Flexible Substrate Manufacturing via Sacrificial Layer Transfer
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Solution Overview
Problem
Current methods for producing flexible functional supports with micrometric or sub-micrometric functional elements are hindered by the physico-chemical properties of flexible supports, such as low Young's modulus and insulating nature, making certain manufacturing steps difficult or impossible, and existing processes are complex, costly, and time-consuming.
Innovation Solution
A method involving the deposition of a sacrificial molybdenum oxide layer on a rigid master support, production of the functional element on this layer, and transfer to a flexible support, which can be made of materials like polysiloxanes, allowing for simpler, faster, and less expensive production by circumventing the challenges of working directly on flexible supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If functional elements are manufactured directly on flexible supports using standard techniques, then the supports can be used flexibly, but the low Young's modulus and insulating nature of flexible supports make certain manufacturing steps difficult or impossible
Solution Approach 1:
The patent introduces a rigid master support as an intermediary substrate for manufacturing functional elements. This rigid support provides the necessary mechanical properties (high Young's modulus, conductivity) for standard manufacturing techniques, while the flexible support serves as a separate intermediary that receives the transferred elements. This mediator approach resolves the contradiction by decoupling the manufacturing requirements from the final flexible application.
Solution Approach 2:
The manufacturing process is segmented into two distinct phases: (1) manufacturing functional elements on a rigid master support where standard techniques work effectively, and (2) transferring these elements to a flexible support for final application. This segmentation allows each phase to occur on the most suitable substrate, resolving the contradiction between manufacturability and flexibility.
2Adaptability or versatility
If additional or modified technological steps are used to manufacture functional elements on flexible supports, then flexible functional supports can be produced, but the process becomes more complex and time-consuming
Solution Approach 1:
The patent creates a copy of the functional elements on a flexible support rather than manufacturing them directly on the flexible support. The functional elements are first fabricated on a rigid master support using standard techniques, then transferred to the flexible support. This copying approach maintains process simplicity while achieving the desired flexible functional support.
Solution Approach 2:
The functional elements are preliminarily manufactured on the rigid master support before transfer to the flexible support. This preliminary action allows all complex manufacturing steps to be performed on the rigid support where they work best, simplifying the overall process by avoiding the need to perform these steps on the flexible support.
3Ease of manufacture
If standard manufacturing techniques are used on flexible supports, then the process should be simple, but the insulating nature and low Young's modulus of flexible supports prevent certain steps from being performed
Solution Approach 1:
The rigid master support acts as an intermediary that enables reliable manufacturing of functional elements using standard techniques. This mediator provides the necessary mechanical and electrical properties for reliable fabrication, while the flexible support serves as a separate intermediary for the final application, maintaining process simplicity where possible.
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
Enables the production of flexible supports with functional elements of micrometric or sub-micrometric dimensions, overcoming technological obstacles and achieving more efficient, practical, and cost-effective manufacturing by using a sacrificial layer that can be easily removed, such as molybdenum oxide, and allowing for precise molding and hardening of the flexible support.
Implementation Method 1
deposition of a sacrificial layer on a rigid support
Implementation Method 2
elimination of said sacrificial layer
Data Source
Figure 1~5
Figure 2
Figure 3
AI summary
The invention relates to a method for manufacturing a flexible substrate (310) including at least one functional element (308) which is micrometric or sub-micrometric in size, characterised in that it includes the following steps: depositing a sacrificial layer (302) onto a rigid so-called master substrate (304); forming said functional element (308) on said sacrificial layer (302); and transferring said functional element (308) onto a flexible substrate (310) by removing said sacrificial layer (302).