Additive Adhesive Patterning With Variable Thickness Gradients
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Solution Overview
Problem
Current methods for manufacturing adhesives, such as die-cutting, are inadequate for producing complex shapes like wedges or those with height gradients, limiting precision and versatility in adhesive delivery as devices miniaturize.
Innovation Solution
A continuous additive manufacturing method using actinic radiation-polymerizable adhesive precursor compositions on transparent substrates, where specific irradiation dosages and substrate movements create adhesives with variable thickness and unique shapes, enabling the formation of intricate adhesive patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If die-cutting methods are used to manufacture adhesives, then the manufacturing process is simple, but the ability to produce complex shapes and height gradients is limited
Solution Approach 1:
The adhesive manufacturing process is segmented into discrete additive manufacturing steps, where the adhesive is built layer by layer or in sequential portions. This allows complex shapes and height gradients to be created by controlling the deposition and curing of each segment independently, rather than attempting to create the entire shape in a single die-cutting operation.
Solution Approach 2:
The invention transitions from two-dimensional die-cutting to three-dimensional additive manufacturing. By building adhesives in multiple layers with varying thicknesses, the process can create complex height gradients and volumetric shapes that are impossible to achieve with traditional flat die-cutting methods.
2Manufacturing precision
If traditional adhesive manufacturing methods are used, then the process is well-established, but precision and versatility in adhesive delivery are insufficient for miniaturized devices
Solution Approach 1:
The additive manufacturing process is dynamic and programmable, allowing precise control over adhesive deposition patterns, thickness, and geometry. By adjusting manufacturing parameters such as layer thickness, deposition speed, and curing conditions, the system can adapt to produce various adhesive shapes and sizes suitable for different miniaturized device requirements.
Solution Approach 2:
The invention utilizes parameter changes in the additive manufacturing process, such as varying the irradiation dosage, deposition rate, and layer thickness, to precisely control the final adhesive geometry. These parameter adjustments enable high manufacturing precision while maintaining versatility to produce different adhesive configurations for various applications.
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 allows for the precise and versatile manufacturing of adhesives with complex shapes and gradients, enhancing precision and adaptability in adhesive delivery for miniaturized devices.
Implementation Method 1
irradiating a first portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a first irradiation dosage to form a first adhesive
Data Source
AI summary
A continuous method of manufacturing adhesives is provided. The method includes obtaining an actinic radiation-polymerizable adhesive precursor composition disposed on a major surface of an actinic radiation-transparent substrate and irradiating a first portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a first irradiation dosage. The method further includes moving the actinic radiation-transparent substrate and irradiating a second portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a second irradiation dosage. Optionally, the method also includes irradiating a third portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate prior to moving the substrate. The first irradiation dosage and the third irradiation dosage are often not the same, thereby forming an integral adhesive having a variable thickness in an axis normal to the actinic radiation-transparent substrate.