Variable Depth Micro-Channel Structure for Transparent Electrodes
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Solution Overview
Problem
Existing transparent conductive metal oxides used in display and touch-screen technologies face limitations in transparency, conductivity, and manufacturability, with high costs and limited current-carrying capacity, and existing micro-wire electrodes have issues with even distribution and connectivity.
Innovation Solution
A micro-channel structure with variable depths is created in a substrate, where cured electrical conductors form micro-wires within these channels, enhancing transparency, conductivity, and manufacturability by ensuring even distribution and improved connectivity through embossing and curing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If transparent conductive metal oxides are used to form electrodes, then transparency is maintained, but conductivity and current-carrying capacity are limited
Solution Approach 1:
The patent uses a composite structure combining transparent conductive metal oxide layers with metal layers (silver, aluminum, or metal alloys). This composite approach allows the electrode to maintain high transparency from the oxide layer while achieving low electrical resistivity and high current-carrying capacity through the metal layer, resolving the contradiction between transparency and conductivity.
2Reliability
If thicker layers of metal oxides or metals are used to increase conductivity, then conductivity is improved, but transparency is reduced
Solution Approach 1:
The patent applies different materials with different properties to different layers of the electrode structure. The transparent conductive metal oxide provides transparency in the upper layer, while the metal layer below provides high conductivity. This local differentiation of material properties allows each layer to optimize its function without compromising the other, achieving both high transparency and high conductivity simultaneously.
3Manufacturing precision
If conventional sputtering or vapor deposition is used to deposit electrode materials, then uniform coating is achieved, but substrate material selection is limited and manufacturing cost increases
Solution Approach 1:
The patent changes the deposition parameters by using screen printing or inkjet printing instead of conventional sputtering or vapor deposition. These alternative methods allow for broader substrate material selection and reduced manufacturing costs while still achieving uniform coating through controlled material deposition and curing processes.
4Illumination intensity
If micro-wire electrodes with fine patterns are used to improve transparency, then transparency is enhanced, but even distribution and connectivity become difficult to achieve
Solution Approach 1:
The patent incorporates a cured layer with pre-formed micro-channels before depositing the conductive materials. This preliminary structuring guides the subsequent material deposition process, ensuring that conductive materials are evenly distributed within the micro-channels and properly connected. The pre-formed channel structure prevents random distribution and ensures consistent connectivity across the electrode pattern.
Data Source
AI summary
A micro-channel structure having variable depths includes a substrate and a cured layer formed on the substrate. At least first and second micro-channels are embossed in the cured layer. The first micro-channel has a bottom surface defining a first depth and the second micro-channel has a bottom surface defining a second depth different from the first depth. A cured electrical conductor is making a micro-wire is formed in each of the first and second micro-channels over their respective bottom surfaces.