Study On Roll To Roll Manufacture Process Of High Reliability Fpc Based On Minitab Software

As a specific technology of electronic interconnection, flexible printed circuit(FPC) has a series of advantages such as light, thin, short, small and structural flexibility. Besides, it can be bended statically and dynamically, crimped and folded. With the advantages as above, the FPC market has increased greatly recently as a result of the popularization of smart phone and tablet PC. However, the vehicular market will be a new growth area for FPC due to the improvement of car electronization. Compared to traditional Panel-to-Panel technology which has the disadvantages as low production efficiency, poor dimensional stability and low finished product ratio of fine line, the Roll-to-Roll(RTR) method is more widely used in FPC manufacture for it can improve the automaticity and production efficiency. During the RTR process of FPC manufacture, a lot of critical processes such as RTR exposure, RTR image development, RTR etching and RTR dry film lamination are involved, making strict demands on the process optimization of RTR technology. In this paper, the optimal RTR process parameters of vehicle-mounted FPC with high stability were obtained by the Minitab software and a few multi-parameter experiments. Reliability tests were also carried out to estimate the reliability of products. The main conclusions were showed as follows.1. The Nippon Steel material MB12-16-12 REG was chosen as the best double-side FPC material through the thermal shock test, chemical corrosion resistance test, peel strength test, bending resistance test and voltage-withstand test. The Nippon Steel material TCL181318DH1 was chosen as the best coverlayer through peel strength test, resin overflow test and thermal shock test.2. The effect of coverlayer lamination parameters on coverlayer peel strength including molding pressure, molding temperature, molding time and pre-molding time was investigated though Minitab software and orthogonal test. The optimal process parameters were obtained: molding pressure was 120kg/cm2, molding temperature was 190℃, molding time was 120 s and pre-molding time was 15 s. The demonstration test in which the coverlayer peel strength was 7.15kg/cm showed good bond performance under the conditions of the optimal parameters.3. The effect of developing and etching process parameters on line width including developing pressure(x1), etching velocity(x2), etching pressure(x3) and developing velocity(x4) was investigated though Minitab software and uniform design test. The quadratic polynomial stepwise regression model was obtained. The optimal parameters of developing and etching process were that the developing pressure(x1) was 1.6 kg/cm2, the etching velocity(x2) was 4.0 m/min, the etching pressure(x3) was 1.8 kg/cm2 and the developing velocity(x4) was 2.0 m/min. The demonstration test under the condition of the optimal parameters in which the line width was 50.1μm and the standard deviation was 0.058% indicated obvious optimization of developing and etching process.4. The reliability tests containing bending resistance test, salt spray test, thermal shock test, solderability test and 288 ℃ thermal stress test were implemented to estimate the reliability of vehicle-mounted FPC. The results indicated that the products possessed high reliability and excellent environmental adaptability.5. The application of FPC key process to machine embedded language was studied in order to transfer the quadratic polynomial model into program language, realizing the intelligent control of the developing and etching process.