FRP Precursor Production via Differential Surface Heating
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Solution Overview
Problem
Current methods for producing FRP precursors for printed circuit boards face challenges in achieving good workability, preventing resin spouting from edges, and ensuring uniform thickness and filling properties, particularly when using thermosetting resin films and aggregates like aramid unwoven cloth or thin glass paper.
Innovation Solution
A method involving heating one or both surfaces of a thermosetting resin film and an aggregate under normal pressure, with the heating temperature of the aggregate surface being higher than the film by 5 to 70°C, and using a device with aggregate and film heating means to adhere the resin film to the aggregate, ensuring efficient resin filling without spouting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resin film is heated from the adhering side to the aggregate under normal pressure, then the resin fills bulk gaps in the aggregate while preventing resin spouting from edges, but the heating process requires precise temperature control between 5-70°C difference
Solution Approach 1:
The invention changes the temperature parameter by heating the aggregate surface to a temperature 5-70°C higher than the resin film, creating a temperature gradient that enables resin flow into bulk gaps without spouting. This parameter change resolves the contradiction by achieving uniform resin filling through controlled thermal conditions.
Solution Approach 2:
The invention performs preliminary heating of the aggregate surface before resin application, preparing the aggregate to receive and absorb resin uniformly. This preliminary action ensures that when resin is applied, it flows smoothly into bulk gaps without spouting, achieving precise manufacturing results.
2Ease of manufacture
If the resin is applied directly to the aggregate using Hand Lay-up method, then the workability is improved and environmental load is lowered, but the aggregate may cut or break when narrowing the coater gap to control resin amount
Solution Approach 1:
The invention performs preliminary heating of the aggregate surface to enhance its ability to receive and absorb resin. This preliminary action allows the aggregate to take in resin more effectively, reducing the need to narrow the coater gap excessively, thereby preventing aggregate cutting or breakage while maintaining good workability.
3Manufacturing precision
If multiple FRP precursors with different resin amounts or curing times are produced from one aggregate, then the thickness accuracy and filling property requirements are met, but the process becomes cumbersome and material loss increases
Solution Approach 1:
The invention changes the temperature parameter of the aggregate surface to optimize resin absorption characteristics. By controlling the temperature difference (5-70°C), the aggregate can absorb resin uniformly, achieving the required thickness accuracy and filling properties in a single production run, thereby eliminating the need for multiple different FRP precursors and reducing material loss.
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 approach enhances productivity by allowing resin to fill bulk gaps in the aggregate while preventing resin from spouting out from the edges, resulting in improved workability and uniformity of the FRP precursor.
Implementation Method 1
an aggregate's surface heating process to heat one surface of the aggregate
Implementation Method 2
a film press-adhering process to obtain the FRP precursor wherein under a normal pressure, of both surfaces of the film, an aggregate-side film surface, which is a surface in an aggregate side thereof, is press-adhered to an aggregate's surface, which is one surface of the heated aggregate
Data Source
AI summary
Provided are a method for producing an FRP precursor and a device for producing an FRP precursor, wherein the method and the device have a good productivity, and under a normal pressure, enable filling of a resin into a bulk gap of an aggregate as well as prevent the resin from spouting out from an edge portion thereof. The method for producing the FRP precursor is to produce the FRP precursor by melt-adhering each of a pair of thermosetting resin films 54 to each of both surfaces 40a and 40b of an aggregate 40 that is in a form of a sheet, the method comprising: an aggregate's surface heating process to heat aggregate's both surfaces, i.e., the both aggregate's surfaces 40a and 40b of the aggregate 40, and a film press-adhering process to obtain the FRP precursor wherein under a normal pressure, one aggregate-side film surface 54a of the pair of the films 54 is press-adhered to one surface of the heated both aggregate's surfaces, and another aggregate-side film surface 54a of the pair of the films 54 is press-adhered to another surface of the heated both aggregate's surfaces.