Adhesive Layer Curing for 3D Patterned Workpieces
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Solution Overview
Problem
Current methods for forming three-dimensional patterns on metal surfaces of electronic devices, such as etching or paint-spraying, are complex and contaminative, and fail to produce artistic configurations due to the chemical properties of metals.
Innovation Solution
A production method involving an adhesive layer applied to a workpiece, which is molded to form a three-dimensional pattern, undergoes a first curing process with lower irradiating energy before punching to maintain elasticity and malleability, and a second curing process with higher energy after punching to fix the pattern, ensuring uniform thickness and preventing cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the adhesive layer is fully cured before punching, then the three-dimensional pattern is fixed, but the adhesive layer becomes brittle and cracks during punching
Solution Approach 1:
The adhesive layer undergoes a first curing process before punching to achieve partial curing, which provides preliminary fixation while maintaining sufficient elasticity to prevent cracking during the punching operation
Solution Approach 2:
The patent applies two different curing processes with different irradiating energy intensities: a first curing process with lower energy intensity before punching to maintain flexibility, and a second curing process with higher energy intensity after punching to achieve complete fixation
2Ease of operation
If the adhesive layer is not cured before punching, then the workpiece has good malleability, but the adhesive layer lacks structural integrity and deforms
Solution Approach 1:
A first curing process is performed before punching to provide preliminary structural support to the adhesive layer, preventing excessive deformation while maintaining enough flexibility for the punching operation
Solution Approach 2:
The curing process is divided into two periodic stages: initial curing before punching to provide structural support, and final curing after punching to complete the fixation, with each stage serving a specific functional requirement
3Ease of manufacture
If traditional etching or paint-spraying methods are used to form patterns, then patterns can be created on metal surfaces, but the production process becomes complex and contaminative
Solution Approach 1:
The patent replaces traditional mechanical etching or chemical paint-spraying processes with a molding process that uses a mold to directly form the three-dimensional pattern on the adhesive layer, simplifying the production process and eliminating contamination
Solution Approach 2:
The adhesive layer serves as an intermediary material that is applied to the workpiece, molded to form the desired pattern, and then cured, providing a cleaner and simpler alternative to direct metal etching or painting
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 effectively reduces technical difficulties in forming three-dimensional patterns, increases production efficiency, and ensures uniform thickness and integrity of the patterned workpiece.
Implementation Method 1
the adhesive layer is cured by a first photo-curing process before the workpiece is punched, such that the adhesive layer is not entirely cured and has elasticity
Implementation Method 2
the adhesive layer is cured by a second photo-curing process with higher irradiating energy intensity after the workpiece is punched, such that the adhesive layer is entirely cured
Data Source
AI summary
A production method of workpiece is provided. First, an adhesive layer is applied on a workpiece. The adhesive layer is impressed by a mold, so that the adhesive layer forms a three-dimensional pattern. A first curing process with a first irradiating energy is performed on the adhesive layer. The workpiece is punched after the first curing process is performed on the adhesive layer, so that the workpiece forms a three-dimensional workpiece. A second curing process with a second irradiating energy is performed on the adhesive layer after the workpiece is punched, wherein the second irradiating energy intensity is higher than the first irradiating energy intensity.