Apparatus for manufacturing laminates and method for manufacturing laminates

Abstract

To provide laminate manufacturing equipment and a laminate manufacturing method, each enabling improvement of both of securement of good flatness of the laminate, and productivity.SOLUTION: Laminate manufacturing equipment includes: a first press machine pressurizing a first temporary laminate including a substrate and a film laminated on the substrate, in a first direction parallel to a laminating direction of the first temporary laminate while bringing a first pressurization member into contact with the film, thereby obtaining a second temporary laminate; further a second press machine pressuring the second temporary laminate in the first direction while bringing the second pressurization member into contact with the film, thereby obtaining a third temporary laminate; further a third press machine pressurizing the third temporary laminate in the first direction while bringing the third pressurization member into contact with the film, thereby obtaining a fourth temporary laminate; and further a fourth press machine pressurizing the fourth temporary laminate in the first direction while bringing a fourth pressurization member into contact with the film, wherein a rigidity of the third pressurization member in the first direction is higher than a rigidity of the second pressurization member in the first direction.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to an apparatus for manufacturing a laminate and a method for manufacturing a laminate.

Background Art

[0002] A laminating apparatus that performs three-stage planar pressing to laminate a resin film on a base material has been proposed (Patent Document 1). Patent Document 1 describes using a servo motor for the third-stage planar pressing. Patent Document 1 also describes not using a buffer material for the third-stage planar pressing, or when using a buffer material, using a buffer material with a lower buffering effect than that of the second-stage planar pressing.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the apparatus described in Patent Document 1, when using a buffer material with a low buffering effect for the third-stage planar pressing, it is difficult to obtain good flatness on the surface of the resin film. Also, even when not using a buffer material for the third-stage planar pressing, the time required for the third-stage planar pressing is long, and it is difficult to improve productivity. When using the apparatus described in Patent Document 1, if the time for the third-stage planar pressing is shortened, it is difficult to obtain good flatness on the surface of the resin film even without using a buffer material.

[0005] An object of the present disclosure is to provide an apparatus for manufacturing a laminate and a method for manufacturing a laminate that can achieve both ensuring good flatness and improving productivity.

Means for Solving the Problems

[0006] According to one embodiment of the present disclosure, the present invention comprises: a first press machine that forms a second temporary laminate by pressing a first temporary laminate, which includes a substrate and a film laminated on the substrate, in a first direction parallel to the lamination direction of the first temporary laminate while a first pressing member is in contact with the film; a second press machine that forms a third temporary laminate by pressing the second temporary laminate in the first direction while a second pressing member is in contact with the film; a third press machine that forms a fourth temporary laminate by pressing the third temporary laminate in the first direction while a third pressing member is in contact with the film; and a fourth press machine that presses the fourth temporary laminate in the first direction while a fourth pressing member is in contact with the film, wherein the first pressing member is A laminate manufacturing apparatus is provided, comprising: a first heating plate and a resin elastic member fixed to the first heating plate and in contact with the film; a second pressing member comprising: a second heating plate and a first metal plate in contact with the film and a first cushioning material provided between the second heating plate and the first metal plate; a third pressing member comprising: a third heating plate and a second metal plate in contact with the film and a second cushioning material provided between the third heating plate and the second metal plate; and a fourth pressing member comprising: a fourth heating plate and a third metal plate directly fixed to the fourth heating plate and in contact with the film, wherein the rigidity of the third pressing member in the first direction is higher than that of the second pressing member in the first direction. [Effects of the Invention]

[0007] According to the disclosed technology, it is possible to achieve both good flatness and improved productivity. [Brief explanation of the drawing]

[0008] [Figure 1] This figure illustrates a manufacturing apparatus for a laminate according to the first embodiment. [Figure 2] This figure (1) illustrates a method for manufacturing a laminate using the laminate manufacturing apparatus according to the first embodiment. [Figure 3] This is a diagram (part 2) illustrating a method for manufacturing a laminate using the laminate manufacturing apparatus according to the first embodiment. [Figure 4]This is a diagram (part 3) illustrating a method for manufacturing a laminate using the laminate manufacturing apparatus according to the first embodiment. [Figure 5] This is a diagram (part 4) illustrating a method for manufacturing a laminate using the laminate manufacturing apparatus according to the first embodiment. [Figure 6] Figure (5) illustrates a method for manufacturing a laminate using the laminate manufacturing apparatus according to the first embodiment. [Figure 7] This figure illustrates a method for manufacturing a laminate using a laminate manufacturing apparatus according to the second embodiment. [Modes for carrying out the invention]

[0009] The embodiments will be described in detail below with reference to the attached drawings. In this specification and the drawings, components having substantially the same functional configuration will be denoted by the same reference numerals to avoid redundant explanations.

[0010] (First Embodiment) First, a manufacturing apparatus for laminates according to the first embodiment will be described. Figure 1 is an example of a manufacturing apparatus for laminates according to the first embodiment. Figures 2 to 6 are examples of a method for manufacturing a laminate using the manufacturing apparatus for laminates according to the first embodiment.

[0011] The laminate manufacturing apparatus 1 according to the first embodiment includes, as shown in Figure 1, a first press machine 91, a second press machine 92, a third press machine 93, a fourth press machine 94, a feeding section 95, and a receiving section 96. As shown in Figures 2 to 6, the first press machine 91 forms a second temporary laminate 52 from a first temporary laminate 51, the second press machine 92 forms a third temporary laminate 53 from a second temporary laminate 52, and the third press machine 93 forms a fourth temporary laminate 54 from a third temporary laminate 53. The fourth press machine 94 forms a laminate 55 from a fourth temporary laminate 54. The feeding section 95 is the part into which the first temporary laminate 51, which will be pressed by the first press machine 91, is fed from the outside, and once the first temporary laminate 51 is fed in, it is handed over to the first press machine 91. The receiving section 96 is the part that receives the laminate 55 formed by the fourth press machine 94, and the laminate 55 is removed from the receiving section 96 to the outside.

[0012] As shown in Figure 6, the laminate 55 manufactured by the manufacturing apparatus 1 comprises a base material 30, a film 41, and a film 42. The base material 30 is located between the films 41 and 42. The laminate 55 is used, for example, as a wiring board. In this embodiment, for convenience, the film 41 side of the base material 30 is referred to as the upper side or one side, and the film 42 side as the lower side or the other side. Also, the film 41 side surface of each part is referred to as the upper surface or one surface, and the film 42 side surface is referred to as the lower surface or the other surface. However, the laminate 55 can be used upside down or arranged at any angle.

[0013] The substrate 30 has a core 10, a wiring layer 21, and a wiring layer 22. The wiring layer 21 is provided on one surface of the core 10. The wiring layer 21 includes a wiring pattern, and a portion of one surface of the core 10 is exposed from the wiring layer 21. The wiring layer 22 is provided on the other surface of the core 10. The wiring layer 22 includes a wiring pattern, and a portion of the other surface of the core 10 is exposed from the wiring layer 22. One surface of the substrate 30 has irregularities caused by the wiring pattern of the wiring layer 21, and the other surface of the substrate 30 has irregularities caused by the wiring pattern of the wiring layer 22.

[0014] Films 41 and 42 are, for example, insulating resin films and function as insulating layers. Film 41 covers one side of the substrate 30 and fills in the recesses on that side of the substrate 30. Film 42 covers the other side of the substrate 30 and fills in the recesses on the other side of the substrate 30.

[0015] As shown in Figures 2(a) and 2(b), the first press machine 91 includes an upper plate 111, a lower plate 121, a plurality of drive shafts 150 parallel to each other, an upper pressing member 110, and a lower pressing member 120. The upper plate 111 and the lower plate 121 are supported by the drive shafts 150. The lower surface of the upper plate 111 and the upper surface of the lower plate 121 are parallel to each other and face each other. For example, the upper plate 111 is fixed to the drive shafts 150, and the lower plate 121 is supported on the drive shafts 150 so as to be movable up and down along the drive shafts 150. The lower plate 121 is driven, for example, using a hydraulic cylinder. The lower plate 121 may also be driven using an air cylinder. That is, the first press machine 91 is, for example, a hydraulic press or an air press. The vertical direction is an example of a first direction.

[0016] The upper pressing member 110 includes a heating plate 112, a metal plate 113, and a resin elastic member 114. The resin elastic member 114 is fixed to the metal plate 113, and the metal plate 113 is fixed to the heating plate 112. The heating plate 112 is attached to the lower surface of the upper plate 111. The heating plate 112 includes a heater that heats the resin elastic member 114 via the metal plate 113. The heater is, for example, a sheathed heater. The metal plate 113 is, for example, a stainless steel plate. The material of the resin elastic member 114 is, for example, rubber. The lower surface of the resin elastic member 114 contacts the upper surface of the first temporary laminate 51. The upper pressing member 110 is an example of the first pressing member. The heating plate 112 is an example of the first heating plate.

[0017] The lower pressing member 120 includes a hot plate 122, a metal plate 123, and a resin elastic member 124. The resin elastic member 124 is fixed to the metal plate 123, and the metal plate 123 is fixed to the hot plate 122. The hot plate 122 is attached to the upper surface of the lower plate 121. The configurations of the hot plate 122, the metal plate 123, and the resin elastic member 124 are the same as those of the hot plate 112, the metal plate 113, and the resin elastic member 114, respectively. The upper surface of the resin elastic member 124 contacts the lower surface of the first temporary laminate 51. The lower pressing member 120 is an example of the first pressing member. The hot plate 122 is an example of the first hot plate.

[0018] As shown in Fig. 2(a), in the first press 91, the first temporary laminate 51 conveyed from the input section 95 is disposed between the resin elastic member 114 and the resin elastic member 124. For example, the first temporary laminate 51 is placed on the lower pressing member 120 such that the lower surface of the film 42 contacts the upper surface of the resin elastic member 124. At the stage before the pressing by the first press 91, the film 41 is laminated on the base material 30 so as to contact the upper surface of the wiring layer 21, but does not fill the concave portion on the upper surface of the base material 30. Also, the film 42 is laminated on the base material 30 so as to contact the lower surface of the wiring layer 22, but does not fill the concave portion on the lower surface of the base material 30.

[0019] After the first temporary laminate 51 is disposed between the resin elastic member 114 and the resin elastic member 124, as shown in Fig. 2(b), the lower plate 121 rises, and the upper surface of the film 41 contacts the lower surface of the resin elastic member 114. When the lower plate 121 further rises, the resin elastic member 114 elastically deforms along the irregularities on the upper surface of the base material 30, and the resin elastic member 124 elastically deforms along the irregularities on the lower surface of the base material 30 while the first temporary laminate 51 is pressed. As a result, the film 41 enters the concave portion on the upper surface of the base material 30, and the film 42 enters the concave portion on the lower surface of the base material 30.

[0020] In this way, the second temporary laminate 52 is formed. In the second temporary laminate 52, the film 41 fills the concave portion on the upper surface of the base material 30, and the film 42 fills the concave portion on the lower surface of the base material 30. Also, on the upper surface of the film 41, there are irregularities reflecting the irregularities on the upper surface of the base material 30, and on the lower surface of the film 42, there are irregularities reflecting the irregularities on the lower surface of the base material 30.

[0021] Thereafter, the lower plate 121 descends, and the second temporary laminate 52 is conveyed to the second press machine 92.

[0022] As shown in FIGS. 3(a) and 3(b), the second press machine 92 includes an upper plate 211, a lower plate 221, a plurality of drive shafts 250 parallel to each other, an upper pressing member 210, and a lower pressing member 220. The upper plate 211 and the lower plate 221 are supported by the drive shafts 250. The lower surface of the upper plate 211 and the upper surface of the lower plate 221 are parallel to each other and face each other. For example, the upper plate 211 is fixed to the drive shafts 250, and the lower plate 221 is supported by the drive shafts 250 so as to be movable up and down along the drive shafts 250. The lower plate 221 is driven using, for example, a hydraulic cylinder. The lower plate 221 may be driven using an air cylinder. That is, the second press machine 92 is, for example, a hydraulic press machine or an air press machine.

[0023] The upper pressing member 210 includes a heating plate 212, a cushioning material 213, and a metal plate 214. The metal plate 214 is fixed to the heating plate 212 via the cushioning material 213. The heating plate 212 is attached to the lower surface of the upper plate 211. The heating plate 212 includes a heater that heats the metal plate 214 via the cushioning material 213. The heater is, for example, a sheathed heater. The cushioning material 213 has a composite material including, for example, rubber and aramid fibers. The thickness of the cushioning material 213 is, for example, 2.0 mm to 2.5 mm. The metal plate 214 is, for example, a stainless steel plate. The thickness of the metal plate 214 is, for example, 1 mm to 2 mm. The lower surface of the metal plate 214 contacts the upper surface of the second temporary laminate 52. The upper pressing member 210 is an example of the second pressing member. The heating plate 212 is an example of a second heating plate, the cushioning material 213 is an example of a first cushioning material, and the metal plate 214 is an example of a first metal plate.

[0024] The lower pressing member 220 includes a heating plate 222, a cushioning material 223, and a metal plate 224. The metal plate 224 is fixed to the heating plate 222 via the cushioning material 223. The heating plate 222 is attached to the upper surface of the lower plate 221. The configurations of the heating plate 222, cushioning material 223, and metal plate 224 are the same as those of the heating plate 212, cushioning material 213, and metal plate 214, respectively. The upper surface of the metal plate 224 contacts the lower surface of the second temporary laminate 52. The lower pressing member 220 is an example of a second pressing member. The heating plate 222 is an example of a second heating plate, the cushioning material 223 is an example of a first cushioning material, and the metal plate 224 is an example of a first metal plate.

[0025] As shown in Figure 3(a), in the second press machine 92, the second temporary laminate 52 is placed between the metal plate 214 and the metal plate 224. For example, the second temporary laminate 52 is placed on the lower pressing member 220 such that the lower surface of the film 42 is in contact with the upper surface of the metal plate 224.

[0026] After the second temporary laminate 52 is placed between the metal plates 214 and 224, the lower plate 221 rises as shown in Figure 3(b), and the upper surface of the film 41 comes into contact with the lower surface of the metal plate 214. As the lower plate 221 rises further, the metal plate 214 and the cushioning material 213 elastically deform along the irregularities on the upper surface of the base material 30, and the second temporary laminate 52 is pressed as the metal plate 224 and the cushioning material 223 elastically deform along the irregularities on the lower surface of the base material 30. As a result, the irregularities on the upper and lower surfaces of the base material 30 are alleviated.

[0027] In this way, the third temporary laminate 53 is formed. Compared to the second temporary laminate 52, the flatness of the upper surface of the film 41 and the lower surface of the film 42 is higher in the third temporary laminate 53.

[0028] Subsequently, the lower plate 221 descends, and the third temporary laminate 53 is transported to the third press machine 93.

[0029] As shown in Figures 4(a) and 4(b), the third press machine 93 includes an upper plate 311, a lower plate 321, a plurality of drive shafts 350 parallel to each other, an upper pressing member 310, and a lower pressing member 320. The upper plate 311 and the lower plate 321 are supported by the drive shafts 350. The lower surface of the upper plate 311 and the upper surface of the lower plate 321 are parallel to each other and face each other. For example, the upper plate 311 is fixed to the drive shafts 350, and the lower plate 321 is supported on the drive shafts 350 so as to be movable up and down along the drive shafts 350. The lower plate 321 is driven, for example, using a hydraulic cylinder. The lower plate 321 may also be driven using an air cylinder. That is, the third press machine 93 is, for example, a hydraulic press machine or an air press machine.

[0030] The upper pressing member 310 includes a heating plate 312, a cushioning material 313, and a metal plate 314. The metal plate 314 is fixed to the heating plate 312 via the cushioning material 313. The heating plate 312 is attached to the lower surface of the upper plate 311. The heating plate 312 includes a heater that heats the metal plate 314 via the cushioning material 313. The heater is, for example, a sheathed heater. The configurations of the heating plate 312 and the metal plate 314 are the same as those of the heating plate 212 and the metal plate 214, respectively. On the other hand, the configuration of the cushioning material 313 differs from that of the cushioning material 213, and the vertical rigidity of the cushioning material 313 is higher than that of the cushioning material 213. Therefore, the vertical rigidity of the upper pressing member 310 is higher than that of the upper pressing member 210. The cushioning material 313 includes, for example, a composite material containing a mixture of rubber and fluororesin or a composite material containing rubber and glass fiber. The thickness of the cushioning material 313 is, for example, 0.5 mm to 1.0 mm. The lower surface of the metal plate 314 contacts the upper surface of the third temporary laminate 53. The upper pressing member 310 is an example of the third pressing member. The heating plate 312 is an example of the third heating plate, the cushioning material 313 is an example of the second cushioning material, and the metal plate 314 is an example of the second metal plate.

[0031] The lower pressing member 320 includes a heating plate 322, a cushioning material 323, and a metal plate 324. The metal plate 324 is fixed to the heating plate 322 via the cushioning material 323. The heating plate 322 is attached to the upper surface of the lower plate 321. The configurations of the heating plate 322, cushioning material 323, and metal plate 324 are the same as those of the heating plate 312, cushioning material 313, and metal plate 314, respectively. The upper surface of the metal plate 324 contacts the lower surface of the third temporary laminate 53. The lower pressing member 320 is an example of a third pressing member. The heating plate 322 is an example of a third heating plate, the cushioning material 323 is an example of a second cushioning material, and the metal plate 324 is an example of a second metal plate.

[0032] As shown in Figure 4(a), in the third press machine 93, the third temporary laminate 53 is placed between the metal plate 314 and the metal plate 324. For example, the third temporary laminate 53 is placed on the lower pressing member 320 such that the lower surface of the film 42 is in contact with the upper surface of the metal plate 324.

[0033] After the third temporary laminate 53 is placed between the metal plates 314 and 324, the lower plate 321 rises as shown in Figure 4(b), and the upper surface of the film 41 comes into contact with the lower surface of the metal plate 314. As the lower plate 321 rises further, the metal plate 314 and the cushioning material 313 elastically deform along the irregularities on the upper surface of the base material 30, and the third temporary laminate 53 is pressed as the metal plate 324 and the cushioning material 323 elastically deform along the irregularities on the lower surface of the base material 30. As a result, the irregularities on the upper and lower surfaces of the base material 30 are further reduced.

[0034] In this way, the fourth temporary laminate 54 is formed. Compared to the third temporary laminate 53, the flatness of the upper surface of the film 41 and the lower surface of the film 42 is higher in the fourth temporary laminate 54.

[0035] Subsequently, the lower plate 321 descends, and the fourth temporary laminate 54 is transported to the fourth press machine 94.

[0036] As shown in Figures 5(a) and 5(b), the fourth press machine 94 includes an upper plate 411, a lower plate 421, a plurality of drive shafts 450 parallel to each other, an upper pressing member 410, and a lower pressing member 420. The upper plate 411 and the lower plate 421 are supported by the drive shafts 450. The lower surface of the upper plate 411 and the upper surface of the lower plate 421 are parallel to each other and face each other. For example, the upper plate 411 is fixed to the drive shafts 450, and the lower plate 421 is supported by the drive shafts 450 so as to be movable up and down along the drive shafts 450. The lower plate 421 is driven, for example, using a servo motor. That is, the fourth press machine 94 is, for example, a servo press machine.

[0037] The upper pressing member 410 has a heating plate 412 and a metal plate 414. The metal plate 414 is directly fixed to the heating plate 412 without a buffer. The metal plate 414 is mechanically fixed to the heating plate 412, for example, using screws. The heating plate 412 is attached to the lower surface of the upper plate 411. The heating plate 412 includes a heater for heating the metal plate 414. The heater is, for example, a sheathed heater. The metal plate 414 is, for example, a stainless steel plate. The lower surface of the metal plate 414 is in contact with the upper surface of the fourth temporary laminate 54. At least the area of ​​the lower surface of the metal plate 414 that is in contact with the upper surface of the fourth temporary laminate 54 is flat. The upper pressing member 410 is an example of the fourth pressing member. The heating plate 412 is an example of the fourth heating plate, and the metal plate 414 is an example of the third metal plate.

[0038] The lower pressing member 420 has a heating plate 422 and a metal plate 424. The metal plate 424 is directly fixed to the heating plate 422 without a buffer. The metal plate 424 is mechanically fixed to the heating plate 422, for example, using screws. The heating plate 422 is attached to the upper surface of the lower plate 421. The configurations of the heating plate 422 and the metal plate 424 are the same as those of the heating plate 412 and the metal plate 414, respectively. The upper surface of the metal plate 424 is in contact with the lower surface of the fourth temporary laminate 54. At least the area of ​​the upper surface of the metal plate 424 that is in contact with the lower surface of the fourth temporary laminate 54 is flat. The lower pressing member 420 is an example of the fourth pressing member. The heating plate 422 is an example of the fourth heating plate, and the metal plate 424 is an example of the third metal plate.

[0039] As shown in Figure 5(a), in the fourth press machine 94, the fourth temporary laminate 54 is placed between the metal plate 414 and the metal plate 424. For example, the fourth temporary laminate 54 is placed on the lower pressing member 420 such that the lower surface of the film 42 is in contact with the upper surface of the metal plate 424.

[0040] After the fourth temporary laminate 54 is placed between the metal plates 414 and 424, the lower plate 421 rises as shown in Figure 5(b), and the upper surface of the film 41 comes into contact with the lower surface of the metal plate 414. As the lower plate 421 rises further, the fourth temporary laminate 54 is pressed down. At this time, since the upper pressing member 410 and the lower pressing member 420 do not contain any cushioning material, the metal plates 414 and 424 do not deform substantially. As a result, the unevenness of the upper and lower surfaces of the base material 30 is further reduced.

[0041] In this way, the laminate 55 is formed. In the laminate 55, the flatness of the upper surface of the film 41 and the lower surface of the film 42 is higher compared to the fourth temporary laminate 54. Because the metal plates 414 and 424 do not deform substantially, the upper surface of the film 41 and the lower surface of the film 42 become substantially flat.

[0042] Subsequently, the lower plate 421 descends, and the laminated body 55 is transported to the receiving section 96, making it possible to remove it from the outside.

[0043] In the pressing process using the fourth press machine 94, the lower plate 421 rises at a first speed until just before the upper surface of the film 41 contacts the lower surface of the metal plate 414, and then rises at a second speed lower than the first speed. During the rise at the second speed, the upper surface of the film 41 contacts the lower surface of the metal plate 414, and the fourth temporary laminate 54 is pressed. In other words, when the upper surface of the film 41 contacts the lower surface of the metal plate 414 and the fourth temporary laminate 54 is pressed, the position of the lower plate 421 is adjusted little by little. This is to obtain good flatness on the upper surface of the film 41 and the lower surface of the film 42. The time of the rise at the second speed depends on the amount of deformation of the films 41 and 42 in the fourth press machine 94. Note that neither the first speed nor the second speed needs to be constant; for example, the second speed may be changed according to the reaction force from the films 41 and 42.

[0044] According to the first embodiment, in the fourth press machine 94, the metal plate 414 is directly fixed to the heating plate 412 and the metal plate 424 is directly fixed to the heating plate 422, so that the metal plates 414 and 424 do not deform substantially. Therefore, the upper surface of the film 41 and the lower surface of the film 42 become substantially flat.

[0045] Furthermore, in the fourth temporary laminate 54 formed by pressing with the first press 91, the second press 92, and the third press 93, even if the upper surface of film 41 and the lower surface of film 42 are not flat, their flatness is improved. Therefore, the amount of deformation of films 41 and 42 in the fourth press 94 can be small. Consequently, the time it takes for the lower plate 421 to rise at the second speed in the fourth press 94 can be suppressed.

[0046] If, for example, the pressing by the third press machine 93 is omitted and the third temporary laminate 53 formed by the second press machine 92 is pressed by the fourth press machine 94 to obtain the same level of flatness as in this embodiment, then the amount of deformation of the films 41 and 42 in the fourth press machine 94 needs to be increased. In this case, the time required for pressing by the fourth press machine 94 will be longer.

[0047] For example, in this embodiment, the time required for pressing by the first press machine 91 is 60 seconds, the time required for pressing by the second press machine 92 is 60 seconds, the time required for pressing by the third press machine 93 is 60 seconds, and the time required for pressing by the fourth press machine 94 is 60 seconds. In contrast, if the pressing by the third press machine 93 is omitted as described above, the time required for pressing by the fourth press machine 94 will be longer, for example, 75 seconds. After one second temporary laminate 52 has been transported from the first press machine 91 to the second press machine 92, the first press machine 91 can press another new first temporary laminate 51 simultaneously with the pressing by the second press machine 92. The same applies to subsequent press machines. Therefore, in the above example, when using the manufacturing apparatus 1 according to this embodiment, the laminate 55 can be removed from the receiving section 96 every 60 seconds, whereas when using the apparatus in which the pressing by the third press machine 93 is omitted, the laminate 55 can be removed from the receiving section 96 every 75 seconds.

[0048] Thus, according to this embodiment, productivity can be improved while ensuring good flatness on the upper surface of film 41 and the lower surface of film 42.

[0049] Furthermore, since the main structural difference between the second press machine 92 and the third press machine 93 lies in the configuration of the pressing members, if design information for either the second press machine 92 or the third press machine 93 is available, the design of the other machine is relatively easy.

[0050] Preferably, the laminate manufacturing apparatus 1 has a sensor that measures the thickness of the fourth temporary laminate 54 that is conveyed to the fourth press machine 94. In this case, the fourth press machine 94 can adjust the stopping position of the rising of the lower plate 421 at the first speed to a more appropriate position, in other words, a position where the distance between the film 41 and the metal plate 414 is shorter, according to the measurement result from the sensor. Therefore, it is possible to shorten the time required for rising at the second speed and further improve productivity.

[0051] The sensor described above is installed, for example, in the third press machine 93, and measures the thickness of the fourth temporary laminate 54 based on the distance between the upper pressing member 310 and the lower pressing member 320 after pressing in the third press machine 93. The thickness of the fourth temporary laminate 54 could also be measured immediately before the start of pressing in the fourth press machine 94, but the workpieces (first temporary laminate 51, second temporary laminate 52, third temporary laminate 53, fourth temporary laminate 54, and laminate 55) are transported within the manufacturing apparatus 1 sandwiched between transport films (not shown). For this reason, it is difficult to directly measure the thickness of the workpieces. In contrast, by measuring the distance between the upper pressing member 310 and the lower pressing member 320 after pressing, the thickness of the fourth temporary laminate 54 can be determined by subtracting the known thickness of the transport film.

[0052] In this embodiment, the vertical rigidity of the cushioning materials 313 and 323 is higher than that of the cushioning materials 213 and 223, respectively. Therefore, the cushioning materials 313 and 323 are less prone to deformation in the vertical direction than the cushioning materials 213 and 223, and the distance between the upper pressing member 310 and the lower pressing member 320 after pressing is less prone to fluctuation than the distance between the upper pressing member 210 and the lower pressing member 220 after pressing by the second press machine 92. Therefore, the thickness of the third temporary laminate 53 can be measured with higher precision than that of the third temporary laminate 53 after pressing by the second press machine 92. Accordingly, compared to the case where pressing by the third press machine 93 is omitted and the stopping position of the rising lower plate 421 at the first speed is adjusted according to the measurement result of the thickness of the third temporary laminate 53, the stopping position of the rising lower plate 421 can be adjusted to a more appropriate position, in other words, a position where the distance between the film 41 and the metal plate 414 is shorter. Therefore, it becomes possible to shorten the time required for ascent at the second speed and further improve productivity.

[0053] (Second Embodiment) Next, a laminate manufacturing apparatus according to the second embodiment will be described. The second embodiment differs from the first embodiment mainly in the configuration of the third press machine 93. Figure 7 is a diagram illustrating a method for manufacturing a laminate using the laminate manufacturing apparatus according to the second embodiment.

[0054] In the second embodiment, as shown in Figures 7(a) and 7(b), the third press machine 93 has an upper pressing member 330 instead of an upper pressing member 310, and a lower pressing member 340 instead of a lower pressing member 320.

[0055] The upper pressing member 330 includes a heating plate 312, a cushioning material 333, and a metal plate 334. The metal plate 334 is fixed to the heating plate 312 via the cushioning material 333. The heating plate 312 is attached to the lower surface of the upper plate 311. The configuration of the cushioning material 333 is the same as that of the cushioning material 213. On the other hand, the configuration of the metal plate 334 differs from that of the metal plate 214. The material of the metal plate 334 is the same as that of the metal plate 214, but the vertical dimension (thickness) of the metal plate 334 is greater than that of the metal plate 214. Therefore, the vertical rigidity of the upper pressing member 330 is higher than that of the upper pressing member 310. The thickness of the metal plate 334 is, for example, 2 mm to 5 mm. The lower surface of the metal plate 334 contacts the upper surface of the third temporary laminate 53. The upper pressing member 330 is an example of a third pressing member. The cushioning material 333 is an example of the second cushioning material, and the metal plate 334 is an example of the second metal plate.

[0056] The lower pressing member 340 includes a heating plate 322, a cushioning material 343, and a metal plate 344. The metal plate 344 is fixed to the heating plate 322 via the cushioning material 343. The heating plate 322 is attached to the upper surface of the lower plate 321. The configurations of the heating plate 322, cushioning material 343, and metal plate 344 are the same as those of the heating plate 312, cushioning material 333, and metal plate 334, respectively. The upper surface of the metal plate 334 contacts the lower surface of the third temporary laminate 53. The lower pressing member 340 is an example of a third pressing member. The cushioning material 343 is an example of a second cushioning material, and the metal plate 344 is an example of a second metal plate.

[0057] As shown in Figure 7(a), in the third press machine 93, the third temporary laminate 53 is placed between the metal plates 334 and 344. For example, the third temporary laminate 53 is placed on the lower pressing member 340 such that the lower surface of the film 42 is in contact with the upper surface of the metal plate 344.

[0058] After the third temporary laminate 53 is placed between the metal plates 334 and 344, the lower plate 321 rises as shown in Figure 7(b), and the upper surface of the film 41 comes into contact with the lower surface of the metal plate 334. As the lower plate 321 rises further, the metal plate 334 and the cushioning material 333 elastically deform along the irregularities of the upper surface of the base material 30, and the third temporary laminate 53 is pressed as the metal plate 344 and the cushioning material 343 elastically deform along the irregularities of the lower surface of the base material 30. As a result, similar to the first embodiment, the irregularities of the upper and lower surfaces of the base material 30 are further reduced.

[0059] In this way, the fourth temporary laminate 54 is formed.

[0060] The other configurations are the same as in the first embodiment.

[0061] The same effects as those of the first embodiment can be obtained with the second embodiment as well.

[0062] Instead of the cushioning materials 333 and 343 of the second embodiment, the cushioning materials 313 and 323 of the first embodiment may be used, respectively. In other words, the upper pressing member of the third press machine 93 may be made of a combination of cushioning material 313 and metal plate 334, and the lower pressing member may be made of a combination of cushioning material 323 and metal plate 344. The rigidity of the upper and lower pressing members of the third press machine 93 in the vertical direction can be increased.

[0063] Although the number of wiring layers and films in the laminate 55 shown in Figure 6 is one on one side and one on the other side of the core layer, a new laminate may be created by adding more wiring layers to this laminate 55 as a base material and laminating other films using the manufacturing apparatus 1. By repeating this process, it is possible to manufacture a wiring board containing more wiring layers and films (insulating layers).

[0064] Furthermore, three or more presses may be included between the first press 91 and the fourth press 94. In this case as well, the rigidity of the upper and lower pressing members in the vertical direction should be increased with each subsequent press.

[0065] Although preferred embodiments have been described in detail above, the invention is not limited to the embodiments described above, and various modifications and substitutions can be made to the embodiments described above without departing from the scope of the claims. [Explanation of symbols]

[0066] 1 Manufacturing equipment 30 Base material 41, 42 film 51, 52, 53, 54 Temporary laminate 55 Laminate 91, 92, 93, 94 Press machine 110, 120, 210, 220, 310, 320, 330, 340, 410, 420 Pressing members Plates 111, 121, 211, 221, 311, 321, 411, 421 112, 122, 212, 222, 312, 322, 412, 422 heat plate 113, 123, 214, 224, 314, 324, 334, 344, 414, 424 metal plate 114, 124 Resin elastic members 150, 250, 350, 450 drive shaft 213, 223, 313, 323, 333, 343 Buffer material

Claims

1. A first press machine that presses a first temporary laminate, which includes a base material and a film laminated on the base material, in a first direction parallel to the lamination direction of the first temporary laminate, while bringing a first pressing member into contact with the film, to form a second temporary laminate. A second press machine that presses the second temporary laminate in the first direction while bringing the second pressing member into contact with the film to form a third temporary laminate, A third press machine that presses the third temporary laminate in the first direction while bringing the third pressing member into contact with the film to form a fourth temporary laminate, A fourth press machine presses the fourth temporary laminate in the first direction while the fourth pressing member is in contact with the film, It has, The first pressing member is The first hot plate and, A resin elastic member fixed to the first heating plate and in contact with the film, It has, The second pressing member is The second heating plate and, A first metal plate in contact with the film, A first cushioning material is provided between the second heating plate and the first metal plate, It has, The third pressing member described above is The third hot plate and, A second metal plate in contact with the aforementioned film, A second cushioning material is provided between the third heating plate and the second metal plate, It has, The fourth pressing member is The fourth hot plate and, A third metal plate is directly fixed to the fourth heating plate and is in contact with the film, It has, A laminate manufacturing apparatus in which the rigidity of the third pressing member in the first direction is higher than the rigidity of the second pressing member in the first direction.

2. The apparatus for manufacturing a laminate according to claim 1, wherein the rigidity of the second cushioning material in the first direction is higher than the rigidity of the first cushioning material in the first direction.

3. The apparatus for manufacturing a laminate according to claim 1, wherein the dimension of the second metal plate in the first direction is greater than the dimension of the first metal plate in the first direction.

4. The rigidity of the second cushioning material in the first direction is higher than the rigidity of the first cushioning material in the first direction. The apparatus for manufacturing a laminate according to claim 1, wherein the dimension of the second metal plate in the first direction is greater than the dimension of the first metal plate in the first direction.

5. The apparatus for manufacturing a laminate according to any one of claims 1 to 4, wherein the fourth press machine is a servo press machine.

6. The apparatus for manufacturing a laminate according to claim 5, wherein the first press, the second press, and the third press are hydraulic presses or air presses.

7. The apparatus for manufacturing a laminate according to claim 5, wherein the third press machine has a sensor for measuring the thickness of the fourth temporary laminate.

8. The apparatus for manufacturing a laminate according to any one of claims 1 to 4, wherein the second metal plate is elastically deformed when the third temporary laminate is pressed, and the third metal plate is not deformed when the fourth temporary laminate is pressed.

9. A step of forming a second temporary laminate by pressing a first temporary laminate, which includes a base material and a film laminated on the base material, in a first direction parallel to the lamination direction of the first temporary laminate, while bringing a first pressing member into contact with the film, The process involves pressing the second temporary laminate in the first direction while bringing the second pressing member into contact with the film to form a third temporary laminate, The process involves pressing the third temporary laminate in the first direction while bringing the third pressing member into contact with the film to form a fourth temporary laminate, The process involves pressing the fourth temporary laminate in the first direction while bringing the fourth pressing member into contact with the film, It has, The first pressing member is The first hot plate and, A resin elastic member fixed to the first heating plate and in contact with the film, It has, The second pressing member is The second heating plate and, A first metal plate in contact with the film, A first cushioning material is provided between the second heating plate and the first metal plate, It has, The third pressing member described above is The third hot plate and, A second metal plate in contact with the aforementioned film, A second cushioning material is provided between the third heating plate and the second metal plate, It has, The fourth pressing member is The fourth hot plate and, A third metal plate is directly fixed to the fourth heating plate and is in contact with the film, It has, A method for manufacturing a laminate, wherein the rigidity of the third pressing member in the first direction is higher than the rigidity of the second pressing member in the first direction.

10. The method for manufacturing a laminate according to claim 9, wherein the second metal plate is elastically deformed when the third temporary laminate is pressed, and the third metal plate is not deformed when the fourth temporary laminate is pressed.

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