Adhesion-Controlled Film for Selective Continuous Transfer
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Solution Overview
Problem
Existing selective transferring technologies are inefficient and difficult to apply to flexible substrate devices, as they require a plane substrate with protrusions, which is not compatible with the continuous transferring process using a roll stamp, limiting their application in manufacturing flexible substrate devices.
Innovation Solution
A selective continuous transferring apparatus using an adhesion-controlled film, where a roll with an elastic surface contacts a source substrate and a receiving substrate with a predetermined patterned sticking layer to selectively transfer elements directly from the source to the receiving substrate, reducing the number of transfer processes and enabling efficient and easy selective transferring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a plane substrate with protrusions is used for selective transferring, then selective transferring can be achieved, but it is incompatible with continuous transferring process using roll stamp
Solution Approach 1:
The patent uses a flexible receiving substrate with a thin film structure that can be continuously fed through a roll stamp process. The substrate includes a sticking layer formed as a thin film pattern that enables selective element attachment while maintaining flexibility and continuous processability, resolving the contradiction between selective transferring precision and compatibility with continuous transferring.
Solution Approach 2:
The patent changes the physical parameters of the receiving substrate by controlling the thickness and material properties of the sticking layer. By adjusting these parameters, the substrate achieves both the necessary adhesion for selective element transfer and the flexibility required for continuous roll stamp processing, thereby resolving the technical contradiction.
2Productivity
If a roll stamp is used for continuous transferring, then continuous processing efficiency is improved, but the roll stamp cannot be easily changed to transfer different patterns
Solution Approach 1:
The patent makes the pattern configurable by forming the sticking layer dynamically through adhesive coating and UV irradiation processes. This allows the transfer pattern to be changed without replacing the roll stamp itself, maintaining continuous processing efficiency while enabling flexible pattern reconfiguration through process parameter changes rather than physical tooling changes.
3Quantity of substance
If elements are entirely transferred on the wafer, then element density is maximized, but space between elements cannot be formed
Solution Approach 1:
The patent applies local quality by forming the sticking layer only in specific predetermined patterns rather than uniformly across the entire substrate. This allows elements to be transferred only to designated locations, creating both high element density in transfer areas and necessary spacing in non-transfer areas, thereby resolving the contradiction between element density and inter-element space.
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 allows for efficient and easy selective transferring of elements in a predetermined position during the continuous transferring process for flexible substrate devices, enhancing productivity and versatility in manufacturing, particularly for devices requiring space between elements, such as those in printed electronics.
Implementation Method 1
The roll 100 has an elastic surface, and contacts a source substrate 510 with a receiving substrate 520 to transfer elements 550
Implementation Method 2
A selective continuous transferring apparatus using an adhesion-controlled film... the elements 550 are attached to the sticking layer 530
Data Source
AI summary
A selective continuous transferring apparatus includes a roll and a sticking layer. The roll has an elastic surface, and contacts a source substrate with a receiving substrate to transfer elements on the source substrate to a lower surface of the receiving substrate 520. A plurality of the elements is arranged on an upper surface of the source substrate. The sticking layer has a predetermined pattern in a partial area of the lower surface of the receiving substrate. The elements are attached to the sticking layer. The roll pressurizes a series of stacked layer of the source substrate, the elements and the receiving substrate, so that the elements disposed corresponding to the sticking layer of the receiving substrate are partially and selectively transferred on the receiving substrate.