Touch Screen Conductive Patterning With Over-Etched Ultrafine Lines
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Solution Overview
Problem
Existing touch screen manufacturing methods struggle to produce conductive patterns with high accuracy and ultrafine line widths, leading to reduced recognition speed and visibility issues, especially when using ITO-based conductive layers on large-area screens.
Innovation Solution
A manufacturing method involving the formation of a conductive layer on a substrate, followed by creating an etching resist pattern and over-etching to achieve a conductive pattern with a line width smaller than the resist pattern, allowing for precise and efficient production of conductive patterns with small taper angles and insulating layers, enabling the formation of ultrafine line widths and large-area touch screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If ITO-based conductive layer is used for large-area touch screen, then coverage area is improved, but recognition speed lowers due to self-RC relay
Solution Approach 1:
The conductive layer is divided into a grid pattern of conductive lines forming multiple small conductive regions rather than a continuous large-area conductive layer. This segmentation reduces the self-RC relay effect by creating electrically isolated segments that can be independently controlled, thereby maintaining fast recognition speed while covering large screen areas.
2Ease of manufacture
If printing method is used to displace ITO, then manufacturing cost is reduced, but fine pattern accuracy and visibility deteriorate
Solution Approach 1:
A dual-layer structure is employed where a printed conductive paste layer serves as an intermediary over a sputtered ITO conductive layer. The printed paste provides the fine pattern accuracy needed for visibility, while the underlying ITO layer maintains electrical performance. This intermediary approach combines the advantages of both printing (cost-effectiveness) and sputtering (precision).
Solution Approach 2:
The conductive system uses a composite structure combining printed conductive paste materials with sputtered ITO materials. Each material contributes its strengths: the printed paste provides fine pattern definition and cost benefits, while the ITO layer provides excellent electrical conductivity and transparency. The composite structure achieves both manufacturing economy and pattern precision.
3Device complexity
If conventional etching is used, then manufacturing process is simple, but conductive pattern line width accuracy deteriorates
Solution Approach 1:
The conductive paste is printed and dried to form a preliminary pattern structure before the etching process. This preliminary action creates a stable mask that defines the final pattern geometry, allowing the subsequent etching process to accurately reproduce fine line widths without requiring complex real-time control during etching.
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 enables the production of touch screens with high precision and ultrafine line widths, improving performance and manufacturing efficiency while reducing the occurrence of shorts and pattern defects, thus enhancing visibility and recognition speed.
Implementation Method 1
forming a first conductive pattern having a line width smaller than the line width of the etching resist pattern by over-etching the conductive layer by using the etching resist pattern
Data Source
AI summary
The present invention provides a method of manufacturing a touch screen, comprising the steps of: a) forming a conductive layer on a substrate; b) forming an etching resist pattern on the conductive layer; and c) forming a conductive pattern having a line width smaller than the line width of the etching resist pattern by over-etching the conductive layer by using the etching resist pattern and a touch screen manufactured by the method. According to the present invention, a touch screen comprising a conductive pattern having an ultrafine line width can be economically and efficiently provided.