How to make the eteched foil heaters :
1. Create the base laminate. The initial steps in making a heater are the selection of foils, which are then laminated to a base substrate. This is usually achieved by using a thin thermoset adhesive layer that has excellent adhesion properties when bonding the two materials.
2. Drill the pilot holes. To keep the manufacturing process and the multiple layers within the heater aligned with each other, machined holes are typically drilled in the base laminate.
3. Imaging. This stage involves multiple process steps to pattern the conductive elements on the base laminate.
4. Etching. The panel is now subjected to a series of chemical etching, stripping and cleaning processes in order to chemically remove the foil not protected by the resist and leave the heating element pattern on the panel.
5. Top dielectric laminate. The next processing step is to apply a top dielectric (cover layer) on the panel. The top film is also polyimide with a high performance adhesive coating on one side. Before laminating the cover layer, the film is drilled in a relevant pattern to match the heater pattern and tool holes in the base laminate. The cover provides access to the heating element, including openings for connecting wires and components.
6. Optional rear PSA. At this stage, a pressure sensitive adhesive (PSA) can be placed on the back of the panel if desired by the customer. The PSA can be pre-cut into different shapes so that certain parts of the PSA are not on customer-specified heater zones.
7. Exercise. The final manufacturing step is to remove the finished part from the panel. This is usually done with steel straight dies.
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