US 5,160,567 AGranted

System and method for manufacturing copper clad glass epoxy laminates

AssigneeAllied-Signal Inc.

InventorsJiri D. Konicek, Robert P. Smith, Jerry C. Zeroth

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Abstract

A system of conveyors and handlers for manufacturing copper clad laminates is disclosed. The system has a layup station including at least two clean rooms in which B-stage and copper foil sheets are respectively placed. A sandwich comprising a copper foil sheet placed into contact with a press plate is conveyed from the first to the second clean room where a B-stage sheet is positioned against the copper foil. The resulting uncured laminate is then transferred with its press plate to a stacking station until a predetermined number of laminates, separated by press plates, is stacked into a "book". One or more books are then conveyed through press loading equipment where heat and pressure are applied to cure the laminates. The books are then transferred to a breakdown station where the cured laminates and press plates are successively and sequentially stripped from the book. The press plates are conveyed back to the layup station for recycling into "new" books with each press plate cleaned immediately prior to reentering the first clean room. To minimize the migration of B-stage dust or fibers from the second to the first clean room, the ambient atmospheric air pressure within the first clean room is maintained at a greater pressure than the air pressure within the second clean room.

Claims25

Dependent claims

(a) a layup station including at least two clean rooms communicating with each other through an opening provided in an adjoining common wall area;
the first clean room adapted to contain copper foil and successively receive a plurality of press plates, the second clean room adapted to contain said B-stage sheets, a first layup region in the first clean room on which is received on said press plate with a sheeted layer of copper foil on at least one surface of the press plate;
means for conveying the sandwich including the press plate and sheeted layer of copper foil from the first clean room, through the opening, into the second clean room having a second layup region on which a sheet of B-stage is placed into contact with the sandwich against the copper foil side thereof;
a stacking station, downstream from the second clean room, for sequentially receiving the sandwiches to form a stacked book of said sandwiched laminates separated from each other with a press plate;
said book including, and resting upon, a carrier plate delivered to said stacking station and on which said sandwiches are successively stacked;
(b) a pressing station to which at least one book is conveyed from the stacking station and wherein heat and pressure is applied to said book to melt and then harden the B-stage laminates to adhere the copper foils to their associated B-stage;
and
(c) a breakdown station to which said at least one book is delivered from the pressing station, said breakdown station including:
i. breakdown press plate handler means movable between pickup and deposit positions for engaging an uppermost exposed press plate within the book and transferring it to the deposit position;
ii. press plate conveyor means for receiving the transferred press plate at the deposit position and conveying same to the first cleaning room for recycling in the buildup of a subsequent book;
iii. cleaning means, positioned within the press plate conveyor means, for cleaning the press plate before it is conveyed to the first clean room;
and
iv. means for conveying the carrier plate, following removal of all the press plates from the book via the handler means, to the stacking station for recycling.

10 more elements

A method of manufacturing a copper clad laminate having a B-stage substrate sheet which is an epoxy-coated web of glass cloths with at least one first sheet of copper foil respectively adhered to at least one side of the B-stage, comprising the steps of providing a plurality of press plates and a supply of copper foil within a first clean room;

providing a supply of B-stage sheets in a second clean room;
positioning the copper foil on at least one surface of the press plate;
conveying the sandwich including the press plate and copper foil from the first clean room into the second clean room;
placing a sheet of B-stage into contact with the sandwich against the copper foil side thereof;
delivering the resulting laminate to a stacking station;
and repeating the foregoing steps to form a stacked book of said sandwiched laminates separated from each other with said press plates;
wherein said clean rooms communicate with each other through an opening through which the laminates are transferred from the first to second clean rooms, and comprising the further step of maintaining an over-pressure within the first clean room, relative to the second clean room, to prevent the migration of B-stage dust of fibers from the second to the first room.

4 more elements

A system for manufacturing a copper clad laminate, the laminate having a B-stage substrate sheet with at least one first sheet of copper foil respectively adhered to at least one side of the B-stage, comprising a layup station including at least two clean rooms communicating with each other through an opening provided in an adjoining common wall area;

the first clean room adapted to contain copper foil and successively receive a plurality of press plates, the second clean room adapted to contain said B-stage sheets, a first layup region in the first clean room on which is received one said press plate with a sheeted layer of copper foil on at least one surface of the press plate;
means for conveying the sandwich including the press plate and sheeted layer of copper foil from the first clean room, through the opening, into the second clean room having a second layup region on which a sheet of B-stage is placed into contact with the sandwich against the copper foil side thereof;
a stacking station, downstream from the second clean room, for sequentially receiving the sandwiches to form a stacked book of said sandwiched laminates separated from each other with a press plate;
said book including, and resting upon, a carrier plate delivered to said stacking station and on which said sandwiches are successively stacked.

1 more element

Dependencies are inferred from the claim text.