Liquid Crystal Polymer Melting Point Modification for PCB Lamination
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Solution Overview
Problem
Conventional liquid crystal polymers have a consistent melting point, making it difficult to accurately control the thickness of laminated plates during high-temperature laminating processes in printed circuit board manufacturing, as most of the polymer melts, leading to significant thickness changes.
Innovation Solution
A method involving heating and cooling liquid crystal polymers to specific temperatures and for defined periods to alter their melting points, resulting in modified polymers with a wider range of melting points, allowing for more precise control over the laminating process and reducing thickness variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional liquid crystal polymer with consistent melting point is used in laminating process, then the polymer can be processed, but the thickness of laminated plates cannot be accurately controlled due to significant thickness changes
Solution Approach 1:
The patent applies parameter changes by modifying the melting point of the liquid crystal polymer through controlled heating and cooling processes. The polymer is heated to a first temperature (lower than or equal to the first melting point) and maintained for a first time period, then cooled to a second temperature to form a modified liquid crystal polymer with a second melting point higher than the first melting point. This parameter change in melting point allows the polymer to withstand lamination temperatures without excessive melting, thereby improving thickness control precision.
2Ease of manufacture
If high-temperature laminating process is used to manufacture circuit boards, then the laminating can be completed, but the conventional liquid crystal polymer cannot endure the high temperature
Solution Approach 1:
The patent changes the thermal parameter (melting point) of the liquid crystal polymer by subjecting it to controlled thermal treatment. The polymer is heated to a first temperature and held for a first time period, then cooled to a second temperature, resulting in a modified polymer with an elevated melting point. This enables the polymer to reliably endure the high-temperature laminating process required for circuit board manufacturing.
3Ease of manufacture
If most of the liquid crystal polymer is melted during lamination, then the lamination process can proceed, but the thickness of the laminated plates changes considerably
Solution Approach 1:
The patent modifies the melting point parameter of the liquid crystal polymer through controlled thermal processing. By heating the polymer to a first temperature (lower than or equal to the first melting point) and maintaining it for a first time period, then cooling to a second temperature, the polymer's melting point is elevated to a second melting point higher than the first. This ensures that during lamination at temperatures close to the original melting point, only a controlled portion of the polymer melts, maintaining thickness consistency while still allowing the lamination process to proceed.
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
The modified liquid crystal polymers exhibit a higher melting point range, enabling more accurate management of laminated layer thickness and reducing process errors, as only a portion of the polymer melts during lamination, maintaining a consistent thickness from 50 μm to 45 μm.
Implementation Method 1
heating the liquid crystal polymer to a first temperature and maintaining at the first temperature for a first time period
Implementation Method 2
cooling the liquid crystal polymer from the first temperature to a second temperature to form a first modified liquid crystal polymer
Implementation Method 3
The conventional liquid crystal polymer has a consistent melting point so that most of the liquid crystal polymer is melted during the laminating process
Data Source
AI summary
A method of manufacturing a modified liquid crystal polymer includes: providing a liquid crystal polymer having a first melting point; heating the liquid crystal polymer to a first temperature and maintaining at the first temperature for a first time period, in which the first temperature is lower than or equal to the first melting point; and cooling the liquid crystal polymer to a second temperature to form a first modified liquid crystal polymer, the second temperature being lower than the first temperature, the first modified liquid crystal polymer having a second melting point, in which the second melting point is higher than the first melting point.