Laminate Dam Formation for Uniform Resin Thickness
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Solution Overview
Problem
Conventional methods for forming dams in optical devices to prevent resin protrusion face issues such as height differences leading to unbonded regions or uneven thickness, which are exacerbated by the use of thixotropic resin compositions or UV irradiation methods that increase costs and tact time.
Innovation Solution
A dam forming method that accelerates the application speed of a non-thixotropic resin composition continuously or stepwise from the start to the end of the application, followed by curing, to maintain dam thickness uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thixotropic resin composition is used to suppress wetting and spreading, then the dam thickness is maintained uniformly, but the material cost increases and the resin may not achieve required characteristics
Solution Approach 1:
The invention changes the application parameters (speed, acceleration profile) rather than changing the material properties. By accelerating the application speed continuously or stepwise during resin deposition, the method compensates for wetting and spreading effects without requiring expensive thixotropic resin compositions, thus maintaining dam thickness uniformity while using conventional materials
Solution Approach 2:
The invention applies preliminary control measures during the application process itself. By pre-programming the acceleration profile of the application head, the system proactively prevents thickness variation before it occurs, eliminating the need for post-application corrections or special material properties
2Manufacturing precision
If a spot UV irradiator is used to track and irradiate the resin composition, then the dam shape is maintained, but the equipment cost and tact time increase
Solution Approach 1:
The invention extracts and eliminates the UV irradiator component from the system. By removing this complex and expensive equipment, the invention simplifies the manufacturing line while achieving the same goal of preventing resin spreading through a different mechanism (application speed acceleration rather than post-application curing)
Solution Approach 2:
The invention replaces the mechanical/optical system of UV irradiation with a controlled motion system. Instead of using UV light to prevent spreading, the method uses precisely controlled application head acceleration to deposit resin in a way that inherently maintains uniform thickness without requiring additional curing equipment
3Manufacturing precision
If a spot UV irradiator tracks the nozzle, then the dam thickness is maintained, but the application speed must be reduced increasing tact time
Solution Approach 1:
The invention introduces dynamic control of the application head speed during the deposition process. By continuously or stepwise accelerating the application head, the system adapts the deposition rate to compensate for resin spreading, maintaining thickness uniformity while actually increasing overall application speed compared to the constrained speed required for UV tracking methods
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 effectively suppresses height differences in dams, preventing unbonded regions and uneven thickness, while reducing material and equipment costs by avoiding thixotropic resins and UV irradiation.
Implementation Method 1
curing the applied dam-forming resin composition
Data Source
AI summary
A dam forming method and a method for manufacturing a laminate capable of suppressing the occurrence of a height difference in the thickness of a dam. A dam forming method is used in a method for manufacturing a laminate in which a first base member and a second base member are laminated via a fill material, including: forming a dam surrounding an application region for the fill material on the first base member; and applying the fill material to the application region. The dam forming method includes: applying a dam-forming resin composition on peripheral edges of the first base member by accelerating the application speed of the dam-forming resin composition continuously or stepwise from the start to the end of the application; and curing the applied dam-forming resin composition.