Roll-to-Roll Touch Screen Electrode Patterning
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Solution Overview
Problem
The manual cutting of transparent electrode films for touch screen panel manufacturing leads to low productivity and high error rates, with a risk of foreign substances being introduced into the panels.
Innovation Solution
A roll-to-roll method is employed to form electrode patterns on substrates with engraved patterns, using a first roll for rewinding, a second roll for transferring, guide rolls for substrate guidance, an electrode material coating unit, and an electrode material sweeping unit to fill the electrode material into the engraved patterns by applying pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cutting method is used to manufacture touch screen panels, then flexibility in processing is maintained, but productivity is extremely deteriorated and error rate increases
Solution Approach 1:
The patent replaces the manual mechanical cutting system with an automated printing system that directly forms electrode patterns on the transparent electrode film during the rolling process. The printing unit uses a print head with nozzles to deposit electrode material according to a predetermined pattern, eliminating the need for separate manual cutting operations and integrating the patterning function into the continuous manufacturing process.
2Reliability
If manual cutting of transparent electrode film is performed, then processing flexibility is preserved, but foreign substances are introduced and error rate increases
Solution Approach 1:
The patent merges the electrode pattern formation process with the transparent electrode film manufacturing process by integrating a printing unit directly into the rolling system. The printing unit deposits electrode material onto the film as it passes through the rollers, combining what were previously separate operations (film production and electrode patterning) into a single continuous process, thereby reducing the number of handling steps and potential contamination points.
Solution Approach 2:
The patent introduces a carrier film as an intermediary medium that carries the electrode material and transfers it to the transparent electrode film. The carrier film with the pre-formed electrode pattern is fed through the rolling system, and the electrode pattern is transferred to the final product, allowing precise pattern formation without direct manual intervention and reducing contamination risk.
3Productivity
If automated roll-to-roll method is implemented, then productivity is improved and error rate is reduced, but device complexity increases
Solution Approach 1:
The patent designs the printing unit with a multi-functional print head that can perform both the deposition of electrode material and the formation of the electrode pattern in a single operation. The print head incorporates multiple nozzles that can be selectively activated to create complex patterns, eliminating the need for separate masking, cutting, and assembly operations, thereby reducing overall system complexity despite the automated process.
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 enables continuous and uniform production of touch screen panels, significantly improving productivity and reducing error rates by automating the manufacturing process.
Implementation Method 1
an electrode material coating unit installed on the transfer path of the substrate and configured to coat an electrode material on the substrate
Implementation Method 2
an electrode material sweeping unit installed at the rear of the electrode material coating unit in a transfer direction of the substrate and configured to push the electrode material on the surface of the substrate and fill the pushed electrode material in the engraved pattern by contacting the surface of the substrate and applying a predetermined pressure to the substrate
Data Source
AI summary
The apparatus for manufacturing the touch screen panel according to the present invention includes: a first roll by which a wound film is unwound; a second roll around which a film having an electrode pattern is wound; a guide roll disposed between the first and second rolls to guide the transfer of the film; a resin applying part applying a resin on the film to form a resin layer; a pattern molding part including a mold having a relief pattern and pressing the mold onto the resin layer to form an intaglio pattern on the resin layer; an electrode material applying part applying an electrode material on a surface of the resin; an electrode material sweeping part removing the electrode material from the surface of the resin layer; and a hardening part hardening the electrode material filled in the intaglio pattern of the resin surface.