The production of printed circuit boards is often a headache for electronic enthusiasts. Many electronic enthusiasts often use amateur painting methods such as paint, knife, and adhesive paste to produce a printed circuit board. Slower and harder to produce high quality printed circuit boards. The manufacture of printed circuit boards has even become a "stop-the-language" for many beginners to enter the electronic hall. In today's increasingly popular computer, computer-aided design has become a hot topic in the electronics industry. Using computer design printed boards, although the design has a graphic specification, accurate size, easy to modify, easy to save, but the production of printed board The process is still more complicated. It is necessary to pass through chemical processes such as photolithography and photolithography, which consumes more materials, has a longer cycle, and costs more. Under normal circumstances, sending e-mail to the printed circuit board factory, the factory to make the fastest speed, and send it by express mail also need a week, about 100 yuan fee. A mature circuit board will often require several trials to be successful.
In response to these problems, we have been exploring and researching for a long time and finally developed a low-cost, simple-to-use, small-scale, fast-printed circuit board production system. The system consists of a fast microcomputer-controlled digital thermal transfer platemaking machine and a rapid corrosion machine. Among them, the thermal transfer platemaking machine was inspired by the research of laser printers. Our researchers found that the "carbon powder" of laser printers that we are familiar with is not an inorganic toner but a black plastic particle containing magnetic substances. . It is electrostatically attracted by the toner cartridge of the laser printer. The graphics and characters with extremely high precision are arranged on the cartridge. After the static electricity is eliminated, it is transferred to the printing paper and fixed at a high temperature to form a laser printer. Our research personnel, under the indication of this discovery, developed a thermal transfer paper with high-temperature non-adhesive properties, a rapid microcomputer-controlled thermal transfer platemaking machine, and a rapid corrosion machine. With this system, printed circuit boards can be produced in small batches very quickly. This system has the following significant advantages over conventional photolithography methods for making circuit boards:
1. High-precision version: It can achieve the plate-making accuracy of laser printer resolution. In addition to producing fine circuit patterns, high-resolution images can also be produced. Using it can not only produce a fine printed circuit board, and can even produce exquisite metal signs, metal craft paintings and so on.
2. Low plate making cost: The plate making cost for making a circuit board is only equivalent to the cost of a thermal transfer paper.
3. Fast plate making speed: The rapid thermal transfer plate making machine can quickly transfer the printed circuit pattern printed on the thermal transfer paper by the laser printer to the circuit board to form an anti-corrosion layer to make a 200mm x 300mm printed circuit board. It only takes 10 to 20 minutes. It is suitable for the rapid production of circuit board prototypes in factories, research institutes, schools, and electronics malls.
4. Multi-purpose: At the same time can be produced at the same time a two-panel, single-character panel, can also be made into two characters with a double panel.
5. High degree of automation, operation is very simple: rapid thermal transfer platemaking machine, using 89c2051 as the main control chip. The plate-making machine measures and sets the temperature of the rubber roller; the circuit board enters and exits; the power supply is turned on, and the time delay function of the motor provided to avoid overheating of the roller is the full automatic control of the touch switch. 6. Equipment cost-effective: The use of this thermal transfer-type rapid plate-making system to replace the traditional printing plate production process, equipment, low cost, high cost, generally buy equipment for the month to quickly create printed circuit board production and operation, the month can be Recover all investment. The operation and working principle of the plate making machine will use the computer to make the printed circuit board pattern, print it on the specially processed special thermal transfer paper by the laser printer, and then cover the transfer paper on the copper plate and send it to the plate making mechanism version. .
The working principle of the plate making machine mainly adopts the principle of heat transfer. Its structure is similar to that of a laser printer. There are two sets of four specially-made high-temperature-resistant silicone cylindrical roller transmission mechanisms. Using two infrared quartz heating tubes, a set of two silica gel cylindrical rollers are evenly heated to 180.5°C. At the same time, each set of two silicone cylindrical rollers is two pressure rollers, and its maximum surface temperature can reach 300°C. The two sets of rubber rollers are driven by the synchronous motor through the transmission system and rotate at a constant speed of two revolutions per minute.
When the thermal transfer paper and the copper press plate pass through the gap between the relatively high temperature and high pressure silicone cylindrical rollers, the absorbed toner on the thermal transfer paper will melt. Because the thermal transfer paper is specially treated, its surface is coated with several layers of special materials by the polymer technology, so that the thermal transfer paper has the characteristics of high temperature-resistant and non-adhesion. When the temperature reaches 180.5°C, the thermal transfer paper has a drastic drop in the melting power of the melted toner. Under the effect of the pressure, the melted toner is completely absorbed on the copper-clad plate. After the copper-clad plate is cooled, the fastened printing is formed. Graphics complete the entire heat transfer process. The same principle, if you need to transfer the layout of the components on the other side of the printed board, can also be carried out at the same time, making the printed board to a more professional level.
What needs to be explained here is that the entire heat transfer process requires a particularly high temperature, and the control of the temperature is very important. For example: the best melting point of the toner is generally 180.5°C. When the temperature is too high, the over-melted toner will spread around the original lines, resulting in blurred graphics, poor accuracy, and severe paper scorching. . When the temperature is too low or the temperature is not uniform, the transfer effect will be poor, and it will not even be transferred. In actual use, due to factors such as air temperature, humidity, paper, and board thickness affecting the transfer effect, the control of temperature is very important for the transfer effect. For this reason, the thermal transfer plate-making machine temperature control sensor adopts imported pt-1000 type thin film platinum resistance, so that the temperature control precision can reach 0.1°C, which meets the higher temperature requirement of plate making.
When the pattern is transferred to the copper plate, the printer's toner forms a patterned protective layer on the surface of the copper plate. Since the toner of the laser printer is made of a polymer material containing a resin and has a good corrosion resistance to the etching solution (fecl3 solution), a delicate printed circuit board can be formed after the corrosion of the fecl3 solution. In order to make the corrosion of the circuit board quicker and easier, an etching machine is also required to rapidly corrode the circuit board to save time, reduce the waste of the fecl3 solution, and increase the efficiency. The rapid corrosion machine quickly heats the fecl3 solution above 60°C, and then uses a corrosion-resistant small circulating submersible pump to spray the fecl3 solution evenly through the special nozzle to the printed board.
Generally, it is corroded with a high concentration of FeCl3 solution under the condition of heating to 80°C, and it can be etched in 5-6 minutes. Due to the fast etching process, the side etching can be reduced and the fineness of the printed circuit board can be more perfect and reliable. The redox reaction of the fecl3 solution is accelerated by heating, so that the copper on the copper-clad plate surface is accelerated to cu2+. At the same time, the cu2+ deposited on and near the surface of the copper-clad plate is taken away by the impact of the water stream, so that the chemical reaction proceeds more quickly and more fully. This machine is particularly suitable for large area printing plate production.
The entire corrosion process is carried out in a semi-closed condition, which has the advantages of cleanliness and reduced evaporation of the etching solution, and is therefore very suitable for the production of printed circuit boards in small batches by laboratories, research institutes and factories. After the printed circuit board is corroded, the circuit board is drilled with a special drill. This special drill is fitted with a cylinder, which can finish the high-speed drilling and can also abrade the toner near the drill hole to form a Very clean pad. The other toner covering the copper foil forms a good solder mask.
Using this system, metal signs and metal artwork can also be produced. It is also very exquisite, with a distinctly distinct level, and at a very low cost. With the advantages of its rapid plate making, it is believed that it will be more widely used in these industries in the near future. Applications. Although the accuracy of the printed circuit board produced by this system can reach a very high level of professionalism, it also has some defects: Due to different laser printers, excessive weather humidity, and partial defects of the thermal transfer paper, toner will appear. Local adhesion on the thermal transfer paper is not good. In addition, the system is not equipped with a CNC drilling machine, and metal holes cannot be formed when a double-sided panel is manufactured. Therefore, further improvement is needed.
In response to these problems, we have been exploring and researching for a long time and finally developed a low-cost, simple-to-use, small-scale, fast-printed circuit board production system. The system consists of a fast microcomputer-controlled digital thermal transfer platemaking machine and a rapid corrosion machine. Among them, the thermal transfer platemaking machine was inspired by the research of laser printers. Our researchers found that the "carbon powder" of laser printers that we are familiar with is not an inorganic toner but a black plastic particle containing magnetic substances. . It is electrostatically attracted by the toner cartridge of the laser printer. The graphics and characters with extremely high precision are arranged on the cartridge. After the static electricity is eliminated, it is transferred to the printing paper and fixed at a high temperature to form a laser printer. Our research personnel, under the indication of this discovery, developed a thermal transfer paper with high-temperature non-adhesive properties, a rapid microcomputer-controlled thermal transfer platemaking machine, and a rapid corrosion machine. With this system, printed circuit boards can be produced in small batches very quickly. This system has the following significant advantages over conventional photolithography methods for making circuit boards:
1. High-precision version: It can achieve the plate-making accuracy of laser printer resolution. In addition to producing fine circuit patterns, high-resolution images can also be produced. Using it can not only produce a fine printed circuit board, and can even produce exquisite metal signs, metal craft paintings and so on.
2. Low plate making cost: The plate making cost for making a circuit board is only equivalent to the cost of a thermal transfer paper.
3. Fast plate making speed: The rapid thermal transfer plate making machine can quickly transfer the printed circuit pattern printed on the thermal transfer paper by the laser printer to the circuit board to form an anti-corrosion layer to make a 200mm x 300mm printed circuit board. It only takes 10 to 20 minutes. It is suitable for the rapid production of circuit board prototypes in factories, research institutes, schools, and electronics malls.
4. Multi-purpose: At the same time can be produced at the same time a two-panel, single-character panel, can also be made into two characters with a double panel.
5. High degree of automation, operation is very simple: rapid thermal transfer platemaking machine, using 89c2051 as the main control chip. The plate-making machine measures and sets the temperature of the rubber roller; the circuit board enters and exits; the power supply is turned on, and the time delay function of the motor provided to avoid overheating of the roller is the full automatic control of the touch switch. 6. Equipment cost-effective: The use of this thermal transfer-type rapid plate-making system to replace the traditional printing plate production process, equipment, low cost, high cost, generally buy equipment for the month to quickly create printed circuit board production and operation, the month can be Recover all investment. The operation and working principle of the plate making machine will use the computer to make the printed circuit board pattern, print it on the specially processed special thermal transfer paper by the laser printer, and then cover the transfer paper on the copper plate and send it to the plate making mechanism version. .
The working principle of the plate making machine mainly adopts the principle of heat transfer. Its structure is similar to that of a laser printer. There are two sets of four specially-made high-temperature-resistant silicone cylindrical roller transmission mechanisms. Using two infrared quartz heating tubes, a set of two silica gel cylindrical rollers are evenly heated to 180.5°C. At the same time, each set of two silicone cylindrical rollers is two pressure rollers, and its maximum surface temperature can reach 300°C. The two sets of rubber rollers are driven by the synchronous motor through the transmission system and rotate at a constant speed of two revolutions per minute.
When the thermal transfer paper and the copper press plate pass through the gap between the relatively high temperature and high pressure silicone cylindrical rollers, the absorbed toner on the thermal transfer paper will melt. Because the thermal transfer paper is specially treated, its surface is coated with several layers of special materials by the polymer technology, so that the thermal transfer paper has the characteristics of high temperature-resistant and non-adhesion. When the temperature reaches 180.5°C, the thermal transfer paper has a drastic drop in the melting power of the melted toner. Under the effect of the pressure, the melted toner is completely absorbed on the copper-clad plate. After the copper-clad plate is cooled, the fastened printing is formed. Graphics complete the entire heat transfer process. The same principle, if you need to transfer the layout of the components on the other side of the printed board, can also be carried out at the same time, making the printed board to a more professional level.
What needs to be explained here is that the entire heat transfer process requires a particularly high temperature, and the control of the temperature is very important. For example: the best melting point of the toner is generally 180.5°C. When the temperature is too high, the over-melted toner will spread around the original lines, resulting in blurred graphics, poor accuracy, and severe paper scorching. . When the temperature is too low or the temperature is not uniform, the transfer effect will be poor, and it will not even be transferred. In actual use, due to factors such as air temperature, humidity, paper, and board thickness affecting the transfer effect, the control of temperature is very important for the transfer effect. For this reason, the thermal transfer plate-making machine temperature control sensor adopts imported pt-1000 type thin film platinum resistance, so that the temperature control precision can reach 0.1°C, which meets the higher temperature requirement of plate making.
When the pattern is transferred to the copper plate, the printer's toner forms a patterned protective layer on the surface of the copper plate. Since the toner of the laser printer is made of a polymer material containing a resin and has a good corrosion resistance to the etching solution (fecl3 solution), a delicate printed circuit board can be formed after the corrosion of the fecl3 solution. In order to make the corrosion of the circuit board quicker and easier, an etching machine is also required to rapidly corrode the circuit board to save time, reduce the waste of the fecl3 solution, and increase the efficiency. The rapid corrosion machine quickly heats the fecl3 solution above 60°C, and then uses a corrosion-resistant small circulating submersible pump to spray the fecl3 solution evenly through the special nozzle to the printed board.
Generally, it is corroded with a high concentration of FeCl3 solution under the condition of heating to 80°C, and it can be etched in 5-6 minutes. Due to the fast etching process, the side etching can be reduced and the fineness of the printed circuit board can be more perfect and reliable. The redox reaction of the fecl3 solution is accelerated by heating, so that the copper on the copper-clad plate surface is accelerated to cu2+. At the same time, the cu2+ deposited on and near the surface of the copper-clad plate is taken away by the impact of the water stream, so that the chemical reaction proceeds more quickly and more fully. This machine is particularly suitable for large area printing plate production.
The entire corrosion process is carried out in a semi-closed condition, which has the advantages of cleanliness and reduced evaporation of the etching solution, and is therefore very suitable for the production of printed circuit boards in small batches by laboratories, research institutes and factories. After the printed circuit board is corroded, the circuit board is drilled with a special drill. This special drill is fitted with a cylinder, which can finish the high-speed drilling and can also abrade the toner near the drill hole to form a Very clean pad. The other toner covering the copper foil forms a good solder mask.
Using this system, metal signs and metal artwork can also be produced. It is also very exquisite, with a distinctly distinct level, and at a very low cost. With the advantages of its rapid plate making, it is believed that it will be more widely used in these industries in the near future. Applications. Although the accuracy of the printed circuit board produced by this system can reach a very high level of professionalism, it also has some defects: Due to different laser printers, excessive weather humidity, and partial defects of the thermal transfer paper, toner will appear. Local adhesion on the thermal transfer paper is not good. In addition, the system is not equipped with a CNC drilling machine, and metal holes cannot be formed when a double-sided panel is manufactured. Therefore, further improvement is needed.
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