Air Molding Micro-Cavity Array Surface with Inclined Smooth Bottom
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Solution Overview
Problem
Existing methods for preparing micro-cavity array surface products with inclined smooth bottom surfaces face challenges in controlling the opening shape and ensuring surface quality, particularly at the microscale, due to limitations in machining and chemical etching techniques.
Innovation Solution
An air molding method utilizing a pre-spreading auxiliary microstructure polymer template, followed by plasma treatment, uniform polymer film application, and vacuum drying to create a micro-cavity array surface product with an inclined smooth bottom surface, allowing for controlled preparation and improved surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining or chemical etching is used to prepare micro-cavity array surface, then the micro-cavity can be formed, but the surface quality of the bottom cannot be guaranteed and the opening shape cannot be controlled
Solution Approach 1:
The patent uses an auxiliary template with a predetermined smooth bottom surface structure that is copied onto the micro-cavity array surface through air molding. The template's bottom surface structure serves as a master model, and the polymer material replicates this structure to form the micro-cavity bottoms, thereby achieving high surface quality without complex machining or etching processes
Solution Approach 2:
The patent introduces an auxiliary template as an intermediary element between the desired micro-cavity structure and the final product. This template acts as a mediator that transfers the precise bottom surface geometry to the polymer material through air pressure molding, enabling controlled opening shapes and high surface quality without direct machining of the final product
2Shape
If diamond grinding tools are used to form inclined bottom surface, then the inclined shape can be achieved, but the opening shape control and ground surface quality cannot be guaranteed
Solution Approach 1:
The patent copies the precise inclined bottom surface geometry from the auxiliary template directly onto the polymer material through air molding. The template's inclined surface structure is replicated with high fidelity, achieving the desired shape without the surface quality degradation associated with diamond grinding
Solution Approach 2:
The patent replaces the mechanical diamond grinding system with an air molding system. Instead of using mechanical abrasion to form the inclined surface, the invention uses controlled air pressure to mold the polymer material against the template, eliminating the surface quality issues inherent in mechanical grinding while maintaining shape accuracy
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 effectively enhances the surface quality by replicating the shape features of the auxiliary template and filling unsmooth structures, resulting in a micro-cavity array surface product with a controllable and high-quality inclined smooth bottom surface.
Implementation Method 1
heating and solidifying the liquid polymer film
Implementation Method 2
setting a pressure in the vacuum drying oven according to a designed pressure
Implementation Method 3
performing a plasma treatment on the auxiliary microstructure polymer template
Data Source
AI summary
The present invention provides a method for preparing a micro-cavity array surface with an inclined smooth bottom surface based on an air molding method. The method includes: preparing a micro-cavity array surface; preparing an auxiliary microstructure polymer template, and performing plasma treatment on the auxiliary microstructure polymer template; uniformly spreading a layer of a liquid polymer film to be formed on the auxiliary microstructure polymer template subjected to the plasma treatment; placing a gap bead in an empty position on the micro-cavity array surface; placing the auxiliary microstructure polymer template spread with the liquid polymer film on the gap bead on the micro-cavity array surface, maintaining this state, and feeding the auxiliary microstructure polymer template into a vacuum drying oven; and heating and solidifying the liquid polymer film, and separating the micro-cavity array surface to obtain the micro-cavity array surface with the inclined smooth bottom surface.