EVA層壓氣泡原因分析及改善

1、1Laminator EVA bubble issue Improvement reportDept.: ENGDate: 2010-1-28 CIT No.: CIT Value 1)GBA EVA bubble failed rate improve from 27.9% to 0.71%;2)Bubble number improve from 2.7ea/PCS to 0.91ea/PCSD1 D4CITD3 D2D5 D6D7 D8D4Laminator EVA bubble issue Improvement report2D1D3D1 D2 D4D5 D6D7 D8Topic S

2、election1.12/09 ENG Pi-run GBA時(shí)，在EVA Check站點(diǎn)發(fā)現(xiàn)組件角部氣泡問(wèn)題嚴(yán)重，F(xiàn)ail rate達(dá)到27.9%，bubble size: 2mm2-50mm2；近30%的產(chǎn)品不符合出貨標(biāo)準(zhǔn)，按質(zhì)量檢驗(yàn)標(biāo)準(zhǔn)需要報(bào)廢；2.RD Lab生產(chǎn)出的GBA產(chǎn)品bubble符合QA檢驗(yàn)標(biāo)準(zhǔn)；Process Engineer : Zhang Xu, Li TingtingJob :1.Recipe optimization.2.Experiment arrangement.3.Data collection and analysis.Daily ReviewTeam Lea

3、der : JS_TINJob : 1.Job instruction. 2.Manpower arrangement現(xiàn)場(chǎng)實(shí)驗(yàn)現(xiàn)場(chǎng)實(shí)驗(yàn)Team Organization:RD Engineer :Xu Tao;Job :1. Technology support.Laminator EVA bubble issue Improvement report3D2: Describe the Problem ( (問(wèn)題描述及現(xiàn)況掌握問(wèn)題描述及現(xiàn)況掌握 : :12/09 產(chǎn)線(xiàn)從產(chǎn)線(xiàn)從GBU轉(zhuǎn)換轉(zhuǎn)換GBA Pi-run 時(shí)，在時(shí)，在EVA check站點(diǎn)發(fā)現(xiàn)模組站點(diǎn)發(fā)現(xiàn)模組suffer EVA bubb

4、le issue;GBA total pi-run 86 PCS, NG 24 PCS, Fail rate 27.9%, size 2mm2-50mm2，平均每片組件有2.7個(gè)bubble；GBU fail rate 0.5%;Bubble主要有兩種type，一種是弧形Delamination bubble，另一種是邊緣鋸齒狀Drilled bubble。D2D3D1 D2 D4D5 D6D7 D8Delamination bubbleDrilled bubbleEVA check bubble chartLaminator EVA bubble issue Improvement repo

5、rt4Short term action:D3D3D1 D2 D4D5 D6D7 D8檢查設(shè)備狀態(tài)：LAM1 fail rate: 18.6%, LAM2 fail rate: 9.3%; CUF3 fail rate: 19%, CUF4 fail rate:9%; no common tool;檢查Recipe status：Laminator and cure recipe have no modified history；Constrain high fail rate tool LAM1 and CUF3;Laminator EVA bubble issue Improvement

6、report5D4: Define & Verify Root Cause:D4D3D1 D2 D4D5 D6D7 D8分析兩種分析兩種Type bubble形成的原因：形成的原因：Delamination bubble因Back sheet和Glass之間應(yīng)力作用，層壓后低粘結(jié)性會(huì)導(dǎo)致Delamination現(xiàn)象，隨放置時(shí)間增加將變的更worse；在固化后，Delamination部分將形成弧形的長(zhǎng)條形bubble；（輕微的delamination可以被修復(fù)）；提高溫度和延長(zhǎng)加壓時(shí)間可以改善粘結(jié)性；curingDelamination bubble放置5min放置20minLamin

7、ator EVA bubble issue Improvement report6D4: Define & Verify Root Cause:D4D3D1 D2 D4D5 D6D7 D8分析兩種分析兩種Type bubble形成的原因：形成的原因：Drilled bubble層壓后，高溫下處于熔融狀態(tài)的EVA，因back sheet和Glass間應(yīng)力導(dǎo)致EVA有微小程度的收縮，空氣很容易鉆進(jìn)back sheet和Glass間形成反沖氣泡(Drilled bubble不可以被Cure修復(fù))；降低溫度和減少加壓時(shí)間可以減少Drilled bubble；Delamination bubbl

8、e和Drilled bubble與時(shí)間溫度的影響關(guān)系是反向的；GlassEVABack sheetaircuringDrilled bubbleLaminator EVA bubble issue Improvement report7D4: Define & Verify Root Cause:D4D3D1 D2 D4D5 D6D7 D8對(duì)比RD lab和FAB Process差異：RD lab采用一步層壓+固化方式，層壓和固化一步完成; FAB采用的是二步層壓+固化方式，層壓和固化使用不同的設(shè)備；考慮到Delamination Bubble和Drilled bubble形成的原因，

9、RD LAB process 在EVA完全交聯(lián)之前不會(huì)釋放層壓壓力，從而不會(huì)形成氣泡；FAB process 層壓和固化銜接段是氣泡形成的時(shí)期；在FAB使用RD LAB相同的一步層壓+固化方式，可以完全解決氣泡問(wèn)題；但process time 為47min，tact time=470S，為生產(chǎn)不可接受；類(lèi)別LaminatorCuring溫度抽真空加壓溫度時(shí)間RD lab140542NANAFAB D8001405414035RD lab和FAB process 對(duì)比Laminator EVA bubble issue Improvement report8D4D3D1 D2 D4D5 D6D7

10、 D8GBU BOM VS GBA BOM對(duì)比GBU和GBA產(chǎn)品差異：在Laminator process GBU使用三井EVA材料，而GBA使用的為積水EVA材料;比較GBU和GBA bubble performance, 相同delamination狀況下GBA比GBU worse；GBU VS GBA Delamination bubbleLaminator EVA bubble issue Improvement report9D4D3D1 D2 D4D5 D6D7 D8從廠(chǎng)商提供技術(shù)資料上對(duì)比EVA材質(zhì)上差異：相對(duì)三井EVA，積水EVA需要額外的10分鐘加熱時(shí)間；GBU層壓條件：13

11、5，抽真空3min，加壓3min；GBA層壓條件：135，抽真空5min，加壓4min，如果延長(zhǎng)其加壓時(shí)間到15min，可以完全沒(méi)有bubble；但tact time將增加到200s；三井 EVA VS.積水EVALaminator EVA bubble issue Improvement report10D5D3D1 D2 D4D5 D6D7 D81.Laminator process window check:調(diào)整 Laminator recipe觀(guān)察delamination and drilled bubble狀況，高溫下其Process window較窄:在很小的條件范圍內(nèi)，Delam

12、ination和drilled bubble 變化明顯，且經(jīng)常同時(shí)出現(xiàn)；較佳的lamination 條件是控制層壓后沒(méi)有drilled bubble，0.5mm-1mm delamination，通過(guò)Cure對(duì)Delamination進(jìn)行修復(fù)，可以控制較好的bubble performance；Laminator EVA bubble issue Improvement report11D5D3D1 D2 D4D5 D6D7 D82.Laminator recipe fine tune:微調(diào)Laminator recipe 溫度和加壓時(shí)間，溫度138，加壓4min-4.5min；Recipe

13、condition VS. bubble QtyLaminator EVA bubble issue Improvement report12D6D3D1 D2 D4D5 D6D7 D8spec20-50mm2 bubble chart4-20mm2 bubble chartFine tune recipeFine tune recipe25%0.7%3.6%specAfter fine tune recipe, Bubble fail rate trend down to 0.71%; average bubble 0.97ea/PCS;Laminator EVA bubble issue Improvement report13Update ENG EVA check OI(OI No. Yt-W-ENG-0085)Update Lami