A method and equipment for manufacturing multilayer lamination buffer pads for circuit boards

Abstract

This invention discloses a method and equipment for manufacturing multilayer laminated buffer pads for circuit boards, relating to the field of buffer pad manufacturing technology. It includes a feedforward unwinding section, an electromechanically coupled precision coating section, an adaptive drying and recycling section, a high-pressure calendering section, an online verification and physical marking section, and a process logic controller as the control center, arranged sequentially along the running direction of the flexible substrate. The feedforward unwinding section includes a feedforward unwinding device frame. This invention establishes an electromechanical collaborative interlocking mechanism across the unwinding, coating, drying, calendering, and testing sections through the control unit. Combined with real-time acquired tension deformation, wet film thickness, exhaust concentration, and ultrasonic flaw detection data, if relevant physical parameters deviate or exceed preset safety and quality limits, it immediately generates corresponding advance displacement compensation, cascaded frequency reduction blocking, or thermal parameter setting commands to ensure that the final thickness and internal density of the laminated buffer pad remain within acceptable ranges.

Description

Technical Field

[0001] This invention relates to the field of cushioning pad manufacturing technology, and in particular to a method and equipment for manufacturing multilayer laminated cushioning pads for circuit boards. Background Technology

[0002] In advanced lamination processes for printed circuit boards (PCBs) and copper clad laminates (CCLs), multilayer lamination buffer pads are widely used in the lamination process to protect copper foil, optimize heat distribution, and significantly improve product yield due to their unique structural and performance advantages, such as high elastic deformation capacity, excellent thermal conductivity, and thermal stress release performance. With the increasingly stringent requirements for material precision in 5G communication and IC substrates, buffer pads must possess precise absolute thickness, extremely high density, and excellent interlayer bonding strength. However, traditional buffer pad production methods have many problems that urgently need to be solved. In the production process, manual control dominates, and the mechanical devices in each manufacturing step operate relatively independently, lacking effective integration and coordination.

[0003] In existing technologies, traditional cushioning pad production equipment is typically segmented, lacking a physical-level closed-loop operation between each process. During substrate unwinding and conveying, the difficulty in real-time compensation for tension deformation and the failure to effectively account for the elastic rebound factor after substrate winding result in the finished product's thickness accuracy failing to meet micron-level requirements, leading to significant deviations between actual performance and design standards. Inaccurate tension control can cause microscopic tensile deformation of the substrate, affecting coating uniformity and easily resulting in localized thickness deviations, severely impacting the uniformity of pressure distribution during subsequent PCB lamination.

[0004] Furthermore, in the drying and coating stages of the buffer pads, production equipment often operates in isolation. The evaporation load of the oven cannot control the amount of adhesive supplied for coating at the front end. When the coating amount is too large or the drying rate is mismatched, a "skin" phenomenon is easily formed on the material surface, locking the solvent inside the coating and causing microbubbles or delamination defects. Due to the lack of dynamic feedback and cascade control across processes, these internal physical defects are often only discovered after the product is completed or even during the next pressing and use. This not only causes serious waste of resources but also greatly increases the production costs and quality risks for downstream customers.

[0005] Furthermore, current quality monitoring methods mainly rely on manual sampling or offline testing after the product is finished. Manual sampling is not only inefficient but also cannot guarantee comprehensive monitoring of every segment of the continuous production line. Offline testing suffers from severe feedback lag, making it difficult to dynamically self-tune the upstream production process based on real-time monitoring results. Therefore, in the entire manufacturing process, each production step is relatively independent, lacking effective cross-variable electromechanical coupling, making it difficult to intelligently guarantee product density and yield.

[0006] Therefore, there is an urgent need for advanced manufacturing equipment and methods that can integrate and optimize the manufacturing process of multilayer lamination buffer pads for circuit boards, and achieve closed-loop control of tension, coating gap, volatile concentration and final quality feedback, thereby improving the overall precision and intelligence of manufacturing and meeting the market demand for high-performance lamination materials. Summary of the Invention

[0007] The purpose of this invention is to provide a method and equipment for manufacturing multilayer laminated buffer pads for circuit boards, so as to solve the problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a smart manufacturing method for multilayer lamination buffer pads on circuit boards, comprising the following steps: S100, Tension Feedforward Detection and Advance Compensation Generation: The tension deformation characteristics of the flexible substrate during the traction process are obtained in real time by the tension sensing roller group of the unwinding section, and the control unit converts them into the advance displacement compensation amount of the servo coating mechanism. S200, Dynamic closed-loop control of coating gap: The flexible substrate is extruded and coated with adhesive by coating roller group, and the real-time coating thickness on the discharge side is obtained by thickness gauge. Combined with the advance displacement compensation, the servo motor is driven to adjust the mechanical gap of coating roller group to eliminate the thickness error caused by tension rebound. S300, Volatilization Limit Constraint and Cascade Intervention: The coated substrate is heated and dried through a multi-segment tunnel oven. The exhaust concentration is obtained in real time by the sensor group. When the mechanical opening of the exhaust regulating valve reaches the limit and the concentration exceeds the standard, the control unit triggers the synchronous deceleration action of the entire traction mechanism and the mechanical thickness reduction cut-off action of the coating roller group in sequence. S400, High-Pressure Calendering and Online Transmission Flaw Detection: The dried substrate is subjected to high-pressure densification calendering by heating the calendering roller group, and the physical acoustic wave attenuation characteristics inside the material are obtained by using the ultrasonic array of the online verification probe to identify bubbles or delamination defects. S500, Defect Tracking and Physical Parameter Self-Tuning: When a defect is detected, the control unit tracks the physical location of the defect section based on the rotational angular displacement data of the main traction shaft, and adjusts the heating execution parameters of the tunnel oven in conjunction with the control unit for self-tuning and secondary flaw detection verification.

[0009] Preferably, step S200 includes the following steps: S210. The thickness of the wet film on the discharge side is collected in real time by the thickness gauge, and the thickness detection feedback is transmitted to the control unit. S220. The control unit superimposes and compares the thickness detection feedback with the advance displacement compensation amount in step S100 to determine whether the current physical gap of the coating roller group meets the standard. If yes, the current servo drive parameters are maintained and the operation continues; otherwise, the process proceeds to S230. S230. Generate control instructions based on theoretical springback and current thickness deviation, drive mechanical ball screw to move the moving surface roller of coating roller group inward or outward to complete micron-level gap dynamic compensation, and return to step S210.

[0010] Preferably, step S300 includes the following steps: S310: The concentration of volatiles in the oven is collected by the sensor group, and the exhaust proportional regulating valve is driven by the control unit to adjust the exhaust cross section. S320: Determine whether the exhaust proportional regulating valve has reached the fully open mechanical limit and the concentration continues to exceed the limit. If not, maintain the current exhaust state and continue operation; if yes, proceed to S330. S330: Trigger the first cascade protection, reduce the operating speed of the entire traction main shaft, drive all traction rollers to reduce the material conveying speed proportionally, and determine whether the current conveying speed has dropped to the lower limit threshold for maintaining the tension of the substrate. If not, continue to reduce the speed; if so, proceed to S340. S340, trigger the second cascade protection, send a reverse command to the servo motor, forcibly reduce the physical gap of the coating roller group to block the coating action, and coordinate with the cylinder of the pneumatic marking mechanism to press down to mark the abnormal section.

[0011] Preferably, step S500 includes the following steps: S510: Analyze the acoustic wave amplitude transmitted by the online verification probe to determine whether there is a gas-solid interface reflection signal representing a defect. If not, determine that the internal density of the material meets the standard and continue the operation; if yes, proceed to S520. S520, reduce the heating power of the heating elements of the multi-segment tunnel oven to reduce the curing temperature, and simultaneously record the rotational displacement of the main traction shaft. S530: Calculate the material's travel distance based on the rotational displacement, and determine whether the new material section after parameter adjustment has been transported to the online verification probe station. If not, continue traction and wait; if yes, proceed to S540. S540. Re-perform density flaw detection on the current material to determine whether the acoustic wave amplitude has recovered to the qualified threshold. If yes, lock the current self-tuning parameters and proceed to S400. If no, further reduce the overall conveying speed and return to step S520 for a new round of cycle tuning.

[0012] The present invention also provides a smart manufacturing equipment for multilayer lamination buffer pads of circuit boards. The equipment is used in any of the smart manufacturing methods described above, and includes a feedforward unwinding assembly, a precision coating assembly, a drying and waste removal assembly, a calendering assembly, and an online verification assembly arranged sequentially along the travel direction of the flexible substrate. The feedforward unwinding assembly includes a frame, an unwinding shaft rotatably mounted on the frame, and a tension sensing roller assembly spanning the substrate conveying path. Load strain gauges that undergo elastic deformation under pressure are provided between the bearing seats at both ends of the tension sensing roller assembly and the frame. The precision coating assembly includes a coating machine base, a coating roller assembly rotatably mounted on the coating machine base, a ball screw mechanism for driving the coating roller assembly to open and close intermittently, and a laser thickness gauge located on the discharge side. When the tension sensing roller assembly undergoes physical deflection deformation due to the traction tension of the substrate, it outputs an electrical signal. The control unit receives the electrical signal and links the servo drive motor of the ball screw mechanism to drive the coating roller assembly to generate a matching mechanical linear displacement before the substrate elastically rebounds, thereby compensating for the coating thickness in advance.

[0013] Preferably, the coating roller assembly includes a fixed-thickness back roller and a movable face roller that can be moved laterally, and the screw nut pair of the ball screw mechanism is fixedly connected to the bearing seat of the movable face roller. The servo drive motor is configured to simultaneously receive the measured thickness feedback from the laser thickness gauge and the deformation feedforward of the tension sensing roller group. It drives the ball screw mechanism to push and pull the movable roller, thereby changing the cross-sectional area of ​​the glue injection in real time to eliminate the deviation caused by the stretching and springback of the substrate.

[0014] Preferably, the drying and waste discharge assembly includes a multi-section tunnel oven, an exhaust duct connecting the inner cavity of the oven, and an exhaust proportional regulating valve installed on the exhaust duct. A sensor group for monitoring the volatile concentration is inserted in the exhaust duct. The valve core of the exhaust proportional regulating valve is linked to the monitoring data of the sensor group and expands and contracts within the exhaust duct to change the exhaust cross section. When the valve core is displaced to the maximum exhaust mechanical limit and the concentration monitored by the sensor group exceeds the safety threshold, the control unit links the entire traction main shaft to synchronously reduce the speed. When the rotational speed of the traction spindle drops to the lower limit for maintaining substrate tension, the ball screw mechanism of the precision coating assembly is reversed, mechanically closing the physical gap between the movable face roller and the thickness-fixed back roller, thereby blocking the input of wet adhesive.

[0015] Preferably, a pneumatic marking mechanism with electromechanical linkage is further provided between the precision coating component and the drying and waste discharge component; The pneumatic marking mechanism includes a support gantry spanning above the substrate and a stamping cylinder vertically positioned on the support gantry. While the physical gap of the coating roller assembly is mechanically closed, the stamping cylinder synchronously receives a trigger signal and drives the marking module at its end to extend downwards, performing anti-counterfeiting stamping and isolation marking on the surface of abnormal substrate sections that are in a glue-free state.

[0016] Preferably, the calendering assembly includes upper and lower counter-arranged heating steel rolls and a servo hydraulic cylinder that abuts against the bearing seat of the heating steel rolls. The telescopic rod of the servo hydraulic cylinder pushes downward to provide a high-pressure densification load for the substrate. The online verification component includes a verification frame spanning the discharge end, on which ultrasonic flaw detectors that physically transmit light through the upper and lower surfaces of the substrate are arrayed.

[0017] Preferably, the device further includes a rotational angular displacement detection element that is mechanically driven coaxially with the traction spindle; When the ultrasonic flaw detector detects acoustic wave reflection attenuation representing the gas-solid interface inside the material, the control unit adjusts the heating power of the heating element in the tunnel oven in conjunction with the control unit, and physically follows and positions the trajectory of the heating power adjustment section based on the physical mechanical rotation stroke generated by the rotational angular displacement detector as it rotates with the main shaft; when the section is transported to the bottom of the verification frame, the ultrasonic flaw detector is triggered to perform secondary structural flaw detection.

[0018] The technical effects and advantages of this invention are as follows: This invention establishes an electromechanical collaborative interlocking mechanism across unwinding, coating, drying, calendering, and inspection stages through a control unit. Combined with real-time acquired data on tension deformation, wet film thickness, exhaust concentration, and ultrasonic flaw detection, once relevant physical parameters deviate or exceed preset safety and quality limits, it immediately generates corresponding advance displacement compensation, cascaded frequency reduction blocking, or thermal parameter tuning commands. It then sends real-time linkage feedback to the servo drive and execution equipment of the corresponding process, realizing closed-loop control of the entire process from multi-dimensional physical quantity feedforward detection and cross-process data superposition and comparison to dynamic intervention of mechanical actions. This ensures that the final thickness and internal density of the laminated buffer pad remain stable within the qualified range, thereby achieving unmanned physical correction, high safety, and adaptive polarization production in the manufacturing process of multilayer laminated buffer pads for circuit boards. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0020] Figure 2 This is a schematic diagram of the method flow of the present invention.

[0021] Figure 3 This is a schematic diagram of the logic control of the present invention.

[0022] In the diagram: 1. Feedforward unwinding assembly; 11. Frame; 12. Unwinding shaft; 13. Tension sensing roller assembly; 2. Precision coating assembly; 21. Coating machine base; 22. Coating roller assembly; 23. Laser thickness gauge; 3. Drying and waste removal assembly; 31. Tunnel oven; 32. Exhaust duct; 33. Proportional regulating valve; 4. Calendering assembly; 41. Heated steel roller; 5. Online verification assembly; 51. Verification frame; 52. Ultrasonic flaw detector. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.

[0024] The intelligent manufacturing solution disclosed in this invention breaks through the mechanical barriers of isolated operation of each process in traditional pressing and buffer pad production lines. It establishes an electromechanical collaborative interlocking mechanism across unwinding, coating, drying, calendering, and inspection stages through a bottom-level control unit. To make the concept, mechanical action execution logic, and physical effects of this invention clearer, the control logic and mechanical linkage process of this invention will be analyzed in depth below with specific embodiments. The embodiments presented in this specification are arranged in a progressive order of electromechanical complexity. Each subsequent embodiment introduces a higher-level cross-process physical collaborative mechanism based on the mechanical framework and control logic of the previous embodiment.

[0025] In the first embodiment of the present invention, in the continuous roll-to-roll production of modern high-precision circuit board lamination buffer pads, the flexible substrate inevitably undergoes microscopic physical stretching under the drag of the traction shaft. The elastic rebound of this stretching deformation in the subsequent curing stage is the physical root cause of the buffer pad's final thickness deviation. To eliminate this deviation from the mechanical source, this embodiment provides a basic collaborative architecture based on physical tension feedforward detection and direct physical intervention in the coating mechanical gap.

[0026] like Figures 1-3As shown, in this embodiment, the intelligent manufacturing equipment has a feedforward unwinding assembly 1 and a precision coating assembly 2 arranged along the travel direction of the flexible substrate in terms of physical spatial layout. The feedforward unwinding assembly 1 serves as the starting point of the entire production line. Its robust frame 11 rotatably supports the unwinding shaft 12. After the substrate is released from the unwinding shaft 12, it inevitably crosses the tension sensing roller group 13 that lies across the conveying path. This tension sensing roller group 13 is not an ordinary guide roller; between its two ends of the mechanical bearing housing and the rigid connection points with the frame 11, load strain gauges capable of undergoing micro-elastic deformation under pressure are provided. During continuous mechanical traction operations, the actual physical tension generated by the tightening of the substrate surface forces the tension sensing roller group 13 to undergo slight physical deflection and downward pressure. The load strain gauges convert this physical stress into an analog electrical signal in real time.

[0027] The control unit continuously receives the electrical signal and substitutes it into the built-in substrate elastic modulus compensation model to dynamically calculate the microscopic tensile amount of the substrate under the current physical tension and the theoretical springback amount that will inevitably occur after peeling traction. This theoretical springback amount is then converted into an advance displacement compensation pulse by the control unit and sent directly across processes to the servo drive unit of the precision coating component 2 to achieve advance compensation generation.

[0028] In the operation of the precision coating assembly 2, the substrate passes through the coating roller group 22, which consists of a thickness-fixing back roller and a moving face roller, and is coated with polymer adhesive within this physical gap. A laser thickness gauge 23, mounted on a fixed bracket on the discharge side, performs non-contact real-time measurement of the wet film thickness immediately after leaving the extrusion zone, and continuously transmits this physical thickness detection feedback back to the control unit. At this point, the core mechanism of the collaborative control comes into play: the control unit does not simply issue action commands based on the delayed feedback from the laser thickness gauge 23, but rather performs a mathematical superposition and comparison of the physical thickness detection feedback with the advanced displacement compensation amount extracted from the previous steps in the underlying logic. Through this superposition, the control unit can accurately determine whether the current physical gap, after the substrate's subsequent rebound, still meets the physical thickness requirements of the final product.

[0029] If the superimposed comparison results indicate that the current mechanical clearance is insufficient to counteract the elastic rebound of the substrate, the control unit immediately generates a control command containing a defined mechanical stroke. Upon receiving this command, the output shaft of the servo drive motor rotates, and its rotational torque is precisely converted into linear mechanical thrust by the ball screw mechanism. This thrust acts directly on the bearing housing of the movable face roller, overcoming the static friction of the linear guide rail, forcing the movable face roller to move inwards towards or outwards away from the fixed-thickness back roller, causing the coating roller assembly 22 to undergo micron-level physical displacement, closing or opening. This dynamic closed-loop control changes the cross-sectional area of ​​the adhesive feed in real time in physical space, forcibly increasing the wet film redundancy thickness corresponding to the rebound amount, thereby completely eliminating the interference of substrate stretching on the thickness accuracy of the buffer pad at the mechanical action level.

[0030] In another embodiment of the present invention, based on the precise thickness control achieved in the aforementioned embodiments, another major physical variable in the manufacturing process of the buffer pad comes from the release of volatile organic compounds (VOCs) from the adhesive layer after coating during baking. With the increase in production line speed or changes in the adhesive formulation, the accumulation rate of volatiles in the oven can easily exceed the physical suction limit of the exhaust system, potentially leading to safety hazards or causing the adhesive layer to be dry on the surface but not inside. Therefore, this embodiment, based on the mechanical foundation and control logic of Embodiment 1, further introduces a multi-segment tunnel-type oven 31 and a corresponding volatile limiting constraint and cascade intervention mechanism.

[0031] The substrate, precisely coated by the coating roller assembly 22, is continuously fed into a multi-section tunnel-type oven 31 under mechanical tension for high-temperature baking and curing. The oven cavity is connected to an external negative pressure ventilation system via a large-diameter exhaust duct 32. At the physical throat of this exhaust duct 32, an exhaust proportioning valve 33 is installed to determine the gas flow rate. Simultaneously, a high-temperature resistant sensor assembly is deeply embedded inside the exhaust duct 32, specifically designed to continuously sample the concentration of volatiles in the airflow.

[0032] In normal mechanical operation, the monitoring data from the sensor array is directly fed back to the control unit. The control unit drives the valve core inside the exhaust proportional regulating valve 33 to make linear displacement within the slide rail by outputting an analog voltage, thereby maintaining the pressure and concentration balance within the oven by changing the physical exhaust cross-sectional area. However, when the coating amount surges, causing a large amount of volatiles to emerge, the valve core may be driven to its maximum stroke, triggering the mechanical full-open limit. The control unit strictly monitors this physical critical state. Once it is confirmed that the exhaust proportional regulating valve 33 has no mechanical room to expand its cross-section, and the physical concentration fed back by the sensor array continues to rise and approaches the safety threshold, the conventional single PID loop fails, and a higher-dimensional cross-process cascaded collaborative intervention must be triggered.

[0033] At this point, the control unit forcibly takes over the global mechanical transmission authority, triggering the first cascade protection: a frequency reduction command is sent to the high-power virtual spindle servo system driving the main traction shaft. Relying on the electronic gear synchronization mechanism built into the equipment's underlying structure, the rotational angular velocity of all take-up / unwind, guide, and traction rollers across the entire line is strictly and proportionally reduced. This synchronous speed reduction action directly extends the physical residence time of the substrate in the tunnel oven 31, reducing the solvent evaporation load per unit time without changing the physical coating gap, allowing the exhaust duct 32 to readjust to the current emission capacity.

[0034] During the reduction of the overall conveyor speed, the control unit has a mechanical operating lower limit threshold set to maintain the substrate sag and tension. If the continuous decrease in rotation speed reaches this uncompromising physical bottom line—that is, further deceleration would cause the substrate to loosen and stack—the most stringent second-level protection mechanism is immediately triggered. This mechanism requires a physical blockage of the material input at the front end: the control unit sends a high-priority forced reverse command to the precision coating assembly 2 in Example 1. The ball screw mechanism, originally used for fine-tuning, is driven at full power, forcibly pushing the movable face roller towards the thickness-fixing back roller, thus mechanically closing the physical gap of the coating roller group 22 and forcibly cutting off the coating of wet adhesive.

[0035] Furthermore, to prevent the waste material with little or no adhesive caused by the emergency thickness reduction from flowing into subsequent finished rolls, this embodiment also deploys an electromechanical pneumatic marking mechanism in coordination between the physical gaps of these two components. At the same instant the gap of the coating roller group 22 closes, the control unit synchronously outputs an excitation current to the solenoid valve of the pneumatic marking mechanism, and compressed air instantly fills the upper chamber of the stamping cylinder vertically fixed to the supporting gantry. The piston rod of the cylinder overcomes the resistance of the return spring and thrusts downwards, driving the physical marking module at its end to slam against the surface of the abnormal substrate section with no adhesive, implementing an indelible anti-counterfeiting stamping and physical isolation mark. This series of cross-component mechanical actions and precise coordination ensures absolute safety and waste traceability when the equipment encounters physical exhaust limits.

[0036] In another embodiment of the present invention, the aforementioned embodiments solved the safety cascade response of thickness feedforward control and evaporation exhaust. However, another core indicator of a high-quality cushioning pad is the density of its internal structure, which must be free of tiny air bubbles or delamination defects. Given that the density of the pressed cushioning pad is determined by both the high mechanical pressure at the back end and the thermal parameters at the front end, this embodiment adds a high-pressure calendering component 4 and an online verification component 5 to the collaborative network constructed in the previous two embodiments, achieving defect tracking based on the final physical structure and full self-tuning of electromechanical parameters.

[0037] The substrate exiting the drying and waste removal assembly 3 has only a partially solidified surface and must enter the high-pressure calendering assembly 4 to undergo extreme physical load compression. The main structure of the calendering assembly 4 consists of heavy-duty heated steel rollers 41 arranged with upper and lower counterweights. Above the thick bearing seats of the steel rollers, a high-frequency responsive servo hydraulic cylinder is abutted. The hydraulic oil in the hydraulic cylinder, under the precise flow distribution of the servo valve, pushes the telescopic rod downwards, providing a constant and high-intensity physical densification load to the substrate passing between the steel rollers, forcibly squeezing out or crushing any residual microbubbles inside.

[0038] The substrate that has undergone densification and calendering then passes through a verification frame 51 located at the end of the discharge process. The verification frame 51 is densely packed with an array of ultrasonic flaw detectors 52 capable of emitting and receiving physical transmission waves on the upper and lower surfaces of the substrate.

[0039] The control unit analyzes the physical acoustic wave amplitude received by the ultrasonic flaw detector 52 in real time. When the material is dense and flawless, the sound wave penetrates in a straight line and the amplitude is maintained at the reference level. However, once there are air bubbles or stratifications hidden in the material that have not been eliminated by the rolling mill roll, the sound wave will be strongly reflected and scattered when it encounters the gas-solid physical interface, resulting in a significant attenuation of the amplitude of the sound wave after penetration.

[0040] When the control unit detects the physical acoustic attenuation characteristic representing the density defect, it does not blindly shut down the machine. Instead, the control unit determines that there is a defect in the current curing process and sends a command to the solid-state relay of the multi-segment tunnel oven 31 in front to forcibly cut off or reduce the physical heating power of the heating element in a specific heating section, thereby reducing the surface curing temperature and buying time for the internal gas to escape.

[0041] It should be noted that, due to the physical space span of several meters between the oven heating zone and the online verification rack 51 at the rear, the control unit must accurately know when the substrate baked with the new heating parameters will reach the flaw detection station. Otherwise, blind and continuous adjustments will cause the control system to fall into an endless state of oscillation and ringing. To address this, the equipment has a rotational angular displacement detector rigidly connected to the main traction shaft. The control unit accumulates the physical mechanical rotation pulses generated by the rotation of the main traction shaft in real time, multiplies them by the physical circumference of the mechanical traction roller, and accurately calculates the actual straight-line travel distance of the material on the production line.

[0042] Through this robust mechanical rotational stroke accumulation, the control unit precisely tracks and positions the trajectory of the heating power adjustment section. The system patiently maintains full-line traction, quietly waiting for the new substrate, which has undergone cooling and adjustment, to traverse the long mechanical guide rollers until it precisely appears directly beneath the verification frame 51. At this point, the control unit reactivates the ultrasonic flaw detector array 52 to perform secondary physical structural flaw detection on this specific section.

[0043] If the flaw detection results show that the cooling measures have successfully eliminated the bubbles and the acoustic wave amplitude has recovered to above the qualified physical threshold, the control unit will write this verified thermal parameter into the steady-state register, permanently lock it as the new normal operating standard, and return to routine rolling monitoring.

[0044] Conversely, if the physical defects persist, indicating that simply lowering the temperature is insufficient to salvage the current density crisis, the control unit will again activate the synchronous deceleration mechanism of the entire traction mechanism in Example 2, further extending the physical intervention time of mechanical calendering and baking, and initiating a new round of corner accumulation tracking and flaw detection cycles. This collaborative control mode, from detecting end-body physical structural anomalies to tracing and adjusting the front-end thermal output, and then relying on mechanical rotation ranging to implement closed-loop verification, completely realizes unmanned physical correction and adaptive polarization production of large roll-to-roll buffer pad manufacturing equipment.

[0045] In another embodiment of the present invention, a smart manufacturing method for multilayer lamination buffer pads of circuit boards suitable for the above-mentioned equipment is also provided, comprising the following steps: S100, Tension Feedforward Detection and Advance Compensation Generation: The tension deformation characteristics of the flexible substrate during the traction process are obtained in real time by the tension sensing roller group of the unwinding section, and the control unit converts them into the advance displacement compensation amount of the servo coating mechanism.

[0046] S200, Dynamic closed-loop control of coating gap: The flexible substrate is coated with adhesive by extrusion using coating roller group, and the real-time coating thickness on the discharge side is obtained by using thickness gauge. Combined with the advance displacement compensation, the servo motor is driven to adjust the mechanical gap of coating roller group to eliminate the thickness error caused by tension rebound.

[0047] In this embodiment, step S200 includes the following steps: S210. The thickness of the wet film on the discharge side is collected in real time by the thickness gauge, and the thickness detection feedback is transmitted to the control unit. S220. The control unit superimposes and compares the thickness detection feedback with the advance displacement compensation amount in step S100 to determine whether the current physical gap of the coating roller group meets the standard. If yes, the current servo drive parameters are maintained and the operation continues; otherwise, the process proceeds to S230. S230. Generate control instructions based on theoretical springback and current thickness deviation, drive mechanical ball screw to move the moving surface roller of coating roller group inward or outward to complete micron-level gap dynamic compensation, and return to step S210.

[0048] S300, Volatilization Limit Constraint and Cascade Intervention: The coated substrate is heated and dried through a multi-segment tunnel oven. The exhaust concentration is obtained in real time by the sensor group. When the mechanical opening of the exhaust regulating valve reaches the limit and the concentration exceeds the standard, the control unit sequentially triggers the synchronous deceleration action of the entire traction mechanism and the mechanical thickness reduction cut-off action of the coating roller group.

[0049] In this embodiment, step S300 includes the following steps: S310: The concentration of volatiles in the oven is collected by the sensor group, and the exhaust proportional regulating valve is driven by the control unit to adjust the exhaust cross section. S320: Determine whether the exhaust proportional regulating valve has reached the fully open mechanical limit and the concentration continues to exceed the limit. If not, maintain the current exhaust state and continue operation; if yes, proceed to S330. S330: Trigger the first cascade protection, reduce the operating speed of the entire traction main shaft, drive all traction rollers to reduce the material conveying speed proportionally, and determine whether the current conveying speed has dropped to the lower limit threshold for maintaining the tension of the substrate. If not, continue to reduce the speed; if so, proceed to S340. S340, trigger the second cascade protection, send a reverse command to the servo motor, forcibly reduce the physical gap of the coating roller group to block the coating action, and coordinate with the cylinder of the pneumatic marking mechanism to press down to mark the abnormal section.

[0050] S400, High-Pressure Calendering and Online Transmission Testing: The dried substrate is subjected to high-pressure densification calendering by heating the calendering rollers. The ultrasonic array of the online verification probe is used to obtain the physical acoustic attenuation characteristics inside the material to identify bubbles or delamination defects.

[0051] S500, Defect Tracking and Physical Parameter Self-Tuning: When a defect is detected, the control unit tracks the physical location of the defect section based on the rotational angular displacement data of the main traction shaft, and adjusts the heating execution parameters of the tunnel oven in conjunction with the control unit for self-tuning and secondary flaw detection verification.

[0052] In this embodiment, step S500 includes the following steps: S510: Analyze the acoustic wave amplitude transmitted by the online verification probe to determine whether there is a gas-solid interface reflection signal representing a defect. If not, determine that the internal density of the material meets the standard and continue the operation; if yes, proceed to S520. S520, reduce the heating power of the heating elements of the multi-segment tunnel oven to reduce the curing temperature, and simultaneously record the rotational displacement of the main traction shaft. S530: Calculate the material's travel distance based on the rotational displacement, and determine whether the new material section after parameter adjustment has been transported to the online verification probe station. If not, continue traction and wait; if yes, proceed to S540. S540. Re-perform density flaw detection on the current material to determine whether the acoustic wave amplitude has recovered to the qualified threshold. If yes, lock the current self-tuning parameters and proceed to S400. If no, further reduce the overall conveying speed and return to step S520 for a new round of cycle tuning.

[0053] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for intelligent manufacturing of multilayer lamination buffer pads for circuit boards, characterized in that, Includes the following steps: S100, Tension Feedforward Detection and Advance Compensation Generation: The tension deformation characteristics of the flexible substrate during the traction process are obtained in real time by the tension sensing roller group of the unwinding section, and the control unit converts them into the advance displacement compensation amount of the servo coating mechanism. S200, Dynamic closed-loop control of coating gap: The flexible substrate is extruded and coated with adhesive by coating roller group, and the real-time coating thickness on the discharge side is obtained by thickness gauge. Combined with the advance displacement compensation, the servo motor is driven to adjust the mechanical gap of coating roller group to eliminate the thickness error caused by tension rebound. S300, Volatilization Limit Constraint and Cascade Intervention: The coated substrate is heated and dried through a multi-segment tunnel oven. The exhaust concentration is obtained in real time by the sensor group. When the mechanical opening of the exhaust regulating valve reaches the limit and the concentration exceeds the standard, the control unit triggers the synchronous deceleration action of the entire traction mechanism and the mechanical thickness reduction cut-off action of the coating roller group in sequence. S400, High-Pressure Calendering and Online Transmission Flaw Detection: The dried substrate is subjected to high-pressure densification calendering by heating the calendering roller group, and the physical acoustic wave attenuation characteristics inside the material are obtained by using the ultrasonic array of the online verification probe to identify bubbles or delamination defects. S500, Defect Tracking and Physical Parameter Self-Tuning: When a defect is detected, the control unit tracks the physical location of the defect section based on the rotational angular displacement data of the main traction shaft, and adjusts the heating execution parameters of the tunnel oven in conjunction with the control unit for self-tuning and secondary flaw detection verification.

2. The intelligent manufacturing method according to claim 1, characterized in that, Step S200 includes the following steps: S210. The thickness of the wet film on the discharge side is collected in real time by the thickness gauge, and the thickness detection feedback is transmitted to the control unit. S220. The control unit superimposes and compares the thickness detection feedback with the advance displacement compensation amount in step S100 to determine whether the current physical gap of the coating roller group meets the standard. If yes, the current servo drive parameters are maintained and the operation continues; otherwise, the process proceeds to S230. S230. Generate control instructions based on theoretical springback and current thickness deviation, drive mechanical ball screw to move the moving surface roller of coating roller group inward or outward to complete micron-level gap dynamic compensation, and return to step S210.

3. The intelligent manufacturing method according to claim 1, characterized in that, Step S300 Includes the following steps: S310: The concentration of volatiles in the oven is collected by the sensor group, and the exhaust proportional regulating valve is driven by the control unit to adjust the exhaust cross section. S320: Determine whether the exhaust proportional regulating valve has reached the fully open mechanical limit and the concentration continues to exceed the limit. If not, maintain the current exhaust state and continue operation; if yes, proceed to S330. S330: Trigger the first cascade protection, reduce the operating speed of the entire traction main shaft, drive all traction rollers to reduce the material conveying speed proportionally, and determine whether the current conveying speed has dropped to the lower limit threshold for maintaining the tension of the substrate. If not, continue to reduce the speed; if so, proceed to S340. S340, trigger the second cascade protection, send a reverse command to the servo motor, forcibly reduce the physical gap of the coating roller group to block the coating action, and coordinate with the cylinder of the pneumatic marking mechanism to press down to mark the abnormal section.

4. The intelligent manufacturing method according to claim 1, characterized in that, Step S500 includes the following steps: S510: Analyze the acoustic wave amplitude transmitted by the online verification probe to determine whether there is a gas-solid interface reflection signal representing a defect. If not, determine that the internal density of the material meets the standard and continue the operation; if yes, proceed to S520. S520, reduce the heating power of the heating elements of the multi-segment tunnel oven to reduce the curing temperature, and simultaneously record the rotational displacement of the main traction shaft. S530: Calculate the material's travel distance based on the rotational displacement, and determine whether the new material section after parameter adjustment has been transported to the online verification probe station. If not, continue traction and wait; if yes, proceed to S540. S540. Re-perform density flaw detection on the current material to determine whether the acoustic wave amplitude has recovered to the qualified threshold. If yes, lock the current self-tuning parameters and proceed to S400. If no, further reduce the overall conveying speed and return to step S520 for a new round of cycle tuning.

5. A smart manufacturing equipment for multilayer lamination buffer pads on circuit boards, the equipment being used to implement the smart manufacturing method according to any one of claims 1-4, comprising a feedforward unwinding assembly, a precision coating assembly, a drying and waste removal assembly, a calendering assembly, and an online verification assembly arranged sequentially along the travel direction of the flexible substrate, characterized in that: The feedforward unwinding assembly includes a frame, an unwinding shaft rotatably mounted on the frame, and a tension sensing roller assembly spanning the substrate conveying path. Load strain gauges that undergo elastic deformation under pressure are provided between the bearing seats at both ends of the tension sensing roller assembly and the frame. The precision coating assembly includes a coating machine base, a coating roller assembly rotatably mounted on the coating machine base, a ball screw mechanism for driving the coating roller assembly to open and close intermittently, and a laser thickness gauge located on the discharge side. When the tension sensing roller assembly undergoes physical deflection deformation due to the traction tension of the substrate, it outputs an electrical signal. The control unit receives the electrical signal and links the servo drive motor of the ball screw mechanism to drive the coating roller assembly to generate a matching mechanical linear displacement before the substrate elastically rebounds, thereby compensating for the coating thickness in advance.

6. The manufacturing equipment according to claim 5, characterized in that, The coating roller assembly includes a fixed-thickness back roller and a movable face roller that can be moved laterally. The screw nut pair of the ball screw mechanism is fixedly connected to the bearing seat of the movable face roller. The servo drive motor is configured to simultaneously receive the measured thickness feedback from the laser thickness gauge and the deformation feedforward of the tension sensing roller group. It drives the ball screw mechanism to push and pull the movable roller, thereby changing the cross-sectional area of ​​the glue injection in real time to eliminate the deviation caused by the stretching and springback of the substrate.

7. The manufacturing equipment according to claim 5, characterized in that, The drying and waste discharge assembly includes a multi-section tunnel-type drying oven, an exhaust duct connecting the inner cavity of the drying oven, and an exhaust proportional regulating valve installed on the exhaust duct. A sensor group for monitoring the volatile concentration is inserted in the exhaust duct. The valve core of the exhaust proportional regulating valve is linked to the monitoring data of the sensor group and expands and contracts within the exhaust duct to change the exhaust cross section. When the valve core is displaced to the maximum exhaust mechanical limit and the concentration monitored by the sensor group exceeds the safety threshold, the control unit links the entire traction main shaft to synchronously reduce the speed. When the rotational speed of the traction spindle drops to the lower limit for maintaining substrate tension, the ball screw mechanism of the precision coating assembly is reversed, mechanically closing the physical gap between the movable face roller and the thickness-fixed back roller, thereby blocking the input of wet adhesive.

8. The manufacturing equipment according to claim 7, characterized in that, A pneumatic marking mechanism with electromechanical linkage is also provided between the precision coating component and the drying and waste discharge component; The pneumatic marking mechanism includes a support gantry spanning above the substrate and a stamping cylinder vertically positioned on the support gantry. While the physical gap of the coating roller assembly is mechanically closed, the stamping cylinder synchronously receives a trigger signal and drives the marking module at its end to extend downwards, performing anti-counterfeiting stamping and isolation marking on the surface of abnormal substrate sections that are in a glue-free state.

9. The manufacturing equipment according to claim 5, characterized in that, The calendering assembly includes upper and lower counter-arranged heating steel rolls and a servo hydraulic cylinder that abuts against the bearing seat of the heating steel rolls. The telescopic rod of the servo hydraulic cylinder pushes downward to provide a high-pressure densification load for the substrate. The online verification component includes a verification frame spanning the discharge end, on which ultrasonic flaw detectors that physically transmit light through the upper and lower surfaces of the substrate are arrayed.

10. The manufacturing equipment according to claim 9, characterized in that, The device also includes a rotational angular displacement detection component that is mechanically driven coaxially with the traction spindle; When the ultrasonic flaw detector detects acoustic wave reflection attenuation representing the gas-solid interface inside the material, the control unit adjusts the heating power of the heating element in the tunnel oven in conjunction with the control unit, and physically follows and positions the trajectory of the heating power adjustment section based on the physical mechanical rotation stroke generated by the rotational angular displacement detector as it rotates with the main shaft; when the section is transported to the bottom of the verification frame, the ultrasonic flaw detector is triggered to perform secondary structural flaw detection.

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