TFT LCD display production process step 3 – ACF Lamination – The Invisible Bond

Purpose:

Anisotropic Conductive Film (ACF) lamination applies a structured conductive adhesive tape onto the designated Lead-In Terminals (LIT) of the TFT glass. The film contains millions of microscopic conductive particles (gold-coated polymer spheres) suspended in an insulating epoxy matrix, designed to provide vertical electrical conduction (Z-axis) while maintaining absolute electrical insulation in the horizontal (X/Y-axis) plane.

Process Characteristics & Equipment:

Maxen utilizes Fully Automated Reel-to-Reel ACF Pre-Lamination Modules equipped with Constant-Heat and Fast-Ramp Pulse-Heat Tool Heads. The equipment features independent Digital Pressure Transducers and Inline Infrared Thermal Imagers to track heat dissipation.

• Process Parameters: The pre-lamination is executed at a controlled temperature of 70°C ± 2°C, a pressure of 0.15 to 0.3 MPa, and a cutting length precision of ±0.05mm.

Factory Processing Time:

Tape feeding, precision alignment, vacuum clamping, cutting, and localized pre-pressing are completed in 2.5 to 4.0 seconds per terminal edge.

Continuous Improvement (Kaizen) & Vision:

To accommodate ultra-fine pitch trends (<20 μm spacing for high-resolution displays), Maxen is upgrading to Dual-Layer ACF Film Feeding Structures that separate the captive particle layer from the adhesive base. Our Kaizen target is a zero-bubble lamination matrix via optimized constant-vacuum buffering shoes. This will reduce raw ACF material waste by 8% and support the production of ultra-narrow bezel smart displays.