Functional Film Transfer Using Separation Film Mediator
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Solution Overview
Problem
The transfer of functional film portions onto substrates often results in defects such as dust contamination, irregularities, and mechanical damage due to the exposure of adhesive layers during separation from the base plate, which are costly to prevent and incompatible with high-throughput manufacturing.
Innovation Solution
A method utilizing two distinct adhesive layers, where the first layer secures the film assembly during manufacturing and transfer, and the second layer ensures final bonding, with grooves in the film and separation film to minimize exposure and mechanical stress, allowing for controlled separation and application without defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the film portion is peeled off from the base plate using traditional methods, then the film can be transferred to the substrate, but dust or pollution attaches to the adhesive layer creating defects and altering adhesion power
Solution Approach 1:
A separation film is introduced as an intermediary layer between the functional film and the base plate. This separation film remains attached to the base plate during the peeling process, creating a protected interface that prevents dust and pollution from contacting the adhesive layer. The separation film acts as a barrier that mediates the separation process while maintaining adhesive integrity.
Solution Approach 2:
The separation film is pre-positioned on the base plate before the functional film is applied. This preliminary arrangement ensures that when the functional film is later peeled from the base plate, the adhesive layer never directly contacts the environment, as the separation film is already in place to protect the interface.
2Productivity
If traditional peeling methods are used to separate the film from the base plate, then transfer is achieved, but mechanical defects such as scratches, stretches, marks, crushing or tearing occur at the separation location
Solution Approach 1:
The separation film serves as a mediator that absorbs the mechanical stress of the peeling process. By gripping and peeling the separation film instead of the functional film edge, the damaging forces are directed at the separation film which is designed to withstand this stress, thereby protecting the functional film from mechanical defects.
Solution Approach 2:
The problematic peeling action is extracted from the functional film and applied instead to the separation film. The separation film is specifically designed to be gripped and peeled without causing damage, effectively removing the harmful peeling action from the functional film while maintaining the transfer function.
3Reliability
If additional precautionary measures are taken to avoid dust defects during separation, then adhesion quality improves, but manufacturing cost increases and throughput decreases
Solution Approach 1:
The separation film is pre-positioned on the base plate before the functional film application. This preliminary setup creates a protected environment for the adhesive layer throughout the entire process, eliminating the need for additional precautionary measures during and after peeling, thereby maintaining high manufacturing throughput.
Solution Approach 2:
The separation film acts as a built-in protective intermediary that is integrated into the manufacturing process itself, rather than requiring separate protective measures. This integrated approach maintains production efficiency while ensuring adhesive quality.
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 defects by maintaining the adhesive layer's integrity during transfer, reducing contamination and mechanical damage, and enables precise application of functional films onto substrates with high quality and efficiency.
Implementation Method 1
The functional film is initially retained on a base plate by an adherent structure which comprises a first adhesive layer which retains an assembly comprising the functional film, a second adhesive layer and a separation film to the base plate
Implementation Method 2
a second adhesive layer which bonds the functional film to the separation film
Data Source
Figure 1~3
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Figure 6~7
AI summary
A method of transferring a portion of a functional film (1) onto a substrate from a base plate (100) comprises the formation of a groove (S1) which passes through the said functional film and also a separating film (2) placed between the functional film and the base plate. A portion (2p) of the separating film is then detached from the base plate with the portion of the functional film. The portion of said separating film protects the portion of the functional film in the rest of the method. According to one improvement, the portion of the functional film which is detached from the base plate comprises a useful portion (1p) and a margin (1m) that are connected together by the portion (2p) of the separating film. The useful portion (1p) of the functional film may then be gripped and handled via the margin (1m).