Touch Sensing Electrode Structure With Masking Layer
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Solution Overview
Problem
Conventional methods for manufacturing metal conductive electrodes in touchscreens result in low yield rates and uneven etching, leading to increased electric impedance and potential breakage, along with oxidation issues due to moisture exposure, which affects the service life and durability of touchscreens.
Innovation Solution
A method involving a masking layer with a predetermined circuit pattern is used to precisely control the width of metal conductive electrodes and apply a weatherproof layer to protect them from oxidation, incorporating multiple adhesion layers and weatherproof layers to seal and isolate the electrodes, while also reducing the moiré effect through a blackening effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet etching is used to form metal conductive electrodes, then the manufacturing process is simple, but side etching occurs causing uneven electrode width and high electric impedance
Solution Approach 1:
A masking layer is introduced as an intermediary component between the etching fluid and the metal conductive electrode layer. This masking layer selectively protects specific regions during etching, preventing side etching and ensuring uniform electrode width while maintaining manufacturing simplicity
Solution Approach 2:
The masking layer is formed in advance before the etching process, establishing a predetermined circuit pattern that guides the etching fluid. This preliminary action ensures that the metal conductive electrodes are etched only in desired regions, preventing unwanted side etching and achieving precise width control
2Illumination intensity
If metal conductive electrodes are made with very small width to avoid visual perception, then the touchscreen appearance is improved, but the electrodes become more susceptible to oxidation and have lower yield rate
Solution Approach 1:
The patent uses composite material structure with multiple layers: metal conductive electrode layer, adhesion layer, and weatherproof layer. This composite structure provides both the required electrical conductivity and protection against oxidation, enabling thin electrode widths without compromising reliability
Solution Approach 2:
The weatherproof layer creates a protective environment around the metal conductive electrodes, isolating them from oxygen and moisture in the external environment. This effectively creates an inert atmosphere that prevents oxidation of the thin metal electrodes
3Reliability
If weatherproof layer is formed before etching, then corrosion protection is provided, but non-uniform thickness causes serious side etching
Solution Approach 1:
The protective function is segmented into two separate layers: adhesion layer for bonding and weatherproof layer for corrosion protection. The masking layer is applied after etching to define the circuit pattern, separating the protection function from the patterning function to avoid interference with etching precision
4Strength
If adhesion layer with multiple sublayers is used, then bonding strength is improved, but process complexity increases
Solution Approach 1:
The adhesion layer is segmented into multiple sublayers, each performing a specific function: intermediate layer for substrate bonding, seed layer for metal deposition, and anti-oxidation layer for corrosion protection. This segmentation achieves superior bonding strength while keeping each sublayer's function simple and well-defined
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 stabilizes the width of metal conductive electrodes, increases yield rates, and significantly extends the service life of touchscreens by preventing oxidation and improving environmental durability, while also enhancing light transmittance and color accuracy.
Implementation Method 1
a weatherproof layer is formed to completely cover the metal conductive electrodes
Implementation Method 2
a masking layer with a predetermined circuit pattern is used to precisely control the width of metal conductive electrodes
Implementation Method 3
a layer of material for forming metal conductive electrodes is adhered to a substrate via at least one adhesion layer
Data Source
AI summary
A method of manufacturing touch sensing electrode structure includes the steps of selecting a predetermined substrate material to form a substrate layer; forming at least one adhesion layer on the substrate layer; forming a masking layer with recessed lines on the adhesion layer; forming metal conductive electrodes in the recessed lines on the masking layer; removing the masking layer for the metal conductive electrodes to present a circuit pattern and etching off portions of the adhesion layer located between the metal conductive electrodes; and forming at least one weatherproof layer on peripheral surfaces of the metal conductive electrodes. The touch sensing electrode structure manufactured according to the above method has high yield rate and is weatherproof, and the metal conductive electrodes thereof have precisely controlled small width.