Segmented Roller Encapsulating Rubber for Flexible Substrate Attachment

Solution Overview

Problem

The existing methods for attaching a backing film to a flexible substrate result in non-uniform force distribution, leading to irreversible deformation and size variations of the flexible substrate, which can cause misplacement of terminals and circuit failures during bonding with a flexible circuit board.

Innovation Solution

A method and device using a rolling mechanism with a roller encapsulated in segmented roller encapsulating rubber, optionally incorporating a cutter wheel and spacer, to distribute pressure uniformly and prevent excessive deformation, ensuring consistent attachment of the backing film to the flexible substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a roller with continuous roller encapsulating rubber is used to attach the backing film to the flexible substrate, then the attachment process can be completed, but the flexible substrate undergoes irreversible deformation and size variation due to non-uniform pressure distribution

Engineering Contradiction:

Improveattachment processVSAvoidsize uniformity of flexible substrate

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The roller encapsulating rubber is divided into multiple independent segments along the rolling direction. Each segment can independently deform and recover under pressure, preventing stress accumulation at the edges. This segmentation resolves the technical contradiction by maintaining attachment functionality while eliminating the non-uniform pressure distribution that caused substrate deformation and size variation.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a roller with continuous roller encapsulating rubber is used to attach the backing film to the flexible substrate, then the attachment process can be completed, but excessive pressure accumulates at both sides of the roller causing irreversible deformation

Engineering Contradiction:

Improveattachment processVSAvoidexcessive pressure and deformation

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The roller encapsulating rubber is divided into multiple independent segments along the rolling direction. Each segment can independently deform and recover under pressure, preventing stress accumulation at the edges. This segmentation resolves the technical contradiction by maintaining attachment functionality while eliminating the non-uniform pressure distribution that caused substrate deformation and size variation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The segmented structure of the roller encapsulating rubber provides inherent cushioning by allowing each segment to independently absorb and distribute pressure. This prevents excessive pressure accumulation at the edges before it can cause harmful deformation to the flexible substrate, effectively cushioning the substrate from damaging forces.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Area of stationary object

If the size of the roller is increased for high generation production line with larger substrates, then the coverage area increases, but the problem of non-uniform pressure and substrate deformation becomes more severe

Engineering Contradiction:

Improveroller coverage areaVSAvoidsize uniformity of flexible substrate

Core Design Contradiction:

Area of stationary objectVSManufacturing precision

Solution Approach 1:

The roller encapsulating rubber is divided into multiple independent segments along the rolling direction. Each segment can independently deform and recover under pressure, preventing stress accumulation at the edges. This segmentation resolves the technical contradiction by maintaining attachment functionality while eliminating the non-uniform pressure distribution that caused substrate deformation and size variation.

Inventive Principle:

Principle #1Segmentation

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

The solution achieves uniform force distribution, reducing size variations of the flexible substrate and improving the attachment process, thereby enhancing product yield by minimizing misplacement and circuit failures.

Implementation Method 1

a roller is encapsulated on an external surface thereof with roller encapsulating rubber made of organic material with elasticity

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

pressing the flexible substrate placed on the first worktable and the backing film placed on the second worktable with a rolling mechanism to attach them together

Methodology Applied

Scientific EffectPressure distribution: Pressure Gradient

Data Source

PatentUS10464297B2Method and device for attaching backing film to flexible substrate and roller

Publication Date: 2019.11.05 BOE TECHNOLOGY GROUP CO LTD

AI summary

A method and a device for attaching a backing film to a flexible substrate and a roller for use therewith. The method includes placing the flexible substrate on a surface of a first worktable facing a second worktable and placing the backing film on a surface of the second worktable facing the first worktable; pressing the flexible substrate and the backing film by a rolling mechanism to attach them together. The rolling mechanism includes a roller having a surface encapsulated with segmented roller encapsulating rubber.