Thermally Conductive Sheet Transfer via Movable Plate and Belt
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing thermally conductive sheets face challenges in maintaining the shape and dimensional accuracy of the sheets during the transfer process due to their soft and deformable nature.
Innovation Solution
A method involving the formation of an adhesive sheet using a resin composition with fillers, followed by a scoop-up step using a movable plate with a transfer belt, and an arrangement step on a rough surface of a second film, which helps in minimizing deformation and maintaining dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a soft and deformable sheet is used for thermal conduction, then adhesion and filling capability are improved, but dimensional accuracy and shape stability during transfer deteriorate
Solution Approach 1:
The sheet is pre-formed and pre-shaped on a first film before transfer. The preliminary shaping action ensures the sheet achieves its final dimensional accuracy before being transferred to the second film, preventing deformation during the transfer process while maintaining the softness needed for adhesion and filling.
Solution Approach 2:
A transfer film serves as an intermediary carrier between the first film (where the sheet is formed) and the second film (where the sheet is applied). This intermediary allows the soft, deformable sheet to be transferred while maintaining its shape, as the transfer film provides a stable medium that prevents direct contact and deformation during handling.
2Reliability
If grease is used instead of sheet for thermal conduction, then thermal resistance is reduced, but workability and fixation capability deteriorate
Solution Approach 1:
The invention changes the physical state parameter from liquid (grease) to solid/semisolid (sheet), while maintaining the thermal conductivity properties. This parameter change enables the material to be processed, handled, and fixed without dripping or pump-out issues, while still achieving low thermal resistance through the use of thermally conductive fillers.
Solution Approach 2:
The sheet is formed as a composite material combining resin (providing structural integrity and workability) with thermally conductive fillers (providing low thermal resistance). This composite structure resolves the contradiction by integrating the advantages of both materials: the resin provides fixation capability and prevents dripping, while the thermally conductive fillers maintain low thermal resistance.
Data Source
Figure 1(a)~1(c)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
A method for producing a sheet, including a sheet forming step of forming a raw material sheet on a smooth surface of a first film using a resin composition containing a resin and fillers, stamping the raw material sheet into a given shape, and removing an unnecessary portion, thereby forming an adhesive sheet; a scoop-up step of sending forward a movable plate that has a transfer belt surrounding the movable plate into a gap between the adhesive sheet and the first film, thereby scooping up the adhesive sheet onto the movable plate via the transfer belt; and an arrangement step of sending back the movable plate to arrange on a rough surface of a second film the adhesive sheet that has been scooped up onto the movable plate, in which the scoop-up step includes sending forward the movable plate while feeding the transfer belt to a side of a main surface of the movable plate from a side of a back surface of the movable plate, and the arrangement step includes sending back the movable plate while feeding back the transfer belt to the side of the back surface of the movable plate from the side of the main surface of the movable plate.