Rolled-Up Electronic Component Perforated Sacrificial Layer
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Solution Overview
Problem
Current methods for producing rolled-up electrical and electronic components, such as capacitors and antennas, face challenges including large active component areas, long roll lengths, and non-reproducible rolling processes, often requiring harmful etching agents and solvents, which are environmentally unfriendly and time-consuming.
Innovation Solution
A method involving a sacrificial layer with perforated functional and insulating layers applied to a substrate, where the perforations act as predetermined breaking points for rolling, using water-soluble polymers or stable polymers for the sacrificial layer, and materials like Ti, Cr, and Al2O3 for conductive and insulating layers, allowing for efficient and environmentally friendly rolling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sacrificial layer is used for rolling up components, then the component structure can be formed, but the rolling process becomes non-reproducible and time-consuming with long durations
Solution Approach 1:
Perforations are created in the functional or insulating layer before the rolling process, establishing predetermined breaking points that guide the rolling behavior. This preliminary structuring ensures reproducible rolling patterns and reduces process variability, eliminating the need for lengthy trial-and-error rolling procedures.
Solution Approach 2:
The functional or insulating layer is segmented through perforations that create discrete breaking points. This segmentation allows the layer to be divided into manageable sections during rolling, enabling controlled and reproducible formation of the rolled-up structure without requiring excessive time for the entire process.
2Reliability
If large active component areas are used to achieve desired capacitance, then electrical performance is improved, but the roll length increases and production time increases
Solution Approach 1:
The invention transitions from a two-dimensional planar layout to a three-dimensional rolled-up structure. By stacking multiple layers and rolling them into a compact cylindrical form, large active component areas are achieved within a small footprint, enabling high capacitance without proportionally increasing roll length or production time.
Solution Approach 2:
Multiple functional layers are nested within each other in a stacked configuration before rolling. This nesting arrangement allows the layers to be compactly organized, enabling large total active areas to be contained within a compact rolled structure, thus maintaining high productivity while achieving desired electrical performance.
3Ease of manufacture
If harmful etching agents are used to remove sacrificial layers, then the sacrificial layer can be effectively removed, but environmental harm and safety issues arise
Solution Approach 1:
The sacrificial layer is designed as a disposable temporary structure that can be easily removed after serving its purpose of enabling layer stacking. By using materials like photoresist or water-soluble polymers that can be removed with benign solvents or water, the invention eliminates the need for harmful etching agents while maintaining manufacturing efficiency.
Solution Approach 2:
The sacrificial layer acts as an intermediary material that facilitates the stacking and rolling process but is subsequently removed. By choosing sacrificial materials that can be eliminated through environmentally friendly means (water, mild solvents), the harmful intermediary step of using aggressive etchants is replaced with a benign removal process.
4Reliability
If long roll lengths are used to achieve many turns, then component performance is improved, but the rolling process becomes more complex and less reproducible
Solution Approach 1:
Perforations are pre-formed in the layers to create predetermined breaking points that guide the rolling process. This preliminary structuring ensures that even for long roll lengths requiring many turns, the rolling follows a reproducible path defined by the perforation pattern, reducing process complexity and improving reliability.
Solution Approach 2:
The perforation pattern provides localized structural features at specific positions along the layer. These local quality variations (perforations at specific intervals) guide the rolling behavior throughout the entire length, enabling reproducible rolling of long structures without requiring complex overall process control.
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 cost-effective, time-saving production of rolled-up components with many turns and large roll lengths, ensuring a uniform and high-speed rolling process without stress on the layer stack, using environmentally friendly solvents like water and ethylenediaminetetraacetic acid.
Implementation Method 1
The sacrificial layer is subsequently removed and the layer stack is rolled up
Implementation Method 2
A hydrogel can also be used as the lower part of the layered structure; this hydrogel is brought into contact with water, absorbs the water, swells, and causes the layer stack to roll up
Implementation Method 3
plasma or wet chemical etching of a silicon substrate is known, such that the deposited, strained two-dimensional structure is rolled up
Implementation Method 4
plasma or wet chemical etching of a silicon substrate is known
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
AI summary
The present invention relates to the fields of physics, material sciences and micro and nano electronics, and concerns a method for producing a rolled-up electrical or electronic component, as can be used for example as a capacitor, or in aerials. The object of the present invention is to provide a low-cost, environmentally friendly and time-saving method for producing a rolled-up electrical or electronic component with many windings. The object is achieved by a method for producing a rolled-up component in which at least two functional and insulating layers, alternately arranged fully or partially over one another, are applied to a substrate with a sacrificial layer, wherein at least the functional or insulating layer that is arranged directly on the sacrificial layer has a perforation, at least on the two sides that are arranged substantially parallel to the rolling direction.