Touch Panel Laser Ablation via Transparent Substrate Energy Absorption
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Solution Overview
Problem
The existing methods for manufacturing touch sensitive panels using laser ablation to form electrode patterns in transparent conductive layers often damage the second conductive layer, leading to compromised throughput, increased manufacturing costs, or thicker panels due to the need for additional layers or different materials.
Innovation Solution
A method involving a layered structure with a thick transparent support substrate that absorbs and diffuses laser energy, reducing the energy density by 50% or more, allowing for the formation of electrode patterns in the first conductive layer without damaging the second layer, using materials like colourless polyimide, polyetherimide, or polycarbonate as the substrate, which are transparent and efficient at absorbing specific laser wavelengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser ablation is used to form electrode patterns in the first transparent conductive layer, then manufacturing throughput is improved and cost is reduced, but the second transparent conductive layer is damaged
Solution Approach 1:
A light blocking layer is introduced as an intermediary element between the first and second transparent conductive layers. This layer selectively blocks laser radiation during the ablation process, preventing damage to the second conductive layer while allowing the formation of electrode patterns in the first layer. The light blocking layer acts as a mediator that protects the second layer without interfering with the laser processing of the first layer.
Solution Approach 2:
The light blocking layer is designed as a temporary, disposable protective element that is applied only during the laser ablation process. It serves its protective function during manufacturing and can be removed or is left as part of the final structure depending on the specific implementation. This approach avoids the need for expensive permanent structural modifications or additional functional layers.
2Object-affected harmful factors
If the second conductive layer is formed only after the electrode pattern is formed in the first conductive layer, then damage to the second layer is prevented, but manufacturing throughput is compromised
Solution Approach 1:
The light blocking layer is applied in advance to the second conductive layer before the laser ablation process begins. This preliminary protective action enables both conductive layers to be present simultaneously during manufacturing, allowing for continuous processing and high throughput while preventing damage to the second layer during the laser forming of electrode patterns in the first layer.
3Object-affected harmful factors
If lenses are configured to diverge the laser beam to reduce energy density at the far side of the substrate, then damage to the second layer is reduced, but manufacturing costs are higher
Solution Approach 1:
The light blocking layer provides a simple, cost-effective solution compared to complex optical systems. Instead of using expensive lenses and beam divergence configurations, a straightforward light blocking layer is applied to achieve the same protective effect, significantly reducing manufacturing costs while maintaining effectiveness in preventing damage to the second conductive layer.
4Object-affected harmful factors
If an additional light blocking layer is added between the conductive layers and the substrate, then the second conductive layer is protected, but the touch sensitive panel is thicker and manufacturing costs are higher
Solution Approach 1:
The light blocking layer is designed as an ultra-thin protective element that provides effective laser radiation blocking while minimizing thickness increase. The layer is applied only where needed for protection and can be removed or is left as a minimal addition to the overall structure, avoiding significant increases in panel thickness while maintaining cost-effectiveness.
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 approach maintains high throughput, reduces manufacturing costs, and produces a thin touch panel without the need for additional layers or materials, effectively preventing damage to the second conductive layer during the laser ablation process.
Implementation Method 1
the laser beam and transparent support substrate are configured such that the laser beam energy density is reduced by 50% or more by the transparent support substrate
Implementation Method 2
forming an electrode pattern in the first transparent conductive layer by laser ablation of the first transparent layer by a laser beam incident on the first transparent layer
Data Source
AI summary
A method of manufacturing a transparent conductive film for a touch sensitive panel, comprising: providing a layered structure comprising a plurality of homogeneous layers which include at least a first transparent conductive layer, a second transparent conductive layer, and a transparent support substrate between the first transparent conductive layer and the second transparent conductive layer, the transparent support substrate being the thickest layer of the layered structure; forming an electrode pattern in the first transparent conductive layer by laser ablation of the first transparent layer by a laser beam incident on the first transparent layer from a side of the transparent support substrate on which the first transparent layer is provided; wherein the laser beam and transparent support substrate are configured such that the laser beam energy density is reduced by 50% or more by the transparent support substrate.