Pocket Roller for Continuous Chip Placement on Moving Web
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for assembling rigid electronic chips with flexible substrates in a roll-to-roll setting require frequent stopping and starting of the web, which is inefficient and costly.
Innovation Solution
A method and system that utilize a roller with a sleeve featuring an array of pockets to continuously place rigid objects onto a moving web without significantly altering the web's speed, using an adhesive surface to attach the objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the web is stopped to place chips on it, then the chip placement can be performed accurately, but the production efficiency decreases and time is lost
Solution Approach 1:
The pocket roller is pre-loaded with multiple rows of chips in pockets before the web arrives. This preliminary preparation allows chips to be ready for immediate transfer when the web passes by, eliminating the need to stop the web for chip loading while maintaining accurate placement
Solution Approach 2:
The pocket roller acts as an intermediary device that holds chips and transfers them to the moving web. This mediator enables continuous web movement while still achieving precise chip placement through the mechanical transfer mechanism from roller pockets to web surface
2Manufacturing precision
If the web is stopped frequently for chip placement, then precise control of chip positioning is achieved, but the process time increases
Solution Approach 1:
The web moves continuously through the process without stopping. The pocket roller rotates continuously and transfers chips at the appropriate position, maintaining continuous useful action throughout the placement process rather than interrupting with stop-start cycles
Solution Approach 2:
Chips are pre-positioned in the rotating pocket roller before web contact. This preliminary arrangement ensures that when the web passes by, chips are already in the correct positions for transfer, eliminating time loss while maintaining positioning precision
3Ease of manufacture
If the web speed is changed during chip placement, then chip transfer can be accomplished, but the simplicity of the process is reduced
Solution Approach 1:
The pocket roller is pre-loaded with chips at a stationary loading station before the web arrives. This preliminary chip loading eliminates the need for complex speed variations during the actual transfer, maintaining process simplicity
Solution Approach 2:
The pocket roller serves as a mechanical intermediary that simplifies the transfer process. By using the roller's rotation and pocket mechanism, the system achieves chip transfer without complex speed control variations, maintaining ease of manufacture
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
Enables continuous web movement during chip placement, improving efficiency and reducing costs by eliminating the need for frequent web stops, while also allowing for integration with other web processes like coating.
Implementation Method 1
engaging the roller sleeve with an adhesive surface of the web, and separating the moving web from the roller sleeve such that the plurality of rigid objects is attached to the adhesive surface of the web
Data Source
AI summary
Methods and systems of using pocket roller (110, 130) to place objects on a continuously moving web (2) are provided. The objects are received in an array of pockets (124) on a major surface of a roller sleeve (120). The roller sleeve (120) engages with an adhesive surface (22) of the continuously moving web (2) to place the objects on the web (2).