New energy single-sided double-contact FPC production process

Abstract

The present application relates to the field of FPC, and discloses a new energy single-sided double-contact FPC production process, comprising the following steps: S1, preparing a cover film roll and a blackened pure copper foil roll; S2, first using die cutting process to open a window in the whole roll of the first cover film in a roll-to-roll manner; S3, using an existing coating and compounding process to compound the blackened pure copper foil with the required width and the die-cut cover film to form a composite roll; S4, and using a roll-to-roll manner to age the composite roll of S3; then baking the aged composite roll; S5, cleaning the bottom film of the composite roll of S4 to remove the blackened layer on the back of the composite roll; S6, using a double-sided dry film pressing equipment or a coating photosensitive oil equipment to press or coat the composite roll of S5 in a roll-to-roll manner; S7, positioning hole target punching is performed on the composite roll of S6 in a roll-to-roll manner, and the number of positioning holes is four, which are respectively located at the four corners of the composite roll.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of FPC, in particular to a new energy single-sided double-contact FPC production process. BACKGROUND

[0002] The single-sided double-contact FPC is a flexible circuit board, which has the following characteristics: single-sided wiring, conductive lines are only located on one side of the substrate; double-contact design, although the lines are on one side, but through the via or special design, realize double-sided contact, convenient for connection;

[0003] The existing problems on the market at present are as follows: at present, the new energy single-sided double-contact FPC cannot realize the roll-to-roll process due to the limitation of production process, the traditional sheet production process is complex, the manufacturing cost is high, and the efficiency is slow, and the quality yield is low in the production process;

[0004] The technical problem solved by the present application is to provide a process for realizing roll-to-roll production of single-sided double-contact FPC products. SUMMARY

[0005] The technical problem solved by the present application is to provide a process for realizing roll-to-roll production of single-sided double-contact FPC products, which can reduce the process cost, reduce the production process, improve the production efficiency, and improve the product yield; the first side cover film is processed by die cutting process, and the hole position is formed by windowing in a roll-to-roll manner, which is to prepare for the subsequent copper clad film compounding; the blackened copper foil and the die cut cover film are compounded by using the existing coating and compounding process; the positioning hole is impacted by using the target punching technology, and the front and back surfaces are exposed by using the LDI exposure machine; the windowing and the line of the compound roll are aligned by using four positioning holes and cooperating with visual detection.

[0006] A new energy single-sided double-contact FPC production process, comprising the following steps:

[0007] S1, preparing a cover film roll and a blackened pure copper foil roll;

[0008] S2, first, the first side cover film is processed by die cutting process in a roll-to-roll manner, and the whole roll is windowed,

[0009] S3, using the existing coating and compounding process, the blackened pure copper foil with the required width and the die cut cover film are compounded to form a compound roll;

[0010] S4, and the compound roll of S3 is aged in a roll-to-roll manner; then the aged compound roll is baked;

[0011] S5, the compound roll of S4 is cleaned to remove the blackened layer on the back of the compound roll;

[0012] S6. Using a double-sided dry film pressing equipment or a photosensitive oil coating equipment, the composite roll of S5 is double-sided pressed or coated in a roll-to-roll manner.

[0013] S7. Using a roll-to-roll method, perform positioning hole punching on the composite material roll of S6; and there are four positioning holes, located at the four corners of the composite material roll respectively;

[0014] S8. Use an LDI exposure machine for alignment exposure, roll to roll, using four positioning holes for alignment, so that the front and back windows and lines of the composite material roll overlap.

[0015] S9. Develop the composite material roll from S8; etch and remove the film from the developed composite material roll; after removal, perform AOI scanning and target punching in a roll-to-roll manner.

[0016] Preferably, in step S9, the composite roll also needs to be cleaned; the cover film is laminated in a roll-to-roll manner; the rolls are pressed together; and then the rolls are cut, baked, reinforced, OSP process is performed, the shape is trimmed, and FQC process is performed.

[0017] Preferably, the roll-to-roll method involves using an unwinding machine to unwind the material while simultaneously processing it, and then using a rewinding machine to rewind the processed material for use in the next process step.

[0018] Preferably, the baking temperature in step S4 is 165 to 175 degrees Celsius, and the baking time is 8 hours.

[0019] Preferably, in step S4, the maturation process passes through multiple temperature zones in sequence, and the temperature zones include 100 degrees, 120 degrees and 150 degrees, and the total maturation time is 5 to 6 minutes.

[0020] Preferably, step S5 uses an FPC cleaning line to clean the composite material roll; step S9 uses an FPC cleaning line to clean the composite material roll.

[0021] Preferably, in step S7, a target punch vision punching machine is used to punch holes in the composite material roll.

[0022] Preferably, in step S9, a double-sided developing machine is used to develop the composite material roll, and a double-sided vacuum etching and demolding machine is used to etch the composite material roll.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows: The new energy single-sided double-contact FPC production process of the present invention uses a die-cutting process to process the first cover film, and opens windows to form holes in a roll-to-roll manner, in order to prepare for subsequent copper clad film lamination; the existing coating and lamination process is used to laminate the blackened copper foil and the die-cut cover film; the positioning holes are impacted by the target punching technology, and the front and back are aligned by the LDI exposure machine; using four positioning holes, combined with visual inspection, the openings and lines of the composite roll are aligned.

[0024] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Fig. 1 This is a schematic diagram of the die-cutting machine structure of the present invention.

[0027] Fig. 2 This is a schematic diagram of the FPC window opening structure of the present invention.

[0028] Fig. 3 This is a schematic diagram of the FPC target punching structure of the present invention.

[0029] Fig. 4 This is a schematic diagram of the curing machine structure of the present invention.

[0030] Fig. 5 It is the existing FPC production process.

[0031] In the diagram: 1. Die-cutting section unwinding machine; 2. Die-cutting machine; 3. Die-cutting section rewinding machine; 4. Window opening position; 5. Target punch position; 6. Cover film unwinding machine; 7. Blackened pure copper foil unwinding machine; 8. Curing machine; 9. Curing section rewinding machine. Detailed Implementation

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Please see Figs. 1-5In this embodiment of the invention, a production process for a new energy single-sided double-contact FPC includes the following steps:

[0034] S1. Prepare cover film rolls and blackened pure copper foil rolls;

[0035] S2. First, use a die-cutting process to open the window on the first cover film in a roll-to-roll manner;

[0036] S3. Using existing coating and lamination processes, blackened pure copper foil of the required width and die-cut cover film are laminated to form a composite roll.

[0037] S4, and then the S3 composite material roll is cured by roll-to-roll method; then the cured composite material roll is baked;

[0038] S5. Perform bottom film cleaning on the composite material roll of S4 to remove the blackened layer on the back of the composite material roll with windows.

[0039] S6. Using a double-sided dry film pressing equipment or a photosensitive oil coating equipment, the composite roll of S5 is double-sided pressed or coated in a roll-to-roll manner.

[0040] S7. Using a roll-to-roll method, perform positioning hole punching on the composite material roll of S6.

[0041] S8. Use an LDI exposure machine for alignment exposure, roll to roll, using four positioning holes for alignment, so that the front and back windows and lines of the composite material roll overlap.

[0042] S9. Develop the composite material roll from S8; etch and remove the film from the developed composite material roll; after removal, perform AOI scanning and target punching in a roll-to-roll manner.

[0043] Specifically, prepare rolls of cover film and blackened pure copper foil; ensure the quality of the materials meets requirements, especially the surface blackening treatment of the copper foil; process the first cover film using a die-cutting process, creating openings on roll to roll to prepare for subsequent copper clad laminate lamination; use existing coating and lamination processes to laminate the blackened copper foil and the die-cut cover film; the lamination process requires precise control of thickness and adhesion to ensure the smooth progress of subsequent processes; the laminated rolls undergo curing and baking to ensure full adhesion of the composite film material and achieve the expected performance requirements; clean the base film of the laminated rolls to remove the blackening from the openings on the back side. The first layer improves the quality of subsequent coating and exposure processes, preventing contamination or uneven coating. Double-sided lamination or coating is performed using lamination or photosensitive oil coating equipment to ensure uniform film thickness and provide good protection. The positioning holes are punched using a target punch technique, which is crucial for subsequent alignment exposure and ensures the accuracy of the circuit design. Front and back alignment exposure is performed using an LDI exposure machine. Four positioning holes, combined with visual inspection, are used to align the windows and lines of the composite roll. After development, etching and stripping are performed, followed by AOI scanning and target punching. AOI scanning can detect defects, ensuring product quality meets standards.

[0044] Furthermore, in step S9, the composite rolls need to be cleaned; the cover film is laminated in a roll-to-roll manner; the rolls are pressed together; and then the rolls are cut, baked, reinforced, OSP process is performed, the shape is trimmed, and FQC process is completed.

[0045] Specifically, the cleaning step is to remove any residual impurities or chemicals, ensuring that they do not affect the quality of the film or the performance of the circuit board in subsequent processes; the cleaning process also helps remove chemicals left over from the developing or etching process, reducing potential contamination; the new cover film is bonded to the composite roll in a roll-to-roll manner; this protects the circuit layers and provides support for subsequent lamination and cutting; it ensures the uniformity of the film and avoids the formation of bubbles or wrinkles; lamination equipment is used to ensure a tight bond between the cover film and the composite roll; pressure and temperature are strictly controlled to achieve optimal adhesion; after lamination, the integrity and uniformity of the film directly affect the subsequent electrical and physical properties; cutting is the process of transforming the composite roll into the required final size, using a roll-to-sheet cutting method for convenient subsequent use; ensuring that each FPC sheet is sized consistently to avoid waste; baking helps remove residual solvents or moisture, and... The process involves several steps: hardening the material to increase its stability; strict control of baking temperature and time to avoid overheating or underbaking; reinforcement typically involves strengthening critical parts of the FPC to increase its tensile strength or temperature resistance; this step is crucial for improving the long-term reliability and durability of the FPC; OSP (Optical Separation Process) provides corrosion protection to the copper layer and prevents oxidation; OSP is an environmentally friendly process that, compared to traditional coating technologies, effectively protects the circuit board surface and improves conductivity; shaping involves adjusting the external edges of the FPC to ensure it meets design requirements, typically including removing excess edge material to ensure precision and aesthetics; the final step is FQC (Final Quality Control), which performs a final quality inspection on all produced FPCs; FQC includes dimensional checks, appearance checks, and functional checks (such as circuit connectivity and electrical performance testing) to ensure that all product specifications meet standards.

[0046] Furthermore, the roll-to-roll method involves using an unwinding machine to unwind the material while simultaneously processing it, and then using a rewinding machine to rewind the processed material for use in the next process step.

[0047] Specifically, the entire production process employs an unwinding and rewinding operation mode. Unwinding and rewinding are used at each necessary step, allowing for the processing of longer FPCs, such as two meters long, in a single operation, whereas existing technologies involve multiple processing steps on sheet-like materials. The unwinding machine unfolds the material for processing, while the rewinding machine rewinds the processed material back into the next process, ensuring the continuity and efficiency of the production line. The coordination between the unwinding and rewinding machines is crucial for the roll-to-roll process, as they ensure uniform material tension, smooth flow, and continuous processing. The unwinding machine needs precise control of the unwinding speed and tension to prevent excessive tension or slack, while the rewinding machine ensures a certain tension during rewinding to prevent unevenness in the roll material. This improves production efficiency, enabling continuous large-scale production and reducing downtime. It also saves manpower and time; automated unwinding and rewinding reduce manual intervention and increase the degree of automation in production. Furthermore, it optimizes material utilization by precisely controlling the tension of the roll material, avoiding material waste.

[0048] Furthermore, the baking temperature in step S4 is 165 to 175 degrees Celsius, and the baking time is 8 hours.

[0049] Specifically, in the baking process of step S4, the temperature is controlled between 165°C and 175°C, and the baking time is 8 hours. Such temperature and time settings are crucial to ensure the full curing of the composite material. Too high or too low a temperature, or insufficient baking time, will affect the adhesion of the film and the final performance of the material. The main purpose of the baking process is to remove any solvents or moisture, while hardening the material and enhancing its stability. The long baking time of 8 hours helps to ensure complete curing of the material, reduce residual solvents, and make the composite film more robust and adaptable to subsequent processing and use.

[0050] Furthermore, in step S4, the maturation process sequentially passes through multiple temperature zones, including 100 degrees, 120 degrees and 150 degrees, and the total maturation time is 5 to 6 minutes.

[0051] Specifically, the material passes through multiple temperature zones in sequence, including 100°C, 120°C, and 150°C, with a total curing time of 5 to 6 minutes. The temperature zoning and rapid curing settings help to precisely control the bonding and curing process of the material. By gradually increasing the temperature, it can be ensured that the composite film material is gradually and fully heat-treated in different temperature ranges, while avoiding damage to the material or uneven curing caused by excessively rapid temperature rise.

[0052] 100°C range: used for initial heating to allow the material to begin adapting to temperature changes;

[0053] 120°C range: Further heating promotes initial adhesion of the film layers;

[0054] 150°C range: Reaching the highest temperature allows the membrane material to achieve optimal adhesion in a short time.

[0055] Furthermore, step S5 uses an FPC cleaning line to clean the composite material roll; step S9 uses an FPC cleaning line to clean the composite material roll.

[0056] Specifically, using an FPC cleaning line to clean composite rolls ensures that the material remains clean and uncontaminated at every critical process stage. The cleaning line can efficiently remove any residual chemicals, grease, and impurities that may remain from the lamination process, ensuring the smooth operation of subsequent processes. The use of an FPC cleaning line provides an automated cleaning solution for the production line, reducing manual intervention and improving cleaning effectiveness. Especially after composite rolls have undergone multiple processes, residues may accumulate on the surface; using a cleaning line ensures the quality of each step and improves the consistency and performance of the final product.

[0057] Furthermore, in step S7, a target punch vision punching machine is used to punch holes in the composite material roll.

[0058] Specifically, the composite material roll is punched using a target punch vision punching machine. This step can accurately achieve the impact of positioning holes. Vision punching machines are usually equipped with a high-precision vision system that can detect the position and alignment of the composite material roll in real time, ensuring the accuracy and consistency of punching.

[0059] High precision: Real-time monitoring through a vision system ensures accurate alignment of the holes and avoids deviations.

[0060] Automation reduces human intervention, improves production efficiency, and reduces human error.

[0061] High consistency ensures that the hole positions of each roll of material meet the design requirements, thus ensuring the accuracy of the circuit.

[0062] Furthermore, in step S9, a double-sided developing machine is used to develop the composite material roll, and a double-sided vacuum etching demolding machine is used to etch the composite material roll.

[0063] Specifically, a double-sided developing machine can process both sides of a composite roll simultaneously, ensuring the uniformity and consistency of the developing process; it can remove the photosensitive material after exposure, leaving only the circuit pattern, and ensure that both sides reach the same quality standard, avoiding omissions or unclear patterns.

[0064] The double-sided vacuum etching demolding machine achieves uniform etching of composite material rolls through vacuum technology; double-sided etching means that both sides are processed at the same time, which greatly improves production efficiency; it ensures the accuracy of the etching process and can perform efficient demolding and etching on the surfaces of both materials at the same time, thereby forming the required circuit pattern.

[0065] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A production process for single-sided double-contact FPC in new energy applications, characterized in that, Includes the following steps: S1. Prepare cover film rolls and blackened pure copper foil rolls; S2. First, use a die-cutting process to open the window on the first cover film in a roll-to-roll manner; S3. Using existing coating and lamination processes, blackened pure copper foil of the required width and die-cut cover film are laminated to form a composite roll. S4, and then the S3 composite material roll is cured by roll-to-roll method; then the cured composite material roll is baked; S5. Perform bottom film cleaning on the composite material roll of S4 to remove the blackened layer on the back of the composite material roll with windows. S6. Using a double-sided dry film pressing equipment or a photosensitive oil coating equipment, the composite roll of S5 is double-sided pressed or coated in a roll-to-roll manner. S7. Using a roll-to-roll method, perform positioning hole punching on the composite material roll of S6, and the number of positioning holes is four, located at the four corners of the composite material roll respectively. S8. Use an LDI exposure machine for alignment exposure, roll to roll, using four positioning holes for alignment, so that the front and back windows and lines of the composite material roll overlap. S9. Develop the composite roll from S8; The developed composite material roll is etched and stripped. After stripping, AOI scanning and target punching are performed in a roll-to-roll manner. The baking temperature in step S4 is 165 degrees to 175 degrees, and the baking time is 8 hours. In step S4, the curing process passes through multiple temperature zones in sequence, and the temperature zones include 100 degrees, 120 degrees and 150 degrees, and the curing time for the whole process is 5 to 6 minutes. In step S7, a target punch visual punching machine is used to punch holes in the composite material roll.

2. The new energy single-sided double-contact FPC production process according to claim 1, characterized in that, In step S9, the composite rolls also need to be cleaned; the cover film is laminated in a roll-to-roll manner; the rolls are pressed together; and then the rolls are cut, baked, reinforced, OSP process is performed, the shape is trimmed, and FQC process is completed.

3. The new energy single-sided double-contact FPC production process according to claim 1, characterized in that, The roll-to-roll method involves using an unwinding machine to unwind the material while simultaneously processing it, and then using a rewinding machine to rewind the processed material for use in the next process step.

4. The new energy single-sided double-contact FPC production process according to claim 1, characterized in that, Step S5 uses an FPC cleaning line to clean the composite material roll; Step S9 uses an FPC cleaning line to clean the composite material roll.

5. The new energy single-sided double-contact FPC production process according to claim 1, characterized in that, Step S9 involves developing the composite roll using a double-sided developing machine and etching the composite roll using a double-sided vacuum etching and demolding machine.

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