Imprinting Mold Separation Using Rotating Vacuum Absorption
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Solution Overview
Problem
The existing methods for fabricating flat plate displays using imprinting molds require significant mechanical force to separate the substrate and mold, which can lead to damage and is impractical for large-area substrates due to the need for larger molds and increased separation distances.
Innovation Solution
A fabricating apparatus and method that uses a movable separation part with rotating absorption parts and a transfer jig to apply a shear force, allowing for the separation of the imprinting mold from the substrate with a relatively small force by rotating the absorption parts along an oblique and horizontal path, minimizing damage and enabling separation regardless of mold size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If simultaneous separation of imprinting mold and substrate is used, then separation is achieved in one step, but relatively large mechanical force is required which may damage both substrate and mold
Solution Approach 1:
The patent divides the single simultaneous separation action into multiple sequential separation stages. The separation process is segmented into: (1) separating the imprinting mold from the liquid polymeric precursor first, and (2) then separating the substrate from the molded structure. This segmentation reduces the mechanical force required at each stage compared to simultaneous separation of all components.
Solution Approach 2:
The patent introduces a movable support that can dynamically adjust its position and absorption force during the separation process. The movable support transitions from an initial position where it absorbs the liquid polymeric precursor to a final position where it absorbs the molded structure, allowing dynamic force distribution that reduces peak mechanical forces on the substrate and mold.
2Force
If sequential separation of imprinting mold from substrate is used, then relatively small mechanical force is required, but separation distance increases and mold is likely to damage
Solution Approach 1:
The patent introduces a movable support as an intermediary component between the imprinting mold and the substrate. This movable support acts as a mediator that: (1) absorbs the liquid polymeric precursor during molding, (2) supports the molded structure during separation, and (3) reduces the separation distance by providing a stable intermediate platform. The intermediary prevents direct contact and reduces the risk of mold damage while minimizing the separation distance.
3Area of stationary object
If larger molds are used for large area substrates, then coverage is improved, but separation becomes more difficult due to increased weight and size
Solution Approach 1:
The patent employs a movable support that can dynamically adjust its position and absorption characteristics during the separation process. For large area substrates, the movable support transitions from absorbing the liquid polymeric precursor to absorbing the molded structure, allowing the system to handle larger molds without proportionally increasing the separation force requirement. The dynamic adjustment distributes the load more effectively across the separation process.
Solution Approach 2:
The patent segments the separation process into distinct stages where the movable support performs different functions at different times. This segmentation allows the system to handle large area substrates by: (1) using the movable support to absorb and stabilize the liquid polymeric precursor during molding, and (2) then using it to support the molded structure during separation, reducing the overall force requirement compared to attempting to separate the entire large assembly in one action.
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 reduces the force required for separation, minimizes damage to the mold and substrate, and enhances productivity by allowing for faster assembly and the use of larger substrates with existing equipment.
Implementation Method 1
a movable separation part configured to rotatably move from a one side toward the other side of the imprinting mold to vacuum-absorb the imprinting mold
Data Source
AI summary
Disclosed is a method of fabricating and apparatus of a flat plate display that is able to separate a substrate and an imprinting mold from each other with a relatively small force. The fabricating apparatus of a flat plate display includes an imprinting mold which is boned with a substrate to form a thin film pattern on the substrate, the imprinting mold comprising projections and grooves; and a movable separation part configured to rotatably move from a one side toward the other side of the imprinting mold to vacuum-absorb the imprinting mold.