Thin Plate Laminate Mold Retention Structure for Precision Resin Bonding
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Solution Overview
Problem
Existing methods struggle to accurately and stably form concave/convex shapes on thin film-like resin layers laminated on thin plate-like substrates, particularly when the features are fine, leading to inconsistencies in functionality.
Innovation Solution
The method involves creating a mold retention structure where heated molds are arranged on both sides of the workpiece, and these molds are compressed between two rollers to uniformly apply pressure, ensuring high-accuracy thermocompression bonding of the film-like resin composition and the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional compression methods are used to form concave/convex shapes on thin film-like resin layers, then the processing can be completed, but the manufacturing precision and stability of the concave/convex shape formation deteriorates due to pressure unevenness
Solution Approach 1:
A mold retention structure is introduced as an intermediary component between the compression means and the mold. This structure includes a mold retention part that holds the mold and a pressing surface that receives uniform compression force. The intermediary structure distributes the compression force evenly across the mold surface, preventing pressure unevenness and enabling stable, high-precision formation of concave/convex shapes on thin film-like resin layers.
Solution Approach 2:
The invention changes the physical state and distribution parameters of compression force by introducing the mold retention structure. The structure transforms concentrated or uneven compression force into uniformly distributed pressure across the mold surface, which directly improves the manufacturing precision of the concave/convex shape formation while enhancing processing stability.
2Manufacturing precision
If the film-like resin layer is made extremely thin to achieve desired functionality, then the lightweight and compact properties are improved, but the manufacturing precision of concave/convex shape formation deteriorates due to difficulty in stable processing
Solution Approach 1:
The mold retention structure serves as a mediator that facilitates the processing of extremely thin film-like resin layers. By providing a stable platform with uniform pressure distribution, it enables precise formation of concave/convex shapes on thin films without the processing difficulties that would otherwise arise from the film's thinness and fragility.
Solution Approach 2:
The compression system is segmented into distinct functional components: the compression means, the mold retention structure, and the mold. This segmentation allows the mold retention structure to specifically address the challenge of thin film processing by providing dedicated support and uniform pressure distribution, thereby improving ease of manufacture for thin-film applications.
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 allows for the stable and precise formation of concave/convex shapes on the film-like resin layer, suppressing pressure unevenness and enhancing the processing accuracy, which is critical for maintaining the predetermined functionality of the substrate.
Implementation Method 1
molds, which have been heated to a thermal deformation temperature of the film-like resin composition
Implementation Method 2
compressing the outer surfaces of the molds by rotating the compression rollers to integrally thermocompression-bond the film-like resin composition and the substrate
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
[Summary] [Object] To provide a method for the production of a thin plate-like laminate having a film-like resin layer in which a concave/convex shape can stably be formed with high accuracy on the film-like resin layer laminated on a thin plate-like substrate. [Achieving Means] There are provided a step of creating a mold retention structure 100 in which molds 110, which have been heated to a thermal deformation temperature of a film-like resin composition 84, are arranged on both surface sides of a workpiece 85, and a step of introducing the mold retention structure in which the heated molds are arranged between two compression rollers 52, 54 and compressing outer surfaces of the molds by rotating the compression rollers to integrally thermocompression-bond the film-like resin composition and a substrate 81 to form a thin plate-like laminate 80 having a film-like resin layer 82.