PRINTED CIRCUIT BOARD LAYOUT TRANSFER USING MODIFIED LAMINATOR

Abstract

The present invention relates to a method for transferring printed circuit board (PCB) layouts using a modified laminator system. The method comprises the following steps: printing the PCB design using a laserjet printer on glossy paper and transferring the toner-based ink to a clean copper board using a modified laminator. The laminator, originally designed for sealing plastic pouches, has been adjusted to operate at higher temperatures and pressures, making it suitable for toner transfer. A microcontroller is employed to monitor the laminator's thermal sensors and control roller motion, enhancing both precision and safety. Additionally, the laminator retains its original functionality, allowing it to switch between regular lamination and PCB transfer operations at the touch of a button.

Specification

Description:Field of the Invention
The invention relates to the technical field of PCB boards, more particular to a method for transferring printed circuit board (PCB) layouts using a modified laminator system.
Background of the Invention
Traditional methods of transferring PCB designs using manual tools like irons suffer from inconsistent results, incomplete toner transfers, and imprecise alignment. This modified laminator system resolves these issues by automating temperature and pressure control. The incorporation of a microcontroller optimizes roller motion and thermal sensor monitoring, ensuring consistent, high-quality toner transfer with minimal user intervention. The system also features a failsafe mechanism that shuts down the heater in the event of a thermal sensor failure, ensuring safe operation.
Unlike conventional laminators, this system uses a microcontroller to monitor the thermal sensors and control the timing of the roller motion. This provides more precise control over the toner transfer process.
A beeper alerts the user of any system issues or alarm conditions, including thermal sensor failures. The system includes a failsafe that automatically shuts down the heater, preventing overheating and ensuring safe operation.
In addition to handling copper-clad toner transfer, the system can easily switch back to its original laminating function or handle 'dry transfer foil to metal' applications with the push of a button.
The system automates the multiple passes required to ensure full toner transfer, eliminating the need for manual handling and reducing user error.
Drawings
Fig.1: Photograph of the modified laminator system
Detailed Description of the Invention
The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
In any embodiment described herein, the open-ended terms "comprising," "comprises," and the like (which are synonymous with "including," "having" and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like. As used herein, the singular forms "a", "an", and "the" designate both the singular and the plural, unless expressly stated to designate the singular only.
The present invention automated the manual process by automating temperature and pressure control during the transferring PCB designs. The present invention method for transferring printed circuit board (PCB) layouts using a modified laminator system, the modified laminator system comprises:
• a microcontroller that senses the OEM thermal sensor's condition and controls the timing of the roller motion and ensures precise control over the temperature and movement of the rollers during the transfer process;
• a beeper provides audible alerts based on the selected operation mode or any alarm conditions, enhancing user interaction and system monitoring; and
• A control algorithm to manage the roller speed and number of passes, ensuring optimal toner transfer conditions
Wherein method for transferring printed circuit board (PCB) layouts using a modified laminator system, comprising the following steps:
1. System Design and Integration:
• A standard laminator was modified to handle increased temperature and pressure for PCB toner transfer. The integration of a microcontroller added functionality for monitoring thermal sensors and controlling roller timing.
2. Software and Control Algorithm Development:
• A control algorithm was developed to manage the roller speed and number of passes, ensuring optimal toner transfer conditions. The microcontroller also handles safety features, including failsafe shutdowns.
3. Testing and Calibration:
• Testing was conducted on various copper boards of different thicknesses and copper weights. The system was calibrated to ensure that the temperature and pressure settings were optimized for each board type.
The system achieved precise, repeatable toner transfers across multiple tests. The automation of multiple passes reduced manual effort and increased consistency in the quality of the transferred toner. The safety features functioned as designed, providing reliable alerts and automatic shutdown in case of system issues.
Advantages of the present invention
1. Microcontroller-Controlled System:
o The integration of a microcontroller provides intelligent control over the system's thermal sensors and roller motion, improving precision and safety during the toner transfer process.
2. Failsafe and Alarm Features:
o The system includes a beeper for audible feedback and alerts in case of alarm conditions, such as thermal sensor failure. In such cases, the heater automatically shuts down, ensuring safe operation.
3. Automated Multi-Pass Functionality:
o The system handles multiple passes through the laminator, eliminating manual re-feeding of the board and ensuring complete toner transfer with minimal user intervention.
4. Temperature and Pressure Control:
o The laminator can adjust to different board thicknesses, copper weights, and environmental conditions, providing precise control over temperature and pressure for optimal toner transfer.
5. Dual-Purpose Design:
o The laminator retains its original functionality, allowing it to perform traditional lamination tasks in addition to handling specialized PCB and dry-transfer foil operations.
6. Cost-Effective and Time-Efficient:
o This modification offers a low-cost solution for producing high-quality PCBs, making it ideal for small businesses, hobbyists, and educational institutions.
7. Safety and Reliability:
o The system's failsafe mechanism ensures reliable and safe operation, protecting both the user and the equipment from overheating or other malfunctions.
The modified laminator provides several practical applications, particularly in small-scale PCB production, educational settings, and research environments:
1. Prototyping and Small-Scale PCB Production:
o Ideal for engineers and hobbyists needing to produce precise, small-batch PCBs quickly and affordably.
2. Educational Institutions:
o An excellent tool for teaching students about PCB design and fabrication, with an easy-to-use interface for hands-on learning.
3. Research and Development:
o Perfect for rapid iterations of PCB designs during prototyping phases, saving time and improving design efficiency.
4. DIY Enthusiasts:
o Offers an accessible, affordable solution for hobbyists seeking to create high-quality PCBs at home without industrial-grade equipment.

, Claims:1. A modified laminator system, comprises of:
a) a microcontroller that senses the OEM thermal sensor's condition and controls the timing of the roller motion and ensures precise control over the temperature and movement of the rollers during the transfer process;
b) a beeper provides audible alerts based on the selected operation mode or any alarm conditions, enhancing user interaction and system monitoring; and
c) A control algorithm to manage the roller speed and number of passes, ensuring optimal toner transfer conditions
2. The modified laminator system as claimed in the claim 1, wherein process comprising the following steps:
a) System Design and Integration:
• A standard laminator was modified to handle increased temperature and pressure for PCB toner transfer. The integration of a microcontroller added functionality for monitoring thermal sensors and controlling roller timing.
b) Software and Control Algorithm Development:
• A control algorithm was developed to manage the roller speed and number of passes, ensuring optimal toner transfer conditions. The microcontroller also handles safety features, including failsafe shutdowns.
c) Testing and Calibration:
• Testing was conducted on various copper boards of different thicknesses and copper weights. The system was calibrated to ensure that the temperature and pressure settings were optimized for each board type.
3. The modified laminator system as claimed in the claim 1, wherein system achieved precise, repeatable toner transfers across multiple tests. The automation of multiple passes reduced manual effort and increased consistency in the quality of the transferred toner. The safety features functioned as designed, providing reliable alerts and automatic shutdown in case of system issues.

Documents