Press machine and method for manufacturing multilayer products

Abstract

A press machine (1) for manufacturing a multilayer product (3) comprises a feeding means, a planar acting means (2), and a pressure regulator (4). The feeding means is configured to introduce a base product and one or more films into the work station. The planar acting means (2) is configured to apply force to the base product and one or more films in order to manufacture a multilayer product (3) and operates in the work station. The pressure regulator (4) is associated with the planar acting means (2) and is configured to set the force applied by the acting means. The planar acting means (2) is also configured to apply a time-varying force which can be adjusted by the pressure regulator (4).

Description

Technical Field

[0001] The object of the present invention is a press machine that can be used to bond materials and / or semi-finished products in the form of sheets, foils or more generally "thin films" (such as thin metal foils or polymer foils with one or more protective surface films), and can be used in various manufacturing applications, for example, but not limited to, the manufacture of printed circuit boards or manufacture by electrochemical or photochemical etching. Furthermore, the object of the present invention is a method for manufacturing multi-layer products made of semi-finished sheets (or foils).

[0002] The machine can be inserted into, or can be inserted into, a line of machines defined as "two-step lamination". Here, two-step lamination refers to a manufacturing process carried out in two steps.

[0003] Generally, each of the two steps is controlled by one of the following machines. That is, - the so-called "vacuum laminator" (known in technical terms as "MVC"), and - the so-called "flattening press" (known in technical terms as "flat press").

Background Art

[0004] In the field of so-called laminating machines, various types of assemblies are known that can act on flat foils or "thin-layered" semi-finished products. Usually, such techniques are based on an appropriate mode of advancing and holding the "base" thin-layered element, which has to be bonded (as required) with extremely thin films or coating strips on one or both sides of its surface.

[0005] In this step of the cycle, the purpose is to attach the film to a given semi-finished product.

[0006] The quality of this process is primarily evaluated through the level of film's fit and adhesion to the semi-finished product or its potential lithography.

[0007] The problem that arises during the process concerns the fact that the film is primarily applied to rough surfaces with raised channels or patterns or depressions.

[0008] Unfortunately, it is difficult to implement a process that can achieve a suitable level of quality, and therefore, a process that can avoid air bubbles or wrinkles between the semi-finished product and the film after assembly.

[0009] Currently, conventional technology solves problems related to the fit and adhesion between semi-finished products and films by applying a certain force to multilayer products.

[0010] Unfortunately, especially with regard to electrical circuits, good fit of the applied film alone is not sufficient; it is also necessary to obtain extremely good flatness of the circuit board after the process is complete.

[0011] In fact, the sole purpose of this step is for the applied film to conform to the shape of the pattern on the semi-finished product, so the semi-finished-polymer composite will not be perfectly flat after vacuum lamination.

[0012] Therefore, the second step of the current process focuses solely on making the semi-finished-film composite completely smooth and flat by compressing it with a straightened steel sheet.

[0013] Such flattening presses traditionally allow for setting a target pressure to be reached (such pressure can be expressed as a ratio of a given force applied to the compression area by a suitable machine or actuator), and typically, currently available machines continuously compress the semi-finished-film composite with the nominal force required to achieve the target pressure across the entire composite area.

[0014] However, in the initial steps of the approach between the machine and the composite, the contact area between the two is very small. This is because only the higher undulations are subjected to pressure. Therefore, the nominal force is not evenly distributed across the composite but concentrates in a small area of ​​the composite. As a result, a very high specific pressure is generated at the initial stage of machine use.

[0015] As the flattening press approaches and time passes, the contact area increases and the pressure decreases until it reaches the set target pressure. Unfortunately, the initial pressure peak causes the so-called squeezing phenomenon and / or damage to the possible electronic circuits inside the semi-finished-film composite. [Overview of the project]

[0016] Therefore, the technical problem of the present invention is to provide a press machine and related methods for manufacturing multilayer products that overcome the aforementioned drawbacks of the prior art.

[0017] Therefore, an object of the present invention is to provide a press machine and method for manufacturing multilayers that enable the achievement of optimal flatness.

[0018] Therefore, a further objective of this solution is to provide a press machine and method for manufacturing multilayer products that avoid the possibility of damage to the final product.

[0019] Finally, a further object of the present invention is to provide a press machine and method for manufacturing multilayers that are versatile for covering multiple production lines.

[0020] The specified technical problems and identified objectives are substantially achieved by a press machine having the technical features described in one or more of the claims of the appended patent claims. Dependent claims may correspond to possible embodiments of the present invention.

[0021] According to the present invention, a press machine for manufacturing a multilayer product is shown, which comprises supply means configured to introduce a base product and one or more films to be arranged on the base product into a working station.

[0022] The press machine comprises planar acting means operating in a working station, configured to apply a force to the base product and one or more films so as to manufacture a multilayer product.

[0023] The planar acting means is configured to apply a force that varies over time.

[0024] The machine comprises a pressure regulator associated with the planar acting means, configured to set the force applied by the acting means.

[0025] The pressure regulator is configured to adjust a force that varies over time.

[0026] Advantageously, by combining the pressure regulator and the planar acting means, it is possible to obtain a high level of product quality.

[0027] The high level of product quality is ensured by specific final parameters of the multilayer product, such as the conformity, adhesion between the base product and one or more films, and the flatness of the multilayer product.

[0028] Furthermore, the present invention provides a method for manufacturing a multilayer product.

[0029] The method for manufacturing a multilayer product includes supplying a base product to a working station and then supplying and arranging one or more films on the base product.

[0030] The method also includes adjusting a force that varies over time through a pressure regulator and applying the force that varies over time to the base product and one or more films to manufacture a multilayer product.

[0031] Further features and advantages of the present invention will become apparent from the exemplary, and therefore non-limiting, description of the press machine and related methods for manufacturing multilayer products. [Brief explanation of the drawing]

[0032] Such explanations are provided below with reference to the accompanying drawings, which are provided for illustrative purposes only and therefore not for limiting purposes. [Figure 1A] This is a schematic diagram of a possible embodiment of a press machine for manufacturing multilayer products. [Figure 1B] Figure 1A is a schematic diagram of a possible embodiment of a press machine for manufacturing multilayer products at a different point in time. [Figure 1C] Figures 1A and 1B are schematic diagrams of possible embodiments of a press machine for manufacturing multilayer products at different points in time. [Modes for carrying out the invention]

[0033] Referring to the attached drawing, Figure 1 shows an overall view of a press machine for manufacturing multilayer product 3, which will be referred to as press machine 1 below for the sake of clarity.

[0034] The press machine 1 basically comprises a feeding means, a planar acting means 2, and a pressure regulator 4.

[0035] The supply means is configured to introduce the base product and one or more films to be placed / bonded onto the base product into the work station.

[0036] The base product used may be a circuit board or panel equipped with electronic circuits, and therefore may be characterized by a specific pattern shape (and variations in height or thickness in the planar unfolding, even at the "micrometer" level).

[0037] The surface pattern of the base product may have raised ridges or recessed channels.

[0038] The film manufactured for attachment to the base product may be, for example, a photosensitive polymer film.

[0039] According to possible embodiments, an adhesive may be present between the base product and one or more films.

[0040] In other words, three dielectric sheets containing hot glue can be used inside a multilayer product. When these sheets are heat-compressed, they allow the adhesive to flow into the circuitry of the base product.

[0041] The planar acting means 2, which operates at the work station, is configured to apply force to the base product and one or more films in order to manufacture the multilayer product 3.

[0042] Specifically, the planar acting means 2 is configured to apply a time-varying force.

[0043] In other words, the planar acting means 2 compresses the multilayer product 3 with a time-varying force that reaches a limit pressure.

[0044] Advantageously, the force applied to the multilayer product 3 by the planar acting means 2 increases or decreases over time as the contact area between the multilayer product 3 and the planar acting means 2 increases or decreases, thereby ensuring that the limit pressure is achieved and maintained.

[0045] In other words, as the contact area increases, the pressure is adjusted accordingly by the gradual compression of the ridges that characterize the product pattern, thus ensuring a balance of limit pressures.

[0046] Advantageously, the planar acting means 2 ensures proper fit and adhesion of the film to the base product or its possible lithography, even when the base product is not smooth but "rough" (i.e., a base product whose surface irregularities or "height distribution" are not uniform in its plane, but have variations even at the "micrometer" level, such as due to the presence of conductive tracks provided on the base substrate of the base product itself) and / or has raised or recessed channels and / or patterns.

[0047] According to a possible embodiment, at least one of the planar working means 2 is a vacuum laminator equipped with at least one vacuum chamber.

[0048] Advantageously, the vacuum chamber prevents air bubbles from forming between the base product and one or more films placed on top of it.

[0049] A laminator is designed to adhere one or more films to the top surface of a base product using a combination of force, temperature, and vacuum.

[0050] Advantageously, if present, temperature activates the adhesive between the base product and one or more films, ensuring strong adhesion between the various layers within the multilayer product 3.

[0051] According to a possible embodiment, at least one of the planar working means 2 is a planar press equipped with an adjustment sensor connected to a pressure regulator 4.

[0052] Advantageously, the planarization press compresses the multilayer product 3, making it completely smooth and flat.

[0053] Thanks to the flat surface of the planarizing press and the temperature applied to the planar working means 2, the adhesive between the base product and one or more films is uniformly dispersed within the multilayer product 3.

[0054] Advantageously, the flattening press makes it possible to produce a uniform, glossy, multilayer product 3.

[0055] Preferably, the planar acting means 2 comprises a deformable membrane.

[0056] The deformable film is configured to expand on the multilayer product 3 while the multilayer product 3 is being manufactured.

[0057] Advantageously, the deformable film of the planar acting means 2 expands over any irregularities, ensuring the proper shape of the multilayer product 3 by compressing one or more films relative to the base product.

[0058] A pressure regulator 4, which is associated with or can be associated with the planar acting means 2, is configured to set the force applied by the planar acting means 2.

[0059] The pressure regulator 4 is configured to adjust the time-varying force applied by the planar acting means 2.

[0060] According to a possible embodiment, the pressure regulator 4 is configured to adjust and set a time-varying force by defining a force gradient at different time intervals.

[0061] In other words, by using a pressure regulator 4 that defines the force gradient at different time intervals, it is possible to achieve uniformity in the ratio between the function curve of the applied pressure and the function curve of the amount of contact area between the multilayer product 3 and the planar action means 2.

[0062] Advantageously, the uniformity of the pressure curve and contact area ratio facilitates the flow of the adhesive, reducing the possibility of adhesive leakage from the edges of the base product and damage to electrical circuits.

[0063] Preferably, the pressure regulator 4 is configured to set and adjust a variable force to specify a limit value for the force gradient at each time interval.

[0064] According to a possible embodiment, the pressure regulator 4 is configured to determine the limit duration of a time interval based on a predetermined force gradient.

[0065] According to another possible embodiment of the press machine 1, the pressure regulator 4 includes or specifies a database.

[0066] The database may include, for each multilayer product 3, one or more limit values ​​for the force gradient and / or limit durations for the time interval.

[0067] Preferably, the pressure regulator 4 includes a pressure sensor configured to measure pressure fluctuations on the multilayer product 3 as a time-varying force changes.

[0068] According to a possible embodiment, the pressure regulator 4 also includes a database containing one or more limit pressure values.

[0069] The limit pressure value is associated with, or can be associated with, a predetermined expected outcome.

[0070] The pressure controller 4 is also configured to compare the measured pressure fluctuations with one or more limit pressure values ​​and adjust the time-varying force based on that comparison to obtain a specific expected result.

[0071] Preferably, the pressure controller 4 includes a database having one or more adjustment thresholds.

[0072] According to this possible embodiment, the pressure regulator 4 is configured to compare one or more values ​​measured by the adjustment sensor of the flattening press with an adjustment threshold.

[0073] In possible embodiments, the pressure controller 4 is configured to set and adjust the temperature parameters inside the planar acting means 2.

[0074] Preferably, the pressure controller 4 includes a contact sensor that can pre-calculate the contact area between the multilayer product 3 and the planar action means 2.

[0075] According to possible embodiments not shown in the figures, the contact sensor includes a radar system.

[0076] The present invention also provides a method for manufacturing a multilayer product 3 using a press machine 1.

[0077] This method provides essential steps for manufacturing the multilayer product 3, as well as other possible optional steps that may provide additional aspects or alternative means for carrying out the manufacturing method.

[0078] The method for manufacturing multilayer product 3 basically involves four steps.

[0079] A step of supplying the product to the work station.

[0080] A step of supplying a film to a work station by placing one or more films on a base product.

[0081] A step of adjusting the time-varying force through the pressure regulator 4.

[0082] A step of applying a time-varying force to a base product and one or more films by a planar acting means 2 in order to manufacture a multilayer product 3.

[0083] Preferably, the method includes the step of setting the temperature and / or force and / or vacuum parameters of the planar acting means 2, either optionally or unintentionally.

[0084] Next, the aforementioned parameters are maintained until multilayer product 3 is obtained.

[0085] According to one aspect of the present invention, the method includes the step of defining a vacuum inside the planar working means 2 and on the multilayer product 3.

[0086] During the step of applying a time-varying force to the multilayer product 3, a vacuum is maintained inside the planar acting means 2.

[0087] Advantageously, the vacuum step makes it possible to remove air trapped inside the planar working means 2 and / or the multilayer product 3.

[0088] This method includes a step of defining a limit operating pressure during a step of applying a time-varying force, and a subsequent step of gradually decreasing the limit operating pressure.

[0089] The step of defining the limit pressure is performed while maintaining a vacuum inside the planar action means 2.

[0090] The step of defining the limit pressure is performed by introducing high pressure onto the surface of the multilayer product 3.

[0091] During this step, the pressure regulator 4 can adjust the pressure applied over time.

[0092] According to one aspect of the present invention, the method also includes the step of programming a force gradient adapted to define a time-varying force at different time intervals.

[0093] The step of programming the gradient may be provided to apply stepwise steps of increasing or decreasing the force gradient in response to an increase or decrease in the contact area between the multilayer product 3 and the planar acting means 2 over a given time interval.

[0094] Advantageously, the application of a gradual force gradient, particularly a gradual decrease in pressure, allows for the uniform discharge of any adhesive contained within the multilayer product 3.

[0095] Next, according to a possible embodiment of the present invention, the high pressure applied to the surface of the multilayer product 3 is removed, and thanks to the step of maintaining a vacuum, the product settles into a stationary position.

[0096] Preferably, the method includes the step of removing the vacuum on the multilayer product 3. By removing the vacuum, high pressure is then reapplied inside the planar acting means 2.

[0097] Advantageously, the absence of vacuum and the application of high pressure generate suitable thrust for adapting multilayer product 3.

[0098] In other words, the shape of the multilayer product 3 is no longer determined solely by the planar acting means 2, particularly by the deformable film, but is determined by the air that can freely reach any point on the surface of the multilayer product 3.

[0099] Advantageously, the present invention provides a press machine 1 for manufacturing a multilayer product 3 and a method for manufacturing a multilayer product 3, which can overcome the drawbacks of the prior art.

[0100] Advantageously, the present invention enables the achievement of superior flatness, thereby ensuring a reduction in the possibility of damage to the final product, and furthermore, as a result, increases flexibility to cover a larger number of production lines.

Claims

1. A press machine (1) for manufacturing multilayer products (3), - A supply means configured to introduce a base product and one or more films to be placed on the base product into a work station, - Planar acting means (2) operating at the work station, configured to apply force to the base product and one or more films in order to manufacture a multilayer product (3), - A pressure regulator (4) associated with the planar acting means (2) is configured to set the force applied by the acting means, A press machine (1) wherein the planar acting means (2) is configured to apply a time-varying force, and the pressure regulator (4) is configured to adjust the time-varying force.

2. The press machine (1) according to claim 1, wherein the pressure regulator (4) is configured to adjust and set the time-varying force by defining force gradients at different time intervals.

3. The press machine (1) according to claim 2, wherein the pressure regulator (4) is configured to set and adjust the fluctuating force to specify a limit value for the force gradient at each time interval.

4. The press machine (1) according to claim 2 or 3, wherein the pressure regulator (4) is configured to specify a limit duration of a time interval according to a predetermined force gradient.

5. The press machine (1) according to claims 3 and 4, wherein the pressure regulator (4) comprises or specifies a database including one or more limit values ​​of force gradients and / or limit durations of time intervals for each multilayer product (3).

6. The press machine (1) according to any one or more of claims 1 to 5, wherein the pressure regulator (4) comprises a pressure sensor configured to measure the pressure fluctuation on the multilayer product (3) when the time-varying force changes.

7. The press machine (1) according to claim 6, wherein the pressure regulator (4) comprises a database including one or more limit pressure values ​​associated with or associable with a predetermined expected result, and the pressure regulator (4) is further configured to compare the measured pressure fluctuation with the one or more limit pressure values ​​and adjust the time-varying force in accordance with the comparison to obtain a given expected result.

8. The press machine (1) according to any one or more of claims 1 to 7, wherein the pressure regulator (4) is configured to set and adjust the internal temperature parameter of the planar acting means (2).

9. The press machine (1) according to any one or more of claims 1 to 8, wherein at least one of the planar acting means (2) is a vacuum laminator having at least one vacuum chamber.

10. The press machine (1) according to any one or more of claims 1 to 9, wherein at least one of the planar acting means (2) is a flattening press equipped with an adjustment sensor connected to the adjuster.

11. The press machine (1) according to any one or more of claims 1 to 10, wherein the planar acting means (2) comprises a deformable membrane, the deformable membrane being configured to expand on the multilayer product (3) during the manufacturing of the multilayer product (3).

12. A method for manufacturing a multilayer product (3) using a press machine (1) according to any one or more of claims 1 to 11, - Steps include supplying the base product to the work station, - A step of supplying one or more films to a work station by placing them on the base product, - A step of adjusting the time-varying force through a pressure regulator (4), A method for manufacturing the multilayer product (3), comprising the step of applying the time-varying force to the base product and the one or more films by a planar acting means (2).

13. - A step of setting the temperature and / or force and / or vacuum parameters of the planar acting means (2), The method according to claim 12, further comprising the step of maintaining the parameters until the multilayer product (3) is obtained.

14. - A step of defining a vacuum inside the planar acting means (2) and on the multilayer product (3), The method according to claim 12 or 13, further comprising the step of maintaining a vacuum inside the planar acting means (2) during the step of applying the time-varying force to the multilayer product (3).

15. The method according to any one or more of claims 12 to 14, comprising the steps of defining a limit operating pressure during the step of applying the time-varying force, and a subsequent step of gradually decreasing the limit operating pressure.

16. The method according to claim 14 or 15, further comprising the step of removing the vacuum on the multilayer product (3).

17. The method according to any one of claims 1 to 16, comprising the step of programming a force gradient adapted to define the time-varying force at different time intervals.

18. The method according to claim 17, wherein the step of programming a force gradient provides applying a stepwise increase or decrease of the force gradient in response to an increase or decrease in the contact area between the multilayer product (3) and the planar acting means (2) over a given time interval.

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