How PCB Laminates and Prepreg is Made

Summary

The video provides a detailed overview of the laminate manufacturing process, beginning with the sourcing of glass fabric rolls and the application of resin and copper foil. Key steps include tension hanging, dipping in resin, heating in a treater tower for semi-curing, and quality control using advanced scanning technology to ensure consistency. After treatment, the laminate materials are cut or rolled and assembled with stainless steel plates and copper foil in a cleanroom environment to prevent contamination. This meticulous approach ensures high-quality products while emphasizing cleanliness to avoid defects during pressing.

Takeaways

• 😀 The manufacturing process begins with large rolls of glass fabric sourced from glass weavers, resembling textile production.
• 🛠️ The core components for laminating include glass fabric, resin, and copper foil.
• 🔥 A treater system applies resin to the glass under tension, followed by heating in a treater tower to achieve a semi-cured state.
• 📏 Resin content is adjusted based on the specific core type being produced (e.g., 4 mil or 5 mil cores) using metering bars and advanced monitoring technology.
• 🔬 Quality control is enhanced with DCM technology, which continuously scans the resin and cure content across the web to prevent defects.
• ✂️ After treatment, the glass fabric is cut into specific sizes (e.g., 38x50 inches) based on production needs.
• 🧼 Cleanroom environments are critical for manufacturing, as contaminants can lead to defects in the final product.
• 🚫 Strict protocols require personnel to wear protective suits to maintain cleanliness in areas where copper foil and stainless steel plates are handled.
• 📦 Finished laminate sheets are trimmed to customer-specified panel sizes, with common sizes being 24x8 inches and larger configurations for specific applications.
• 🌍 Panel sizes may vary by region, with manufacturers aiming to maximize the number of parts per panel to reduce costs.

Q & A

What materials are used in the manufacturing process described in the transcript?

The main materials used are glass fabric, resin, and copper foil.

How is the glass fabric processed during manufacturing?

The glass fabric is woven like textiles, with warp and fill yarns, and comes in large rolls from glass weavers.

What role does the resin play in the manufacturing process?

The resin is applied to the glass fabric in a dip pan, where it is circulated and then cured in the treater tower.

What is the purpose of the treater tower in the manufacturing process?

The treater tower heats the glass fabric with resin to a semi-cured stage, preparing it for further processing.

How is the resin content monitored during the manufacturing process?

Resin content is monitored using metering bars and advanced technology to ensure consistency across the material.

What are the standard sheet sizes mentioned for the final product?

Standard sheet sizes include 38x50 Master size, 46x38, and sometimes 24x18 panels.

Why is cleanliness critical in the manufacturing environment?

Cleanliness is vital because contaminants on the copper surface can lead to defects like shorts or opens in the final product.

What safety measures are implemented to maintain cleanliness in the production areas?

Workers must wear full bunny suits to prevent contamination, and materials are handled in clean room environments.

How does the manufacturing process ensure a consistent quality product?

The use of cure monitors and DCM technology helps in continuously checking the resin and cure content during production.

What happens to the material after it goes through the treater?

After treatment, the material is either cut into specified sizes or rolled up for conversion into final panels.