Bonded Nanofiber Porous Films for Damage-Free Carrier Separation
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Solution Overview
Problem
The separation of thin nanofibers from a carrier member during lamination is challenging, leading to damage, increased processing time, and higher manufacturing costs due to the need for inspection and repair of damaged areas.
Innovation Solution
Bonding nanofiber layers together before separating them from the carrier member to enhance mechanical strength and reduce damage, thereby simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nanofibers are separated from the carrier member before lamination, then the nanofibers can be processed individually, but the thin nanofibers become damaged due to sticking to the carrier member
Solution Approach 1:
The patent applies preliminary action by bonding the nanofiber layers to each other while still attached to the carrier member before separation. This creates a mechanically strengthened structure that can be separated without damage. The bonding process is performed in advance, creating a unified multi-layer structure that resists the adhesive forces between individual nanofibers and the carrier surface.
2Manufacturing precision
If nanofibers are separated and inspected for damage, then product quality can be maintained, but manufacturing time and costs increase significantly
Solution Approach 1:
The patent performs the protective bonding action in advance, before separation and inspection steps. By creating the bonded multi-layer structure while on the carrier, the nanofibers are mechanically strengthened against damage during subsequent handling and separation. This preliminary bonding reduces the incidence of damage, thereby reducing or eliminating the need for extensive inspection and repair operations.
Solution Approach 2:
The patent converts the potential harm of nanofibers sticking to the carrier (which causes damage) into a benefit by performing the bonding process while the nanofibers are still attached. The adhesive interaction that would normally cause damage during separation is instead utilized to securely hold the nanofibers in place during the bonding process, ensuring proper alignment and contact between layers.
3Manufacturing precision
If multiple post-processing operations are performed to repair damaged nanofibers, then product defects are reduced, but manufacturing complexity and costs increase
Solution Approach 1:
The patent performs the critical bonding action before separation and post-processing steps. By creating the bonded structure while the nanofibers are still supported by the carrier member, the nanofibers are protected from damage during separation. This preliminary protective measure reduces the need for subsequent repair operations and simplifies the overall manufacturing process.
Data Source
AI summary
Embodiments described herein relate to methods of producing coupled porous films. In some aspects, a method can include disposing a first porous material onto a first carrier member, and coupling the first porous material to a second porous material to obtain a coupled porous material. The method further includes removing the first carrier member from the coupled porous material to obtain a coupled porous film. The method may also include disposing the second porous material onto a second carrier member prior to coupling the first porous material to the second porous material, and removing the second carrier member from the coupled porous material.