Microporous Sheet Electroforming with Recessed Edge Joints
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Solution Overview
Problem
The existing process for mass-producing microporous sheets results in fractured structures with varying protrusions and warping deformations, leading to alignment accuracy issues and moisture leakage in atomization modules.
Innovation Solution
A method for fabricating microporous sheets using electroforming, where a metal layer with dummy and microporous sheets is formed, allowing for precise definition of sheet shape and size, and enabling quick peeling without additional punching or cutting, resulting in consistent fracture surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing mass-production process is used to remove microporous sheets, then production efficiency is maintained, but fractured structures with varying protrusions and warping deformations are formed on edges
Solution Approach 1:
The patent applies preliminary action by pre-forming recessed portions at the edges of the microporous sheets during the electroforming process. These recessed portions are created before the sheets are removed from the mold, ensuring that when fracture occurs during removal, the fracture surfaces are predetermined and uniform, eliminating random warping and protrusions while maintaining efficient production
2Ease of manufacture
If microporous sheets are removed from metal layer, then sheets are separated from substrate, but alignment accuracy is affected due to fractured structures
Solution Approach 1:
The patent pre-forms recessed portions at the edges of microporous sheets during electroforming, creating predetermined fracture surfaces before separation occurs. This ensures that when sheets are removed from the metal layer, they fracture along uniform, predetermined lines rather than randomly, maintaining alignment accuracy while enabling easy separation
Solution Approach 2:
The patent applies local quality by creating recessed portions specifically at the edge regions of the microporous sheets, while the central regions maintain their full thickness and structural integrity. This localized modification at the edges enables controlled fracture at specific locations without affecting the overall sheet quality or alignment surfaces
3Ease of manufacture
If conventional removal process is used, then microporous sheets are detached, but warping deformations cause moisture leakage in atomization module
Solution Approach 1:
The patent pre-forms recessed portions at the edges of microporous sheets during the electroforming process. When sheets are detached from the metal layer, these pre-formed recessed portions create uniform fracture surfaces that prevent warping deformations. This ensures the sheets remain flat and properly sealed in the atomization module, preventing moisture leakage while maintaining easy detachment
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 ensures consistent fracture surfaces, improving alignment accuracy and addressing moisture leakage issues by restricting fracture surfaces to designed concave joints, thus enhancing the quality of atomization modules.
Implementation Method 1
depositing a metal layer on the pattern layer through an electroforming process, in which the metal layer includes a dummy metal sheet and a plurality of microporous sheets
Data Source
AI summary
A microporous sheet and a method for fabricating the same are provided. The method includes: providing a substrate; forming a pattern layer on the substrate; depositing a metal layer on the pattern layer through an electroforming process, in which the metal layer includes a dummy metal sheet and a plurality of microporous sheets, and each of the microporous sheets is connected to the dummy metal sheet through at least one connection structure; and peeling off the metal layer from the substrate, and removing the microporous sheets from the metal layer.