Composite Structure Selective Coating via Embossed Lacquer
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Solution Overview
Problem
Existing technologies fail to produce precisely fitting coatings for miniaturized optical and electronic components, particularly for smooth surface areas, which is essential for their functionality.
Innovation Solution
A composite structure comprising a carrier layer, a cured embossing lacquer layer with specific recesses, and a functional layer, where the embossing lacquer layer is embossed to create microchannels that are selectively coated with a functional layer, ensuring precise alignment and application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coating methods are used on miniaturized elements, then coating application is possible, but precise fitting and exact alignment of the coating with smooth surface areas cannot be achieved
Solution Approach 1:
The embossing lacquer layer is pre-structured with recesses and smooth surface areas before coating application. This preliminary structuring creates a template that guides the coating material to deposit only on the intended smooth areas, ensuring precise fitting and exact alignment without requiring complex alignment procedures during the coating process itself
Solution Approach 2:
The embossing lacquer layer acts as an intermediary between the carrier layer and the functional coating. It provides a structured intermediate surface with defined smooth areas that control coating deposition, eliminating the need for direct complex alignment between the carrier and coating layers
2Manufacturing precision
If the embossing lacquer layer has deep recesses to ensure selective coating, then coating precision is improved, but the roughness of the surface increases
Solution Approach 1:
The embossing lacquer layer exhibits local quality differentiation: recess areas with greater depth for selective coating retention, and plateau areas with controlled roughness for smooth surface appearance. This local variation in depth and surface quality enables both precise selective coating and acceptable overall surface finish
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 enables self-aligned, locally limited coating and wetting, allowing for the production of optical elements, light filters, electronic components, and sensors with precise metallic or semiconductor coatings, enhancing their performance and accuracy.
Implementation Method 1
applying a release lacquer layer (5) that exclusively wets and fills the recess of the embossed recess of the hardened embossing lacquer layer (2)
Implementation Method 2
curing the embossed lacquer layer to form a hardened embossed lacquer layer (2)
Data Source
Figure 1
Figure 2~2e
Figure 3~3b
AI summary
The present invention provides a composite structure comprising a carrier layer (1), a hardened embossing lacquer layer (2) and a functional layer (3) in that order, wherein the hardened embossing lacquer layer (2) has an area comprising an embossed and functional-layer-free miniaturized depression (4) and which is completely covered outside the depression with the functional layer (3), as well as a method for producing the composite structure and uses of the composite structure.