Metal-clad laminate sheet heat treatment for peel strength
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Solution Overview
Problem
Conventional metal-clad laminate sheets with thermoplastic liquid crystal polymer film and metal foil face a challenge in balancing high peel strength with high-frequency transmission characteristics, as a metal foil with low surface roughness improves frequency characteristics but compromises peel strength, and vice versa.
Innovation Solution
A method involving thermocompression-bonding a metal foil with low surface roughness to a thermoplastic liquid crystal polymer film and applying a specific heat treatment within a temperature range of 1°C to 50°C higher than the melting point of the polymer for 1 second to 10 minutes, ensuring sufficient peel strength while maintaining high-frequency characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal foil with low surface roughness is used, then high-frequency characteristics are improved, but peel strength between the metal foil and thermoplastic liquid crystal polymer film becomes insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling heat treatment temperature (1°C to 50°C higher than melting point) and time (1 second to 10 minutes) to modify the thermoplastic liquid crystal polymer film's properties, enabling it to achieve sufficient peel strength with low-roughness metal foil while maintaining high-frequency characteristics
Solution Approach 2:
The patent utilizes phase transitions of the thermoplastic liquid crystal polymer by heating it to its melting point or higher during heat treatment, causing the polymer to transition from solid to molten state and back, which enhances adhesion between the metal foil and film while preserving the film's optical and electrical properties
2Strength
If a metal foil with great surface roughness is used, then peel strength between the metal foil and thermoplastic liquid crystal polymer film is improved, but high-frequency characteristic deteriorates due to high insertion loss
Solution Approach 1:
The patent changes the parameters of the thermoplastic liquid crystal polymer film through controlled heat treatment at specific temperatures and durations, allowing the film itself to provide sufficient adhesion strength without relying on metal foil surface roughness, thereby enabling use of smooth metal foils for high-frequency applications
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 method achieves a metal-clad laminate sheet with enhanced peel strength and high-frequency characteristics, even when the metal foil has a low surface roughness, effectively addressing the balance between adhesion and frequency performance.
Implementation Method 1
heat-treating the laminate sheet at or above the melting point of the thermoplastic liquid crystal polymer film
Implementation Method 2
the thermoplastic liquid crystal polymer film kept under tension to obtain a laminate sheet, and heat-treating the laminate sheet at or above the melting point
Implementation Method 3
thermocompression-bonding the thermoplastic liquid crystal polymer film and the metal foil together between heating rolls
Implementation Method 4
heat-treating the laminate sheet at or above the melting point of the thermoplastic liquid crystal polymer film
Data Source
AI summary
A method for manufacturing a metal-clad laminate sheet including forming a laminate sheet having the thermoplastic liquid crystal polymer film and the metal foil bonded together; and providing the laminate sheet with a heat treatment which satisfies conditions (1) and (2) below: (1) a heat treatment temperature ranges between 1° C. inclusive and 50° C. exclusive higher than a melting point of the thermoplastic liquid crystal polymer film. (2) a time for the heat treatment ranges from one second to 10 minutes.