Mechanical Abrasion for Electronic System Recycling

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Solution Overview

Problem

Conventional patterning methods for composite materials are costly, energy-intensive, and environmentally unfriendly, with limitations in throughput and adaptability, particularly for roll-to-roll processing and recycling of electronic systems.

Innovation Solution

Mechanical abrasion using programmable actuators to remove patternable material from composite materials, allowing for rapid formation of user-defined patterns without chemical removal, enabling efficient recycling of electronic systems and reducing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional chemical etching or additive printing methods are used for patterning composite materials, then manufacturing precision can be achieved, but production cost increases and productivity decreases

Engineering Contradiction:

Improvepatterning precisionVSAvoidproduction throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces conventional chemical etching or additive printing methods with a mechanical abrasion system. A mechanical abrador selectively removes material from the composite substrate through controlled mechanical contact, achieving precise patterning while enabling faster processing speeds and higher throughput compared to chemical or additive approaches

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system controls patterning precision by adjusting mechanical parameters including abrador pressure, substrate feed rate, and abrador geometry. These parameter changes allow precise control over pattern dimensions and features while maintaining high production speeds, resolving the contradiction between precision and productivity

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If conventional patterning methods with chemical removal are used, then pattern formation is achieved, but energy consumption increases and environmental harm worsens

Engineering Contradiction:

Improvepattern formation accuracyVSAvoidchemical waste and energy consumption

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes mechanical abrasion for chemical etching processes. This eliminates the need for hazardous chemical baths, waste treatment systems, and associated energy consumption for heating and agitating chemical solutions, while maintaining precise pattern formation capabilities through controlled mechanical material removal

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system converts the potential harm of material removal into a beneficial process by using controlled mechanical abrasion that removes only the necessary patternable material without requiring harsh chemicals. The mechanical process is inherently cleaner, converting what could be chemical pollution into a sustainable manufacturing approach

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Adaptability or versatility

If digital printing methods are used for rapid pattern adaptation, then adaptability improves, but production cost increases due to lower throughput

Engineering Contradiction:

Improvepattern change flexibilityVSAvoidprocessing speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent implements a dynamic patterning system where the abrador can be programmatically controlled to create different patterns without physical reconfiguration. The system adapts to new patterns through software control of the mechanical abrador's motion path, pressure, and speed, enabling rapid pattern changes while maintaining high production throughput unlike slower digital printing methods

Inventive Principle:

Principle #15Dynamics

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 enables low-cost, high-throughput, and environmentally friendly patterning and recycling of composite materials, improving processing speed and adaptability while minimizing chemical usage and waste generation.

Implementation Method 1

patterns are formed via mechanical abrasion of a composite material that includes a patternable material disposed over a substrate

Methodology Applied

Scientific EffectMechanical abrasion: Abrasion

Data Source

PatentUS10378080B2Systems and methods for recycling electronic systems

Publication Date: 2019.08.13 COOLEDGE LIGHTING

AI summary

In accordance with certain embodiments, devices are recycled by removing one or more electronic components from a portion of the device and urging one or more regions of the portion of the device toward an abrasion head. The abrasion head mechanically removes at least a portion of patternable material in each of the one or more regions. The steps are repeated for subsequent portions of the device.