Multi-Height Printing Plate for Uniform Alignment Film
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Solution Overview
Problem
The issue of uneven display brightness in liquid crystal display panels due to non-uniform PI film thickness leads to poor display with pit-like defects during lighting checks, as the alignment film is not adequately adhered to the substrate's grooves, particularly when using ultra-high ink containing APR plates.
Innovation Solution
A printing plate with protrusions of varying heights is used to coat the substrate, where main and auxiliary protrusions are designed to store alignment solution, reducing the likelihood of protrusions covering grooves and ensuring uniform film thickness by increasing the alignment film's thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ultra-high ink containing APR plates are used to increase PI film thickness, then film thickness uniformity is improved, but alignment film adhesion to circuits in grooves deteriorates causing pit-like defects
Solution Approach 1:
The printing plate surface is segmented into multiple protrusions of different heights (first protrusions and second protrusions), creating distinct functional zones. The higher first protrusions prevent groove coverage while the lower second protrusions enable alignment solution deposition, resolving the contradiction between thickness uniformity and adhesion reliability.
Solution Approach 2:
Different regions of the printing plate are given different local properties through varying protrusion heights. The first protrusions (higher) are positioned to avoid groove areas for adhesion, while second protrusions (lower) are positioned to deposit alignment solution for thickness uniformity, achieving both requirements simultaneously.
2Manufacturing precision
If PI film thickness is increased to improve uniformity, then proportion of thickness difference is reduced, but alignment solution filling in local positions becomes insufficient
Solution Approach 1:
The printing plate is divided into protrusions of two height levels, creating controlled void spaces between and around the protrusions. These segmented structures regulate alignment solution distribution, ensuring adequate filling in local positions while maintaining overall thickness uniformity.
Solution Approach 2:
The solution moves from controlling only film thickness (one dimension) to controlling both thickness and solution distribution through multi-height protrusions (adding vertical dimension variation). This dimensional approach allows simultaneous optimization of thickness uniformity and solution filling quantity.
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 method effectively prevents poor displays with pit-like defects by ensuring the alignment solution is filled in local positions, improving film thickness uniformity and reducing the occurrence of such defects during lighting checks.
Implementation Method 1
pressing one side of the printing plate which is stored with the alignment solution fit with the array substrate... the alignment solution stored in an entire surface of the printing plate flows into a surface of the array substrate
Implementation Method 2
a gap is formed between two adjacent protrusions, and the gap is used for storing the alignment solution... the alignment solution stored in an entire surface of the printing plate flows into a surface of the array substrate
Data Source
AI summary
A method of manufacturing an alignment film, a liquid crystal display panel, a printing plate are provided. The printing plate is used for coating a substrate with an alignment solution and comprises protrusions distributed at intervals on the substrate, and a gap is formed between two adjacent protrusions, and the gap is used for storing the alignment solution. The protrusions include a plurality of main protrusions presented as an array distribution and a plurality of auxiliary protrusions distributed in the array of the main protrusions. A height of each of the main protrusions is greater than a height of each of the auxiliary protrusions.