Bonding Sheet Connection with Direct Adhesive-Layer Joining
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Solution Overview
Problem
Existing sheet bonding devices require time-consuming manual replacement of sheet rolls, leading to increased costs and variability in replacement time due to skill dependence, and face challenges with reliable connection and increased costs for adhesive tapes as wafer diameters increase, resulting in potential disconnection and waste.
Innovation Solution
A sheet connection device using adhesive rollers, a joining unit, and feed rollers to separate and connect bonding sheets with thermal welding or adhesion, eliminating the need for additional bonding members and reducing connection margins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tapes are used to connect bonding sheets, then sheet connection is achieved, but costs increase due to supply mechanism and consumable sticking members
Solution Approach 1:
The invention extracts and removes the adhesive tape component from the sheet connection system. Instead of using adhesive tapes with sticking members, the patent directly connects the bonding sheets through their own adhesive layers by separating the release sheets, thereby eliminating the need for separate adhesive tapes and their supply mechanisms.
Solution Approach 2:
The bonding sheets are designed to serve dual functions: both as the functional bonding material and as the connection medium. The adhesive layer on the bonding sheet itself is used for both bonding to the substrate and for connecting to the next bonding sheet, eliminating the need for separate adhesive tapes.
2Reliability
If sticking member width is increased to prevent disconnection, then connection reliability improves, but costs for the sticking member increase pronounced
Solution Approach 1:
The invention removes the sticking member (adhesive tape) from the system entirely. The bonding sheets connect directly to each other through their own adhesive layers, eliminating the need for separate sticking members that would require increased width to handle tensile forces.
Solution Approach 2:
The bonding sheets serve themselves by using their own adhesive layers for connection. The adhesive layer on each bonding sheet both bonds to the substrate and connects to the next bonding sheet, eliminating the need for external adhesive tapes and their associated costs.
3Ease of operation
If manual replacement of sheet rolls is performed, then sheet replacement is achieved, but replacement time increases and varies by worker skill
Solution Approach 1:
The invention prepares the bonding sheets in advance by pre-arranging multiple bonding sheets with their release sheets separated and adhesive layers exposed. This preliminary preparation allows for quick connection without requiring manual intervention during the replacement process, thereby reducing replacement time and eliminating variability based on worker skill.
4Area of stationary object
If bonding sheet width is increased to cover larger wafer diameters, then coverage is improved, but tensile force required to pull out sheet increases
Solution Approach 1:
The invention segments the bonding sheet system into multiple individual bonding sheets that are connected in sequence. Each bonding sheet maintains the necessary width for wafer coverage, but the connection between sheets is optimized through direct adhesive layer bonding without additional adhesive tapes, reducing the overall tensile force requirement.
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
Enables reliable, precise, and cost-effective connection of bonding sheets, reducing replacement time and costs, and preventing disconnection during sheet supply.
Implementation Method 1
a pair of adhesive rollers, which are provided on the upstream side in the supply direction so as to be movable closer to and away from each other with respect to the bonding sheet arranged therebetween, and are capable of holding the bonding sheet therebetween when being moved closer to each other
Implementation Method 2
The joining unit is configured to connect the connecting end portion and the connected end portion to each other by adhesion or welding
Implementation Method 3
connect the connecting end portion and the connected end portion to each other by adhesion or welding
Data Source
AI summary
The sheet connection device (1) includes: adhesive rollers (10, 10); a joining unit (20) and a cutting unit (30); and feed rollers (40, 40). The cutting unit (30) is capable of forming a connected end portion (SE2) by cutting the second bonding sheet (S2). The adhesive rollers (10, 10) separate the first bonding sheet (S1) into an adhesive sheet (SA) and a release sheet (SP) to form a separated portion (50) by feeding the first bonding sheet (S1) while holding a connecting end portion (SE1) of the first bonding sheet (S1). The feed rollers (40, 40) inserts the connected end portion (SE2) into the separated portion (50) by feeding the second bonding sheet (S2) toward the connecting end portion (SE1). The joining unit (20) connects the connecting end portion (SE1) and the connected end portion (SE2) to each other by adhesion or welding.