Micro Patch Coating Device for LCD Color Filters
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Solution Overview
Problem
Conventional coating technologies for color filters in LCDs and plasma display panels face issues such as low material utility rate, complexity, high equipment costs, and limited pattern variation, making them unsuitable for large-scale and cost-effective production.
Innovation Solution
A micro patch coating device with a micro channel structure that alternates the flow of coating and auxiliary fluids to form two-phase fluids, which are then directly applied to a substrate to create micro patches, allowing for efficient and flexible pattern formation without the need for high precision injection or repeated exposure procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods (spin coating, extrusion spin coating, slot die coating) are used to form uniform liquid films, then coating uniformity is improved, but material utility rate deteriorates (low material utilization)
Solution Approach 1:
The coating die is divided into multiple independent coating heads, each capable of coating different regions of the substrate. This segmentation allows precise control of coating material application at each location, reducing waste and improving material utilization while maintaining coating uniformity through localized optimization.
Solution Approach 2:
The invention changes the coating parameters by using a moving coating die with controlled linear velocity that can be independently adjusted relative to the substrate speed. By optimizing the coating head velocity and substrate speed ratio, the system achieves uniform coating with improved material efficiency, eliminating the need for excessive material application followed by removal or rework.
2Manufacturing precision
If photolithography method is used for pattern definition, then pattern precision is improved, but device complexity and production cost deteriorate
Solution Approach 1:
The invention extracts and eliminates the photolithography process from the coating system by directly forming patterns through the moving coating die. The pattern definition function is integrated into the coating process itself through programmable motion control, removing the need for separate photolithography equipment and reducing overall device complexity while maintaining pattern precision.
Solution Approach 2:
The coating and patterning functions are merged into a single integrated process using the moving coating die. By combining material deposition with pattern formation through controlled motion, the system eliminates the need for separate photolithography and etching steps, reducing equipment complexity and production cost while achieving the required pattern precision.
3Illumination intensity
If dyeing method is used for color filter fabrication, then color characteristics are improved, but operation complexity and equipment cost deteriorate
Solution Approach 1:
The invention applies preliminary action by pre-mixing color pigments into the coating material before the coating process. This eliminates the need for post-coating dyeing operations and complex dyeing equipment, as the color characteristics are established during material preparation. The moving coating die then directly deposits the pre-colored material, simplifying the overall process while maintaining color quality.
Solution Approach 2:
The invention replaces the mechanical/chemical dyeing process with a material science approach by incorporating pigments directly into the coating formulation. This substitution eliminates the need for separate dyeing equipment, exposure systems, and chemical processing lines, reducing equipment cost and complexity while preserving the desired color characteristics through advanced material design.
4Loss of substance
If ink injection method is used for micro patch formation, then material utility rate is improved, but manufacturing precision deteriorates (difficulty in achieving uniform micro patches)
Solution Approach 1:
The invention uses pneumatic or hydraulic control mechanisms within the coating die to precisely regulate the flow and deposition of coating material. By controlling the fluid dynamics at the coating head, the system achieves uniform micro patch formation with high material efficiency, eliminating the precision and uniformity problems associated with ink injection methods while maintaining high material utility rate.
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 improves material utilization, reduces production costs, and enables the creation of complex patterns on larger display panels with higher efficiency and flexibility, addressing the limitations of existing technologies.
Implementation Method 1
at least one coating fluid and at least one auxiliary fluid are conveyed into a coating die (1) comprising a micro channel structure, generating a two-phase fluid having alternate arrangement of the coating fluid and the auxiliary fluid
Data Source
AI summary
A micro patch coating device includes a coating die with a micro channel structure. A coating fluid is supplied through a coating fluid inlet and an auxiliary fluid is supplied through an auxiliary fluid inlet. After a segment of a predetermined length of the coating fluid is formed at a two-phase fluid output section, the coating fluid flow is intercepted. In turn, a segment of predetermined length of the auxiliary fluid is formed at the two-phase fluid output section, and then the auxiliary fluid flow is intercepted. A two-phase fluid is formed and flows out of the coating die to the substrate to form micro patches thereon.