the printing roller; and rolling the printing roller on a substrate to print the pattern material of the printing roller on the substrate.