Structured Transfer Tape for Large-Area Nanostructure Replication
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Solution Overview
Problem
The existing methods for patterning or forming nanostructures and microstructures on large glass substrates are difficult and not cost-effective, particularly for applications in display, lighting, and photovoltaic devices, where efficient light extraction, distribution, and antireflection are required.
Innovation Solution
A transfer tape is developed with a carrier, a template layer, and a backfill layer, where the template layer is removable while leaving the structured surface of the backfill layer intact, using a release coating and adhesion promotion layers to facilitate the transfer of nanostructures onto glass substrates, enabling cost-effective and high-yield fabrication of nanostructures and microstructures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lamination transfer methods with sacrificial template layers are used, then nanostructures can be formed on glass substrates, but the process becomes complex and costly due to the need to remove the sacrificial template layer while leaving the structured backfill layer intact
Solution Approach 1:
The patent extracts the sacrificial template layer from the final product structure, using it only as a temporary form-giving element during fabrication. The template layer is designed to be completely removable after transferring the nanostructure pattern to the backfill layer and substrate, eliminating the need to maintain complex sacrificial structures in the final device.
Solution Approach 2:
The patent performs preliminary actions by first forming the template layer with desired nanostructures, then using it to pattern the backfill layer before removing the template. This preliminary structuring approach allows complex nanostructures to be created through simple template replication rather than direct fabrication on the final substrate.
2Reliability
If dry etching or thermal decomposition processes are used to remove the sacrificial template layer, then the template can be removed, but the process becomes time-consuming and reduces productivity
Solution Approach 1:
The patent changes the chemical parameters of the template layer by using materials with specific solubility characteristics. The template layer is formulated to be soluble in mild aqueous solutions, allowing removal through simple dissolution rather than time-consuming dry etching or thermal decomposition processes.
Solution Approach 2:
The template layer is designed as a disposable, sacrificial element that is easily removed after serving its form-giving purpose. By using water-soluble materials, the template can be discarded through simple rinsing rather than requiring complex removal equipment or lengthy processing steps.
3Area of stationary object
If nanostructures are fabricated directly on large glass substrates, then the structures can be applied to display and photovoltaic devices, but the process becomes difficult and not cost-effective
Solution Approach 1:
The patent moves the fabrication process to a different dimensional approach by using flexible transfer tapes that can be rolled and handled in convenient formats. Large-area nanostructures are fabricated on flexible substrates that can be rolled up, stored, and transferred to large glass substrates in a controlled manner, making large-area fabrication practical and cost-effective.
Solution Approach 2:
The patent segments the fabrication process into separate steps: first creating the nanostructured pattern on a flexible transfer tape, then transferring it to the large glass substrate. This segmentation allows the complex nanostructure fabrication to be performed on manageable flexible substrates rather than attempting to directly pattern large rigid glass substrates.
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 allows for the efficient transfer of structured surfaces onto glass substrates, enhancing light extraction, distribution, and antireflection capabilities in display, lighting, and photovoltaic devices, while reducing production costs and improving yield.
Implementation Method 1
The sacrificial template layer is typically removed by a dry etching process using oxygen plasma, a thermal decomposition process, or a dissolution process.
Implementation Method 2
The sacrificial template layer is typically removed by a dry etching process using oxygen plasma, a thermal decomposition process, or a dissolution process.
Implementation Method 3
a release coating disposed upon the non-planar structured surface of the template layer
Implementation Method 4
one of which can be an adhesion promotion layer
Data Source
AI summary
Organic light emitting diode (OLED) devices are disclosed that include a first layer; a backfill layer having a structured first side and a second side; a planarization layer having a structured first side and a second side; and a second layer; wherein the second side of the backfill layer is coincident with and adjacent to the first layer, the second side of the planarization layer is coincident with and adjacent to the second layer, the structured first side of the backfill layer and structured first side of the planarization layer form a structured interface, the refractive index of the backfill layer is index matched to the first layer, and the refractive index of the planarization layer is index matched to the second layer.