Curved Tube Microdevice Transfer for Continuous 360° Patterning
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Solution Overview
Problem
Conventional methods for patterning electrodes on curved surfaces, such as medical catheters, are inefficient and limited in applying continuous patterns over 360° due to low productivity and restricted rotation capabilities.
Innovation Solution
A method involving coating an adhesive layer on a tube's external surface, providing a micro device pattern on a substrate, and transferring it by rotating the tube while moving the substrate linearly, allowing for continuous pattern application beyond 360° through the use of a supporter system that applies tension and controls the position of the substrate and tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional laser beam or ink printing methods are used to form patterns on curved surfaces, then electrode patterning can be achieved, but productivity is low and transfer efficiency is poor
Solution Approach 1:
The patent uses a pre-formed patterned substrate as a template or master copy. The adhesive layer is transferred from this substrate to the curved surface, copying the electrode pattern efficiently. This eliminates the need for time-consuming laser beam scanning or ink printing processes, significantly improving productivity and reducing pattern formation time.
2Adaptability or versatility
If a discontinuous pattern transfer method is used on cylinder-shaped curves, then some area can be covered, but continuous patterns of 360° or greater cannot be transferred
Solution Approach 1:
The patent employs a dynamic transfer process where the substrate or curved surface can rotate or move continuously during the adhesive transfer process. This dynamic capability allows the method to handle continuous patterns of 360° or greater by maintaining continuous contact between the adhesive layer and the curved surface throughout the rotation, overcoming the limitation of static discontinuous transfer methods.
3Ease of operation
If adhesive layer coating is performed without pre-curing, then transferability is maintained, but control over adherence strength is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-curing the adhesive layer to a specific degree before the transfer process. This partial curing creates an adhesive layer with controlled adherence strength - strong enough to remain on the substrate during handling but weak enough to transfer cleanly to the curved surface. This preliminary action provides reliable control over both transferability and final adherence strength.
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 approach enables efficient transfer of micro device patterns over the entire circumference of a tube, increasing transfer efficiency and allowing for a higher density of patterns without limitations in the circumferential direction.
Implementation Method 1
coating an adhesive layer on an external circumferential surface of a tube
Implementation Method 2
fixing the transferred micro device pattern to the adhesive layer by curing the adhesive layer
Data Source
AI summary
A method for transferring a micro device on a curved surface according to an exemplary embodiment of the present invention includes: coating an adhesive layer on an external circumferential surface of a tube; providing a micro device pattern on one side of a substrate; positioning an external circumferential surface of the tube to contact the substrate and allow a length direction of the device pattern to cross a radius direction of the tube, and rotating the tube with respect to an axis-direction of the tube and simultaneously moving at least one of the tube and the substrate in a rectilinear way to transfer the micro device pattern on the substrate to the adhesive layer; and fixing the transferred micro device pattern to the adhesive layer by curing the adhesive layer.