WO2013021400A1

WO2013021400A1 - Panel lamination apparatus and method

Info

Publication number: WO2013021400A1
Application number: PCT/IT2011/000291
Authority: WO
Inventors: Dario TAMBORINI; Osvaldo Novello
Original assignee: Automatic Lamination Technologies S.R.L.
Priority date: 2011-08-05
Filing date: 2011-08-05
Publication date: 2013-02-14

Abstract

The invention relates to a lamination apparatus (100) of a panel (1) in an automatic processing line and to the respective lamination method. Such apparatus comprises : a lamination unit (200) of the panel (1); first handling means (300, 40) of the panel (1) to convey the panel from an input (IN) of the apparatus toward an input portion (PI) of the lamination unit (200) along an advancing direction (D) of the panel in a respective advancing way; - second handling means (400, 500) of the panel (1) interposed along the advancing direction (D), between an output portion (P2) of the lamination unit (200) and an output (OUT) of the apparatus to convey the laminated panel (1) in the advancing way toward the output (OUT). The apparatus is characterized in that the second handling means comprise grip and haulage means (500) suitable to engage with pressure with the laminated panel (1) exiting from the output portion (P2) of the lamination unit (200) to haul said panel (1) along the advancing direction (D) toward the output (OUT).

Description

DESCRIPTION

PANEL LAMINATION APPARATUS AND METHOD

TECHNOLOGICAL BACKGROUND OF THE INVENTION

Application field

The present invention relates to a method and an apparatus for laminating panels in an automatic processing line. In particular, the invention relates to a method and an apparatus for handling such panels along the processing line to assist laminating operations of the panels.

Description of the known art

As known, in the manufacture of printed circuit boards, lamination apparatuses are used to apply a dry film, made of photosensible material or photo-resist, on panels which are suitable to form a substrate for such circuit boards.

These lamination apparatuses of a known type comprise an input unit for receiving the panel to be laminated and to convey it towards a respective lamination unit.

Such input unit comprises, for example, a plurality of motorized rollers rotating to allow the conveying of the panel to be laminated towards the lamination unit.

This lamination unit comprises, for example, respective lamination rolls which are opposite each other along a direction substantially orthogonal to the conveying direction of the panel so that to define a respective lamination region. Once the panel, moving forward, reaches such lamination region, the movement^■ of the panel is momentarily stopped to allow the lamination rolls to move the one toward the other orthogonally to the conveying direction of the panel. In particular, in the case of a hot lamination operation, such lamination rolls are suitable to move up to engage themselves with pressure on the panel. Instead, in the case of a pre-lamination operation, the lamination rolls are suitable to move and to stop at a distance from the panel of a few tenths of a millimeter, i.e. they do not engage themselves with pressure on the panel.

It should be noted that, both, in the case of a hot lamination and in the case of a pre-lamination, the lamination rolls are configured to rotate in the opposite direction one with respect the other to apply the dry film of photosensible material to the panel and, at the same time, to allow the panel conveying towards an output unit of the lamination apparatus. Such output unit is, for example, a roller conveyor unit which is suitable to receive the laminated panel in order to convey it towards an output of the apparatus or a next processing line.

The lamination apparatuses of a known type, as described above, show some drawbacks.

In fact, these known apparatuses do not allow to laminate panels, or substrates in general having thicknesses less than or egual to 0.05 mm. In particular, such apparatuses are unsuitable for laminating these panels having reduced thickness due to the excessive flexibility of these panels, which makes difficult to move them in an automatic processing line.

For the lamination of such panels having thickness less than or equal to 0.05 mm, currently, manual processing operations are used which generate a high percentage of processing rejects as well as create discontinuities during the processing. In addition, due to these disadvantages, it is currently impossible to draw up procedures of an automatic processing line of such panels having reduced thickness by connecting in series different apparatuses to process the panels at different cycles.

In addition, in reference to a pre-lamination operation of panels having thicknesses well over 0.05 mm, the apparatuses of a known type that move these panels, can cause unwanted pre-adhesion of the dry film to the panels resulting in worsening of the total processing work performed .

SUMMARY OF THE INVENTION

The aim of the present invention is to devise and make available an apparatus for laminating a panel in an automatic processing line which ensures to remedy at least partially the inconveniences complained above with reference to known solutions.

This aim is achieved by a panel lamination apparatus in accordance with independent claim 1.

Preferred embodiments of such lamination apparatus are described in the dependent claims 2-13.

The object of the present invention is also a method of laminating a panel in accordance with independent claim 14.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the apparatus for laminating panels according to the invention will result from the description below of preferred embodiments, given as an indication and without limitation, with reference to the attached drawings, wherein:

- Figure 1 shows a schematic perspective view of a portion of an apparatus for laminating a panel according to a preferred embodiment of the invention;

- Figure 2 shows a schematic and side perspective view of an output portion of the apparatus of Figure 1 in a phase of the lamination procedure of the panel;

- Figure 3 shows a schematic perspective view of the output portion of the apparatus of Figure 1 in an another phase of the lamination procedure of the panel;

- Figures 4A-4F schematically show sectional views along a processing direction of a portion of the apparatus of Figure 1 showing operation phases of the apparatus for laminating of the panel;

- Figure 5 shows schematically a perspective enlarged view of a^{^} panel support device of the apparatus of Figure 2.

DETAILED DESCRIPTION

With reference to the above mentioned figures 1, 2, 3, 4A-4F, 5, an apparatus for laminating a panel 1 in an automatic processing line, in the following called simply lamination apparatus or only apparatus, according to an example of the invention on the whole is indicated by the reference number 100.

For the purposes of the present description, . it should be noted that the term lamination, in the following, will indicate both a hot lamination operation, in order to apply a dry film on the panel 1 by using pressure, and a pre-lamination operation in which the dry film is deposed without exerting pressure on the panel 1.

Furthermore, it should be noted that, in the following, the term panel will indicate, indifferently, both a substrate element used for the manufacturing of Printed Circuit Boards (PCB) , and a substrate for solar cells, a silicon substrate, and any another substrate for the same or different applications. In particular, the apparatus 100 is configured to laminate, in a hot lamination process, panels or substrates 1, having, for example, a thickness less than or equal to 0.05 mm. Such panels 1 have, for example, a length in the range 180mm- 610mm and a width in the range 120mm-510mm.

It should be noted that the apparatus 100 is configured for laminating, in a pre-lamination procedure, even panels 1 having a thickness greater than 0.05 mm.

Also, it should be pointed out that in the above mentioned figures, the same or similar elements are indicated with the same numerical references.

With reference to Figures 1, 4A-4F, the lamination apparatus 100 of the invention comprises input handling means, in particular, a first handling unit 300 of the panel 1 which is suitable to receive the panel 1 to be laminated at a respective input IN of the apparatus 100.

Such first handling unit 300 is configured to convey the panel 1 toward an input portion PI of a lamination unit 200 to move it forward along a processing direction D. The processing direction D is indicated in the figures by an arrow D. Note that this arrow also represents an advancing direction and way of the panel 1 during processing. Such first handling unit 300 is, for example, a roller unit including a plurality of input rollers 30 powered by a respective motorization unit (not shown in the figures) . These input rollers 30 are suitable to rotate to allow the moving forward of the panel 1 in the advancing direction and way D. In an alternative embodiment, the first movement unit 300 could include conveyor belts.

Note that, in a preferred embodiment of the lamination apparatus 100, the panel 1 to be laminated can be automatically conveyorized on the rollers 30 from an output of an equipment that has performed previous operations on the same panel 1. Alternatively, the panel can be manually positioned on the input rollers 30.

With reference to Figures 4A-4F, the first handling unit 300 also comprises an introduction roll 31 and a clamping roll 32, placed in a distal position from the input IN and opposing each other along a direction substantially orthogonal to the advancing direction D of the panel 1. Such introduction roll 31 and clamping roll 32 are configured to rotate in the opposite direction to each other to allow the panel 1 to advance towards the input portion PI of the lamination unit 200.

In one embodiment, the input handling means of the lamination apparatus 100 include, advantageously, a support device 40 of the panel 1 to be laminated acting to accompany the forward movement of the panel itself. Such support device 40 is interposed between the first handling unit 300 and the input portion PI of the lamination unit 200, along the advancing direction D. Such device 40 is configured to receive and support the panel 1 advancing from the first handling unit 300. In addition, such support device 40 is connected to a respective motorized unit 41 in order to translate in a reciprocating way along the advancing direction D both in the advancing way of the panel 1 and in the opposite way. In particular, when moving in the way of advancing of the panel 1, the support device 40 is suitable to accompany the panel 1 exiting from the introduction roll 31 and clamping roll 32 toward the input portion PI of the lamination unit 200.

In one embodiment, the support device 40 comprises a support bar, substantially flat, having a transversal development with respect to the advancing direction D.

In a further embodiment, the support device 40 comprises two bars positioned transversely with respect to the advancing direction D interconnected and substantially parallel to each other. These parallel bars are likely to form a guide passage for the panel 1.

In a further embodiment, with reference to Figures 2 and 5, the support device 40 of the panel 1 is realized in a guide 42 tapered in the advancing way D and having a transversal development in the advancing direction D. In particular, such tapered guide 42 is provided with a respective transverse opening to receive the panel 1 (not shown in Figure 5) and an opposed outlet gap 43.

The lamination unit 200, of the lamination apparatus 100 includes lamination groups 200', for example, two lamination groups opposing each other in a direction substantially orthogonal to the advancing direction D of the panel 1.

Each lamination group 200' comprises a lamination roll 201 operatively associated with a respective tacking bar 202 of a known type for an expert in the field.

It should be noted that in an initial phase of the lamination process or tacking phase, which will, be described in the following, each tacking bar 202 is configured to allow the dry film of photosensible material 203 to adhere on opposing portions 5 of a bottom wall 2 and a top wall 3 of the panel 1. In more detail, the dry film 203 is made to adhere to these opposing portions 5 at the edge 6 of the panel 1, transversal to the advancing direction D.

The above-mentioned lamination rolls 201 are configured to rotate axially in opposite directions the one with respect the other to laminate the panel 1 by applying in continuous way the dry film 203 on both walls, bottom 2 and top 3, of the panel 1.

At the same time, these rotating lamination rolls

201 are configured to allow the laminated panel 1 to advance toward output handling means 400 of the lamination apparatus 100.

Such output handling means comprise a second handling unit 400 of the panel 1. In a preferred embodiment, such second handling unit 400 comprises conveyor belts. This second handling unit 400 is interposed between an output portion P2 of the lamination unit 200 and an output OUT of the lamination apparatus

100. In addition,^' such second handling unit 400 is configured to receive the panel 1 when the lamination phase has been completed and to convey it to the output

OUT of the apparatus 100 or a subsequent processing line.

Moreover, advantageously, such output handling means include grip and haulage means 500 suitable to engage with pressure on the laminated panel 1 exiting from the output portion P2 of the lamination unit 200 to haul the panel 1 to the advancing direction and way D, towards the above mentioned output OUT.

In particular, such grip and haulage means 500 comprise at least one grip element 501 of the laminated panel 1. With reference to the example of Figures 1 and 3, the lamination apparatus 100 of the invention, comprises two grip elements 501. In a preferred embodiment shown in Figures 1, 3, 4A-4F, these grip elements are pliers 501.

In an alternative embodiment, these grip elements

501 may be clamping jaws suitable to engage with pressure on the panel 1.

In addition, such at least one grip element 501 is solidly fixed to a moveable transporter 502 configured to be moved in a reciprocating way along the advancing direction D, both in the way of advancing of the panel 1 and in the opposite way, i.e. toward the output portion P2 of the lamination unit 200.

In addition, the moveable transporter 502 comprises a bridge element 504 having a transverse development with respect to the advancing direction D of the panel 1. The at least one grip element 501 mentioned above includes a support 503 fixed to the bridge element 504.

Preferably, the lamination apparatus 100 of the invention comprises a Central Processing Unit CPU, such as a microprocessor or a microcontroller, such as to manage the units described above and operatively connected to a main system memory (both are not shown in the figures) . Such Central Processing Unit is operatively connected to the lamination unit 200 to enable and control the roto- translatory movements of the lamination groups 200'. In addition, the Central Processing Unit is operatively connected to the first 300 and the second 400 handling units to control the handling of the respective rolls and belts units.

In addition, the Central Processing Unit is operatively connected to the above-mentioned grip and haulage means 500 to enable translation of the same along the direction D, either in the advancing way D of the panel 1 or in the opposite one. Fully similar considerations also apply to control the movement of the support device 40 through the respective motorized unit 41.

In addition, the lamination apparatus 100 includes an input/output interface module, electrically connected to the Central Processing Unit to enable the entry of processing parameters (input) by an external operator and to display (output) processing data. This interface module is realized, for example, by a keyboard and a display or a touch-screen display.

It should be noted that the Central Processing Unit is pre-arranged to load program codes to be executed into the main system memory to implement the lamination method of the present invention.

With reference to Figures 4A-4F, will be now described an exemplary embodiment of the method of laminating panels 1 according to the invention.

In an initial phase of the lamination method, the panel 1 to be laminated is placed on the input rollers 30 of the first handling unit 300 to be conveyed towards the input portion PI of the lamination unit 200.

As shown in Figure 4A, during the advancing, the panel 1 is conveyed by the opposite rotations of the introduction roll 31 and clamping roll 32 till to meet with the support device 40 which comes from a beginning cycle position or set point position.

In this set point position, the support device 40 is moved away from lamination groups 200'.

In a subsequent phase, shown in Figure 4B, the support device 40 translates in the advancing direction and way D to support and lead the panel 1 toward the input portion PI of the lamination unit 200, in particular toward the tacking bars 202.

At the same time, such tacking bars 202, rotating in opposite directions, the one with respect to the other, reach a pre-set tacking position. In such tacking position, the tacking bars 202 are placed side by side each other in a direction substantially orthogonal to the advancing direction D of the panel so as to define a lamination region. When the panel 1, by moving, reaches the region between the tacking bars 202 in the tacking position, the movement of the support device 40 stops, i.e. the support device 40 is arrived at the end of its race. The support device 40 continues to support, advantageously, in this position, the panel 1.

In a following moment of the tacking phase, in reference to Figure 4C, the lamination groups 200' translate the one toward the other, in the direction indicated by the arrows Fl, to engage the tacking bars 202 to press on the panel 1.

After the tacking phase, the lamination groups 200' move away each other, in the direction indicated by arrows F2, disengaging the tacking bars 202 from the panel 1. Following such disengagement, the tacking bars 202 leave the dry film of photosensible material 203, attached to the lower wall 2 and to the top wall 3 of the panel 1 at the transversal edge 6 of the panel, as shown in Figure 4D.

Still referring to Figure 4D, tacking bars 202 axially rotate with respect to the lamination rolls 201 and in the opposite direction to each other to get away from the lamination region. At this point, the Central Processing Unit enables, the lamination rolls 201 to translate toward the panel 1 to start the lamination process .

In particular, with reference to Figure 4E, the lamination rolls 201 translate one toward the other in the direction indicated by arrows F3.

As known to an expert in the field, when the lamination apparatus 100 of the invention has to perform a hot lamination process on the panel 1, the lamination rolls 201 are moved the one toward the other until to close themselves with pressure on the panel 1. Conversely, if the case the process to be performed by the apparatus is a pre-lamination process, the lamination rolls 201 are moved the one toward the other until to stop a few tenths of a millimeter from the panel 1.

Both in the case of hot lamination and in the case of pre-lamination, the lamination rolls 201, rotating in the opposite direction to each other, apply in a continuous way the dry film 203 on both walls bottom 2 and top 3 of the panel 1.

Once the Central Processing Unit has identified an input signal indicative of the entry of a panel 1 between the introduction roll 31 and clamping roll 32, the moveable transporter 502 receives by the same Central Processing Unit a respective command to move (arrow F4 ) in the opposite way with respect the advancing way of the panel 1, along the direction D, moving from a respective rest position (or set point) to a waiting/hold position close to the output portion P2 of the lamination unit 200 (see figure 4E) . It should be noted, furthermore, that starting from such set-point position, the movable transporter 502 also moves in a direction substantially orthogonal to the advancing direction D in order to accost the pliers 501 to the conveyor belts of the second handling unit 400.

When the moving forward panel 1 reaches a hold position, the pliers 501 are closed to engage the panel 1 itself with pressure.

Subsequently, with reference to Figure 4F, the moveable transporter 502 moves in the advancing direction and way D, to haul the panel 1 kept gripped toward the output OUT.

It should be noted that when the moveable transporter 502 reaches a release position, the pliers 501 are opened, releasing the laminated panel 1 on the conveyor belt of the second handling unit 400 to be conveyed outside the lamination apparatus 100.

In this case, the moveable transporter 502 (with its pliers 501) moves in a direction orthogonal to the advancing direction D, away from the belts of the second handling unit 400, and at the same time away from the laminated panel 1, in order to get back into the set-point position waiting for the beginning of a new cycle.

The lamination apparatus 100 for panels 1 and the related lamination method according to the examples described have many advantages.

First, the Applicant has verified that the proposed lamination apparatus 100 allows to perform hot lamination and pre-lamination processes, of panels 1 and flexible substrates having thicknesses less than or equal to 0.05 mm. In particular, thanks to the pliers 501 that engage with pressure on the panel 1 exiting from the lamination unit 200 and to moveable transporter 502, connected to the pliers, that hauls the panel 1 toward the output OUT of the apparatus, the lamination apparatus 100 is capable to handling such flexible panels in an automatic processing line. The apparatus 100 of the invention can be integrated into an automatic processing line by connecting different apparatuses in series in order to subject such flexible panels 1 to different processing cycles, avoiding manual processing steps.

In addition, the lamination apparatus 100 of the invention can be advantageously also be used to perform pre-lamination operations of panels having thicknesses greater than 0.05 mm. In fact, the Applicant has verified that with the lamination apparatus 100 which provides gripping and hauling of the panels 1 exiting from the lamination unit 200, unwanted pre-adhesion of the dry film to the panels 1 are avoided. In this way, the subsequent vacuum lamination operation of the pre- laminated panel is optimized.

To the embodiments of the lamination apparatus of a panel, described above and of the corresponding laminating method, a technician in the field, in order to satisfy contingent needs, can make changes, adjustments and replacements of elements with others functionally equivalent, without exit from the ambit of the following claims. Each of the features described as belonging to a possible embodiment can be achieved independently from the other embodiments described.

Claims

1. Lamination apparatus (100) of a panel (1) in an ' automatic processing line, including:

a lamination unit (200) of the panel (1);

- first handling means (300, 40) of the panel (1) to convey said panel from an input (IN) of the apparatus toward an input portion (PI) of the lamination unit (200) along an advancing direction (D) of the panel in a respective advancing way;

- second handling means (400, 500) of the panel (1) interposed along said advancing direction (D) , between an output portion (P2) of the lamination unit (200) and an output (OUT) of the apparatus to convey the laminated panel (1) in the advancing way toward said output (OUT), characterized in that said second handling means comprise grip and haulage means (500) suitable to engage with the laminated panel (1) exiting from said output portion (P2) of the lamination unit (200) to haul said panel (1) along said advancing direction (D) toward the output (OUT) .

2. Lamination apparatus (100) according to claim 1, wherein said grip and haulage means (500) comprise at least one grip element (501) of the panel (1) joined to a

- transporter (502) configured to be moved in reciprocating way along the advancing direction (D) both in the advancing way of the panel (1) and in the opposite way.

3. Lamination apparatus (100) according to claim 2, ^•wherein said at least one grip element (501) is chosen in the group consisting of:

- pliers,

- j aw .

4. Lamination apparatus (100) according to claim 2, wherein said transporter (502) comprises a bridge element (504) transversal with respect the advancing direction (D) of the panel (1), this at least one grip element (501) comprising a support (503) attached to this bridge element .

5. Lamination apparatus (100) according to claim 1, wherein said first handling means comprise a handling unit (300) including rollers interposed between said input (IN) and said input portion (PI) of the lamination unit (200 ) .

6. Lamination apparatus (100) according to claim 1, wherein said second handling means comprise a handling unit (400) including conveyor belts.

7. Lamination apparatus (100) according to claim 5, wherein said first handling means comprise, in addition, a support device (40; 42) of the panel (1) suitable to lead the advancing movement of the panel, said support device being interposed, along said advancing direction (D), between said handling unit including rollers (300) and said input portion (PI) of the lamination unit (200).

8. Lamination apparatus (100) according to claim 7, wherein said support device (40; 42) is configured to move in a reciprocating way along said advancing direction (D) both in the advancing way of the panel (1) and in the opposite way.

9. Lamination apparatus (100) according to claim 7 or 8, wherein said support device (40; 42) comprises a support bar .

10. Lamination apparatus (100) according to claim 7 or 8, wherein said support device (40; 42) comprises two substantially parallel bars connected to each other.

11. Lamination apparatus (100) according to claim 7 or 8, wherein said support device (42) includes a tapered guide in the advancing way (D) of the panel (1).

12. Lamination apparatus (100) according to claim 1, wherein said lamination unit (200) includes two lamination groups (200') which are opposing each other in a direction substantially orthogonal to the advancing direction (D) of the panel (1), each of said groups comprising a respective lamination roll (201) suitable to rotate to apply a dry film (203) to a respective wall (2, 3 ) of the panel ( 1 ) .

13. Lamination apparatus (100) according to claim 12, wherein each of said two lamination groups (200') comprises a respective tacking bar (202) configured to allow said dry film (203) to adhere on a portion (5) of said walls (2, 3) of the panel (1) .

14. Method of laminating a panel (1) by a respective lamination apparatus (100) in an automatic processing line, comprising the steps of:

- conveying, through first handling means (300, 40) , said panel (1) along an advancing direct-ion (D) of the panel in a respective advancing way from an input (IN) of the apparatus toward an input portion (PI) of a lamination unit (200) ;

- laminating said panel (1) through the lamination unit (200);

- conveying the laminated panel (1) in the advancing way toward an output (OUT) of the apparatus (100) by second handling means (400, 500) interposed along said advancing direction (D), between an output portion (P2) of the lamination unit (200) and said output (OUT) ,

characterized in that said conveying phase comprises the additional phases of:

- engaging with pressure said laminated panel exiting from said output portion (P2) of the lamination unit (200) by grip and haulage means (500),

- hauling, by said grip and haulage means (500) , the laminated panel (1) along said advancing direction (D) toward the output (OUT) .

15. Method of laminating a panel (1) according to claim 14, wherein said phase of engaging with pressure comprises, preliminarily, a phase of moving said grip and haulage means (500) in opposite direction with respect to the advancing way of the panel (1) along said advancing direction (D) in order to bring said grip and haulage means from a rest position to a waiting/hold position, close to the output portion (P2) of the lamination unit (200) .

16. Method of laminating a panel (1) according to claim 14, further including a following phase of opening said grip and haulage means (500), to release, when reached a releasing position, the laminated panel (1) on a respective handling unit (400) of said second handling means, to convey it out from the lamination apparatus (100) .

17. Method of laminating a panel (1) according to claim 14, wherein said phase of conveying the panel (1) toward an input portion (PI) of the lamination unit (200) , comprises a phase of receiving and supporting panel (1), by a support device (40) to lead the panel advancing in said advancing direction (D) and way.