Micro-cut Patterned Article for Tunable Conductivity and Signal Transmissivity
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Solution Overview
Problem
Current methods for patterning functional layers, especially those involving micro-cut inorganic layers, face challenges in achieving precise control over aesthetic appearance and conductivity while being transmissive to electromagnetic signals, particularly in roll-to-roll manufacturing processes.
Innovation Solution
A method involving a carrier layer with a microstructured surface and a micro-cut inorganic layer that is embossed using a microstructured tool, allowing for precise control over the pattern of cut edges, enabling the creation of patterned articles with tunable reflectivity and conductivity, suitable for applications like 5G antennas and communication devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional patterning methods are used for micro-cut inorganic layers, then manufacturing process is simpler, but manufacturing precision and control over aesthetic appearance and conductivity deteriorate
Solution Approach 1:
The patent segments the patterning process into two distinct stages: (1) forming a continuous functional layer with desired thickness and composition using sputtering, and (2) applying a microstructured roller to create the cut pattern. This segmentation allows each process to be optimized independently, achieving high precision in both deposition and patterning without excessive overall complexity.
Solution Approach 2:
The patent replaces conventional mechanical lithography or photolithography systems with a mechanically-driven microstructured roller system. The roller's physical microstructures directly emboss and cut the functional layer, eliminating complex optical alignment and photoresist processing while maintaining precise pattern control through the roller's manufactured geometry.
2Reliability
If continuous inorganic layers are used, then aesthetic appearance and conductivity are improved, but transmissivity to electromagnetic signals deteriorates
Solution Approach 1:
The patent applies local quality by creating non-uniform patterns in the functional layer through micro-cuts. The continuous layer is transformed into a patterned structure where conductive regions (the uncut portions) are spatially distributed, providing localized conductivity pathways while creating gaps that allow electromagnetic signal transmission. This local variation in structure enables simultaneous optimization of both electrical and electromagnetic properties.
3Manufacturing precision
If micro-cut patterns are applied to planar surfaces, then manufacturing precision is improved, but adaptability to non-planar surfaces deteriorates
Solution Approach 1:
The patent introduces dynamics by using a flexible or compliant microstructured roller that can adapt its shape to conform to non-planar substrates. The roller's microstructures maintain their relative geometry while allowing the overall roller form to flex and conform to curved or irregular surfaces, enabling precise patterning on three-dimensional surfaces without sacrificing pattern fidelity.
Solution Approach 2:
The patent transitions from two-dimensional planar patterning to three-dimensional surface patterning by applying the microstructured roller to non-planar substrates. The process maintains pattern precision by preserving the relative spatial relationships of micro-cuts while adapting to surface curvature, effectively adding a dimensional aspect to the patterning capability without compromising manufacturing precision.
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 enables the production of patterned articles with precise control over aesthetic appearance and conductivity, ensuring consistent performance and adaptability to non-planar surfaces, while maintaining transmissivity to electromagnetic signals.
Implementation Method 1
Sputtering is a high-precision vacuum deposition process that can deposit inorganic thin films with single digit nanometer thickness control across large areas
Implementation Method 2
contacting the transfer article with the tool such that the tool embosses and cuts into the transfer article to form a pattern of cuts in the functional layer
Data Source
AI summary
A patterned article includes a carrier layer having a microstructured first major surface and an opposing second major surface. The first major surface includes pluralities of upper and lower edges spaced apart along a thickness direction of the carrier layer and defining respective upper and lower portions of the first major surface. The lower portion is disposed between the upper portion and the second major surface. The article includes a first functional layer disposed on the lower, but not the upper portion of the first major surface. The first functional layer includes at least one first micro-cut inorganic layer including a plurality of cut edges substantially coextensive with the plurality of lower edges. A method of making the patterned article is provided. Articles that can be made by transferring a functional layer from the patterned article are provided.