Resin Sheet Slit Cutting for Substrate Attachment Accuracy
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Solution Overview
Problem
Conventional methods face challenges in accurately attaching resin material to substrates due to deformation during processing, leading to inaccuracies in joining.
Innovation Solution
A method involving attaching a sheet material with resin to a substrate, forming a slit along the outline of the attachment area, and separating the resin material within the slit to maintain it on the substrate, thereby avoiding deformation and improving attachment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If resin material is attached to the first substrate before cutting, then the resin material can be processed together with the substrate, but the resin material deforms during processing leading to inaccurate attachment
Solution Approach 1:
The resin material is attached to the first substrate before the cutting process. By performing the attachment action in advance, the resin material and substrate are processed together as an integrated unit, ensuring that the resin material remains in its intended position throughout subsequent processing steps without deformation
Solution Approach 2:
The resin material is attached only to the specific area where the first functional unit will be located, rather than covering the entire substrate. This localized attachment allows the resin material to be precisely positioned and processed together with the substrate without affecting other areas
2Manufacturing precision
If the resin material is cut along the outline before attachment, then the resin material can be precisely sized, but the resin material deforms during cutting and attachment processes
Solution Approach 1:
The cutting process is performed after the resin material is attached to the substrate, rather than before. This reverses the conventional sequence and allows the resin material to be supported by the substrate during cutting, preventing deformation that would occur if the resin material were cut while free-standing
Solution Approach 2:
The resin material is merged with the substrate through attachment before the cutting process. This combination creates a unified structure where the substrate provides support to the resin material during subsequent processing, preventing the resin material from deforming
3Ease of operation
If the resin material is attached to cover the entire substrate, then the attachment process is simple, but unnecessary resin material remains requiring additional removal steps
Solution Approach 1:
The resin material is attached only to the specific area where the first functional unit will be located, rather than covering the entire substrate. This localized approach maintains attachment simplicity while eliminating the need for additional removal steps, as the resin material is precisely positioned where needed from the start
Data Source
AI summary
A method for manufacturing a joined body composed of a first substrate and a second substrate joined together by sealing resin material attached to a predetermined area of the first substrate includes: attaching a sheet material to the first substrate so as to cover the predetermined area, the sheet material including a sheet base material and the resin material provided on one main surface of the sheet base material; forming, after the attaching, in the sheet material, a slit by reducing a thickness of the resin material along an outline of the predetermined area; and separating, after the forming, part of the resin material inside the slit from the sheet base material to keep the part of the resin material inside the slit on the predetermined area of the first substrate and not to keep the rest of the resin material outside the slit on the first substrate.