Intermittent Resin Coating for Concavo-Convex Pattern Transfer
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Solution Overview
Problem
Conventional transfer methods for forming concavo-convex patterns on resin surfaces result in resin waste and operational issues due to incomplete molding, as molds are not continuously applied along the resin sheet, leading to uncured resin areas and potential resin overflow.
Innovation Solution
An intermittent coating method and apparatus that synchronizes the delivery of ultraviolet curable resin with the movement of the base film, ensuring that only the areas facing the molds receive the resin, preventing waste and overflow by using a diaphragm-controlled coating die and a transfer member with movable molds to apply and cure the resin in a controlled manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If resin is applied continuously on the entire resin sheet, then the resin sheet is fully covered, but resin is wasted in portions not pressed by moulds and may overflow
Solution Approach 1:
The patent divides the continuous resin sheet into discrete portions by applying resin only at specific locations corresponding to mould positions. The resin application device deposits resin in segmented portions rather than continuously across the entire sheet, matching the mould arrangement and eliminating waste in non-mould areas.
Solution Approach 2:
The patent applies resin with local quality by delivering it only to specific regions where moulds are positioned, rather than uniformly across the entire resin sheet. This localized application ensures resin is present only where needed for pattern transfer, preventing waste and overflow in areas without moulds.
2Device complexity
If moulds are fixed on only a part of the periphery of a roll, then the transfer device is simpler, but portions of the resin sheet are not pressed by moulds leading to uncured resin
Solution Approach 1:
The patent employs dynamic coordination between the resin application device and the transfer device. The resin application device moves in synchronization with the transfer device, dynamically adjusting resin application positions to match the fixed mould locations on the roll periphery, ensuring complete pattern transfer without requiring moulds on the entire periphery.
Solution Approach 2:
The patent applies resin preliminarily at specific positions before the resin sheet reaches the mould pressing stage. By pre-positioning resin only where moulds will contact the sheet, the system ensures that when the fixed moulds press the sheet, resin is available exactly where needed for complete and reliable pattern transfer.
3Quantity of substance
If excessive resin is applied, then the resin sheet is well-covered, but resin overflows causing operational troubles
Solution Approach 1:
The patent applies resin with local quality by delivering it only to specific regions where moulds are positioned, rather than uniformly across the entire resin sheet. This localized application ensures resin is present only where needed for pattern transfer, preventing waste and overflow in areas without moulds.
Solution Approach 2:
The patent uses partial action by applying resin only to the necessary portions of the resin sheet corresponding to mould locations, rather than applying excessive resin across the entire sheet. This partial application provides sufficient resin for complete pattern transfer while avoiding overflow and operational issues.
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 effectively prevents resin waste and overflow, enabling precise and efficient transfer of concavo-convex patterns without operational disruptions, resulting in a high-quality transfer process.
Implementation Method 1
an ultraviolet curable resin is applied in a dispenser method or a roll transfer method on a length of resin sheet fed forth from a feeding member; and a stamper, which is moulds, is pressed on the applied ultraviolet curable resin to give a form, and on the ultraviolet curable resin given the form are irradiated ultraviolet rays to cure the resin
Data Source
Figure 1~2(b)
Figure 3
Figure 4
AI summary
An intermittent coating member 10 delivers resin intermittently from a coating die 20 onto a length of base film 41 fed forth from a feeding member 40 to form intermittent coats of a coating film 43 on the base film 41. The coating film 43 is transferred to a transfer member 44 that actuates in synchronism with the coating action for the coating film 43, and is given a transfer by moulds 45 fixed on a mould roll 46. After the transfer, the coating film 43 is cured by an ultraviolet irradiation device 48 and wound up by a winding member 49.