Maskless LCD Printing System with Cliché Plate Cleaning
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Solution Overview
Problem
The photolithography process used in liquid crystal display (LCD) manufacturing is costly and time-consuming due to the need for masks and exposure and development steps.
Innovation Solution
A printing system utilizing a moving rail, a cliché plate, and a printing roller that transcribes a pattern material onto a substrate without a mask, accompanied by a cleaning unit to reduce costs and time, allowing for the patterning of LCD components like light-shielding and color filter layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography process is used to pattern LCD components, then manufacturing precision is achieved, but manufacturing cost increases and production time extends
Solution Approach 1:
The patent extracts and eliminates the mask from the photolithography process, using direct printing methods instead. This removes the need for expensive mask fabrication and handling while maintaining patterning precision through direct inkjet or gravure printing of photoresist patterns.
Solution Approach 2:
The patent uses printing technology to create patterns directly on the substrate by copying design data into physical patterns through printed photoresist. This digital-to-physical copying process eliminates mask requirements and reduces manufacturing costs while preserving pattern accuracy.
2Manufacturing precision
If photolithography process is used to pattern LCD components, then patterning is achieved, but production time increases due to multiple steps
Solution Approach 1:
The patent merges multiple photolithography steps (mask alignment, exposure, development) into a single printing operation. By combining pattern generation and transfer into one direct printing step, the process eliminates intermediate steps and accelerates production while maintaining patterning capability.
Solution Approach 2:
The patent performs preliminary digital pattern design and preparation before the actual printing process. This allows for rapid reconfiguration of patterns without physical mask changes, enabling quick production turnover and faster iteration between different LCD component designs.
3Manufacturing precision
If photolithography process is used, then pattern material layer can be processed, but complexity of the process increases
Solution Approach 1:
The patent replaces the mechanical mask-based photolithography system with a digital printing system. This substitution eliminates complex mask handling mechanisms, alignment systems, and exposure equipment, simplifying the overall process while maintaining pattern formation precision through digital control.
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 decreases manufacturing costs and time by eliminating the need for masks and exposure and development processes, while the cleaning unit ensures efficient reuse of the cliché plate, simplifying the manufacturing process.
Implementation Method 1
a printing roller that transcribes a pattern material on the substrate by passing through the cliché plate
Implementation Method 2
a cleaning unit that cleans the cliché plate
Data Source
AI summary
A printing system comprises a moving rail, a cliché plate and a substrate positioned on the moving rail, a printing roller that transcribes a pattern material on the substrate by passing through the cliché plate. The printing system further comprises a cleaning unit that cleans the cliché plate.