Metal Mesh Conductive Layer for Touch Screen via Embossing
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Solution Overview
Problem
The existing touch screen conductive layers made of ITO are costly and wasteful, with significant material waste and heavy metal emissions during the manufacturing process due to the use of vacuum coating and etching processes.
Innovation Solution
A conductive layer composed of a metal mesh formed by embossing metal wires onto a glass substrate, eliminating the need for etching and reducing material waste, with a structure that includes sensing regions and wire regions electrically connected, and a color matching line for insulation, allowing for a simpler and more cost-effective manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ITO is used as conductive layer through vacuum coating and etching, then electrical conductivity is achieved, but material waste and heavy metal emissions increase
Solution Approach 1:
The patent extracts the harmful etching process from the manufacturing sequence, replacing it with a direct embossing method that forms the conductive layer without material removal. This eliminates the waste generation step while preserving the essential electrical conductivity function.
Solution Approach 2:
The patent changes the manufacturing parameters from vacuum coating followed by etching to direct embossing. This parameter change transforms the process from one that consumes and wastes material to one that forms the conductive layer efficiently with minimal material loss.
2Reliability
If ITO is used as conductive layer through vacuum coating and etching, then electrical conductivity is achieved, but manufacturing cost increases
Solution Approach 1:
The patent removes the expensive etching step from the manufacturing process, significantly reducing equipment requirements and operational costs. The direct embossing method eliminates the need for complex vacuum coating and etching machinery.
Solution Approach 2:
The patent employs a disposable embossing mold that can be easily replaced, eliminating the need for expensive, complex vacuum coating equipment. This approach prioritizes low-cost, single-use tools over high-cost, reusable machinery.
3Shape
If etching process is used to form conductive layer, then conductive patterns are created, but industrial wastewater with heavy metals is produced
Solution Approach 1:
The patent converts the harmful etching process into a beneficial direct embossing process. Instead of removing material to create patterns, the embossing method directly forms the conductive patterns by depositing material in the desired shape, eliminating harmful wastewater generation.
Solution Approach 2:
The patent extracts and eliminates the etching process entirely from the manufacturing sequence, replacing it with a clean embossing method that creates conductive patterns without generating heavy metal-containing wastewater.
4Loss of substance
If mesh structure is used for conductive layer, then material waste is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces complex multi-step mechanical processes (vacuum coating and etching) with a single embossing mechanical action. This substitution simplifies the manufacturing process and reduces the cumulative precision requirements that would arise from multiple sequential steps.
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 metal mesh conductive layer is manufactured through a one-step embossing process, reducing material costs and heavy metal emissions, while maintaining high yield and efficient electrical connectivity, thus addressing the inefficiencies of traditional ITO-based conductive layers.
Implementation Method 1
the mesh cells in each first sensing pattern are electrically connected with each other, the mesh cells in each second sensing pattern are electrically connected with each other
Data Source
AI summary
The present invention relates to a conductive layer of a touch screen. The conductive layer is a mesh composed of metal wires. The mesh comprises a plurality of mesh cells, and the mesh cell comprises a plurality of mesh edges and nodes formed by connecting two adjacent edges. The conductive layer comprises a sensing region and a wire region which is electrically connected to the sensing region. The sensing region comprises a plurality of first sensing patterns and a plurality of second sensing patterns; the first sensing pattern and the second sensing pattern is adjacent and electrically insulated from each other; the mesh cells in each first sensing pattern are electrically connected with each other; and the mesh cells in each second sensing pattern are electrically connected with each other.