Light-Transmissive Sheet Manufacturing via Thermal Crosslinking
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Solution Overview
Problem
The existing methods for manufacturing light-transmissive sheets, which involve radiation cross-linking, require large equipment and safety measures, leading to increased manufacturing costs and potential surface irregularities.
Innovation Solution
A method involving the use of a first support with a B-stage resin, which is heated to convert it to a C-stage in the presence of a second support, reducing surface irregularities and manufacturing costs by eliminating the need for large equipment and radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If radiation cross-linking is used to manufacture light-transmissive sheets, then crosslinking can be performed without generating irregularities on the support and light-transmissive sheet, but large-sized equipment is required due to safety measures and construction of the surrounding environment is required, leading to increased manufacturing costs
Solution Approach 1:
The patent replaces the radiation cross-linking system with a thermal cross-linking system. Instead of using radiation equipment (which requires large-sized equipment and safety measures), the invention uses a heating device to heat the polyorganosiloxane-containing sheet to a temperature of 50°C or higher, achieving cross-linking through thermal energy. This substitution eliminates the need for complex radiation safety infrastructure while maintaining cross-linking effectiveness.
Solution Approach 2:
The patent changes the cross-linking activation parameter from radiation exposure to temperature. By controlling the temperature parameter (heating to 50°C or higher), the polyorganosiloxane undergoes cross-linking reaction. This parameter change allows the use of conventional heating equipment instead of specialized radiation equipment, reducing device complexity and manufacturing costs while achieving the desired cross-linking degree.
2Manufacturing precision
If radiation cross-linking is used to manufacture light-transmissive sheets, then crosslinking can be performed without generating irregularities on the support and light-transmissive sheet, but construction of the surrounding environment is required, leading to increased manufacturing costs
Solution Approach 1:
The patent replaces the radiation cross-linking system with a thermal cross-linking system. Instead of using radiation equipment (which requires large-sized equipment and safety measures), the invention uses a heating device to heat the polyorganosiloxane-containing sheet to a temperature of 50°C or higher, achieving cross-linking through thermal energy. This substitution eliminates the need for complex radiation safety infrastructure while maintaining cross-linking effectiveness.
Solution Approach 2:
The patent employs a simple, conventional heating device instead of expensive radiation equipment. The heating method uses readily available thermal energy sources and standard heating apparatus, which are much cheaper and more accessible than radiation cross-linking equipment. This approach makes the manufacturing process more economical while achieving the same cross-linking result without requiring special facility construction.
3Manufacturing precision
If a sheet before cross-linking containing polyorganosiloxane and phosphor is irradiated with radiation to crosslink the polyorganosiloxane, then crosslinking can be performed without generating irregularities on the support and light-transmissive sheet, but large-sized equipment is used due to safety measures
Solution Approach 1:
The patent replaces the radiation cross-linking system with a thermal cross-linking system. Instead of using radiation equipment (which requires large-sized equipment and safety measures), the invention uses a heating device to heat the polyorganosiloxane-containing sheet to a temperature of 50°C or higher, achieving cross-linking through thermal energy. This substitution eliminates the need for complex radiation safety infrastructure while maintaining cross-linking effectiveness.
Solution Approach 2:
The patent changes the cross-linking activation parameter from radiation exposure to temperature. By controlling the temperature parameter (heating to 50°C or higher), the polyorganosiloxane undergoes cross-linking reaction. This parameter change allows the use of conventional heating equipment instead of specialized radiation equipment, reducing device complexity and manufacturing costs while achieving the desired cross-linking degree.
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 method allows for the easy production of light-transmissive sheets with few surface recesses and projections, achieving a smooth and stable surface while reducing costs associated with large equipment and safety measures.
Implementation Method 1
heating the first resin member to convert the first resin member from the B-stage to a C-stage
Data Source
AI summary
A method of manufacturing a light-transmissive sheet includes: preparing a first support with a first resin in a B-stage being placed on a surface of the first support; preparing a second support; and heating the first resin to convert the first resin from the B-stage to a C-stage, in a state in which the second support is placed on a surface of the first resin.