Laminating Press Floating Plate and Vacuum Sequence
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Solution Overview
Problem
The existing laminating processes for panel-shaped workpieces, such as circuit boards, face inefficiencies due to unpredictable sequences of heating and vacuum evacuation, leading to variable pressing times and quality, and require higher pressures to achieve consistent results.
Innovation Solution
A press design where the lower press plate is mounted floating on a membrane, allowing it to be lifted by a fluid-loaded pressure chamber, ensuring evenness and compensating for tolerances, and featuring a conveyor belt for short-cycle processing, with the upper press table capable of independent movement to maintain a defined sequence of vacuum sealing and heat application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lower press plate is fixed to the lower press table, then the structure is simple and stable, but it cannot compensate for unevenness in the workpiece and tolerances in the press plates
Solution Approach 1:
A membrane is introduced as an intermediary element between the lower press table and the lower press plate. The membrane can deform to compensate for unevenness in the workpiece and tolerances in the press plates, ensuring even contact while maintaining a relatively simple overall structure.
Solution Approach 2:
The lower press plate is made liftable relative to the lower press table, transforming the static fixed connection into a dynamic adjustable connection. This allows the press plate to adapt to variations in workpiece surface and plate tolerance through controlled movement.
2Manufacturing precision
If the heating and vacuum evacuation sequence is random, then the process is simple, but the pressing times vary and quality is inconsistent
Solution Approach 1:
The vacuum press chamber is evacuated before the workpiece is brought into contact with the heated press plate. This preliminary evacuation ensures that vacuum conditions are established first, allowing for controlled and consistent pressing times while maintaining quality uniformity.
3Manufacturing precision
If higher pressing pressures are used, then consistent quality can be achieved, but the pressing time increases and energy consumption rises
Solution Approach 1:
A fluid-loaded pressure chamber is introduced to apply pressing force. The fluid pressure can be precisely controlled to achieve consistent quality while reducing the total pressing time and energy consumption compared to traditional mechanical pressing systems.
4Manufacturing precision
If the lower press plate is made liftable to compensate for unevenness, then contact evenness improves, but the device complexity increases
Solution Approach 1:
A membrane serves as an intermediary between the lower press table and the lower press plate, providing the necessary flexibility to compensate for unevenness without requiring a complex mechanical adjustment mechanism. The membrane deforms naturally to achieve even contact.
Solution Approach 2:
The position parameter of the lower press plate is made variable through the lifting mechanism, allowing adjustment to compensate for tolerances and unevenness. This parameter change approach provides flexibility while keeping the overall structure relatively simple.
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 design enhances process reliability, reduces pressing times, allows for lower pressures, and achieves consistent quality by ensuring a reproducible sequence of vacuum formation and heat application, while maintaining even contact with the workpiece.
Implementation Method 1
The lower, liftable press plate is mounted floating on the lower press table and is lifted in particular by means of a fluid-loaded pressure chamber between the lower press table and the lower press plate
Implementation Method 2
means are provided for evacuating the vacuum press chamber formed by the seal
Implementation Method 3
A plate-shaped workpiece consisting of two copper foils and at least one inner layer made of glass fiber fabric soaked in resin, a so-called prepreg, is placed in the press and laminated under the influence of heat to reach the typical melting temperature of the resin
Implementation Method 4
At the given pressure, the melting resin of the prepreg ensures an intimate connection between the individual layers of the workpiece
Data Source
Figure 1
Figure 2
AI summary
The press has single-piece or two-piece circular seals (16, 17) applied at an upper press table (1) or upper press plate (7) and/or lower press table (2) for forming a vacuum press chamber during a closed condition of the press. An evacuating unit evacuates the vacuum press chamber. A lower press plate (10) is liftable and arranged relative to the lower press table such that a workpiece (6) provided in the press do not arrive in attachment to the heated upper and lower press plates with the closed vacuum press chamber. An independent claim is also included for a method for laminating a plate-like workpiece under heat and pressure.