Dog-Bone Tensile Test Piece via Sacrificial Layer
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Solution Overview
Problem
Existing methods for manufacturing tensile test pieces for flexible materials often result in non-uniform shapes due to laser degradation, making it difficult to accurately evaluate physical properties, and require varying thicknesses based on material size, which is challenging to achieve.
Innovation Solution
A method involving the preparation of a polymer layer with a sacrificial and planarization layer, shaped into a dog-bone form using spin coating and reactive ion etching, with optional copper layer formation, to create a customizable tensile test piece with precise dimensions and uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser-cutting is used to manufacture tensile test pieces, then the manufacturing process is simple, but the gauge part becomes non-uniform due to laser degradation
Solution Approach 1:
A sacrificial layer is introduced as an intermediary between the polymer layer and the gauge part. This sacrificial layer is selectively removed in the gauge region, allowing the polymer layer to be shaped into the desired dog-bone form without direct laser exposure that would cause degradation. The sacrificial layer acts as a protective mediator during the shaping process.
Solution Approach 2:
The sacrificial layer is formed on the polymer layer before the gauge part is shaped. This preliminary formation of the sacrificial layer protects the polymer layer from direct laser exposure during subsequent processing, preventing laser degradation and ensuring uniform gauge part formation.
2Ease of manufacture
If conventional methods are used, then the manufacturing process is simple, but the thickness cannot be customized according to material size
Solution Approach 1:
The thickness of the tensile test piece is controlled by changing the thickness parameter of the polymer layer during the spin coating process. By adjusting the coating conditions and polymer layer thickness, the test piece can be customized to match the size requirements of different flexible materials being tested.
Solution Approach 2:
The manufacturing method is designed to be universally applicable to different material sizes and types. The same process sequence can produce tensile test pieces with varying thicknesses and dimensions, making it adaptable to different testing requirements without requiring separate manufacturing processes.
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 allows for the production of tensile test pieces with consistent shapes and customizable thicknesses, enabling accurate evaluation of flexible material properties like extension, tailored to the specific size of the material being tested.
Implementation Method 1
The forming of the sacrificial layer and the forming of the planarization layer may include a spin coating method
Implementation Method 2
The shaping the polymer layer, the sacrificial layer, and the planarization layer into the sample may include a reactive ion etching (RIE) process utilizing a dog-bone-shaped hard mask
Implementation Method 3
a gauge part of the tensile sample may be non-uniformly formed due to degradation caused by the laser
Data Source
AI summary
A method for manufacturing a tensile test piece according to one or more exemplary embodiments includes: preparing a polymer layer including a non-conductive material; forming a sacrificial layer on the polymer layer; forming a planarization layer on the sacrificial layer; shaping the polymer layer, the sacrificial layer, and the planarization layer into a dog-bone-shaped sample; etching at least a portion of the sample; and drying the sample.