Low-Temperature Foil Pressing for Wiring Substrates
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Solution Overview
Problem
The existing methods for forming foil on a formed member or substrate often result in deteriorated product quality due to heat-induced effects, such as shirt circuits in wiring substrates caused by large toner particles, and bonding issues with heat fixing toner images.
Innovation Solution
A method involving the use of a pressure-sensitive toner with a specific binder resin composition and phase-separated high and low glass transition temperature resins, applied at a temperature of 70° C. or lower to prevent heat-induced deformation and bonding with the foil, ensuring the foil image is formed on the pressure-sensitive toner image without affecting the heat fixing toner image.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If foil is pressed and pressurized against a formed member at a temperature higher than 70° C. to form the foil image on a toner image, then the foil bonds to the toner image, but the formed member and toner image are affected by heating causing product quality deterioration
Solution Approach 1:
The invention changes the temperature parameter from above 70° C. to 70° C. or lower, which fundamentally alters the bonding mechanism from heat-activated to pressure-activated bonding. This parameter change eliminates thermal damage to the formed member and toner image while maintaining effective foil bonding through the pressure-sensitive properties of the toner
Solution Approach 2:
The invention replaces the thermal bonding mechanism with a mechanical pressure-based bonding mechanism. By using pressure-sensitive toner that bonds under pressure without requiring heat, the system substitutes thermal energy with mechanical energy, thereby avoiding heat-induced deformation while achieving reliable foil attachment
2Manufacturing precision
If a toner with large particles (volume fraction of particles having particle diameter of 16 μm or more is 1% or more) is used to form a foil image on a substrate, then the foil image is formed, but shirt circuits occur between parts of the wiring
Solution Approach 1:
The invention changes the particle size distribution parameter of the toner, specifically reducing the volume fraction of large particles (16 μm or more) to less than 1%. This parameter change ensures uniform pressure distribution during foil pressing, preventing toner particle protrusions that could cause shirt circuits while maintaining complete foil image formation
Solution Approach 2:
The invention uses uniform pressure application (similar in concept to hydraulic pressure distribution) across the foil-substrate interface. By controlling the pressure distribution uniformly and using fine-toner particles, the system ensures even bonding without localized pressure points that would create toner protrusions and subsequent electrical shorts
3Stability of the object's composition
If heat fixing toner image is formed on a formed member, then the toner image is fixed, but subsequent foil pressing at high temperature causes bonding with the heat fixing toner image
Solution Approach 1:
The invention performs preliminary action by forming the toner image first and then applying foil under controlled low temperature conditions. The pressure-sensitive toner bonds to the formed member without requiring heat, preventing any interaction with pre-existing heat-fixing toner images and maintaining precise foil positioning
Solution Approach 2:
The invention introduces pressure-sensitive toner as an intermediary bonding agent between the foil and the formed member. This intermediary enables bonding through pressure alone, eliminating the need for high temperature that would cause unwanted interaction with heat-fixing toner images, thereby preserving both the original toner image and accurate foil placement
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 prevents the deterioration of product quality by maintaining the integrity of both the formed member and the substrate, reducing the occurrence of shirt circuits and ensuring accurate bonding of the foil image on the pressure-sensitive toner image while avoiding bonding with the heat fixing toner image.
Implementation Method 1
a pressure-sensitive toner image which is formed on the formed member; and pressing foil against the formed member at a temperature of 70° C. or lower to form the foil image on the pressure-sensitive toner image
Data Source
AI summary
A method of producing a foil formed member, includes: preparing a formed member on which a plastic toner image having plasticity is formed; and pressing foil against the formed member at a temperature of 70° C. or lower to form a foil image on the plastic toner image of the formed member, and a method of producing a wiring substrate, includes: preparing a substrate on which a toner image of a toner, in which a volume fraction of particles having a particle diameter of 16 μm or more is less than 1%, is formed; and forming a foil image on the toner image of the substrate.