UV-Cured Protective Resin Sheet for Residue-Free Workpiece Bonding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for protecting workpieces during processing, such as grinding or division, using adhesive tapes result in residue and vibration issues, leading to potential breakage and scattering of chips due to adhesive residue and thermoplastic resin shrinkage during cooling.
Innovation Solution
A manufacturing method involving a mixed resin of thermoplastic resin with a solubility parameter of 8.5 or higher, combined with a liquid ultraviolet-curable resin, is used to form a protective component by curing with UV rays and integrating it with the workpiece without heating, reducing shrinkage and size variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to protect the workpiece surface, then protection from damage and contamination is achieved, but adhesive residue is left on the workpiece and the workpiece becomes more likely to vibrate during processing
Solution Approach 1:
The invention changes the material parameters by using a thermoplastic resin with specific glass transition temperature (Tg) range (0°C to 100°C) and specific physical properties. The resin is selected based on its flow characteristics at processing temperatures, ensuring it provides protection without leaving residue. The key parameter change is selecting resins with Tg below the processing temperature but above room temperature, allowing the resin to be applied in a viscous state and then solidify to provide stable protection.
Solution Approach 2:
The invention uses composite material structure consisting of the thermoplastic resin layer combined with the workpiece. The resin forms an integrated protective layer that is bonded to the workpiece surface, creating a composite structure that provides both protection and stability during processing, eliminating the need for separate adhesive layers.
2Object-generated harmful factors
If thermoplastic resin is melted and formed into a protective layer, then adhesive residue is eliminated, but heating time of several tens of seconds to several tens of minutes is required, leading to decrease in efficiency
Solution Approach 1:
The invention optimizes the thermal parameters by selecting resins with lower melting points and appropriate heat capacity. The resin formulation allows rapid heating and cooling cycles, reducing the processing time from several tens of seconds or minutes to a much shorter duration. The glass transition temperature range (0°C to 100°C) enables the resin to transition quickly between states, improving processing speed.
Solution Approach 2:
The invention replaces the traditional mechanical adhesive bonding system with a thermal-mechanical system where the thermoplastic resin is heated to become viscous, applied to the workpiece, and then cooled to solidify and bond. This substitution allows for more controlled and faster processing compared to traditional adhesive applications, as the resin's phase change provides automatic bonding without requiring separate curing steps.
3Object-generated harmful factors
If thermoplastic resin sheet is used for thermocompression bonding, then adhesive residue is avoided, but the sheet shrinks in cooling, causing difficulty in forming uniform size and workpiece bending
Solution Approach 1:
The invention carefully controls the thermal parameters during processing, including heating temperature, heating time, and cooling rate. By optimizing these parameters, the resin undergoes minimal thermal expansion and contraction, reducing shrinkage effects. The processing temperature is kept just above the resin's glass transition temperature, minimizing the temperature differential that causes shrinkage during cooling.
Solution Approach 2:
The invention applies preliminary constraints during the heating and bonding process to prevent excessive shrinkage. The workpiece and resin are held in a controlled environment with regulated temperature gradients, preventing uneven cooling that would cause distortion. By anticipating and counteracting the shrinkage tendency through controlled cooling rates and support structures, the final product maintains uniform dimensions and flatness.
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 method reduces shrinkage and size variation of the protective component, preventing residue and vibration, ensuring stable integration and processing without adhesive residue, and maintaining the desired shape and size.
Implementation Method 1
irradiating the resin layer with ultraviolet rays and curing the resin layer to form the protective component with a sheet shape
Implementation Method 2
dissolving a thermoplastic resin whose solubility parameter is equal to or higher than 8.5, in a liquid ultraviolet-curable resin, to prepare a liquid mixed resin
Implementation Method 3
heating the sheet-shaped protective component before or after one surface of the sheet-shaped protective component and the one surface of the workpiece are brought into close contact with each other
Data Source
AI summary
There is provided a manufacturing method of a protective-component-provided workpiece. The manufacturing method of a protective-component-provided workpiece includes a step of dissolving a thermoplastic resin whose solubility parameter is equal to or higher than 8.5, in a liquid ultraviolet-curable resin, to prepare a liquid mixed resin, a step of supplying the mixed resin to a support surface of a support table to form a resin layer with a predetermined thickness, a step of irradiating the resin layer with ultraviolet rays and curing the resin layer to form a protective component with a sheet shape, and a step of heating the sheet-shaped protective component before or after one surface of the sheet-shaped protective component and one surface of the workpiece are brought into close contact with each other, and causing the sheet-shaped protective component to come into close contact with the workpiece and integrate with the workpiece.