Layered Resin-Metal Body Bonding for Flat Multilayer Surfaces
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Solution Overview
Problem
Conventional methods for producing layered bodies are time-consuming and result in irregularities and poor flatness due to shrinkage during resin film formation, and they are susceptible to thermal deterioration.
Innovation Solution
A method involving separately preparing a first resin film with a patterned metal layer and a second resin film with a concave matching the metal pattern, then bonding them together with a silane coupling agent layer to ensure flatness and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a varnish for second resin film formation is applied onto the metal layer and dried to form a layered body, then the layered body can be produced, but shrinkage occurs during curing and irregularities are generated on the surface resulting in poor flatness
Solution Approach 1:
The invention divides the resin film formation process into two separate stages: first forming a resin film with the metal layer, then separately forming a second resin film without the metal layer present. This segmentation prevents the shrinkage-induced irregularities that occur when varnish is applied directly over the metal pattern, as the second resin film forms independently and maintains surface flatness.
Solution Approach 2:
The first resin film is formed in advance with the metal layer, allowing the metal pattern to be established before the second resin film formation process begins. This preliminary action enables the metal layer to serve as a template for the first resin film while avoiding interference with the second resin film's curing process, thereby preventing surface irregularities.
2Ease of manufacture
If conventional production methods are used, then layered bodies can be fabricated, but it takes excessive time due to varnish application and drying steps or compression-molding processes
Solution Approach 1:
The production process is segmented into distinct stages where the first resin film is formed with the metal layer, cured, and then the second resin film is formed separately. This eliminates the time-consuming drying step required when applying varnish over metal patterns, as the second resin film forms independently without requiring extended drying time.
Solution Approach 2:
The invention replaces the conventional mechanical compression-molding process with a chemical curing process. Instead of using compression molds to form the resin film, the resin is applied and then cured through chemical reaction, which significantly reduces the time required for film formation while maintaining quality.
3Ease of manufacture
If varnish is applied onto the metal layer for second resin film formation, then the layered body can be formed, but thermal deterioration occurs more readily
Solution Approach 1:
By separating the resin film formation into two independent stages, the invention eliminates the need to apply varnish directly over the metal layer. The second resin film is formed separately without metal layer interference, preventing the thermal deterioration that occurs when organic varnish components are exposed to high temperatures near the metal pattern.
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
The method allows for rapid production of layered bodies with flat and parallel surfaces, reducing thermal deterioration and maintaining parallelism, suitable for multilayered structures with improved heat resistance and noise resistance.
Implementation Method 1
bonding the first layered body and the second resin film together while fitting the pattern of the metal layer and the concave of the second resin film into each other
Data Source
AI summary
This method for producing a layered body includes: a step A for preparing a first layered body by layering a first resin film and a patterned metal layer; a step B for preparing a second resin film having indentations corresponding to the metal layer pattern; and a step C for mating the metal layer pattern and the indentations in the second resin film and bonding together the first layered body and second resin film.