Solvent Transfer Printing for Irregular 3D Objects
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Solution Overview
Problem
Existing methods for applying patterns made of non-soluble and non-dispersible materials on irregularly shaped objects, such as those with angular or curvilinear surfaces, often result in pleating or breaking due to the rigidity of the substrate, especially when the pattern is spatially extended.
Innovation Solution
A solvent transfer printing method involving the formation of a pattern on a solvent-soluble substrate, partial dissolution of the substrate in a solvent bath, and contact with the object to apply the pattern, followed by drying, with additional steps for maintaining sub-patterns with a mesh layer to prevent pleating and enhance conformal wrapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid substrate is used to carry the pattern, then the pattern can be formed with high precision, but the pattern pleats or breaks when applied to irregularly shaped objects
Solution Approach 1:
The substrate is divided into two functional parts: a rigid support substrate for pattern formation and a soluble sacrificial substrate for pattern transfer. The pattern is first formed on the rigid support substrate with high precision, then transferred to the object surface through the soluble substrate which dissolves during the process, eliminating the rigidity conflict.
Solution Approach 2:
The soluble sacrificial substrate acts as an intermediary carrier between the rigid support substrate and the object surface. It allows the pattern to be formed with high precision on the rigid substrate, then mediates the transfer process by dissolving to release the pattern onto the object, preventing pleating or breaking during application.
2Adaptability or versatility
If the substrate is made flexible to conform to irregular shapes, then the pattern can be applied without pleating, but the manufacturing precision decreases
Solution Approach 1:
The substrate system is segmented into a rigid support substrate for high-precision pattern formation and a flexible soluble sacrificial substrate for conformal transfer. This segmentation allows each substrate to optimize its function: the rigid substrate ensures manufacturing precision while the soluble substrate provides adaptability to irregular shapes during application.
Solution Approach 2:
The soluble sacrificial substrate changes its physical state from solid (providing structural support during pattern formation) to dissolved state (providing flexibility and conformability during application). This parameter change allows the system to achieve both high manufacturing precision and adaptability to irregular shapes at different stages of the process.
3Area of stationary object
If the pattern is spatially extended to cover large areas, then the coverage is improved, but the pattern is more likely to pleat or break on angular objects
Solution Approach 1:
The soluble sacrificial substrate serves as a mediator that supports large-area extended patterns during formation on the rigid substrate, then dissolves during transfer to allow the pattern to conform to angular objects without pleating or breaking. This intermediary function enables both large coverage area and pattern integrity on complex geometries.
Solution Approach 2:
The pattern is preliminarily formed with high precision and extended coverage on the rigid support substrate before transfer. The soluble sacrificial substrate is prepared with this extended pattern, then dissolves during the transfer process to enable the large-area pattern to conform to angular objects without deformation, maintaining both coverage and integrity.
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 the successful application of non-soluble and non-dispersible materials like metals, semiconductors, or cross-linked polymers on complex 3D objects with controlled deformation and extension, maintaining pattern accuracy and flexibility without breaking or pleating.
Implementation Method 1
depositing the solvent-soluble substrate on the surface of a solvent bath, on the side of the substrate opposed to the side on which the pattern is applied, in order to dissolve partially the substrate
Data Source
Figure 1a~1d
Figure 1e~1f
Figure 2A~2B
AI summary
Solvent transfer printing method for applying a pattern (1) made of a non-soluble material and non-dispersible (10) on the surface of an object (2), the method comprising the following steps: m1/ forming a pattern (1) on a surface of a solvent-soluble substrate (3), m2/ depositing the solvent-soluble substrate (3) on the surface of a solvent bath (5), on the side of the substrate opposed to the side on which the pattern is applied, in order to dissolve partially the substrate (3), m3/ dipping the object (2) in the bath (5), so that the surface of the object (2) comes into contact with the pattern (1), m4/ getting the object (2), on which the pattern (1) is applied, out of the bath (5), m5/ drying the object (2).