Non-Parallel Scan Path Imaging for Color Filter Registration
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Solution Overview
Problem
Existing imaging systems face challenges in accurately registering repeating patterns of color features with their corresponding matrix patterns on universal substrates, leading to misregistration and reduced visual quality in color filters, particularly due to limitations in laser-induced thermal transfer processes and photolithographic techniques.
Innovation Solution
A method involving multiple imaging heads with individually addressable channels, where imaging beams are directed to form images on a receiver element along non-parallel and skewed scan paths, with relative motion between the imaging heads and receiver element, and adjustments in activation timing to achieve precise registration with registration regions, using laser-induced thermal transfer processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional laser imaging systems use a limited number of imaging beams or parallel beams, then the system complexity is reduced, but the imaging time increases and productivity decreases
Solution Approach 1:
The imaging system divides the image formation process into multiple sequential passes with different scan paths. Each pass uses a subset of imaging beams to form portions of the complete image, allowing the system to maintain simplicity while achieving high throughput through coordinated multi-pass imaging
Solution Approach 2:
The system employs periodic scanning cycles where imaging beams repeatedly traverse the substrate along different scan paths. Each cycle images a portion of the repeating pattern, and multiple cycles complete the full image set, enabling high productivity without requiring all beams to operate simultaneously
2Manufacturing precision
If photolithographic techniques are used to form matrix patterns, then the matrix registration is improved, but the overall manufacturing precision of color features deteriorates due to misregistration between laser transfer and photolithography
Solution Approach 1:
The system performs preliminary imaging of registration features and matrix patterns using the laser imaging system before final color feature formation. This preliminary action establishes accurate registration references that guide subsequent imaging passes, ensuring precise alignment between color features and matrix patterns without requiring photolithography
Solution Approach 2:
The system uses detected registration features to provide feedback on the actual positions of matrix patterns. This feedback information is used to dynamically adjust the scan paths and timing of imaging beams, compensating for any deviations and maintaining precise registration accuracy throughout the manufacturing process
3Productivity
If imaging beams scan along parallel paths, then the scan efficiency is improved, but the registration accuracy with skewed or rotated patterns deteriorates
Solution Approach 1:
The system dynamically adjusts scan paths from fixed parallel trajectories to variable skewed or rotated paths based on the specific registration requirements of each pattern. The scan parameters (angle, speed, timing) are continuously optimized during operation to maintain both high scanning efficiency and precise registration accuracy for different pattern orientations
Solution Approach 2:
The system changes key scanning parameters including scan path angle, beam speed, and activation timing to match the orientation and characteristics of the patterns being imaged. By adapting these parameters to each specific registration scenario, the system achieves accurate alignment with skewed or rotated patterns while maintaining efficient scanning performance
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 high-quality images of repeating patterns with improved registration accuracy, reducing misregistration issues and enhancing the visual quality of color filters by allowing for precise alignment and overlap of color features with matrix patterns.
Implementation Method 1
Preferred exposure methods use radiation beams such as laser beams to induce the transfer of the colorant to the receiver element
Implementation Method 2
Laser induced 'thermal transfer' processes include: laser induced 'dye transfer' processes, laser-induced 'melt transfer' processes, laser-induced 'ablation transfer' processes, and laser-induced 'mass transfer' processes
Data Source
AI summary
Methods are provided for imaging patterns on a media. The steps of the method include operating a first imaging head with individually addressable channels to direct imaging beams to form a first image on the media while scanning over the media along a scan path. A second imaging head with individually addressable channels is operated, either at the same time or a different time, to direct imaging beams to form a second image on the media while scanning over the media along a second scan path. It is possible that the first scan path may or may not be parallel to the second scan path, and that the first image may or may not be aligned with the second image. The first image may or may not be skewed with respect to the second image.