Screen Printing Touch Panel Fabrication Cost Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high manufacturing cost of capacitive touch panels due to the expensive photolithography process used for forming sensing pads, insulating layers, and bridge line layers limits their popularity in consumer electronics.
Innovation Solution
A touch panel fabrication method utilizing screen printing processes to form patterned sensing pad, insulating, and bridge line layers, which reduces manufacturing costs by using screen printing processes instead of photolithography, with polycrystalline metal oxide materials for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography process is used to form sensing pad layer, insulating layer, and bridge line layer, then manufacturing precision and pattern definition are improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces the photolithography process (optical/chemical system) with a screen printing process (mechanical system). The screen printing process uses a sieve screen to transfer paste material, forming patterns through mechanical contact rather than optical exposure and chemical development. This substitution maintains adequate pattern definition precision while dramatically reducing manufacturing cost and process complexity.
Solution Approach 2:
The screen printing process employs disposable or reusable screen templates that can be easily fabricated and replaced, eliminating the need for expensive photolithography equipment, alignment systems, and chemical materials. The screen itself acts as a disposable patterning element that defines the geometry without requiring sophisticated optical alignment infrastructure.
2Ease of manufacture
If screen printing process is used instead of photolithography, then manufacturing cost is reduced, but pattern definition precision and layer alignment may deteriorate
Solution Approach 1:
The patent segments the patterning process into separate screen printing steps for each layer (sensing pad layer, insulating layer, bridge line layer). Each layer can be patterned independently using the same screen printing process, allowing optimization of each pattern without compromising others. This segmentation enables precise pattern definition through careful screen design while maintaining cost-effectiveness.
Solution Approach 2:
The patent controls pattern definition precision by adjusting screen printing parameters such as screen mesh density, paste viscosity, printing pressure, and drying conditions. By optimizing these parameters, the process achieves adequate pattern resolution and layer alignment without requiring expensive photolithography equipment, thus maintaining precision while reducing manufacturing cost.
Data Source
AI summary
A method of fabricating touch panel includes the following steps. A base is provided. A first transparent conductive layer is formed on the base. A first screen printing process is performed to form a first patterned sacrificial layer on the first transparent conductive layer, and the first patterned sacrificial layer is used to pattern the first transparent conductive layer to form a patterned sensing pad layer. A second screen printing process is carried out to form a patterned insulating layer. A second transparent conductive layer is formed on the base. A third screen printing process is performed to form a second patterned sacrificial layer, and the second patterned sacrificial layer is used to pattern the second transparent conductive layer to form a patterned bridge line layer.