Fluorine-Containing Resin Mold Dimensional Stability

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Solution Overview

Problem

Resin molds face challenges with working lifetime and dimensional stability during repeated transfer printings, leading to deterioration and loss of concavo-convex patterns, which affects their usability in manufacturing components like optical and electronic devices.

Innovation Solution

A resin mold composed of fluorine-containing polymers with specific carbon-fluorine bonds and varying fluorine atom content, combined with high crosslink density and liquid repellent capabilities, is developed to maintain dimensional stability and extend working life through controlled changes in surface distances during multiple printings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If resin molds are used for repeated transfer printings, then productivity increases, but manufacturing precision deteriorates due to loss of concavo-convex patterns

Engineering Contradiction:

Improvenumber of repeated printingsVSAvoiddimensional accuracy of patterns

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the chemical composition parameters of the resin by incorporating fluorine-containing polymers with specific carbon-fluorine bonds and controlling fluorine atom content. This parameter change gives the resin exceptional dimensional stability that prevents pattern distortion even after 1000 repeated printings, thus maintaining manufacturing precision while enabling high productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite resin system by combining fluorine-containing polymers with crosslinking agents. This composite material structure provides both the flexibility needed for transfer printing and the dimensional stability required to maintain pattern precision over hundreds of repetitions, resolving the contradiction between productivity and precision

Inventive Principle:

Principle #40Composite materials

2Productivity

If resin molds are used for repeated transfer printings, then productivity increases, but reliability decreases due to deterioration of mold structure

Engineering Contradiction:

Improvenumber of repeated printingsVSAvoidworking lifetime of mold

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent modifies the resin's chemical parameters by introducing fluorine-containing polymers and controlling crosslink density. These parameter changes create a mold structure that resists deterioration during repeated use, maintaining reliability for at least 1000 printings while enabling high productivity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a resin mold that can be used repeatedly (at least 1000 times) without significant deterioration, effectively transforming from a short-living disposable mold to a long-living durable tool. This extends the working lifetime while maintaining cost-effectiveness for mass production

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If fluorine-containing polymers are used to improve dimensional stability, then manufacturing precision is maintained, but device complexity increases

Engineering Contradiction:

Improvedimensional stabilityVSAvoidresin composition complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent achieves dimensional stability by adjusting specific parameters of the resin composition: fluorine atom content and crosslink density. By controlling these parameters within specific ranges, the patent maintains manufacturing precision while avoiding excessive complexity in the overall device structure

Inventive Principle:

Principle #35Parameter changes

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

The resin mold exhibits minimal dimensional errors and long working life, allowing for repeated use in manufacturing components such as light guide plates, polarization plates, and electronic elements with improved durability and precision.

Implementation Method 1

the first resin includes a first unit and a second unit; the first unit has a first main chain, the second unit has a second main chain; and a first average content of fluorine atom per one atom included in the first main chain is different than a second average content of fluorine atom per one atom included in the second main chain

Methodology Applied

Scientific EffectCarbon-fluorine bond stability: Chemical Bonding