Strip Exposure Machine Image Preparation for Large PCBs
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Solution Overview
Problem
Existing exposure machines are limited by the size of the exposure area, restricting the size of printed circuit boards that can be produced, especially for applications requiring large circuits exceeding one meter in length, such as in the aeronautical and automotive fields.
Innovation Solution
A method for image preparation in a moving web exposure machine that allows for the splicing of multiple images side by side, forming a longer image or a succession of identical patterns with precise regularity, using overlapping areas to ensure continuity and reduce gaps, and implementing strip tracking solutions to manage deviations and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the exposure area size is increased to expose larger images, then the size of printable circuit boards can be increased, but the machine size and cost will increase
Solution Approach 1:
The large image is divided into multiple smaller image segments that are exposed sequentially on different portions of the continuous strip. Each segment is exposed within the fixed exposure area, and the segments are later joined together to form the complete large image, allowing large-scale production without increasing machine footprint.
Solution Approach 2:
The solution transitions from exposing a single large image in one exposure area to exposing multiple smaller images along the temporal dimension (continuous strip progression). By utilizing the continuous motion of the strip and sequential exposure timing, the system effectively extends the printable area without expanding the physical exposure zone.
2Length of moving object
If multiple images are exposed side by side on a continuous strip, then large-sized circuits can be produced, but positioning errors may cause gaps between images
Solution Approach 1:
Overlapping areas are intentionally added between adjacent image segments during the digital image preparation stage, before exposure. This preliminary action ensures that even if positioning errors occur during exposure, the overlapping regions provide a buffer zone that prevents gaps and maintains continuity between segments.
Solution Approach 2:
The overlapping areas act as a cushion or buffer against positioning errors. By pre-positioning these overlapping zones in the digital domain, the system compensates for potential mechanical positioning inaccuracies during the exposure process, ensuring continuous circuit patterns without interruptions.
3Device complexity
If the exposure area is kept fixed to maintain machine size, then large images cannot be exposed in a single operation
Solution Approach 1:
The system maintains continuous exposure operations on a moving continuous strip, allowing multiple image segments to be exposed sequentially without interrupting the strip motion. This continuous process enables the production of arbitrarily long circuits by simply extending the exposure time and strip length, while keeping the exposure area fixed and the machine design simple.
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
Enables the production of large-sized exposed images without increasing the machine's size, allowing for the manufacture of printed circuits exceeding one meter in length with improved continuity and reduced defects.
Implementation Method 1
exposure arrangement, provided opposite the exposure zone of the support, comprising at least one light source and at least one projection device configured to project a succession of images in the exposure zone
Data Source
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AI summary
Image preparation method for a moving strip exposure machine, as well as an exposure machine of this type, said machine being configured to project, from one or more digital files, a succession of images (23) one after the other onto a moving strip in a direction of movement of the machine, in which an overlap zone (26) is ensured on the exposed strip between image n+1 (In+1) and image n (In) projected just before.