WO2012124950A2

WO2012124950A2 - Pattern roll, method for pattern forming and printing apparatus comprising the same

Info

Publication number: WO2012124950A2
Application number: PCT/KR2012/001769
Authority: WO
Inventors: Dong Youl Lee; Kyoung Hoon Chai; Young Sun You; Yong Jin Lee; Young Jin Noh
Original assignee: LG Innotek Co Ltd
Current assignee: LG Innotek Co Ltd
Priority date: 2011-03-11
Filing date: 2012-03-12
Publication date: 2012-09-20
Anticipated expiration: 2013-09-11
Also published as: CN103582568B; CN103582568A; TW201242777A; TWI568593B; KR20120104051A; WO2012124950A3

Abstract

Disclosed is a method for forming a pattern. The method for forming the pattern in order to print a preset pattern includes preparing a pattern roll having an engraved pattern receiving a paste, which is formed by inclining the preset pattern at an acute angle, and transferring the paste onto a base substrate by using the pattern roll.

Description

PATTERN ROLL, METHOD FOR PATTERN FORMING AND PRINTING APPARATUS COMPRISING THE SAME

The disclosure relates to a pattern roll, a method for forming a pattern by using the pattern roll, and a printing apparatus including the pattern roll.

Recently, as various portable electronic appliances such as a mobile phone, a PDA, and a laptop computer have been developed, the demand for a light, slim, short and small flat panel display is gradually increased. Researches and studies have been actively performed on flat panel displays such as an LCD (Liquid Crystal Display), a PDP (Plasma Display Panel), an FED (Field Emission Display), and a VFD (Vacuum Fluorescent Display), and the flat panel displays have been practically used.

In order to form metallic interconnection patterns inside the various devices and color filter patterns of the LCD, various pattern forming schemes such as a screen printing scheme or a photolithography scheme have been employed. However, according to the screen printing scheme, the precision of the pattern may be degraded. In addition, according to the photolithography scheme, complex processes including the lamination, exposure, and development of photoresist are required, and a limitation exists when forming a micro-pattern.

In order to solve the problem, a gravure printing scheme has been employed to print a pattern on a substrate by using a transfer roll.

FIG. 1 is a schematic view showing a gravure printing scheme according to the related art. According to the gravure printing scheme, a printing material 50 is supplied onto a pattern roll 10 by using a doctor blade in order to fill the printing material 50 into the pattern roll 10 having an engraved pattern on the surface, and the printing material is filled into the pattern by using the doctor blade 40. As shown in FIG. 1, the doctor blade 40 includes a knife 42 and a holder 41 supporting the knife and makes contact with the surface of the pattern roll 10. Thereafter, the pattern shape formed on the pattern roll 10 is transferred to a blanket roll 20 including a material such as a rubber, and a pattern 21 transferred to the blanket roll 20 is printed on a substrate 30.

However, according to a scheme of filling the printing material through the doctor blade, a uniform amount of printing material is not filled in the engraved pattern formed on the pattern roll, so that printing failure may be occur. Especially, in view of the engraved pattern, although the printing material is uniformly filled into the engraved pattern in a direction (horizontal direction (a)) identical to the rotation direction (printing direction) of the pattern roll, the printing material is not uniformly filled into the engraved pattern in a longitudinal direction (vertical direction (b)) of the pattern roll.

As shown in FIG. 2, when a pattern 11 filled with the printing material 12 has vertical and horizontal shapes as described above, a filling material primarily moves along an inner part of a pattern part positioned in the horizontal direction (a) and then moves to a pattern part positioned in the vertical direction (b) so that the pattern 11 is filled with the filling material. When the doctor blade and the pattern roll perform a filling work for the printing material while making line contact therebetween, sufficient time may not be ensured until the printing material has been filled into the pattern part positioned in the horizontal direction due to a very fine line width of the pattern, so that filling failure may occur.

The embodiment provides a pattern roll, a method for forming a pattern by using the pattern roll, and a printing apparatus including the pattern roll, capable of improving the precision of the pattern.

According to the embodiment, there is provided a method for forming a pattern in order to print a preset pattern, which includes preparing a pattern roll having an engraved pattern receiving a paste, which is formed by inclining the preset pattern at an acute angle, and transferring the paste onto a base substrate by using the pattern roll.

According to the embodiment, there is provided a pattern roll including an engraved pattern to receive a paste. The engraved pattern includes a first pattern part and a second pattern part crossing each other, the first pattern part is inclined with respect to a circumferential direction of the pattern roll, and the second pattern part is inclined with respect to a longitudinal direction of the pattern roll.

According to the embodiment, there is provided a printing apparatus including the pattern roll.

As described above, in the pattern roll, the method for forming a pattern by using the pattern roll, and the printing apparatus including the pattern roll according to the embodiment, since the engraved pattern of the pattern roll does not include a pattern part parallel to a longitudinal direction of the pattern roll, a uniform amount of the paste can be filled in the engraved pattern, so that a predetermined pattern can be precisely printed.

FIGS. 1 and 2 are schematic views showing problems related to a pattern roll and a printing apparatus according to the related art;

FIG. 3 is a flowchart showing a method for forming a pattern according to the embodiment;

FIG. 4 is a plan view showing a preset pattern formed in a final substrate;

FIG. 5 is a side view showing a pattern roll having an engraved pattern according to the embodiment;

FIG. 6 is a perspective view showing a printing apparatus including the pattern roll and a method for forming the pattern according to the embodiment; and

FIG. 7 is a plan view showing a step of forming the final substrate.

In the description of the embodiments, it will be understood that when a layer (or film), a region, a pattern, or a structure is referred to as being "on" or "under" another substrate, another layer (or film), another region, another pad, or another pattern, it can be "directly or "indirectly" on the other substrate, layer (or film), region, pad, or pattern, or one or more intervening layers may also be present. Such a position of the layer has been described with reference to the drawings.

The thickness and size of each layer shown in the drawings may be exaggerated, omitted or schematically drawn for the purpose of convenience or clarity. In addition, the size of elements does not utterly reflect an actual size.

Hereinafter, the embodiment will be described with reference to accompanying drawings in detail.

Hereinafter, a pattern roll, a method for forming a pattern by using the pattern roll, and a printing apparatus including the pattern roll according to the embodiment will be described in detail with reference to FIGS. 3 to 7.

FIG. 3 is a flowchart showing a method for forming a pattern according to the embodiment, FIG. 4 is a plan view showing a preset pattern formed in a final substrate, and FIG. 5 is a side view showing a pattern roll having an engraved pattern according to the embodiment. FIG. 6 is a perspective view showing a printing apparatus including the pattern roll and a method for forming a pattern according to the embodiment, and FIG. 7 is a plan view showing a step of forming the final substrate.

Referring to FIG. 3, the method for forming the pattern according to the embodiment includes a step of preparing a pattern roll (step ST10), a step of transferring a paste onto a base substrate (step ST20), and a step of forming a final substrate (step ST30).

Hereinafter, the step of preparing the pattern roll (step ST10) will be described in detail.

According to the present embodiment, in order to form a preset pattern 114a shown in FIG. 4, gravure offset printing is performed by using a pattern roll 100 shown in FIGS. 5 and 6. An engraved pattern 112 is formed in the surface of the pattern roll 100.

As shown in FIG. 5, the engraved pattern 112 is formed in the pattern roll 100 corresponding to the preset pattern 114a to be printed on a final substrate 32 as shown in FIG. 4. The engraved pattern 112 is formed by inclining the preset pattern 114a at a predetermined angle θ. The predetermined angle θ may vary according to a pattern shape. For example, the predetermined angle θ preferably includes an acute angle so that a pattern parallel to the longitudinal direction X of the pattern roll 100 is not formed.

The predetermined angle θ may be in the range of 1°to 45° If the angle θ is less than 1° the pattern is substantially parallel to the longitudinal direction X of the pattern roll 100, so that the efficiency to fill a paste into the pattern may be lowered. In addition, if the angle θ exceeds 45 °a great amount of a base substrate 31 (see FIG. 6) is discarded when the base substrate 31 is cut in order to form the final substrate 32 (see FIG. 6) thereafter. Accordingly, the manufacturing cost may be increased.

A paste 50 (see FIG. 6), which is a printing material, may be filled in the engraved pattern 112 for a printing work.

For example, referring to FIG. 4, the preset pattern 114a may include a first part P1 and a second part P2 crossing each other. For example, the first part P1 is parallel to a left or right edge 32a of the final substrate 32, and the second part P2 is parallel to a top or bottom edge 32b of the final substrate 32. Therefore, if the pattern 114a is not inclined at the angle θ in the pattern roll 100, a pattern part parallel to the longitudinal direction X of the pattern roll 100 exists. However, according to the present embodiment, the pattern 114a is inclined at the angle θ to increase time to fill the paste and ensure the mobility of the paste in the printing process thereafter, so that the filling efficiency can be increased.

In order to print the preset pattern 114a, a first pattern part P10 is inclined with respect to a circumferential direction Y of the pattern roll 100, and a second pattern part P20 is inclined with respect to the longitudinal direction X of the pattern roll 100.

The first pattern part P10 is used to print the first part P1 of the preset pattern 114a, and inclined at the predetermined angle θ with respect to the circumferential direction Y of the pattern roll 100. The predetermined angle θ may be in the rage of 1°to 45° Similarly, the second pattern part P20 is used to print the second part P2 of the preset pattern 114a, and inclined at the predetermined angle θ with respect to the longitudinal direction X of the pattern roll 100. The predetermined angle θ may be in the rage of 1°to 45°

As described above, even when a first pattern part a is perpendicular to a second pattern part B, a pattern part parallel to the longitudinal direction of the pattern roll 100 may not be formed. However, since the embodiment is not limited thereto, the first pattern part P10 may be formed at various angles with respect to the second pattern part P20. Hereinafter, the step of transferring the paste onto the base substrate (step ST20) will be described in detail. Referring to FIG. 4, a doctor blade 40 makes contact with the engraved pattern 112 of the pattern roll 100 in order to fill a paste 50 serving as a printing material in the engraved pattern 112. The doctor blade 40 may include a knife 42 and a jig part 41 to support the knife 42. The doctor blade 40 moves in contact with the pattern roll 100 while filling the paste 50 in the engraved pattern 112.

Thereafter, the pattern roll 100 can transfer the paste 21 onto a blanket roll 20. For example, the blanket roll 20 has a cylindrical shape, so that the blanket roll 20 may be rotatably installed. A blanket including rubber may be wound around an outer peripheral surface of the blanket roll 20.

Next, the blanket roll 20 rotates on the base substrate 31 to transfer the paste 21 onto the base substrate 31.

Hereafter, the step of forming the final substrate (step ST30) will be described in detail.

Referring to FIG. 7, the final pattern 114a formed on the base substrate 31 has a predetermined angle θ with respect to the base substrate 31. In detail, the final pattern 114a may be inclined with respect to the base substrate 31 at an angle as great as an angle made between the engraved pattern 112 formed in the pattern roll 100 and the pattern roll 100. Therefore, in order to obtain the preset pattern 114a, the base substrate 31 may be cut at the angle θ In other words, in order to form the final substrate 32, the base substrate 31 is cut in such a manner that the edge of the base substrate 31 is inclined at the angle θ with respect to the edge of the final substrate 31, thereby obtaining the final substrate 32 having the preset pattern 114a shown in FIG. 4.

Accordingly, even if the preset pattern 114a has a pattern part parallel to the longitudinal direction X of the pattern roll 100, a predetermined angle θ is applied to the engraved pattern 112 formed in the pattern roll 100, so that the filling efficiency of the paste 50 can be increased. Therefore, the precision of the pattern can be improved, and a high quality printing result can be obtained. In addition, a desirable pattern can be obtained without the modification of the preset pattern 114a.

Any reference in this specification to "one embodiment", "an embodiment", "example embodiment", etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effects such feature, structure, or characteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure.　 More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims.　In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

Claims

A method for forming a pattern in order to print a preset pattern, the method comprising:

preparing a pattern roll having an engraved pattern receiving a paste, which is formed by inclining the preset pattern at an acute angle; and

transferring the paste onto a base substrate by using the pattern roll.
The method of claim 1, wherein the engraved pattern includes a first pattern part and a second pattern part crossing each other,

the first pattern part is inclined with respect to a circumferential direction of the pattern roll, and

the second pattern part is inclined with respect to a longitudinal direction of the pattern roll.
The method of claim 2, wherein an angle between the first pattern part and the circumferential direction is in a range of 1°to 45°.
The method of claim 3, wherein an angle between the second pattern part and the longitudinal direction is in a range of 1°to 45°.
The method of claim 2, wherein the first pattern part is perpendicular to the second pattern part.
The method of claim 1, further comprising forming a final substrate by cutting the base substrate after transferring the paste onto the base substrate.
The method of claim 6, wherein, in the forming of the final substrate, the base substrate is cut such that an edge of the final substrate is inclined at the acute angle with respect to an edge of the base substrate.
A pattern roll comprising an engraved pattern to receive a paste, wherein the engraved pattern includes a first pattern part and a second pattern part crossing each other,

the first pattern part is inclined with respect to a circumferential direction of the pattern roll, and

the second pattern part is inclined with respect to a longitudinal direction of the pattern roll.
The pattern roll of claim 8, wherein an angle between the first pattern part and the circumferential direction is in a range of 1°to 45°.
The pattern roll of claim 9, wherein an angle between the second pattern part and the longitudinal direction is in a range of 1°to 45°.
The pattern roll of claim 8, wherein the first pattern part is perpendicular to the second pattern part.
A printing apparatus comprising a pattern roll including an engraved pattern to receive a paste, wherein the engraved pattern includes a first pattern part and a second pattern part crossing each other,

the first pattern part is inclined with respect to a circumferential direction of the pattern roll, and

the second pattern part is inclined with respect to a longitudinal direction of the pattern roll.
The printing apparatus of claim 12, wherein an angle between the first pattern part and the circumferential direction is in a range of 1°to 45°
The printing apparatus of claim 13, wherein an angle between the second pattern part and the longitudinal direction is in a range of 1° to 45°.
The printing apparatus of claim 12, wherein the first pattern part is perpendicular to the second pattern part.