Производство и сборка печатных плат промышленного уровня: Полное руководство по процессу

In high-end fields such as industrial automation, новая энергия, and communication equipment, industrial-grade PCBs (Печатные платы) serve as the core carriers that support electronic components and ensure stable equipment operation. Compared with consumer-grade PCBs, industrial-grade PCBs must withstand far more demanding working environments—high/low temperature cycles, humidity and dust, strong electromagnetic interference, и т. д.. This poses extremely high requirements for manufacturing processes, выбор материала, and assembly precision.
This article provides a systematic overview of the full-process essentials of industrial-grade ПХБ производство and assembly—from design standards, производственные процессы, assembly techniques, and quality inspection to delivery assurance—to help enterprises improve product reliability and market competitiveness.

Preparation: PCB Design Standards and Core Principles

Design is the “source” of industrial-grade PCBs and directly determines manufacturing difficulty, product performance, and service life. Designs that ignore manufacturability lead to soaring costs and plummeting yield rates; поэтому, it is essential to strictly follow Design for Manufacturability (DFM) principles while addressing the specific requirements of industrial environments.

1. Core Design Standards: Tailored to Industrial Application Needs

• Environmental adaptability design:
  Define temperature and humidity tolerances based on application scenarios (industrial control cabinets, outdoor PV inverters, in-vehicle devices), and select materials with appropriate temperature ratings (НАПРИМЕР., FR-4 TG170+ for high-temperature environments, PTFE for high-frequency communication). For humid environments, increase solder mask thickness and use gold-plated key pins to enhance corrosion resistance.

• EMC (Электромагнитная совместимость) дизайн:
  Industrial environments involve multiple devices operating simultaneously, often causing electromagnetic interference. Proper layout is required to reduce signal crosstalk—separate analog and digital circuits, use shielded or differential routing for sensitive signals (НАПРИМЕР., sensor signals); add filtering capacitors in power loops and place ground vias at key nodes to ensure grounding impedance below 1 Ой.

• Mechanical structure matching:
  Industrial equipment typically has strict installation space limits. Дизайн печатной платы must precisely match enclosure dimensions, reserving mounting holes and ventilation holes to avoid interference with other components. В средах с высокой вибрацией (станки, rail transit equipment), optimize Толщина печатной платы (recommended ≥1.6 mm) and use adhesive reinforcement for critical components.

2. Key DFM Design Considerations: Reducing Manufacturing Risks

Close collaboration with the manufacturer is necessary at the design stage to specify the following process parameters and avoid costly rework:

• Line width and spacing:
  Industrial-grade PCBs often carry high current (НАПРИМЕР., power circuits). Line width must be calculated based on the current (rule of thumb: 1 mm width under 1 oz copper carries 1–1.5 A). Minimum spacing must also be met (≥0.12 mm for standard processes, до 0.08 mm for high-precision processes) to avoid short circuits.

• Vias and pads:
  Via diameters must match pin sizes—standard through-holes ≥0.8 mm; BGA packages often use blind/buried vias to save space. Pad sizes should meet soldering requirements (SMT pads 10%–20% larger than component leads) to avoid cold or weak solder joints.

• File output standards:
  Files submitted to manufacturers must be complete, including Gerber files (top/bottom layers, inner layers, паяльная маска, шелкография), Категория (component model, упаковка, brand), pick-and-place coordinate files, and test specifications to ensure unambiguous communication.

Industrial-Grade PCB Process Flow and Quality Control

The manufacturing process for industrial-grade PCBs is complex, involving dozens of steps. Each step requires precise control of process parameters to ensure electrical performance, механическая прочность, and environmental durability. The key stages include substrate preparation, pattern transfer, травление, бурение, покрытие, паяльная маска, and silkscreen.

1. Substrate Selection and Pre-Processing: Foundation of Quality

The substrate forms the structural backbone of the PCB. Industrial-grade PCBs typically use high-performance materials:

• Выбор материала:
  Standard industrial environments use FR-4 with TG ≥150 °C; high-temperature applications (Автомобиль, аэрокосмическая) use PI (полиимид) with heat resistance above 260 ° C.; high-frequency communication applications use PTFE with stable dielectric constant.

• Pre-processing:
  After cutting, substrates undergo scrubbing, degreasing, and micro-etching to remove oils and oxides and increase copper-to-substrate adhesion. This prevents delamination or blistering during later stages.

2. Pattern Transfer and Etching: Accurate Reproduction of Circuit Patterns

This step transfers the designed circuitry onto the substrate, where accuracy and consistency are critical:

• Pattern transfer:
  Dry-film photolithography is used. A photosensitive dry film is applied, exposed with the circuit pattern using a high-precision exposure machine (resolution ≥2 μm), then developed to remove unexposed areas.

• Травление:
  Acidic etching solutions (НАПРИМЕР., cupric chloride) remove exposed copper, leaving the protected copper to form circuits. Etching time and temperature (45–55 °C) must be tightly controlled to avoid under-etching (residual copper) or over-etching (narrowing of lines). Line-width accuracy is checked for each batch.

3. Drilling and Plating: Ensuring Conductivity and Mechanical Strength

Drilling creates interlayer connections; plating enhances conductivity and improves durability:

• High-precision drilling:
  CNC drills ensure ±0.01 mm accuracy for through-holes, слепые переходы, and buried vias. Blind/buried vias often require a combination of laser drilling and mechanical drilling to prevent positional deviation. Deburring removes copper debris that could cause shorts.

• Покрытие:
  Includes electroless copper, panel plating, and pattern plating. Electroless copper creates a thin conductive layer (0.5–1 μm) inside vias; panel plating increases overall copper thickness; pattern plating adds extra copper (≥20 μm) to pads and key areas to improve current capacity and solder reliability.

4. Solder Mask and Silkscreen: Enhancing Protection and Identification

These steps protect the PCB and provide markings, essential for harsh industrial environments:

• Паяльная маска:
  A protective solder-resist ink is applied, exposing only pads. Industrial PCBs use high-temperature, chemically resistant epoxy-based solder masks (10–20 μm thick). This reduces moisture/dust intrusion and prevents solder bridging.

• Шелкография:
  Printed identification (component labels, polarity marks, manufacturer info). Ink must be wear-resistant and legible in high-temperature and friction environments; minimum character height ≥0.8 mm.

Industrial-Grade PCB Precision Assembly

Assembly attaches electronic components (резисторы, конденсаторы, чипсы, разъемы) to the PCB. Industrial-grade assembly must balance efficiency with high reliability. Пост (Поверхностная технология) и tht (Through-Hole Technology) are commonly used together.

1. Pre-Assembly Preparation: Material Management and Process Planning

• Component inspection:
  Industrial-grade components must meet strict standards. Incoming inspection checks dimensions, electrical parameters (емкость, сопротивление), and appearance (no bent/oxidized leads). Critical components (Процессор, power devices) require OEM authenticity certificates.

• Stencil fabrication:
  SMT uses a stainless-steel stencil to apply solder paste to pads. Aperture size must match pads (5%–10% smaller), with ±0.02 mm precision to ensure consistent solder volume.

2. Core Assembly Processes: Пост + THT Coordination

(1) SMT Surface-Mount Assembly: For Miniaturized, High-Density Components

Suitable for chip components (0402, 0603), BGA, Млн, и т. д.. The process is: solder-paste printing → placement → reflow soldering → AOI inspection.

• Solder-paste printing:
  Паяльная паста (НАПРИМЕР., Sn-Ag-Cu lead-free alloys) is applied to pads through the stencil. Paste thickness (0.12–0.15 mm) and uniformity are checked to avoid insufficient or excessive solder.

• High-precision placement:
  Automated pick-and-place machines use vision systems to mount components with ±0.03 mm accuracy for fine-pitch devices. Components with >0.1 mm offset require correction.

• Стрелка пайки:
  PCBs pass through pre-heat, soak, peak, and cooling phases. Peak temperature (230–250 °C for lead-free paste) melts the solder to form joints. Heating rate must be 2–3 °C/s to avoid thermal shock.

(2) THT Through-Hole Assembly: For High-Reliability, High-Current Components

Suitable for connectors, силовые полупроводники, and mechanical-strength-critical parts.

• Insertion:
  Leads are inserted through holes and fixed to prevent movement.

• Волна пайки:
  After fluxing, the PCB passes over molten-solder waves. Temperature is controlled at 250–270 °C, with conveyor speed 1–1.5 m/min to prevent weak or cold solder joints.

3. Post-Assembly Processing: Cleaning and Rework

Остаток флюса (corrosive) must be removed using IPA or industrial cleaners.
Defective joints identified by AOI (НАПРИМЕР., cold joints, bridges) require manual rework, using temperature-controlled soldering irons (300–350 °C) to avoid damaging components or PCB.