Piece-Processed Adhesive Film Layout for Stronger Component Bonding
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Solution Overview
Problem
Existing adhesive film technologies face challenges in achieving stable and strong connections between substrates and components due to limitations in full lamination and increased manufacturing steps, leading to weak adhesive strength and reduced productivity.
Innovation Solution
An individualized piece-processed adhesive film with openings surrounding components is arranged in the longitudinal direction of a base material film, allowing for full lamination on the substrate surface while avoiding components, thereby enhancing adhesive strength and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive film is laminated multiple times to achieve full coverage around components, then adhesive strength is improved, but manufacturing complexity and time increase significantly
Solution Approach 1:
The adhesive film is divided into multiple individualized pieces, each designed to cover specific areas around components. This segmentation allows single-step lamination to achieve what previously required multiple lamination steps, reducing manufacturing complexity while maintaining full coverage and adhesive strength.
Solution Approach 2:
The individualized adhesive pieces are pre-cut and pre-positioned on the base material film before lamination. This preliminary preparation ensures that when the film is laminated once, the adhesive pieces are already in their final positions around components, eliminating the need for multiple subsequent lamination steps.
2Strength
If adhesive film is laminated multiple times to achieve full coverage, then adhesive strength is improved, but lamination error accumulates making precision difficult
Solution Approach 1:
By segmenting the adhesive film into individualized pieces with pre-defined positions and shapes, the system eliminates cumulative lamination errors. Each piece is precisely positioned in advance, so a single lamination step places all pieces accurately without accumulating errors from multiple steps.
Solution Approach 2:
The individualized adhesive pieces are pre-positioned and fixed on the base material film before lamination. This preliminary positioning ensures that when lamination occurs, all pieces are already aligned correctly, preventing the accumulation of lamination errors that would occur with multiple sequential lamination steps.
3Adaptability or versatility
If adhesive film avoids components in layout, then component connectivity is maintained, but adhesive strength becomes unstable
Solution Approach 1:
The adhesive film is segmented into individualized pieces that strategically surround components rather than avoiding them entirely. This segmentation allows the adhesive to make contact with the substrate at multiple points around each component, providing stable adhesive strength while maintaining component connectivity through the terminal areas.
Solution Approach 2:
The individualized adhesive pieces are designed with varying local properties: they provide adhesive coverage in areas needing bonding while leaving openings in areas requiring component access. This local quality variation allows the film to simultaneously achieve stable adhesive strength around components and maintain component connectivity to terminals.
Data Source
AI summary
An individualized piece-processed adhesive film, a method for manufacturing a connection structure, and a connection structure capable of improving adhesive strength with respect to a substrate on which a component is mounted. An individualized piece-processed adhesive film includes individualized pieces having, with respect to a substrate on which a component is mounted, an opening to surround the component, the individualized pieces being arranged in the longitudinal direction of a base material film. A method for manufacturing a connection structure is to connect terminals of the first electronic component to terminals of the second electronic component by using an individualized piece with an opening to surround a component with respect to the substrate on which the component is mounted. This improves the adhesive strength.