PROCESS FOR THE PRODUCTION OF PLASTIC LAMINATES WITH METAL LAMINAE ESPECIALLY FOR PRINTED CIRCUITS MADE FROM ENDLESS BANDS

Abstract: Process for the production of plastic laminates especially those for printed circuits, the component parts being assembled in packages (11-14) arranged in piles (10), in which process the laminae on the two faces of each laminate are respectively made from two continuous bands (20, 30), laid serpentinewise which, alternatingly, form the upper and lower laminae of each package (11-14) as it is formed, heating of said packages (11-14) being made endothermically by means of electric heating elements created by connecting the ends of the two bands to a suitably powered generator (50) of electric current.

Description: PROCESS FOR THE PRODUCTION OF PLASTIC LAMINATES WITH METAL LAMINAE ESPECIALLY FOR PRINTED CIRCUITS MADE FROM ENDLESS BANDS The invention concerns processes for making plastic la- minates using metal laminae. In the normal way plastic laminates consist of several layers, stably associated generally by pressing, of pla¬ stic materials on a base of paper, fibreglass fabrics or other materials. The plastic materials may be of phenol, melamine, epoxy, polyester, silicon, fluoride or others. In the production of printed circuits a metal lamina,es¬ pecially of copper, is made to adhere. on one or both sides of the circuit during the pressing process. A pile of substantially similar packages is formed, each of which comprises a number of sheets impregnated with pla¬ stic materials with the copper laminae placed outermost. A sheet of metal such as stainless steel or some other is placed between each package and the pile of packages is put in a multiplate press giving heat and pressure simultan¬ eously . - 2 - At the close of the thermic cycle, which includes a cool¬ ing stage, a compact and rigid product is obtained whose individual components are closely associated together. Presses suitable for this kind of production are complex and give a low output because of having many plates, of having to produce heat and pressure at the same time and in well defined and precise sequences, because of having to create, by conduction, even temperatures in the various packages in the pile of which, obviously, only those at the top and bottom of the pile are in contact with the heating plates. The presence of many heating plates not only complicates the structure of the press but also makes package loading and unloading a lengthy operation, while problems occur over short production runs because of the difficulties of amortizing costs. In particular, the penetration of heat from the plates through the pile of packages is hindered because of the distance it must travel to reach the innermost package. These difficulties result in high costs, for the press itself and for running it, in waste of materials, in long processing times and therefore in a more costly product. The invention here presented greatly lessens the above drawbacks while offering considerable advantages as will be explained below. Subject of the invention is a process for making plastic laminates, especially those for printed circuits, by the formation of piles of packages each comprising a high-insu¬ lation plate, of prepreg or another material, herinafter called "prepreg", and metal laminae ,especially of copper, here¬ inafter called "laminae", on both surfaces of said prepreg. Sheets of stainless steel or other material, hereinafter called "sheets" are placed between one package and another. The pile of packages is placed in a press where pressure and heat are applied simultaneously. According to the invention the two laminae are made from two continuous bands. The first section of the first band is laid on the first surface of prepreg of a first package. In its first section the second band is laid on the se- cond face of the prepreg of the first package, and in its second section, after placing of a sheet and after said band has made a bend at i80°, on the second face of said sheet . A second section of the fir.st band is laid on the second face of the prepreg of the second package next to the first one, and a third section, after a second sheet has been laid, and after a bend of 180°, on the second face of said sheet. The third section of the second band, after making a bend of 180°, is placed on the second face of the prepreg of the third package, and so on through the pile of packages keeping a layer of electrical insulation between the bands. The first and last ends of the two bands are connected to a suitably powered generator of electric current. Thus, when adequate pressure is applied to the pile of packages and on closing the generator's electric circuit, the various sections of the two bands ,matching respective¬ ly with the two faces of the packages, will act as electric heating elements causing close association among the dif- ferent layers and the formation of plastic laminates. Layers or other equivalent means giving a high degree of electrical insulation, are placed between the sheets and continuous bands. Preferably the bands are made of copper. In one preferred execution the ends of the two bands ap- pear on the same side of the pile for easier connection to the generator of electricity. It is of an advantage if the two bands make their 180° bends alternatively on one side of the pile of packages and on the opposite side. Pressure on the pile of packages may be determined by pla¬ cing said pile in a cold press or in an autoclave. In one execution the pile iε put into a die having a plate at the top and bottom connected by supporting and guiding pins . The pressure required for the process is obtained by pla¬ cing said die in a cold press or in an autoclave. The invention clearly possesses advantages. There being no need for the press to provide heat and pres¬ sure simultaneously, it can be a simple one and of many kinds and of different power capacities according to the type of laminate required as long as it can produce suffi¬ cient pressure . Heating is generated inside each package, such as can rise to a uniform temperature on all components in a short time. Series of both large and small quantities can be made. Heating is much quicker compared with that obtainable from present presses in which it has to penetrate some distance before reaching right inside the pile of packages. By using a mixed form of heating, combining the tradition- al type of heating plates at each end of the pile of pack¬ ages with this endothprmic form, processing times are much shorter and productivity is consequently much higher. Work sequences are not only faster but are also simpler reducing waste and therefore appreciably lowering costs. Characteristics and purposes of the invention will become still clearer from the following example of execution il¬ lustrated by a diagrammatically drawn figure. Fig. 1 A pile of packages with metal laminae,made of bands of copper and laid s rpentine-wise , in a cold press. The pile 10,placed between the plates 101, 102 of a press 100, is composed of packages 11-14 each comprising layers 15 of fibreglass fabric impregnated with epoxy resins. Steel sheets 40-44, with interposed layers 18 for electri¬ cal insulation, are placed between one package and another. The sheet 40, laid on the lower plate 102, has placed upon it a layer 18 of insulating material and on top of this the first section 21 of a first copper band 20. Above said section is the layer 15 of prepreg and on top of that is the first section 3! of the second copper band 30 and a layer 18 of electrical insulating material all of which form the first package 11. The sheet 41 and the insulating layer 18 are then laid. After the second band has made a sharp 180° turn 32, it rests on said layer with the section 33 of band. The second layer 15 of prepreg 15 is then laid and on this, after making a bend 22 at 180° d grees, lies the second section 23 of the first band20 forming a second package 12. After an insulating layer 18, a third sheet 42 of stainless sfeel is laid and another insulating layer 18- The band 20 makes another 180° turn 24 and its third sec- tion 25 lies over the sheet 42. After making a second 180° turn 34, the second band 30 is laid above the third layer of prepreg 15 and pact-age 13 is forme . Finally the first band 20 appears at the top of the package with its end 26 while the second band 30 appears with its end 36. At the start of package formation the bands are conuect- ed to join sections 19,29 and to lead 51. The beginning and terminating ends of the bands are con¬ nected, by means of respective join sections 19, 29 and 27, 37, and of leads 51 and 52, to the generator 50 of electric current. On starting up the press 100 with simultaneous closure of the electric circuit, the bands 20 and 30 act as electric heating elements and heat reaches the packages 11-14 as indicated by the arrows. The pressing process with endothermic heating is then car¬ ried out .

Claims: CLAIMS 1. Process for the production of plastic laminates , espe¬ cially for printed circuits, by formation of piles ( 10) of packages ( 11-14) each comprising a high-insulation layer of prepreg ( 15), hereinafter called "prepreg" and metal laminae (20-25) especially copper laminae, herein¬ after called "laminae", on each side of said prepreg, sheets of stainless steel or of other material (40-44), hereinafter called "sheets", being placed between one pack- age and another, then by insertion in a press to receive pressure and heat, characterized in that the two laminae are made from two continuous bands (20,30), the first section (21) of the first band (20) being laid -over the first face of the pre- prag ( 15) of a first package ( 11), a first section (31)of the second band (30) being laid over the second face of the preprag ( 15) of the first package ( 11) and a second section (33), after deposition of a sheet (41) and after a 180° bend, on the second face of this latter sheet (41), a second section (23) of the first band (20) being laid on the second face of the prepreg ( 15) of the second pack¬ age ( 12) and a third section (25),. after deposition of a second sheet (42) and a 180° bend, on the second face of said sheet (42), the third section (35) of the second band (30), after a 180° bend,being placed on the second face of the prepreg ( 15) of the third package ( 13) and so on up to the end of the pile ( 10) of packages ( 11-14), electric insulation being maintained between the two bands (20,30), the first and last ends of the two bands (20,30) being connected to a generator (50) of electric current of suit¬ able power so that by applying adequate pressure on the pile ( 10) of packages ( 11-14) and closing the electric circuit of the generator (50), the various sections of the two bands ( 20 , 30),matching respectively with one face and the other of the packages ( 11-14), act as electric heating elements, creating close association among the different layers ( 15,20,30) and forming plastic laminates. 2. Process as in claim 1, characterized in that layers ( 18) or their equivalent , of- fering high electrical insulation, are placed between the sheets (40-44) and continuous bands (20,30). 3. Process as in claim 1, characterized in that the bands (20,30) are of copper. 4. Process as in claim 1, characterized in that the two ends of the bands (20,30) come out on the same side of the pile ( 10) for easier con¬ nection with the generator (50) of electric current. 5. Process as in claim 1, characterized in that each of the two bands (20,30) are made to form 180° bends alternatively on one side of the pile ( 10) of packages ( 11-14) and on the opposite one. 6. Process as in claim 1, characterized in that pressure on the pile ( 10) of pack¬ ages ( 11-14) is obtained by placing said pile ( 10) inside a cold press ( 100). 7. Process as in claim 1, characterized in that pressure on the pile ( 10) of pack¬ ages ( 11-14) is obtained by putting said pile ( 10) in an autoclave . 8. Process as in claim 1, characterized in that each pile ( 10) of packages is placed inside a die having an upper and lower plate connected by - 9 - supporting and guiding pins, the pressure necessary for the process being obtained by placing said die in a cold press. 9. Process as in claim 1, characterized in that each pile of packages is placed in¬ side a die having upper and lower plates connected by sup¬ porting and guiding pins, the pressure necessary for the process being obtained by placing said die in an autoclave.

Inventors: CERASO BRUNO, CERASO, BRUNO
Applicants: CEDAL SRL, CERASO BRUNO, CEDAL S.R.L., CERASO, BRUNO
Application year: 1993
Main classification: B29C35
IPC codes: B29C43, B29C65, B29K105, B30B9, B32B15, H05K3