Resin Sheet Attachment via Slit Segmentation for Precision Joining
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Solution Overview
Problem
Conventional methods for manufacturing joined bodies using resin materials face challenges in accurately attaching the resin material to the first substrate due to deformation and size discrepancies when cutting and attaching the resin sheet.
Innovation Solution
A method involving the attachment of a sheet material with resin on one surface to the first base material, followed by forming slits for ease of separation, allowing for precise separation of the resin material to remain on the predetermined area, thereby eliminating the need for preliminary cutting and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sheet-like resin material is cut in accordance with the position of the first substrate before attachment, then the resin material can be positioned according to the substrate outline, but the resin material deforms during cutting and attachment, causing size discrepancies
Solution Approach 1:
The resin material is attached to the first substrate in its original sheet form before any cutting or separation operations. This preliminary attachment action ensures that the resin material maintains its intended size and shape characteristics during the attachment process, avoiding deformation that would occur if cutting were performed beforehand. The subsequent slit formation and separation steps then define the final resin material boundaries without causing attachment-related deformation.
2Shape
If the resin material is attached without preliminary cutting, then deformation is minimized, but the resin material covers a larger area than needed, requiring additional separation steps
Solution Approach 1:
The resin material sheet is segmented by forming slits that extend from the perimeter toward the center, dividing the sheet into multiple regions. These slits create separation paths that allow the resin material to be divided into portions that remain attached to the substrate and portions that are removed. This segmentation approach enables precise definition of the final resin material boundaries while maintaining the benefit of attaching the full sheet first to minimize deformation.
3Ease of manufacture
If peeling tape is used to remove unnecessary resin material, then the resin material can be separated from the substrate, but the attachment accuracy is compromised due to resin material deformation during peeling
Solution Approach 1:
Slits are formed in the resin material sheet to create defined separation paths before any peeling or removal operations. These slits segment the resin material into regions that are intended to remain attached and regions that will be removed. By pre-segmenting the material, the subsequent peeling process only affects the designated removal areas, preventing deformation and accuracy issues that would occur if peeling were attempted across the entire sheet without pre-defined separation lines.
Data Source
AI summary
The present invention provides a joined body manufacturing method with which the resin material is accurately attached to the first base material. The method includes: an attaching step of attaching a sheet material having resin material on one main surface of a sheet base material to a first base material such that a predetermined area is covered; a forming step of forming a slit for ease of separation on the sheet material attached to the first base material in accordance with the predetermined area; and a separating step of separating part of the resin material inside the slit from the sheet base material such that the part of the resin material inside the slit remains on the predetermined area of the first base material and part of the resin material outside the slit does not remain on the first base material.