Curable Silicone Sheet Manufacturing Flatness and Uniformity
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Solution Overview
Problem
Current methods for manufacturing curable silicone sheets with hot melt properties often result in sheets with defects and poor flatness and uniformity, particularly when attempting to mold thermosetting silicone compositions, which can lead to breaking or curing issues due to premature curing reactions at high temperatures.
Innovation Solution
A method involving the mixing of organopolysiloxane resin fine particles, a curing agent, and a functional filler, followed by heating and melting at 120°C or lower, then laminating between films with a release surface, and stretching to achieve a specific film thickness, ensuring the melt viscosity is within a controlled range to prevent defects and enhance flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional molding methods are used to manufacture curable silicone sheets from granular compositions, then the sheets can be produced, but they exhibit poor flatness and uniformity with defects and breaking
Solution Approach 1:
The patent changes the physical state parameter of the silicone composition from granular to sheet form by controlling the melting and solidification process. The composition is heated to melt the granules, then cooled and solidified between release films to form uniform sheets with controlled thickness, eliminating the defects associated with conventional granular molding.
Solution Approach 2:
The patent creates a composite structure by laminating the melted silicone composition between release films. This composite approach allows the silicone to be formed into uniform sheets while the release films prevent sticking and facilitate easy removal, improving both flatness and uniformity.
2Reliability
If high temperature is applied during molding of thermosetting silicone compositions, then the curing reaction progresses, but it causes premature curing and prevents obtaining sheet material with hot melt properties
Solution Approach 1:
The patent performs preliminary heating to melt the silicone granules before curing occurs. By controlling the heating temperature and time, the granules are melted and formed into sheets while preventing premature curing reactions. The curing is then completed after the sheet form is established, preserving hot melt properties.
Solution Approach 2:
The patent carefully controls the temperature parameter during processing. The heating temperature is kept below the curing temperature to melt the granules without triggering premature curing. This parameter control allows the material to exhibit hot melt properties while still achieving proper curing after sheet formation.
3Productivity
If a simple manufacturing method is used for curable silicone sheets, then the process is efficient, but the flatness and uniformity are poor
Solution Approach 1:
The patent utilizes phase transition from solid granules to liquid melt and back to solid sheet. By heating the granular composition to melt it, then pouring or spreading it between release films to form a uniform layer, and finally cooling it to solidify, the method achieves excellent flatness and uniformity through a simple process without requiring complex molding equipment.
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 efficiently produces curable silicone sheets with excellent flatness, uniformity, and handling properties, along with improved gap-filling and stress relaxation characteristics, while maintaining hot melt properties, suitable for applications in semiconductor and optical semiconductor devices.
Implementation Method 1
heating and melting at 120°C or lower
Implementation Method 2
stretching the laminate body obtained in step 3 between rollers to mold a curable silicone sheet having a specific film thickness
Data Source
AI summary
Provided herein is: a method of efficiently manufacturing a curable silicone sheet with excellent flatness and uniformity, containing a curable particulate silicone composition with excellent handling/workability and curing properties; and a method of manufacturing a laminate body containing the curable silicone sheet. A method of manufacturing a curable silicone sheet having hot melt properties, comprises the following steps: 1) a step of mixing organopolysiloxane resin fine particles, a curing agent, and a functional filler; 2) a step of kneading while heating and melting the mixture obtained in step 1); 3) a step of laminating the heated and melted mixture obtained in step 2) between films provided with at least one release surface; and 4) a step of stretching the laminate body obtained in step 3) between rollers to mold a curable silicone sheet having a specific film thickness.