Laser-Welded Flexible Circuit Lamination in Reel-to-Reel Production
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Solution Overview
Problem
Current methods for producing flexible printed circuits (FPCs) are slow, environmentally hazardous, and costly, particularly due to the use of chemical etching and wasteful debonding processes, and do not effectively address the need for faster and more cost-effective production methods in the electric vehicle industry.
Innovation Solution
A reel-to-reel manufacturing method using laser ablation to create circuitry patterns on metal foils without chemical etching, combined with novel processes for debonding and sintering, which allows for continuous production of single- and multi-layer FPCs without the need for chemical washes or expensive plating processes, and includes a lamination and welding process for layering circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chemical etching is used to create circuitry patterns, then the manufacturing process is established, but environmental hazards and production costs increase
Solution Approach 1:
The patent replaces chemical etching with laser ablation to create circuitry patterns. The laser beam physically removes material through ablation rather than chemical dissolution, eliminating the need for hazardous chemicals while maintaining manufacturing capability. This substitution directly addresses the environmental hazards associated with chemical etching.
Solution Approach 2:
The patent changes the fundamental parameter of material removal from chemical dissolution to thermal ablation. By using laser energy to heat and vaporize material, the process transitions from a wet chemical process to a dry thermal process, eliminating environmental contamination while preserving the ability to create precise circuitry patterns.
2Ease of manufacture
If traditional gantry methods are used for FPC production, then manufacturing is achieved, but production speed decreases and manual intervention is required
Solution Approach 1:
The patent implements a continuous reel-to-reel manufacturing process where metal foil is fed continuously through the system. Multiple operations including laser ablation, lamination, and welding occur in continuous sequence without stopping, eliminating the stop-and-go nature of traditional gantry methods and significantly increasing production speed.
Solution Approach 2:
The patent performs preliminary actions by pre-laminating metal foil layers and preparing them before the main welding process. This allows the continuous manufacturing process to proceed smoothly without interruptions for material preparation, maintaining high production speed while ensuring proper layer alignment and bonding.
3Ease of operation
If debonding sheets are used in the manufacturing process, then layer separation is achieved, but material waste increases
Solution Approach 1:
The patent makes the metal foil layers self-bonding through direct metallurgical bonding during the welding process. The layers bond to each other inherently without requiring external debonding sheets, eliminating material waste while maintaining the ability to separate and rejoin layers as needed during manufacturing.
Solution Approach 2:
The patent removes the debonding sheet component entirely from the manufacturing process. By using direct metallurgical bonding, the system eliminates the need for sacrificial debonding sheets, achieving layer separation and rejoining without any material waste from disposable sheets.
4Manufacturing precision
If multiple laser types are used for ablation, then complete metal foil removal is achieved, but process complexity increases
Solution Approach 1:
The patent segments the ablation process into distinct stages using different laser types. A first laser performs initial ablation to remove the majority of metal foil, while a second laser completes the removal and refines the edges. This segmentation allows each laser to be optimized for its specific function, achieving complete removal while managing system complexity through modular design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces production time, minimizes environmental impact, and lowers costs by eliminating chemical etching and wasteful debonding, while enabling efficient production of high-quality flexible printed circuits for the electric vehicle industry.
Implementation Method 1
a first laser is used to ablate a first portion of the metal foil
Implementation Method 2
The contemplated types of laser ablate the outer edges of the intended circuitry pattern as the metal foil passes reel-to-reel under a laser scanner
Implementation Method 3
a second laser is used to weld two metal foils together at a weld spot
Implementation Method 4
novel processes for debonding and sintering, which allows for continuous production of single- and multi-layer FPCs
Implementation Method 5
an embossing die is used to deform the metal foil at the weld spot
Implementation Method 6
an embossing die is used to deform the metal foil at the weld spot so that two metal foils are in contact with each other
Data Source
AI summary
A method of layering a layer of circuitry pattern to another layer of circuitry pattern during the manufacturing of a multilayer flexible printed circuit in a reel-to-reel machine. The method includes feeding both layers of circuitry pattern reel-to-reel into the machine, placing a layer of dielectric sheet material on the fly between the two layers of circuitry patterns reel-to-reel, followed by simultaneously passing the two layers of circuitry pattern and the dielectric sheet material under a laser scanner in the reel-to-reel machine to irradiate a laser beam on a layer of circuitry pattern to weld the two layers of circuitry patterns together.