Pressurex Film Improves PCB Quality by Preventing Dry Photoresist Wrinkles

In the fast-paced world of electronics manufacturing, printed circuit boards (PCBs) serve as the backbone of electronic devices, where quality directly impacts product performance, reliability, and market competitiveness. The lamination process, a critical stage in PCB production, often faces persistent challenges with dry film resist wrinkling - a defect that has plagued manufacturers for decades.

Wrinkling during dry film lamination can render expensive circuit boards unusable, creating significant financial losses and production inefficiencies. The root cause typically lies in improper pressure distribution between laminating rollers, where insufficient or uneven pressure prevents the resist from properly adhering to the substrate surface.

The Pressurex® pressure-sensitive film introduces a transformative solution to this longstanding industry problem. This innovative diagnostic tool provides:

• Visual pressure mapping: Clearly displays roller pressure distribution patterns
• Process optimization: Enables precise adjustment of lamination parameters
• Defect prevention: Identifies roller misalignment and pressure inconsistencies
• Quality improvement: Reduces scrap rates by up to 79% in documented cases

Conventional pressure measurement approaches rely on operator experience or basic pressure gauges that cannot visualize distribution patterns. Pressurex® employs microencapsulated color-changing technology that permanently records pressure variations across the entire roller surface, creating an accurate "footprint" of contact pressure.

• Measurement range: 2-43,200 PSI (0.14-3,000 kg/cm²)
• Instantaneous, permanent color response
• No specialized training required
• Compatible with all standard lamination equipment

Pressurex® addresses three primary contributors to lamination defects:

Worn or improperly adjusted roller chucks create uneven pressure distribution. Pressurex® immediately reveals these inconsistencies for corrective action.

Under lamination loads, rollers naturally bend, causing edge speeds to exceed center speeds. This differential creates inward film movement that produces wrinkles. Solutions include:

• Using reinforced rollers
• Implementing crowned roller profiles

Even with adequate overall pressure, localized variations can create defect-prone areas. Pressurex® provides the data needed to achieve uniform pressure distribution.

Testing with automated laminators demonstrated a 79% reduction in circuit defects when increasing pressure from 36 psi to 62 psi. However, the solution requires balancing higher pressure with proper roller configuration to prevent bending-related issues.

Beyond pressure monitoring, optimal lamination requires attention to:

• Material quality consistency
• Equipment maintenance schedules
• Precise temperature and speed control

Pressurex® provides manufacturers with an essential tool for achieving defect-free lamination through precise pressure visualization and control. This innovation represents a significant advancement in PCB production quality assurance.