Prepreg Cutting and Assembly System for Copper Clad Laminates
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Solution Overview
Problem
Conventional copper clad laminate production involves manual sheet separation of prepreg sheets, leading to electrostatic damage, low productivity, and inefficiencies due to storage and retrieval processes, with existing cutting machines not addressing contamination and debris issues during prepreg cutting.
Innovation Solution
An assembly arrangement system comprising a feeding unit, conveyor unit, and assembling unit that cuts and assembles prepreg sheets directly with metal foils and plates without storage, using a heating unit to prevent debris and a controller for synchronized operation, enabling continuous formation and assembly of prepreg sheets into copper clad laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sheet separation is performed to assemble prepreg sheets with copper foils, then assembly can be completed, but electrostatic charges form between prepreg sheets causing damage or breakage and lowering productivity
Solution Approach 1:
The invention extracts the harmful electrostatic interaction by eliminating the storage and manual handling process. Prepreg sheets are cut and immediately assembled with copper foils in a continuous process, removing the intermediate state where electrostatic charges could accumulate and cause damage between sheets.
Solution Approach 2:
The invention implements continuous production by cutting prepreg sheets and assembling them with copper foils in an uninterrupted sequence. This eliminates the discontinuous manual separation process, maintaining continuous motion and preventing electrostatic charge accumulation that occurs during manual handling.
2Ease of manufacture
If manual sheet separation operation is performed, then prepreg sheets can be assembled with copper foils, but the operation is time-consuming and labor-consuming
Solution Approach 1:
The invention replaces the manual mechanical separation operation with an automated cutting and assembling system. The cutting machine automatically cuts prepreg sheets and the assembling unit automatically assembles them with copper foils, eliminating time-consuming manual labor while maintaining assembly feasibility.
Solution Approach 2:
The system performs self-service by automatically cutting and assembling without human intervention. The cutting machine and assembling unit work autonomously in sequence, with the prepreg sheet being immediately processed from cutting to assembly without requiring manual separation operations.
3Adaptability or versatility
If a warehouse is used to store prepreg sheets and retrieval process is implemented, then sheets are available for production, but the process becomes more complex and time-consuming
Solution Approach 1:
The invention performs preliminary action by cutting prepreg sheets immediately after they are needed for assembly, rather than pre-cutting and storing them. This eliminates the warehouse storage requirement and simplifies the process by performing the cutting action right before assembly in a continuous flow.
Solution Approach 2:
The invention merges the cutting and assembling operations into a single integrated process flow. The cutting machine and assembling unit are connected in sequence, eliminating the separate storage and retrieval processes, and combining multiple operations into a unified continuous production system.
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 system increases productivity and yield by eliminating manual separation, reducing damage, and enhancing efficiency through direct assembly and synchronized processing, thereby improving the production rate of copper clad laminates.
Implementation Method 1
uses a heating unit to heat a portion of the prepreg and form a softened portion
Data Source
AI summary
Disclosed is an assembly manufacturing method comprising: cutting a prepreg into a prepreg sheet according to a first parameter; moving the prepreg sheet to an assembly arrangement area according to a second parameter; superimposing a metal foil and a plate according to a fourth parameter to form a copper foil set; and assembling the copper foil set and the prepreg sheet according to a third parameter to form an assembly.