Non-Planar Double-Sided Adhesive Sheet for Wrinkle-Free Conformal Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional double-sided adhesive tapes with adhesive layers on both surfaces of nonwoven fabrics face challenges when applied to non-planar surfaces, leading to wrinkles, gaps, and complex application processes, especially when multiple tapes are required or cuts are needed to conform to shapes.
Innovation Solution
A double-sided adhesive sheet with a pre-formed non-planar shape, featuring an adhesive member and separation films, which allows for direct conforming to non-planar adherends, reducing wrinkles and simplifying the application process by eliminating the need for multiple tape application and cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double-sided adhesive tape is affixed to a non-planar adherend, then the adherend and the adhesive member can be joined together, but wrinkles occur easily in the adhesive member
Solution Approach 1:
The adhesive member is designed with a non-planar shape that includes a curved surface corresponding to the non-planar shape of the adherend. This curvature allows the adhesive member to conform to the adherend's surface, eliminating wrinkles while maintaining reliable joining. The curved surface is specifically shaped to match the three-dimensional contours of the target adherend.
Solution Approach 2:
The invention changes the geometric parameters of the adhesive member from a flat planar shape to a non-planar three-dimensional shape. This parameter change enables the adhesive member to adapt to non-planar adherends, solving both the wrinkle formation problem and maintaining joining reliability on curved surfaces.
2Manufacturing precision
If multiple double-sided adhesive tapes are combined or cuts are added to conform to the adherend shape, then wrinkle occurrence is reduced, but the affixing operation becomes complicated
Solution Approach 1:
The non-planar shape of the adhesive member is formed in advance during manufacturing, before the affixing operation. This preliminary shaping eliminates the need for complex on-site operations such as combining multiple tapes or making cuts, allowing for simple and direct affixing while maintaining surface conformity to the adherend.
Solution Approach 2:
Instead of using multiple separate adhesive tapes that need to be combined, the invention uses a single integrated adhesive member with a non-planar shape. This segmentation into one pre-formed component simplifies the affixing operation while achieving the same surface conformity that would otherwise require multiple pieces.
3Reliability
If a double-sided adhesive tape is used on a non-planar adherend, then joining is achieved, but spaces or gaps are produced between the adherend and the adhesive member
Solution Approach 1:
The non-planar shape of the adhesive member, including its curved surfaces, enables complete contact with the non-planar adherend. This eliminates gaps and spaces between the adherend and adhesive member, maximizing the contact area and ensuring reliable joining strength across the entire interface.
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
Facilitates easy and reliable adhesion to non-planar surfaces, minimizing wrinkles and gaps, while allowing for insulation and reduced adherend size, with the ability to maintain the non-planar shape through thermoplastic polymer separation films.
Implementation Method 1
with the ability to maintain the non-planar shape through thermoplastic polymer separation films
Data Source
Figure 1A~1B
Figure 2~2D
Figure 3~3C
AI summary
A double-sided adhesive sheet is provided in which while it is possible to facilitate an operation of affixing a double-sided adhesive tape to an adherend, it is possible to reduce the occurrence of wrinkles in an adhesive member when the adhesive member is adhered to the adherend. The double-sided adhesive tape (1) includes the adhesive member (2) which is formed in the shape of a film and whose both surfaces in a thickness direction have an adhesive force and a pair of separation films (3) which are arranged so as to sandwich the adhesive member (2) in the thickness direction. The double-sided adhesive tape (1) is formed so as to have a non-planar shape.