Optek DPL-24 User Manual

Operations Technology, Inc.

OPTEK DPL-24 Users Guide

Operations Technology Inc.

30 Lambert Road

PO BOX 408

Blairstown NJ 07825

Phone [phone] • Fax [phone]

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OPTEK DPL-24

Table of Contents

Introduction 4

Overview 5
Principles of Operation 6

Site Requirements 8

Specifications 9
Installation 10

Operation 12

Example 13
Precautions 14

Maintenance 14

Recommended Spare Parts 16
Ordering Information 16

Warranty 18

Index 19

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OPTEK DPL-24

V

A Differential Pressure Laminator

INTRODUCTION

he DPL-24 Differential Pressure Laminator has been designed to give the
operator a superior method for laminating sheet supported emulsions such

T

thicknesses and sizes of substrates. Experimentation is being done on alternative
uses for this device, among them, High Vacuum, Multi-Layer, Pressing of Printed
Circuit Boards and microBGA interconnects.
The substrate, prelaminated either manually, or utilizing the
A cold-roll lamination technique, is placed on the vulcanized rubber
platen mounted in the drawer
and positioned in the vacuum
chamber. Products of
differing thicknesses and
geometries can
be intermixed during a cycle if
adequate “hold-down”
techniques are employed.
The massive 1000 LB
chamber is constructed of
Ductile Iron and uses only
two o-rings. This design
ensures a positive seal for best
vacuum performance.

Utilizing a high quality, high volume 45 CFM, 3 horsepower, rotary
vane vacuum pump, an end point below two Torr is typically achieved.

as dry film solder mask, etc. Such materials can be applied to various

acuum lamination of printed circuit boards has been utilized
for many years. But it was not until the development of the
DPL-24 that a system provided vacuum prior to the
application of positive pressure.

No pressure is applied to the product during the vacuum
dwell cycle. In this way maximum evacuation of air from
between the substrate and the laminate is assured.

During the pressure cycle a flexible diaphragm encapsulates
the product and true isostatic lamination is achieved. Unlike
roll laminators, the DPL–24’s diaphragm descends directly
towards the platen. No lateral stress is applied , hence less
distortion of the film can occur.

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OPTEK DPL-24

OVERVIEW

• The vacuum is displayed on a thermocouple sensing, computer calibrated, digital
gauge located on the front panel.

• The substrate is exposed to this Vacuum Dwell for a time determined by a
precision digital timer which is adjustable from .1 seconds to 9990 hours.

• At the end of the Vacuum Dwell, a preheated silicone rubber diaphragm
descends onto the work-piece and drives the spring-mounted drawer
mechanism into intimate contact with the lower heater platen.

• The temperatures of both the upper and lower heat platens are controlled
independently by digital, proportional, Temperature Controllers.

• A positive pressure of up to 10 PSI is applied to the top of the diaphragm to
bring the combined differential to nearly 25 PSI.

• The Pressure Dwell is adjusted by a precision digital timer identical to that
employed by the Vacuum Dwell.

• Upon completion of a cycle, the drawer mechanism is retracted and the
product(s) removed for further processing.

• The entire process is governed by a microprocessor driven programmable
controller. Programming modifications are available from the factory.

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OPTEK DPL-24

PRINCIPLES OF OPERATION

The following is an explanation and diagram

of the operation of the DPL-24 differential pressure laminator.

When the DPL-24 is turned on, two proportional controllers independently
drive the top and bottom heaters to the heat the diaphragm and platen to the
temperatures set on the front panel. After a brief warmup time, the laminator is
ready for use.

The drawer is pulled open to allow access to load the vulcanized rubber platen
with materials ready for lamination. Products of differing thicknesses and
geometries can be intermixed during a cycle if adequate “hold-down” techniques
are employed. The layered material is placed on the platen mounted in the
sliding drawer. When the drawer is closed, the platen is positioned in the
vacuum chamber, and an O-ring seal on the drawer face contacts the opening in
the vacuum / pressure vessel.

Before the beginning of the cycle there is a vacuum drawn above the
diaphragm. Air at atmospheric pressure is in bottom of the vessel, pushing the
diaphragm upwards. As shown in figure 1, the diaphragm is up above the material
on the drawer platen. The drawer platen is spring loaded upwards to allow the
drawer to be opened and closed.

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OPTEK DPL-24

PRINCIPLES OF OPERATION (CONTINUED)

When the cycle starts, vacuum is drawn on both ports, above and below the diaphragm.
Utilizing a high volume vacuum pump, an end point approaching two Torr is achieved.
This vacuum is displayed on a digital gauge located on the front panel. A programmable
timer adjustable from .1 seconds to 9990 hours determines the vacuum dwell time before
continuing to the next step Figure 2. It is important to note that this dwell time will
allow air between the layers of material to be evacuated before the lamination pressure
cycle begins, eliminating trapped bubbles. Because the vacuum is equal above and below
the diaphragm, it does not move and does not contact the material in the drawer.

At the end of the Vacuum Dwell, positive air pressure at up to 10 PSI is
applied to the port above the diaphragm bringing the pressure differential to nearly
25 PSI. see figure 3, The preheated silicone rubber diaphragm descends onto the
workpiece. This action drives the spring-mounted drawer platen into contact with
the lower heater platen. Isostatic pressure is transferred to the material by the
diaphragm. The stretching effect that occurs with roll type laminators is minimized.
The flexible diaphragm conforms to the surface shape assuring positive contact
between the layers, thereby eliminating voids. The pressure dwell time is controlled
by another timer identical to the vacuum dwell timer.

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