Multilayer Circuit Board Web Handling for Continuous Tension Control
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Solution Overview
Problem
The existing multilayer circuit board manufacturing processes are time-consuming due to the need to manufacture and stack individual layers sequentially, which limits productivity and efficiency.
Innovation Solution
A multilayer circuit board manufacturing apparatus is designed with an uncoiler, process unit, recoiler, tension adjustment unit, position adjustment unit, and transfer rollers to enable continuous manufacturing by maintaining tension, adjusting speed, and facilitating the transfer of members between units, allowing for simultaneous processing and winding of multiple layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual layers are manufactured and stacked sequentially, then each layer can be precisely controlled, but manufacturing time increases significantly
Solution Approach 1:
The patent implements continuous manufacturing by uncoiling a member containing multiple layers and processing them continuously through the apparatus. The uncoiler feeds the member continuously through the process unit, eliminating the need to stop and stack individual layers separately, thus maintaining continuous useful action while preserving layer precision through controlled tension and positioning.
Solution Approach 2:
The member is prepared in advance with multiple layers already arranged in the correct sequence and configuration before entering the processing apparatus. This preliminary arrangement of layers on the uncoiled member allows subsequent processing to occur continuously without time-consuming stacking operations, while the tension adjustment units ensure the pre-arranged layers maintain their precise relative positions throughout processing.
2Productivity
If multiple layers are processed simultaneously, then productivity increases, but tension control becomes more difficult
Solution Approach 1:
The patent divides the tension control function into multiple independent tension adjustment units positioned at different locations along the processing line. Each unit independently controls tension in its local section, allowing simultaneous processing of multiple layers while managing tension control complexity through modular segmentation rather than attempting centralized control of all layers.
Solution Approach 2:
The patent introduces tension adjustment units as intermediary devices between the uncoiler, process unit, and recoiler. These intermediary units act as mediators that actively regulate tension forces transmitted through the member, enabling stable simultaneous processing of multiple layers by decoupling the tension control complexity from the overall system and localizing it to specific adjustment points.
3Productivity
If continuous manufacturing is implemented, then productivity improves, but maintaining constant tension becomes challenging
Solution Approach 1:
The patent implements feedback control through tension adjustment units that continuously monitor and regulate tension in the member during continuous manufacturing. The load units and contact rollers in these adjustment units respond to tension variations in real-time, providing feedback control that maintains constant tension throughout the continuous processing operation, thereby ensuring reliability while enabling high productivity.
Solution Approach 2:
The tension adjustment units are designed to automatically self-regulate tension through their load units and contact roller mechanisms without requiring external intervention. As the member moves continuously through the apparatus, these units self-adjust to maintain constant tension, enabling continuous manufacturing with reliable tension stability through self-service operation.
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 apparatus enables continuous and efficient manufacturing of multilayer circuit boards by maintaining constant tension and speed, preventing bending or distortion, and allowing for simultaneous processing of multiple layers, thereby improving productivity and reducing manufacturing time.
Implementation Method 1
a powder clutch which is connected to at least one of the uncoiler and the recoiler and maintains the tension of the member
Implementation Method 2
a contact roller that moves in contact with the member; and a load unit which is connected to the contact roller and adjusts force that is applied to the member by the contact roller
Data Source
AI summary
The present disclosure relates to a multilayer circuit board manufacturing apparatus. The present disclosure includes: uncoiler configured to provide a member; a process unit configured to perform a process on the member provided from the uncoiler; a recoiler configured to wind the member on which the process is completed in the process unit; and a tension adjustment unit which is located in at least one of the uncoiler, the recoiler, a region between the uncoiler and the process unit, and a region between the process unit and the recoiler, and adjusts tension of the member.