Sacrificial Layer Blanket for Uniform Ink Patterning

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Solution Overview

Problem

Existing blanket technologies for pattern formation in electronic devices, such as organic EL display units, face challenges with uneven ink layer thickness, solvent absorption leading to reduced pattern accuracy, and increased costs due to complex processes and solvent usage, as well as accelerated degradation from swelling and plasma treatment.

Innovation Solution

A blanket with a sacrificial layer on a releasable base, where the sacrificial layer is separated from the base during printing, allowing for the transfer of an ink layer to a substrate without the need for optimizing ink solutions, thereby improving solvent selection flexibility and achieving high-quality patterning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of stationary object

If a blanket made of silicone rubber is used for printing, then the blanket has good elasticity and reusability, but the low wettability causes the ink layer to become uneven in thickness

Engineering Contradiction:

Improveblanket reusabilityVSAvoidink layer thickness uniformity

Core Design Contradiction:

Duration of action of stationary objectVSManufacturing precision

Solution Approach 1:

A release layer is introduced as an intermediary between the silicone rubber blanket and the ink layer. This release layer has high wettability that ensures uniform ink distribution, while its low adhesion to the ink prevents sticking. The release layer acts as a mediator that resolves the conflict between the blanket's low wettability and the requirement for uniform ink layer thickness.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If organic solvent is used to improve ink layer uniformity, then the ink layer becomes more uniform in thickness, but the soft blanket material absorbs the solvent causing drying and reduced pattern accuracy

Engineering Contradiction:

Improveink layer thickness uniformityVSAvoidpattern accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The release layer serves as a protective intermediary between the organic solvent and the silicone rubber blanket. It allows the solvent to be used for achieving uniform ink thickness without being absorbed by the blanket, thus preventing premature drying and maintaining pattern accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The release layer is designed as a consumable component that is discarded after use. This allows the use of organic solvents that would otherwise be absorbed by the blanket, since the release layer protects the blanket from solvent absorption while enabling uniform ink formation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If the blanket is immersed in organic solvent to prevent ink layer drying, then the ink layer remains wettable, but a large amount of solvent is used increasing cost and it is difficult to meet large area requirements

Engineering Contradiction:

Improveink layer wettabilityVSAvoidsolvent usage amount

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The release layer acts as a local intermediary that provides solvent compatibility only where needed (at the ink application surface), eliminating the need to immerse the entire large-area blanket in solvent. This reduces solvent consumption significantly while maintaining ink layer wettability.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If repeated swelling treatment is applied to the blanket, then the ink layer uniformity is improved, but the silicone rubber degrades faster reducing blanket life

Engineering Contradiction:

Improveink layer uniformityVSAvoidblanket life

Core Design Contradiction:

Manufacturing precisionVSDuration of action of stationary object

Solution Approach 1:

The release layer serves as a protective intermediary that enables uniform ink formation without requiring repeated swelling treatments of the blanket. This eliminates the degradation caused by repeated swelling while maintaining ink layer uniformity.

Inventive Principle:

Principle #24Intermediary (Mediator)

5Manufacturing precision

If plasma treatment is applied to the blanket surface to improve wettability, then the ink layer uniformity is improved, but the separability is degraded causing residue

Engineering Contradiction:

Improveink layer uniformityVSAvoidprinting residue

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The release layer acts as an intermediary that provides the necessary wettability for uniform ink formation without compromising the separability between the blanket and the printed pattern. The plasma treatment is applied to the release layer rather than the blanket surface, maintaining both wettability and separability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9589816B2Blanket, printing process, and a method of manufacturing display unit and electronic apparatus

Publication Date: 2017.03.07 MAGNOLIA BLUE CORP

AI summary

A blanket includes a releasable base; and a sacrificial layer being provided on the base and separated from the base in printing.