Microstructured Auxiliary Film for Fast Clean Substrate Separation
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Solution Overview
Problem
Existing auxiliary films with release agents cause pollution and damage to semi-finished products due to varying attachment strengths with heterogeneous materials, leading to inefficient separation and increased production time.
Innovation Solution
An auxiliary film with microstructures forming open-air channels between the film and substrate, enhancing separation efficiency by reducing contact area and facilitating easy removal, thus improving manufacturing process speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a release agent is used as a chemical coating layer on the auxiliary film, then the auxiliary film can be attached to pre-protected surfaces to avoid pollution and provide mechanical strength, but it induces pollution of different levels for the devices on the pre-protected surfaces
Solution Approach 1:
The invention extracts and removes the release agent (chemical coating layer) from the auxiliary film structure, replacing it with a release structure formed by microstructures on the film surface. This eliminates the pollution problem caused by chemical release agents while maintaining the necessary release functionality.
Solution Approach 2:
The auxiliary film incorporates microstructures that create a porous or micro-channel structure on its surface. This allows controlled interaction with the substrate while reducing chemical contamination, enabling mechanical strength provision without the harmful effects of chemical release agents.
2Adaptability or versatility
If the auxiliary film uses heterogeneous materials on the pre-protected surfaces, then it can adapt to different components, but the different attachment strengths cause damages on the components while removing the auxiliary films
Solution Approach 1:
The invention applies local quality by creating microstructures with varying geometries at different locations on the auxiliary film surface. These localized structural variations provide different attachment characteristics in different regions, allowing adaptation to heterogeneous materials without causing damage during removal.
Solution Approach 2:
The auxiliary film surface is segmented into multiple microstructures rather than using a uniform chemical coating. This segmentation allows different regions to have optimized attachment properties for different components, enabling versatile attachment while preventing damage during removal through controlled adhesion zones.
3Reliability
If the auxiliary film has full contact with the substrate, then it provides comprehensive protection, but the separation process becomes time-consuming and reduces manufacturing efficiency
Solution Approach 1:
The auxiliary film incorporates segmented microstructures with spacing between them, creating a patterned surface that provides comprehensive protection through the film body while allowing rapid separation. The segmented structure reduces adhesion area and creates natural separation pathways, enabling quick removal without compromising protection during the manufacturing process.
Solution Approach 2:
The invention uses partial contact through spaced microstructures rather than full continuous contact. This partial action provides sufficient protection for the substrate while significantly reducing the adhesion strength, allowing the auxiliary film to be removed quickly without requiring excessive force or time, thus improving manufacturing efficiency.
Data Source
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AI summary
The present invention provides an auxiliary film comprising a body and a plurality of microstructures formed on a first surface of the body, the microstructures include a concave-convex appearance on the first surface, and the microstructures have two ends extending to the periphery of the first surface respectively. When the auxiliary film is attached to a pre-protected surface of a substrate, the microstructures and the surface of the substrate form several open-air channels to increase the separation efficiency of the main body from the substrate and reduce the overall process time.