Liquid Crystal Polymer Film Processing via Patterned Substrate
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Solution Overview
Problem
The challenge in producing liquid crystal polymer films is that the heat received by each layer during high-temperature lamination is inconsistent due to varying distances from the heat source, leading to differences in the properties of dielectric layers with the same melting point or liquid crystal transition temperature.
Innovation Solution
A method involving lamination of a liquid crystal polymer film on a patterned metal substrate, followed by heating and separation, where the substrate has a trench and strip-shaped platforms, and the process is performed continuously with a series of heating stages at temperatures lower than the melting point, increasing the melting point or liquid crystal transition temperature of the film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-temperature lamination is performed on multi-layered boards, then the dielectric layers are bonded together, but the heat received by each layer is inconsistent due to different distances from the heat source, causing property variations
Solution Approach 1:
The patent applies local quality by treating different regions of the liquid crystal polymer film differently through a patterned substrate. The substrate has different surface characteristics in different areas, causing the polymer to exhibit different molecular orientations and thus different melting points in different regions. This allows different parts of the same dielectric layer to have tailored properties suitable for their specific positions in the multi-layered board.
Solution Approach 2:
The patent changes the melting point parameter of the liquid crystal polymer film by controlling the molecular orientation during the lamination process. By adjusting the substrate temperature and the cooling rate, the polymer chains are oriented in specific directions, which directly changes the melting point of the dielectric layer. This parameter change enables different dielectric layers to have different melting points, compensating for the inconsistent heat distribution during lamination.
2Stability of the object's composition
If the melting point of liquid crystal polymer film is increased to compensate for heat variation, then the stability of dielectric layers is improved, but the process complexity increases
Solution Approach 1:
The patent applies self-service by using the substrate itself to induce the desired molecular orientation in the liquid crystal polymer film. The patterned substrate automatically creates different cooling rates and orientation patterns in different regions during the lamination process, eliminating the need for additional equipment or complex post-processing steps to achieve different melting points. The substrate performs the function of both support and property-modification tool.
3Productivity
If continuous processing is implemented to improve productivity, then the production efficiency increases, but the control of heating uniformity becomes more difficult
Solution Approach 1:
The patent applies preliminary action by pre-heating the substrate to a specific temperature before the liquid crystal polymer film is applied. This preliminary heating ensures that when the film is laminated, the substrate immediately provides the correct thermal environment for the desired molecular orientation. This pre-established thermal condition allows continuous processing while maintaining heating uniformity, as the substrate acts as a thermal buffer that stabilizes the heating process.
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 allows for the production of liquid crystal polymer films with varying melting points or liquid crystal transition temperatures, enhancing stability among laminated dielectric layers by ensuring consistent heat treatment and molecular weight increase.
Implementation Method 1
heating the composite layer at a temperature... increasing the melting point or the liquid crystal transition temperature of the liquid crystal polymer film
Implementation Method 2
The melting point of the liquid crystal polymer film after the heating step is higher than that before heating
Implementation Method 3
heating the composite layer at a temperature... heating the composite layer for a time period of 1 hour to 24 hours
Data Source
AI summary
A method of processing liquid crystal polymer film is provided. The method includes the following steps. A metal substrate is provided. A liquid crystal polymer film is provided. The liquid crystal polymer film and the metal substrate are laminated to form a composite layer. The composite layer is heated at a first temperature and a processed liquid crystal polymer film is obtained through the separation of the heated liquid crystal polymer film from the substrate. A processing device of liquid crystal polymer film is further provided, including a lamination member, a transport member, a heating member, and a separation member.