Printing Roll Pattern Transfer for Uniform LCD Ink Formation
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Solution Overview
Problem
The existing methods for forming patterns in active matrix LCD devices, such as photolithography, are inefficient and require multiple processes, reducing productivity and resulting in non-uniform pattern thickness and accuracy issues.
Innovation Solution
A method using a printing roll with convex patterns to apply and harden ink directly onto a substrate, eliminating the need for a cliché and simplifying the process, allowing for uniform pattern formation and improved accuracy by rotating the printing roll across the substrate with constant pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography process is used to form patterns, then pattern formation is achieved, but multiple processes are required reducing productivity
Solution Approach 1:
The patent combines multiple photolithography processes into a single printing process. The printing roll directly forms patterns on the substrate in one operation, eliminating the need for sequential photolithography steps including photoresist deposition, alignment, exposure, development, and cleaning. This merging of processes maintains pattern formation accuracy while dramatically improving productivity.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate processes from the traditional photolithography workflow. By using a printing roll with convex patterns that directly transfer ink patterns to the substrate, the method removes steps such as photoresist coating, alignment procedures, and development processes, keeping only the essential pattern formation function.
2Manufacturing precision
If multiple photolithography processes are performed, then patterns are formed, but process complexity increases
Solution Approach 1:
The patent extracts the essential pattern formation function from the complex photolithography process. By using a printing roll with pre-formed convex patterns, the method eliminates photoresist deposition, alignment systems, exposure equipment, and development processes, reducing overall process complexity while maintaining pattern accuracy through direct ink transfer.
Solution Approach 2:
The patent uses a printing roll with convex patterns that serves as a physical copy or template for the desired pattern. The convex patterns on the rolling surface are copied onto the substrate through ink transfer, replacing the complex optical copying and chemical development processes of photolithography with a simple mechanical replication process.
3Ease of manufacture
If conventional printing method is used, then pattern formation is achieved, but pattern thickness uniformity is poor
Solution Approach 1:
The patent inverts the conventional printing approach by using convex patterns instead of concave patterns. In traditional printing, ink is placed in recesses and excess is removed. In this invention, ink is applied over convex patterns and the protrusions transfer the ink directly to the substrate, ensuring uniform thickness as the convex surfaces naturally deposit consistent ink layers during rotation.
Solution Approach 2:
The patent performs preliminary action by pre-forming convex patterns on the printing roll surface before the printing process. These pre-formed convex structures ensure that when ink is applied and the roll rotates, the pattern transfer occurs with uniform thickness from the beginning, eliminating the need for post-printing thickness adjustment or multiple printing passes.
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 enhances productivity by simplifying the printing process, improving pattern uniformity, and increasing accuracy, enabling the formation of patterns in a single process with reduced equipment complexity.
Implementation Method 1
forming ink patterns on the etching object layer as a printing roll having convex patterns rotates on the ink in contact therewith
Implementation Method 2
hardening the ink patterns
Data Source
AI summary
A method for forming a patterns includes applying ink onto an etching object layer; forming ink patterns on the etching object layer as a printing roll having convex patterns thereon rotates on the ink and removes portions of the ink which contact the convex portions of the printing roll, thereby forming ink patterns; and hardening the ink patterns.