Air-Floating Roller Bonding for Wrinkle-Free 3D Thin Films
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Solution Overview
Problem
Existing thin film bonding technologies face challenges in achieving flatness due to three-dimensional obstacles and insufficient stiffness of thin films, leading to wrinkles and defects.
Innovation Solution
An air-floating thin film bonding apparatus and roller system that uses a rotatable outer roller with blowing holes and a fixed inner cylinder with through holes to supply positive airflow, filling gap spaces caused by three-dimensional obstacles and increasing the stiffness of the base film for tight bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermocompression bonding is used to bond thin films, then bonding efficiency is improved, but wrinkles and defects occur due to gap spaces caused by three-dimensional obstacles
Solution Approach 1:
The patent introduces an air-floating roller that supplies positive pressure airflow to the second surface of the base film during bonding. This pneumatic approach fills the gap spaces caused by three-dimensional obstacles on the bonding film, enabling the thin base film to maintain flatness and bond tightly without wrinkles or defects, thereby resolving the contradiction between bonding efficiency and manufacturing precision.
2Weight of moving object
If the film thickness is reduced to achieve lightness and thinness, then product weight is reduced, but the film stiffness becomes insufficient leading to unflatness
Solution Approach 1:
The air-floating roller provides continuous positive pressure airflow to the second surface of the thin base film during the bonding process. This pneumatic support compensates for the insufficient stiffness of thin films, preventing unflatness and enabling tight bonding even with ultra-thin films that would otherwise be too flexible to maintain flatness.
3Adaptability or versatility
If three-dimensional obstacles are present on the bonding film, then functional components are integrated, but gap spaces are formed causing bonding defects
Solution Approach 1:
The positive pressure airflow from the air-floating roller actively fills the gap spaces created by three-dimensional obstacles (such as electronic components, connectors, or other functional elements) on the bonding film. This allows the bonding process to accommodate integrated functional components while maintaining uniform contact and flatness across the entire bonded area, preventing wrinkles and bonding defects.
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 system effectively fills gap spaces and prevents wrinkles and defects, ensuring flat and tight bonding of thin films even with three-dimensional obstacles, enhancing the flatness and quality of the film-bonding process.
Implementation Method 1
The air-floating roller can continuously supply an airflow with a positive pressure during bonding to the second surface of the base film to fill the gap space caused by the three-dimensional obstacles
Implementation Method 2
fill the gap space caused by the three-dimensional obstacles
Implementation Method 3
the air-floating roller is disposed adjacent and corresponding to the bonding roller to press the bonding film to bond to the first surface of the base film
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
An air-floating thin film bonding apparatus and its air-floating roller is provided. The apparatus is composed of an air-floating rollers, which can blow out airflow at a specific angle to be applied to the base film with three-dimensional obstacles. The positive pressure provided by the airflow can be utilized to fill the gap space caused by the three-dimensional obstacles. Therefore, the base film can bond to the bonding film tightly to overcome the wrinkles and defects caused by the three-dimensional obstacle and the problem of unflatness of the film-bonding can be solved.