Lamination and pressing of vacuum laminator

2022-05-26 16:15

In the operation of the vacuum laminator of the printed circuit board, it is mainly divided into single-piece lamination and continuous lamination according to the different production methods. Monolithic lamination is a method of laminating printed circuit boards one by one using a monolithic laminator. The single-piece laminator is composed of a hydraulic sliding platform and a pair of heating plates. Continuous lamination is a method of continuous lamination of prepreg and copper foil by laminating machine, which is much more complicated than single lamination, and its production speed has been greatly improved.

 

The copper foil and prepreg material enter the lamination cell where the materials to be pressed by the laminator are laminated together. Many laminate manufacturing plants perform lamination in clean workrooms equipped with filtered air conditioning systems, the purpose of which is primarily to protect the copper foil and prepreg from dust during the lamination operation. Before pressing, pits and indentations appear on the surface of the copper foil of the laminated product due to the electrostatic attraction of the prepreg and the copper foil. During the lamination operation, copper foil is first laid down on a large polished steel platen. A plurality of prepreg sheets are then deposited on the copper foil, the number of prepreg sheets being determined by the desired laminate thickness and the characteristics of the prepreg.

The finished laminate is often difficult to achieve to very tight tolerances because of the thickness tolerances of the copper foils and the non-flatness of each press plate. Some lamination processes can balance all these variables so that a dense material with relatively tight tolerances is finally obtained. If the material is double-sided copper clad, then another copper foil is placed on top of the prepreg laminate. If a single-sided copper clad laminate is desired, the upper press plate can be sprayed with a release agent or, more generally, a release film can be laid on top of the prepreg.

 

The laminate material, together with the press plate, is loaded from the stack of workpieces into a large multi-layer laminator. Several boards can be pressed in each pressed layer, and a typical laminator can press about 80 boards. Each is 36 x 72 inches in area and 1/16 inch thick. The laminator uses a hydraulic press, which produces a pressure of more than 1000 psi square. The heat source uses steam. When pressurized, it transfers heat to each laminate. This is to cure the material and become a uniform sheet. In order to ensure that the material in the middle of each layer gets enough heat to achieve final solidification, several thermocouples are embedded in the middle of the platen to map the temperature curve. A timer automatically records time according to a predetermined curing cycle, and when the corrected time is over, cooling water flows through the platen to terminate the curing cycle. After fully cured, the laminate was trimmed to remove the untidy resin exudate from the peripheral edges. Because of the different coefficients of thermal expansion of the constituent materials, some manufacturers have found that it is best to place the pressed laminate in an oven that has been heated. This allows the material to be relieved of stress due to lamination.

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