Poly-Based Burr Suppressor for PCB Drilling
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Solution Overview
Problem
Current methods for suppressing burrs during printed circuit board (PCB) drilling, such as using backup materials like Melamine or HDF, are inefficient and costly, and can result in debris trapping and undersized holes due to imperfect alignment or warping of the PCB.
Innovation Solution
A burr-suppressing copper foil is developed, comprising a poly-based film with adhesive on both sides, removably attaching a copper foil and a metallic burr suppressor, which acts as an outer layer during drilling, preventing burr formation and allowing for easy recycling of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional backup materials (Melamine or HDF) are used for burr suppression, then burr formation is reduced, but manufacturing cost increases and debris trapping occurs
Solution Approach 1:
The patent uses a disposable aluminum entry material that is inexpensive and single-use, eliminating the need for expensive reusable backup materials like Melamine or HDF. The aluminum material is discarded after one use, avoiding contamination issues while maintaining burr suppression effectiveness.
Solution Approach 2:
The patent introduces an intermediary aluminum entry material between the drill bit and the PCB copper surface. This intermediate layer provides burr suppression without the debris trapping problems of traditional backup materials, as the aluminum can be easily removed after drilling.
2Object-affected harmful factors
If aluminum entry material is placed on PCB during drilling, then burr suppression is achieved, but debris may become trapped creating gaps that allow burrs to form
Solution Approach 1:
The aluminum entry material is designed as a disposable component that is discarded after single use. This eliminates the risk of debris accumulation and trapping, as each new aluminum sheet starts with a clean surface without previous drilling debris.
Solution Approach 2:
The patent extracts the aluminum entry material from the permanent backup material system, making it a removable, disposable component. This allows the aluminum to be easily removed after drilling, preventing debris trapping issues that occur with reusable backup materials.
3Shape
If burr is pushed back into the hole to reduce burr height, then burr visibility is reduced, but hole size decreases causing PCB rejection
Solution Approach 1:
The patent applies preliminary anti-action by preventing burr formation in the first place through the use of aluminum entry material and optimized drilling parameters. This avoids the need for subsequent burr manipulation that would compromise hole size, thereby preventing PCB rejection.
Solution Approach 2:
The patent converts the potentially harmful effect of burr formation into a beneficial process by using controlled aluminum deformation during drilling. The aluminum absorbs the burr-forming energy through controlled deformation, protecting the actual PCB copper holes from burr formation while maintaining hole integrity.
4Object-affected harmful factors
If coated wood core backup material is used for burr suppression, then burr formation is reduced, but material cost increases
Solution Approach 1:
The patent replaces expensive coated wood core backup material with inexpensive disposable aluminum entry material. The aluminum is much cheaper than coated wood core materials and achieves the same burr suppression function through a different mechanism that doesn't require expensive coatings.
Solution Approach 2:
The patent changes the fundamental parameter of backup material from expensive coated wood core to inexpensive aluminum. This material substitution maintains burr suppression effectiveness while dramatically reducing material cost through a complete change in material type and application method.
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 solution effectively reduces burr formation during PCB drilling, prevents debris accumulation, and allows for the use of uncoated wood core materials, reducing costs while maintaining hole size integrity and enabling efficient recycling of materials.
Implementation Method 1
a poly-based film having an adhesive on a first side and an adhesive on a second side. A copper foil contacts the adhesive at the first side of the poly-based film to removably couple the poly-based film to the copper foil. A metallic burr suppressor contacts the adhesive on the second side
Data Source
AI summary
A burr-suppressing copper foils are described. In an embodiment, the burr suppressing copper foil includes a poly-based film having an adhesive on a first side and an adhesive on a second side. A copper foil contacts the adhesive at the first side of the poly-based film to removably couple the poly-based film to the copper foil. A metallic burr suppressor contacts the adhesive on the second side to removably couple the poly-based film to the metallic burr suppressor.