Adhesive Film Segmentation for Flexible Sensor Attachment

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Solution Overview

Problem

Existing methods for attaching adhesive film pieces to sensors, components, and boards are inefficient, as they are typically arranged at equal intervals, making it difficult to attach them to various positions, and can increase costs due to the need for multiple molds or lead to issues with liquid adhesives like rounded edges and decreased dimensional accuracy.

Innovation Solution

A film manufacturing method that allows for the removal of specific adhesive film pieces from a release film, enabling flexible arrangement and attachment to various positions, while reducing costs by avoiding the need for multiple molds and addressing issues with liquid adhesives.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive film pieces are arranged at equal intervals to be close to each other, then cost is decreased by effectively using the film, but it becomes difficult to attach the adhesive film pieces to various positions

Engineering Contradiction:

ImprovecostVSAvoidattachment position flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The adhesive film is divided into multiple individual adhesive film pieces that can be selectively removed. This segmentation allows the adhesive pieces to be distributed at equal intervals for cost-effective manufacturing, while enabling selective removal to achieve various attachment positions on different devices.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of arranging adhesive films at various positions from the start, the invention arranges them at equal intervals and then selectively removes unnecessary pieces. This inverted approach achieves position flexibility through removal rather than through initial varied arrangement, maintaining manufacturing efficiency while enabling versatility.

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If multiple molds are prepared to change the arrangement of adhesive film pieces, then various positions can be attached, but cost increases

Engineering Contradiction:

Improvearrangement flexibilityVSAvoidcost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

All possible adhesive film pieces are prepared in advance on a single mold at equal intervals. The preliminary arrangement includes all potential positions, and the desired configuration is achieved by selectively removing unnecessary pieces during the manufacturing process, eliminating the need for multiple specialized molds.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A single universal mold is used to create all adhesive film pieces at equal intervals, making the mold multi-functional for producing various arrangements. This universal mold replaces the need for multiple specialized molds, each designed for a specific arrangement pattern, thereby reducing cost while maintaining arrangement flexibility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If a dispenser that drops liquid adhesive is used to provide adhesives at any desired positions, then various positions can be attached, but high aspect ratio structures are difficult to make, edges become rounded due to surface tension, and dimensional accuracy decreases due to bleeding

Engineering Contradiction:

Improveposition flexibilityVSAvoiddimensional accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The invention uses pre-formed adhesive film pieces that are discarded after a single use (peeled off from the release film and applied to the substrate). These disposable adhesive pieces eliminate the need for precision liquid dispensing equipment, maintaining dimensional accuracy while enabling flexible positioning. The adhesive film pieces are removed after transferring the adhesive to the substrate, making them single-use components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

The method enables precise attachment of adhesive film pieces to diverse positions, maintains dimensional accuracy, and reduces costs by allowing for flexible arrangement without additional molds, while ensuring efficient removal of defective pieces.

Implementation Method 1

an original film having a plurality of adhesive film pieces provided on a long release film

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS20250206563A1Film manufacturing method, film, wound body, connection structure, method for manufacturing connection structure, and removing device

Publication Date: 2025.06.26 RESONAC CORP

AI summary

A film manufacturing method includes a removing step of removing at least one removal target adhesive film piece from an original film having a plurality of adhesive film pieces provided on a long release film. A film includes a long release film, a plurality of adhesive film pieces, and a non-adhesive region, the plurality of adhesive film pieces include a first adhesive film piece and a second adhesive film piece which are adjacent to each other through the non-adhesive region and a adhesive film piece and a fourth adhesive film piece which are adjacent to each other through a non-adhesive region, and a separation distance between the first adhesive film piece and the second adhesive film piece is different from a separation distance between the third adhesive film piece and the fourth adhesive film piece.