Functional Film Manufacturing via Intermediary Support Layer
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Solution Overview
Problem
The existing manufacturing methods for functional films, particularly those using roll-to-roll techniques, face issues with substrate wrinkling, folding, and contact with guide rollers, leading to defects such as holes, cracks, and scratches in organic and inorganic films, which affect the film's quality and productivity.
Innovation Solution
A manufacturing method involving a substrate with a self-supporting first laminate film on the backside and a protective second laminate film on the surface, allowing for tension-controlled transfer and deposition of inorganic films without damage, using a combination of adhesion and surface roughness to prevent wrinkles and facilitate easy removal during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the substrate is thin and soft to reduce material usage and cost, then productivity and cost efficiency are improved, but vertical wrinkles and folds easily occur during transfer, leading to film defects
Solution Approach 1:
A support film is introduced as an intermediary element between the thin substrate and the guide roller. The support film provides mechanical strength and stability during the transfer process, preventing the thin substrate from wrinkling or folding, while allowing the substrate to maintain its thinness for cost efficiency and productivity.
2Productivity
If the substrate is transferred without support to improve productivity, then transfer speed is increased, but the organic film and inorganic film are easily broken due to substrate deflection
Solution Approach 1:
The support film serves as a mediator that distributes the mechanical stress during transfer, preventing localized deflection and breaking of the functional films. It enables faster transfer speeds while maintaining film integrity by providing uniform support across the substrate surface.
3Device complexity
If the substrate contacts the guide roller during transfer, then the transfer process is simplified, but minute scratches and film destructions occur
Solution Approach 1:
The support film acts as an intermediary layer between the substrate and the guide roller, allowing the transfer process to remain simple with direct contact, while preventing the guide roller from directly touching and scratching the functional films on the substrate surface.
4Shape
If tension is applied to the substrate during transfer to maintain flatness, then substrate deformation is reduced, but force is applied to contact locations, causing film breaking
Solution Approach 1:
The support film distributes the applied tension forces across its larger area, preventing concentrated stress at contact points. This allows the substrate to maintain flatness during transfer without causing localized film breaking, as the support film absorbs and distributes the mechanical loads.
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 method ensures high-quality functional films with reduced defects, improved productivity, and enhanced barrier performance by preventing substrate wrinkling and contact-induced damage during the deposition and transfer processes.
Implementation Method 1
Deposition techniques based on vacuum deposition methods, such as sputtering and plasma CVD, are used to manufacture the functional films
Implementation Method 2
Deposition techniques based on vacuum deposition methods, such as sputtering and plasma CVD, are used to manufacture the functional films
Implementation Method 3
Deposition techniques based on vacuum deposition methods, such as sputtering and plasma CVD, are used to manufacture the functional films
Data Source
AI summary
A manufacturing method of functional film comprising the steps of:a first step of feeding a lengthy substrate with self-support including a first laminate film on a back side, forming an organic film on a front side of the substrate while transferring the substrate, providing a second laminate film on a surface of the organic film, and taking up the substrate into a film roll; anda second step of loading the film roll on a vacuum deposition apparatus, continuously feeding the substrate including the first laminate film and the second laminate film from the film roll, removing the second laminate film while transferring the substrate, forming an inorganic film over the organic film of the substrate, and taking up the substrate into a film roll.