Photopolymerizable Layer Thickness Control via Transparent Support Irradiation
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Solution Overview
Problem
Existing methods for producing polymer layers on supports face challenges in achieving uniform thickness and ensuring strong adhesion, often resulting in complicated processes and low adhesion of polymer layers to the support.
Innovation Solution
A method involving the application of a photopolymerizable liquid composition to a support, where partial polymerization is initiated through irradiation, allowing for the formation of a polymer layer with a predetermined thickness, which adheres well to the support, using transparent supports and controlling layer thickness through irradiation intensity, duration, and support properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polymerization methods are used to produce polymer layers on supports, then complete polymerization can be achieved, but the layer thickness control becomes very complicated and adhesion to the support remains low
Solution Approach 1:
The patent applies partial polymerization by irradiating the photopolymerizable liquid composition through the support to only a limited depth, leaving the upper portion unpolymerized. This partial action enables precise thickness control without requiring complex process adjustments, as the polymerized layer depth is directly determined by the irradiation penetration depth through the transparent support.
2Strength
If conventional polymerization methods are used to produce polymer layers on supports, then complete polymerization can be achieved, but the adhesion of the polymer layer to the support is only low
Solution Approach 1:
The patent creates local quality differentiation by forming a polymerized layer only in the region adjacent to the support through irradiation through the support. This localized polymerization ensures strong adhesion at the support interface where polymerization occurs, while the upper unpolymerized portion remains removable, achieving both strong adhesion and layer uniformity.
3Strength
If the support thickness is increased to provide mechanical stability, then mechanical stability is improved, but transparency for light irradiation decreases
Solution Approach 1:
The patent utilizes parameter changes by selecting supports with specific optical properties (UV transparency) and adjusting the irradiation parameters (intensity, wavelength, duration) to match the support characteristics. This allows optimization of both mechanical stability and light transmission by tuning the irradiation parameters rather than changing the support itself.
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 the simple production of uniform, well-adhering polymer layers with controlled thickness, suitable for applications such as biosensors, by ensuring mechanical stability and transparency, while eliminating distortions and mechanical tolerances.
Implementation Method 1
irradiation of the photopolymerizable liquid composition through the support in such a way that only partial polymerization of the liquid composition takes place
Data Source
AI summary
A method for producing a polymer layer on a transparent support. A photopolymerizable liquid composition is applied to the support. The photopolymerizable liquid composition is irradiated through the support such that polymerization of the liquid composition starts at the surface of the support and ends at a predetermined distance over the surface of the support. Only partial polymerization of the liquid composition takes place. A polymer layer with a predetermined thickness is formed on the support wherein the predetermined thickness is less than the thickness of the photopolymerizable liquid composition. The remaining photopolymerizable liquid composition is removed from the entire polymer layer.