Precision Microspace Formation via Dual-Stage Lamination

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Solution Overview

Problem

Conventional methods for forming precision microspaces are inefficient due to high production steps, limited material selection, and difficulties in maintaining constant configuration and volume, leading to issues like film sag and adhesion problems, especially in liquid-ejecting devices.

Innovation Solution

The method involves setting the uppermost face of a second stage higher than the first stage to prevent film sag and maintaining constant pressure per unit contact area during film laying on a substratum with precision microscopic depressed portions, using a photosensitive laminated film to ensure precise and consistent microspace formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If films are laid on substrata having precision microscopic depressed portions with enhanced compliance and adhesiveness, then adhesion between film and substratum is improved, but films occasionally enter into the precision microscopic depressed portion causing configuration and volume variation

Engineering Contradiction:

Improveadhesion between film and substratumVSAvoidconfiguration and volume of precision microspace

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies different compliance characteristics to different regions of the substratum. The central portion has high compliance to ensure film adhesion, while the peripheral portion has low compliance to prevent film from entering the precision microscopic depressed portion. This local differentiation resolves the contradiction between adhesion and precision by optimizing each region's properties for its specific function.

Inventive Principle:

Principle #3Local quality

2Strength

If pressure per unit contact area is increased at contacting portions to prevent film sag, then film adhesion is improved, but films enter into the precision microscopic depressed portion at periphery portions

Engineering Contradiction:

Improvefilm adhesionVSAvoidprecision microspace configuration

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent implements local quality by creating regions with different compliance characteristics - the central portion maintains high compliance for good film adhesion while the peripheral portion has reduced compliance to prevent film intrusion into precision microspaces. This spatial differentiation of mechanical properties resolves the contradiction between achieving sufficient adhesion and maintaining precision.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If conventional methods with multiple plate-like members and adhesive consolidation are used, then precision microspace formation is achieved, but the number of production steps is great and production efficiency is reduced

Engineering Contradiction:

Improveprecision microspace formationVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges multiple separate components (substratum with precision microscopic depressed portions and a separate film) into a single integrated structure through direct lamination. This eliminates the need for multiple plate-like members and adhesive consolidation steps, thereby maintaining precision microspace formation while significantly reducing production steps and improving productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The precision microscopic depressed portions are pre-formed on the substratum before film lamination. This preliminary action allows the film to be directly laminated onto the substratum to form precision microspaces in a single step, eliminating the need for subsequent complex assembly operations and improving production efficiency.

Inventive Principle:

Principle #10Preliminary action

4Strength

If film compliance is increased to improve adhesion, then film enters into precision microscopic depressed portions, but if film compliance is decreased to prevent entry, then adhesion force weakens causing peeling

Engineering Contradiction:

Improveadhesion forceVSAvoidprecision microspace configuration

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS8187408B2Method of forming precision microspace, process for manufacturing member with precision microspace, and photosensitive laminated film

Publication Date: 2012.05.29 TOKYO OHKA KOGYO CO LTD

AI summary

A method of forming a precision microspace with given configuration and volume; a process for manufacturing a member having a precision microspace with given configuration and volume; etc. There is provided a method of forming a precision microspace by the step of laying a film on a substratum having a precision microscopic depressed portion, comprising the steps of mounting such a substratum on a first stage and setting a second stage covering the outer circumference of the first stage so that the uppermost face of the second stage is higher than that of the first stage; and laying a film on the substratum to thereby obtain a precision microspace with given configuration and volume.