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In order to elevate their competitiveness of the latest 3C products, the manufacturers gradually replace the heavy connector between printed circuit boards by the anisotropic conductive film(ACF) medium for hot bonding lamination in order to reach the goal of developing lightweight electronics products. The ACF lamination process was more commonly used for signal transmission line design. This paper explored ways to apply ACF butt on the battery charging circuit, the applicability for a large current, life reliability, and found out the optimal parameters setting of the ACF lamination process. This paper used the Grey relation analysis and Taguchi method to investigate how major lamination parameters of the preload pressure, the bonging temperature, the bonding pressure, and the holding time influence the tensile strength and impact-resistance for SONY DP3342MS after cold lamination. Three standards of value were set for each parameter factors, with nine experiments being carried out, and the result was substituted into the grey correlation analysis, according to which the optimal setting of ACF lamination parameters was obtained to get the minimum resistance and sufficient tensile strength of the assembly. Finally, thermal cycling tests were repeated based on the reliability after the completion of laminated boards in connection with the optimal setting of ACF lamination parameters in order to ensure that the electrical circuits can be used for a long time. The result has been successfully applied to a series of cell phones of H company.
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