Roll-to-Roll Patterned Layer Milling Without Chemical Etching
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Solution Overview
Problem
Existing methods for manufacturing electrical conductors on flexible backings are inefficient due to multi-step processes, environmental concerns from chemical etching, and costly lubricant usage, which hinder cost-efficiency and resource management.
Innovation Solution
A method involving a multilayer material processed with a cutting fluid applied via roll-to-roll techniques, passed through a nip formed by a milling cutter and patterned cliché cylinder to create patterned layers, reducing the need for chemical etching and lubricant application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chemical etching is used to create patterns on conductive layers, then the patterning process can be performed, but it causes environmental pollution and waste management problems
Solution Approach 1:
The patent replaces chemical etching with a mechanical milling process. A milling wheel with cutting edges mechanically removes material from the conductive top layer to create the desired pattern, eliminating the need for chemical substances and their associated environmental problems.
Solution Approach 2:
The patent extracts and removes the harmful chemical etching step from the manufacturing process, replacing it with a mechanical alternative that achieves the same patterning function without generating chemical waste or pollution.
2Manufacturing precision
If lubricant is applied by aerosol to enhance pattern quality, then the end product quality improves, but it increases costs and contaminates the working environment
Solution Approach 1:
The patent uses a liquid delivery system (hydraulic principle) to apply lubricant directly to the material surface through a delivery means, replacing the aerosol application method. This provides controlled lubricant delivery without the environmental contamination and cost issues of aerosol application.
Solution Approach 2:
The patent introduces a controlled lubricant delivery system as an intermediary between the milling process and the material surface, allowing precise application of lubricant only where needed, rather than using aerosol which disperses lubricant throughout the working environment.
3Manufacturing precision
If aerosol lubricant application is used to improve pattern quality, then manufacturing precision improves, but device complexity increases due to additional cleaning steps
Solution Approach 1:
The patent employs a direct liquid delivery system using hydraulic principles to apply lubricant precisely to the material surface during milling, eliminating the need for subsequent cleaning steps and reducing overall process complexity compared to aerosol application.
4Ease of manufacture
If low feeding rate is used in continuous process, then the mechanical milling process can be performed, but productivity decreases
Solution Approach 1:
The patent implements a continuous manufacturing process where the material is fed continuously through the milling wheel at optimized speeds. The milling wheel rotates continuously and removes material in a sustained manner, maintaining both high productivity and continuous process capability without requiring low feeding rates.
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 approach enables high-quality, cost-efficient, and environmentally friendly production of patterned layers with reduced waste and equipment contamination, improving process control and resource utilization.
Implementation Method 1
providing a cutting fluid on an exposed surface of the multilayer material
Implementation Method 2
The cutting fluid is provided on the exposed surface by roll-to-roll processing
Data Source
Figure 1a~1f
Figure 2a~2b
Figure 3a~3b
AI summary
The document relates to a method of producing a product comprising a substrate with at least one patterned layer from a multilayer material (1), the method comprising: providing the multilayer material (1) comprising at least a first layer (10) and a second layer (20); providing a cutting fluid (8) on an exposed surface of the multilayer material (1); and passing the multilayer material (1) through at least one nip (6), wherein said nip (6) is provided by a milling cutter (51) cooperating with a patterned cliché cylinder (52), to at least partially, as seen in a thickness direction of the first layer (10), remove at least some predetermined portions of material from at least the first layer (10) of the multilayer material (1). The cutting fluid (8) is provided on the exposed surface (15) by roll-to-roll processing the cutting fluid (8) on the exposed surface (15).