Patterning is a processing method to remove various thin films made of metal, resin, and inorganic materials, among others. This can be used in grooving to remove the TEG formed on the panel street. Like the scribe and break method, it is also a dry processing method formulated at MDI. Either mechanical or laser processing can be adopted in this method depending on the film quality.
Mechanical processing and laser processing.
The patterning method by MDI can be adopted in both mechanical scribing with carbide tools and laser scribing by laser irradiation.
For mechanical patterning, in addition to the needle-shaped conventional tools, we develop tools with a special shape to minimize the film peel-off. By utilizing the processing knowledge of scribing wheel, we provide PCD (sintered diamond) tools that are processed to the best-suited shape.
For laser patterning, we conduct patterning with nanosecond, picosecond, and femtosecond lasers of various wavelengths.
For both methods, the processing conditions are defined to reduce the impact on other films underneath the panel while completely removing the film with the required processing width.
Machine development (realization of processing conditions).
In actual patterning, the smoothness of the surface depends on the state of panel and film. Processing at a constant height can result in defective products with residual film or scraped lower layer of the panel. Detailed control of z-axis is required to process the film surface at an appropriate height.
In addition, a short patterning interval is premised to improve the performance of the solar cell panel. Secondary patterning must be performed against slightly undulating patterning while maintaining the minimum interval.
As a processing machine manufacturer, MDI incorporates the optimal conditions into machines that are best-suited for panel processing by customers. Because our designs are built on order, specific functions for the production process can be added to our system, as requested by the customers.
Various film qualities.
Several types of thin films are required for the best performance of the finished device. In most cases, they are made of specific materials chosen by the customers. Depending on the device, different conditions such as minimization of thermal damage or prohibition on water usage are defined.
The patterning or grooving of metal, resin or inorganic films prove to be difficult to satisfy the customer requirements or quality level, in some cases. However, their application range can be widened by utilizing the advantages of mechanical or laser processing.