Laminate Manufacturing Using Dual Elastic Body Pressing
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Solution Overview
Problem
The manufacturing of laminates, such as channel devices, often results in defective products due to insufficient bonding between the substrate and film caused by substrate deformation and unintentional thermocompression bonding at the bottom of shallow recesses, leading to channel blockage.
Innovation Solution
A method involving thermocompression bonding using a first elastic body harder than a second elastic body, where the film is pressed between the two elastic bodies with the substrate positioned between them, to ensure proper bonding while preventing bonding at the recess bottom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressing force is increased to ensure bonding between substrate and film, then bonding quality is improved, but unintentional bonding at the recess bottom occurs causing channel blockage
Solution Approach 1:
The pressing force is made non-uniform across the substrate surface by using an elastic body with specific hardness properties. The elastic body deforms more at regions corresponding to recesses, providing reduced pressing force at the recess bottom while maintaining sufficient pressing force at the bonding regions, thus preventing channel blockage while ensuring bonding quality.
Solution Approach 2:
The hardness parameter of the elastic body is specifically selected and controlled. By adjusting the hardness of the elastic body, the pressing force distribution is optimized to prevent both insufficient bonding and unintentional recess bottom bonding, resolving the contradiction between bonding quality and channel blockage prevention.
2Object-generated harmful factors
If pressing force is decreased to prevent recess bottom bonding, then channel blockage is reduced, but bonding between substrate and film becomes insufficient
Solution Approach 1:
The elastic body creates a non-uniform pressing force distribution where the force is automatically reduced at recess bottom regions while maintaining adequate force at the bonding interfaces. This local differentiation of pressing force prevents channel blockage without compromising overall bonding quality.
Solution Approach 2:
The elastic body acts as a cushioning element that预先 (in advance) prevents excessive pressing force from reaching the recess bottom. By selecting appropriate elastic body hardness, the system is designed to inherently limit the maximum pressing force at vulnerable regions before damage occurs, thus preventing channel blockage while maintaining bonding.
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 enhances the yield of laminate production by preventing blockages and ensuring effective bonding between the substrate and film, thereby reducing defective products.
Implementation Method 1
obtain a laminate by thermocompression bonding between the film and the substrate by pressing the film and the substrate with a first elastic body and a second elastic body
Implementation Method 2
pressing the film and the substrate with a first elastic body and a second elastic body in a state in which the substrate on which the film is disposed is disposed between the first elastic body and the second elastic body
Data Source
AI summary
A manufacturing method capable of manufacturing a laminate including a substrate having a recess and a film with a high yield is provided. The method of manufacturing a laminate of the present invention includes: preparing a substrate having a recess; disposing a film on the substrate so as to cover the recess; and obtaining a laminate by thermocompression bonding between the film and the substrate by pressing the film and the substrate with a first elastic body and a second elastic body in a state in which the substrate on which the film is disposed is disposed between the first elastic body and the second elastic body such that the film is on the first elastic body side, in which the first elastic body is harder than the second elastic body.