Nozzle Roll Coating for LCD Pattern Formation
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Solution Overview
Problem
Current methods for forming patterns in liquid crystal displays are costly and prone to the 'coffee stain effect' due to the use of masks and uniform coating challenges, which increase manufacturing time and result in material waste and non-uniform thickness.
Innovation Solution
A method involving a nozzle to coat pattern material on a roll, removing excess material with a coupling/decoupling plate, and transferring the remaining material to a substrate to form thin, uniform patterns without additional depressions, using a nozzle with optimized diameter, frequency, and viscosity to control material delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pattern material is coated on the whole surface of the printing roll, then the pattern can be transferred to the substrate, but the removed pattern materials cannot be re-used causing financial loss and material waste
Solution Approach 1:
The patent segments the pattern material application process by coating material only on the specific portion of the printing roll that corresponds to the pattern area, rather than coating the entire roll surface. This is achieved by controlling the nozzle to deposit material selectively on the pattern-forming region of the roll, thereby reducing material waste while maintaining pattern transfer quality.
2Manufacturing precision
If pattern material is coated on the whole surface of the printing roll, then the pattern can be transferred to the substrate, but it is difficult to uniformly coat the pattern material on the whole surface of a large area
Solution Approach 1:
The patent applies local quality by coating the pattern material only on the specific local area of the printing roll that corresponds to the pattern region, rather than uniformly coating the entire roll surface. The nozzle is positioned to deposit material selectively on the pattern-forming portion of the roll, achieving uniform pattern coating while simplifying the manufacturing process.
3Device complexity
If a small nozzle is used to directly form the pattern on the substrate, then the pattern can be formed without mask, but a thick edge portion of the pattern may generate a coffee stain effect
Solution Approach 1:
The patent introduces the printing roll as an intermediary between the nozzle and the substrate. The nozzle deposits pattern material on the printing roll surface, which then acts as a template for transferring the pattern to the substrate. This intermediary approach allows for controlled material deposition and transfer, preventing the coffee stain effect while maintaining process simplicity.
4Manufacturing precision
If mask with predetermined pattern is used for photo-process and etching process, then the pattern can be formed with high precision, but the manufacturing cost and process time increase
Solution Approach 1:
The patent extracts and eliminates the mask from the pattern formation process. Instead of using a mask for photo-process and etching, the pattern is directly formed by transferring material from the printing roll to the substrate. This removes the mask-related steps (mask production, alignment, exposure, development) while maintaining pattern formation precision through the controlled material transfer mechanism.
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 reduces manufacturing costs, prevents the coffee stain effect, and achieves thin, uniformly thick patterns with improved resolution and material efficiency.
Implementation Method 1
The nozzle delivers drops of uniform size and shape of the material to the roll
Implementation Method 2
the pattern material remaining on the printing roll is transferred to a substrate to form the pattern
Data Source
AI summary
A method of forming a pattern and a manufacturing method of a liquid crystal display includes forming the pattern with a thin thickness by coating a pattern material on a printing roll using a nozzle, removing a surplus portion of the pattern material from the printing roll by using a plate, and transferring the pattern material remaining on the printing roll to a substrate to form the pattern.