Variable Thickness Adhesive via Photopolymerization
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Solution Overview
Problem
Existing methods for manufacturing adhesives, such as die-cutting, are inadequate for producing adhesives with complex shapes or varying thicknesses, particularly as devices are miniaturized and require higher precision.
Innovation Solution
A method involving additive manufacturing, where an actinic radiation-polymerizable adhesive precursor composition is disposed on a radiation-transparent substrate and irradiated with varying dosages to achieve differential curing and create adhesives with variable thickness and complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If die-cutting or syringe dispensing is used to prepare adhesives, then the manufacturing process is simple, but the precision and ability to create complex shapes or variable thickness is insufficient
Solution Approach 1:
The patent replaces traditional mechanical adhesive application methods (die-cutting, syringe dispensing) with a photopolymerization-based additive manufacturing system. This system uses light irradiation through a transparent substrate to selectively cure adhesive precursor material, enabling precise control of adhesive shape and thickness without complex mechanical cutting or dispensing equipment.
Solution Approach 2:
The patent controls adhesive thickness and shape by varying irradiation parameters (light intensity, exposure time, wavelength) rather than changing physical tooling. By adjusting irradiation dosage, the system can create adhesives of different thicknesses in different regions, enabling complex geometries without additional manufacturing steps.
2Manufacturing precision
If uniform irradiation is applied to adhesive precursor, then the curing process is simple, but the ability to create variable thickness adhesives is lost
Solution Approach 1:
The patent applies different irradiation dosages to different regions of the adhesive precursor material. By using a digital light projector or similar system, specific areas receive higher or lower light doses, causing differential polymerization and resulting in adhesives with spatially varying thickness. This local differentiation enables precise thickness control without mechanical intervention.
Solution Approach 2:
The irradiation system dynamically adjusts light intensity and exposure patterns during the curing process. The system can change irradiation parameters in real-time based on the desired adhesive geometry, allowing flexible creation of variable thickness profiles through software control rather than fixed mechanical tooling.
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 enables the precise formation of adhesives with varying thickness and complex shapes, addressing the limitations of traditional manufacturing techniques and enhancing precision in adhesive application.
Implementation Method 1
irradiating a first portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a first irradiation dosage, and irradiating a second portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a second irradiation dosage
Data Source
Figure 1~2A
Figure 2B~2C
Figure 3~4
AI summary
A method of making an adhesive is provided, including obtaining an actinic radiation-polymerizable adhesive precursor composition disposed against a surface of an actinic radiation-transparent substrate and irradiating a first portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a first irradiation dosage. The method further includes irradiating a second portion of the actinic radiation-polymerizable adhesive precursor composition through the actinic radiation-transparent substrate for a second irradiation dosage. The first portion and the second portion are adjacent to or overlapping with each other and the first irradiation dosage and the second irradiation dosage are not the same. The method forms an integral adhesive having a variable thickness in an axis normal to the surface of the actinic radiation-transparent substrate. Also, an adhesive article is provided, including a substrate having a major surface and an integral adhesive disposed on the major surface of the substrate.