Printing Plate Embossing Pattern Design for Alignment Film Uniformity
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Solution Overview
Problem
The existing methods for printing alignment films in liquid crystal display devices face issues with uniform thickness and irregular alignment due to the impact force from dummy relief patterns on the printing plate, leading to uneven cell gaps and defects in the display panel.
Innovation Solution
A printing plate design featuring pixel array embossing patterns, dummy embossing patterns not overlapping in the rotating direction, and grooved patterns between embossing patterns, which minimizes strain on the alignment film material and prevents unwanted patterns from being transcribed to the substrate, ensuring uniform film thickness and preventing glass substrate damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dummy relief patterns are formed on the printing plate, then the alignment film material can be printed to the pixel array, but impact force is periodically applied to the anilox roller causing non-uniform film thickness
Solution Approach 1:
The patent removes the dummy relief patterns from the printing plate surface that cause impact forces. By extracting only the necessary pixel array embossing patterns and eliminating unnecessary dummy patterns, the periodic impact forces on the anilox roller are eliminated, ensuring uniform alignment film thickness without compromising the printing function.
Solution Approach 2:
The patent applies different surface characteristics to different regions of the printing plate. The pixel array regions maintain embossing patterns for proper alignment film transfer, while the dummy pattern regions are eliminated or modified to have groove patterns that do not create impact forces. This localized differentiation resolves the contradiction between maintaining printing functionality and eliminating harmful impacts.
2Manufacturing precision
If the printing roller applies pressure to transcribe alignment film material, then the film is deposited on the substrate, but the doctor roller may drag on the anilox roller causing unwanted patterns
Solution Approach 1:
The patent converts the potential harmful dragging action into a beneficial smoothing effect by introducing groove patterns in strategic locations. These grooves allow the doctor roller to properly shave excess material without creating dragging traces, as the grooves provide a controlled path for material removal that prevents the roller from catching on raised dummy patterns.
3Device complexity
If dummy embossing patterns are placed near pixel array patterns, then the printing plate structure is simplified, but strain is transmitted to the pixel array causing alignment defects
Solution Approach 1:
The patent extracts and removes the problematic dummy embossing patterns that are positioned too close to the pixel array patterns. By eliminating these nearby dummy patterns, the strain transmission path to the pixel array is broken, preventing alignment defects while maintaining the essential printing functionality through the retained pixel array embossing patterns.
Solution Approach 2:
The patent creates a localized strain-free zone around the pixel array patterns by eliminating dummy patterns in the immediate vicinity. This spatial differentiation ensures that the pixel array regions experience minimal strain for proper alignment, while other regions of the printing plate can have different pattern configurations as needed.
Data Source
AI summary
The present disclosure relates to the device and the method for printing an alignment film. The printing plate comprises: a resin plate; a plurality of pixel array embossing pattern formed on the resin plate, for printing the alignment film to a pixel array formed on the glass substrate of the liquid crystal display device; a plurality of dummy embossing pattern formed on the resin plate at which the pixel array embossing patterns are not formed as seeing in the rotating direction of the printing roller; and a grooved pattern formed on the resin plate between the pixel array embossing patterns and between the dummy embossing patterns.