Conductive Pattern Transfer Web for Curved Substrate Alignment
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Solution Overview
Problem
Existing methods for applying electrically conductive patterns to substrates, such as solar cells and RFID antennas, are limited in efficiency and flexibility, particularly when dealing with three-dimensional or curved surfaces, as they often require direct deposition or etching processes that are not suitable for all substrate types.
Innovation Solution
An apparatus that transfers a pattern of electrically conductive material and adhesive from a flexible web to a substrate using a nip mechanism with pressure rollers, heating, and cooling stations, allowing for precise alignment and adhesion of the conductive pattern, even on non-planar surfaces, and enabling simultaneous transfer of patterns to multiple substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If direct deposition or etching processes are used to apply conductive patterns, then manufacturing precision can be achieved, but the method is not suitable for three-dimensional or curved surfaces and reduces adaptability
Solution Approach 1:
The patent uses a flexible web as a master pattern that can be repeatedly transferred to multiple substrates. The web contains the conductive pattern design and serves as a template that is copied onto each substrate through the transfer process, enabling consistent precision across different substrate types including three-dimensional and curved surfaces.
Solution Approach 2:
The flexible web acts as an intermediary carrier between the pattern design and the substrate. Instead of directly depositing or etching the substrate, the pattern is first created on the flexible web and then transferred to the substrate, allowing the same web to be used across various substrate geometries while maintaining pattern accuracy.
2Productivity
If the entire surface is coated with conductive material and then selectively removed, then conductive patterns can be formed, but material loss increases and manufacturing efficiency decreases
Solution Approach 1:
The conductive pattern is pre-formed on the flexible web before transfer to the substrate. The web is prepared with the exact pattern geometry needed, and only the necessary amount of conductive material is used in the final pattern location, eliminating the need to coat and then remove excess material from the entire substrate surface.
Solution Approach 2:
The pattern is copied from the flexible web to the substrate rather than being directly formed on the substrate through coating and etching. This copying approach ensures that conductive material is only applied where the pattern is needed, significantly reducing material waste and improving manufacturing efficiency.
3Adaptability or versatility
If pattern production is integrated with substrate processing, then process simplicity is maintained, but flexibility in pattern design and substrate type is reduced
Solution Approach 1:
The manufacturing process is segmented into separate functions: the flexible web is prepared with patterns in advance, and then the transfer apparatus handles multiple substrates. This segmentation allows independent optimization of pattern creation and substrate processing, increasing flexibility without requiring excessive integration complexity in a single device.
Solution Approach 2:
The flexible web serves as a universal template that can be transferred to multiple different substrate types and geometries. The same web pattern can be copied onto various substrates including flat, curved, and three-dimensional surfaces, providing pattern production flexibility without requiring separate specialized equipment for each substrate type.
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 allows for efficient and flexible application of conductive patterns on various substrates, including three-dimensional items, by decoupling pattern production from transfer, ensuring accurate alignment and adhesion, and enabling the use of different sintering methods to render the patterns electrically conductive.
Implementation Method 1
a heating station for heating at least one of the web and the substrate prior to, or during, passage through the nip, to a temperature at which the adhesive in the composition is activated
Implementation Method 2
a cooling station for cooling the web after passage through the nip
Implementation Method 3
a pressure roller acts to press the surfaces of the web and the substrate against one another
Data Source
AI summary
An apparatus is disclosed for transferring a pattern of a composition containing particles of an electrically conductive material and a thermally activated adhesive from a surface of a flexible web to a surface of a substrate. The apparatus comprises:respective drive mechanisms for advancing the web and the substrate to a nip through which the web and the substrate pass at the same time and where a pressure roller acts to press the surfaces of the web and the substrate against one another,a heating station for heating at least one of the web and the substrate prior to, or during, passage through the nip, to a temperature at which the adhesive in the composition is activated,a cooling station for cooling the web after passage through the nip, anda separating device for peeling the web away from the substrate after passage through the cooling station, to leave the pattern of composition adhered to the surface of the substrate.