Nickel Mold Flat-Pressing for Bionic Adhesive Structures
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Solution Overview
Problem
Current manufacturing methods for bionic adhesive structures with expanded tips face challenges in large-scale production due to the complexity of processing metal molds with high hole densities and the physical behavior of interfaces during molding, limiting their widespread adoption.
Innovation Solution
A flat-pressing manufacturing method using a micro through-hole nickel-based mold, where a nickel-based mold with a micro through-hole array is prepared and placed on an elastic pad in a magnetic mold closing system, allowing for uniform prepolymer filling and curing, and subsequent demolding to produce bionic adhesive structures with tip expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal molds are used for high hole density arrays, then mold strength and durability are improved, but processing difficulty and interface control complexity increase
Solution Approach 1:
The patent replaces traditional mechanical drilling and machining methods with laser processing technology to create high-density hole arrays in metal molds. The laser processing method can precisely control hole position, size, and density without the mechanical constraints of traditional machining, thereby maintaining mold strength while reducing processing difficulty for high hole density arrays (hole density>10,000/cm2).
Solution Approach 2:
The patent changes the processing parameters by using laser technology instead of mechanical methods, allowing for precise control of hole diameter, spacing, and depth. This parameter control enables the creation of complex high-density hole arrays while maintaining the integrity and strength of the metal mold structure.
2Reliability
If roll-pressing process is used, then tip face sealing is improved, but injection molding and demolding difficulty increase
Solution Approach 1:
The patent inverts the traditional roll-pressing approach by using flat pressing instead. The flat pressing method places the mold directly against the substrate without requiring roller curvature, simplifying the injection molding process and facilitating easier demolding while still achieving effective tip face sealing through proper contact pressure and mold design.
3Manufacturing precision
If silicon-based lithography template is used, then bionic adhesive material preparation is achieved, but mold fragility limits large-scale production
Solution Approach 1:
The patent changes the material parameter from silicon-based templates to metal-based molds, which fundamentally alters the mechanical properties while maintaining the ability to create precise bionic adhesive structures. The metal mold provides the necessary strength and durability for large-scale production while retaining the precision required for bionic adhesive material preparation.
Solution Approach 2:
The patent employs composite material strategies by combining metal mold structures with precise hole array patterns, creating a hybrid solution that integrates the strength of metal with the precision of lithography-based designs. This composite approach enables both high manufacturing precision and large-scale production capability.
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 method enables high-efficiency, high-precision, and low-cost manufacturing of large-area micro/nano structures, overcoming the technical bottlenecks of tip-expanded structure imprinting and improving the universality of micro/nano imprinting technology.
Implementation Method 1
placing the nickel-based mold on an elastic pad in a magnetic mold closing system... apply a uniform pressure on the backing layer and achieve a full filling of cavities of through-holes by the prepolymer
Implementation Method 2
magnetic mold closing system... apply a uniform pressure on the backing layer
Implementation Method 3
coating a prepolymer uniformly on a backing... performing a vacuum treatment on the lower chamber and an inflation treatment on the upper chamber to apply a uniform pressure on the backing layer and achieve a full filling of cavities of through-holes by the prepolymer
Data Source
AI summary
A flat-pressing manufacturing method of a bionic adhesive structure based on a micro through-hole nickel-based mold is disclosed. The method includes the following steps: preparing a nickel-based mold with a micro through-hole array; placing the nickel-based mold on an elastic pad in a magnetic mold closing system; coating a liquid prepolymer uniformly on a backing, and placing a side of the backing coated with the liquid prepolymer on the nickel-based mold, covering a sealing diaphragm on the backing to separate a cavity into an upper chamber and a lower chamber, and performing a vacuum treatment on the lower chamber and an inflation treatment on the upper chamber to apply a uniform pressure on the backing layer and achieve a full filling of prepolymers with different viscosities; and after the filling is completed, curing and demolding to obtain the bionic adhesive structure.