Float Glass Substrate Metal Layer Warpage Suppression
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Solution Overview
Problem
The use of float glass substrates in laminates for printed wiring boards often results in warpage of the laminated product, leading to potential breakage and manufacturing issues due to differences in thermal expansion coefficients between the glass and other layers, particularly when insulating resin is laminated on the metal layer.
Innovation Solution
A laminate is designed with a metal layer selectively provided on the top surface of a float glass substrate, which suppresses warpage by leveraging the unique distortion properties of the float glass substrate, preventing convex warping and maintaining flatness during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a float glass substrate is used in a laminate for printed wiring boards, then the substrate provides low thermal expansion, rigidity, and chemical resistance, but warpage occurs in the laminated product due to differences in thermal expansion coefficients between the glass and other layers
Solution Approach 1:
The patent applies local quality by selectively forming a metal layer only on the top surface of the float glass substrate, creating a composite structure with different thermal expansion characteristics in different regions. This localized metal coating compensates for the thermal expansion differences between the glass substrate and the insulating resin layer, thereby suppressing warpage while maintaining the inherent thermal stability of the glass substrate.
Solution Approach 2:
The patent creates a composite material structure by combining float glass substrate with a metal layer on its surface. This composite structure leverages the low thermal expansion coefficient of glass and the appropriate thermal expansion properties of the metal layer to balance the overall thermal expansion of the laminate, preventing warpage caused by mismatched expansion coefficients between different layers.
2Shape
If a metal layer is formed on the float glass substrate, then warpage is suppressed, but the device complexity increases due to additional manufacturing steps
Solution Approach 1:
The metal layer formed on the float glass substrate serves multiple functions: it acts as an adhesion layer to bond the insulating resin, provides electrical conductivity where needed, and most importantly, compensates for thermal expansion differences to suppress warpage. This multi-functionality reduces the need for additional separate layers or components, thereby limiting the increase in manufacturing complexity.
3Weight of moving object
If the thickness of the metal layer is reduced to achieve weight reduction, then the weight of the laminate decreases, but the warpage suppression effect may be weakened
Solution Approach 1:
The patent optimizes the thickness parameter of the metal layer to achieve the minimum effective thickness that still provides sufficient warpage suppression. By carefully controlling this parameter, the design achieves weight reduction while maintaining adequate thermal expansion compensation functionality, balancing weight and structural stability requirements.
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 configuration effectively reduces warpage in the laminated product, enhancing manufacturing efficiency and preventing breakage, while maintaining the advantages of using a glass substrate such as low thermal expansion, rigidity, and chemical resistance.
Implementation Method 1
differences in thermal expansion coefficients between the glass and other layers
Data Source
AI summary
There is provided a laminate that can suppress the warpage of a laminated product when used for the manufacture of the laminated product. This laminate includes a float glass substrate having a top surface and a bottom surface; and a metal layer provided on the top surface side of the float glass substrate.