Lyophilic Pattern Ink Deposition for Film Thickness Control
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Solution Overview
Problem
Conventional printing methods, such as screen printing and ink-jet printing, face difficulties in forming fine patterns due to the lack of control over ink distribution and alignment, leading to inadequate film thickness and accuracy.
Innovation Solution
A method involving a substrate with a liquid-repellent and lyophilic pattern combination, where the lyophilic pattern has a smaller contact angle than the liquid-repellent surface, allowing for precise ink application and increased film thickness by using auxiliary lyophilic patterns connected to the main lyophilic pattern, enhancing ink retention and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional printing methods (screen printing, ink-jet printing) are used to form fine patterns, then the manufacturing process is simple and cost-effective, but the film thickness on narrow patterns is insufficient and alignment accuracy is poor
Solution Approach 1:
The lyophilic pattern is divided into a main lyophilic pattern and multiple auxiliary lyophilic patterns. The auxiliary patterns are positioned at specific intervals along the main pattern to create additional ink accumulation regions, thereby increasing film thickness on narrow patterns without requiring complex printing equipment
Solution Approach 2:
Different regions of the pattern are given different properties: the main lyophilic pattern provides the primary pattern structure, while the auxiliary lyophilic patterns create localized ink accumulation regions. This local differentiation allows enhanced film thickness specifically where needed without affecting the overall pattern simplicity
2Manufacturing precision
If ink is applied to form thick films on narrow patterns, then film thickness is improved, but ink distribution becomes uncontrolled and alignment accuracy deteriorates
Solution Approach 1:
The pattern is segmented into main and auxiliary lyophilic regions with the auxiliary patterns spaced at specific intervals (0.01 mm to 0.1 mm apart). This segmentation creates controlled ink accumulation zones that enhance film thickness while maintaining precise alignment through the regular spacing structure
Solution Approach 2:
The auxiliary lyophilic patterns are pre-positioned at specific locations before ink application. This preliminary arrangement of the pattern structure guides ink flow and accumulation in advance, ensuring both thick film formation and precise alignment without requiring complex real-time control during printing
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 approach enables the formation of thicker, more accurate patterns with improved film thickness and reduced defects, particularly effective for conductive and semiconductor applications.
Implementation Method 1
a lyophilic pattern having a surface energy different from the liquid-repellent face
Implementation Method 2
the surface of the substrate for printing is made liquid-repellent. On the liquid-repellent (lyophobic) surface, a lyophilic pattern is formed
Data Source
AI summary
According to one embodiment, a method of forming a pattern includes preparing a substrate having a liquid-repellent face and a lyophilic pattern which are located adjacent to each other on a surface of the substrate, the lyophilic pattern having a surface energy different from the liquid-repellent face, bringing ink into contact with the substrate, and applying the ink to the lyophilic pattern by moving a contacted ink surface. The lyophilic pattern includes a linear main lyophilic pattern and an auxiliary lyophilic pattern connected to the lyophilic pattern. A liquid-repellent region is defined in the liquid-repellent face between the main lyophilic pattern and the auxiliary lyophilic pattern.