Roller Apparatus Surface Energy Pattern Transfer
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Solution Overview
Problem
The existing printing methods for liquid crystal display (LCD) devices are complex and prone to defects due to multiple processes and the need for expensive exposure equipment, particularly in forming patterns using photoresist and clichés, which can lead to errors in pattern transfer.
Innovation Solution
A roller apparatus with a blanket having different surface energies is used to form and transfer printing patterns directly onto a substrate, simplifying the process by forming first patterns with higher surface energy and depositing a printing material between them, which then adheres to a substrate with higher surface energy, reducing the need for multiple steps and cliché-based processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a photoresist pattern is formed by cleaning, exposure and development processes, then a pattern can be formed on the substrate, but the fabrication cost increases and the fabricating process becomes complicated
Solution Approach 1:
The invention extracts and eliminates the cliché component from the conventional printing process. Instead of using a cliché to transfer patterns to the roller, the pattern is directly formed on the roller surface through selective adhesion of printing material to specific regions. This removal of the cliché simplifies the overall fabrication process while maintaining pattern formation capability.
Solution Approach 2:
The invention applies preliminary action by pre-forming patterns directly on the roller surface before the actual printing process. The roller surface is prepared with regions of different adhesion properties, and the printing material is selectively adhered to these regions in advance, creating a ready-to-print configuration that eliminates the need for separate photoresist and development steps.
2Manufacturing precision
If a cliché is used to form a printing pattern on the roller, then a pattern can be transferred onto the substrate, but the process becomes complicated and printing defects may occur
Solution Approach 1:
The invention removes the cliché from the printing system entirely. The pattern formation is achieved directly on the roller through controlled adhesion of printing material to regions with different surface energy characteristics. This elimination of the cliché component reduces process complexity and potential sources of printing defects while maintaining pattern transfer fidelity.
Solution Approach 2:
The invention creates a direct copy of the desired pattern on the roller surface itself, rather than using a cliché as an intermediate master. The printing material is selectively adhered to replicate the target pattern directly on the roller, which then serves as the printing surface. This direct copying approach eliminates errors that can occur in the cliché-to-roller transfer step.
3Productivity
If a roller forcibly presses the cliché, then a pattern can be transferred onto the roller, but printing material that should remain on the roller may contact the cliché and attach to the cliché, causing printing defects
Solution Approach 1:
The invention eliminates the cliché from the system, removing the source of the adhesion problem entirely. Without a cliché to press against, the issue of printing material incorrectly transferring to the cliché surface cannot occur. The pattern is formed directly on the roller through selective adhesion to regions with different surface energy, eliminating the need for forced pressing and preventing material loss.
4Manufacturing precision
If multiple processes are performed to form a printing pattern, then a pattern can be formed on the substrate, but the fabricating process becomes complicated and time-consuming
Solution Approach 1:
The invention merges multiple separate processes into a single integrated operation. The pattern formation, material adhesion, and printing surface preparation are combined into one step where the printing material is selectively adhered directly to the roller surface in the desired pattern configuration. This eliminates the sequence of cleaning, exposure, development, and cliché transfer steps, significantly reducing fabrication time while maintaining pattern accuracy.
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 simplifies the fabrication process, reduces costs, and minimizes printing defects by directly forming and transferring patterns onto the substrate, eliminating the need for photoresist patterns and cliché-based processes, thereby improving the efficiency and accuracy of pattern formation.
Implementation Method 1
forming first patterns on a blanket, the first patterns having different surface energy from the blanket; forming the blanket around a roller; rotating the roller and dropping a printing material to form second patterns on the blanket between the first patterns
Implementation Method 2
transferred the second patterns onto a substrate
Data Source
AI summary
Provided are a roller apparatus, a printing method and a method of fabricating an LCD device using the same, which can minimize the number of processes and a printing defect. In the printing method, first patterns are formed on a blanket. The first patterns have different surface energy from that of the blanket, and the blanket is formed around a roller. The roller is rotated and a printing material is dropped to form second patterns on the blanket between the first patterns. The second patterns are transferred from the roller onto a substrate.