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VFD Production Process & QA Lead Getter Exhaust Tip Grid Glass Substrate Contact Lead Anode Wiring Insulation Layer Filament Anode VFD Construction.

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Presentation on theme: "VFD Production Process & QA Lead Getter Exhaust Tip Grid Glass Substrate Contact Lead Anode Wiring Insulation Layer Filament Anode VFD Construction."— Presentation transcript:

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2 VFD Production Process & QA

3 Lead Getter Exhaust Tip Grid Glass Substrate Contact Lead Anode Wiring Insulation Layer Filament Anode VFD Construction

4 Basic VFD Construction Base Glass Wiring pattern etched into aluminium layer Side Glass Front Glass + Sealing cap Grid Anodes Isolation layer Evacuation hole Filament wires Connection leads Phosphor pattern

5 A thin Aluminum film is sputtered on 300×300 mm base glass plate Aluminum Wiring Process Wiring pattern is made by chemical photo etching

6 u The isolation layer is printed on the wiring pattern made by etching process Isolation Layer Carbon pad Printing Process u The carbon layer is added for el-ectrical connection improvement on the through hole made by isolation film u Terminal pad printing is added for later external lead frame connection

7 Phosphor Printing Process u Before printing the phosphor pattern, the sealing paste to be printed for final assembly Max Temp 12:15 AM u Phosphor pattern is printed (one color for one screen),12 different colours are available

8 Self Standing Grid u A set of grids (metal mesh) are bonded over the top of the phosphor, fixed by SSG bond paste

9 CIG and Wire Bonding u IC driver is connected to base glass by aluminium wire u Using IC driver inside VFD, the number of external lead terminals is reduced significantly

10 u Base plate, Metal frame and Front Glass are assembled Final Assembly & Exhausting u The assembled VFD is sealed in oven u Exhausting air creates vacuum tube u Getter flashing removes residual gases

11 u Aging process to equalize phosphor luminance (e.g C, 2hrs, all segments on) Aging & Display inspection u Final inspection: short circuit, failure modes, double check QA u Lead cutting, brushing, soldering & bending process

12 Cleaning 300 x 300 glass Aluminium sputtering Cleaning Photo-resist printing UV exposure Development Etching Photo-resist removal Base-plate wiring continuity test First insulation layer printing Curing Drilling of exhaust hole Cleaning & Drying Second insulation layer printing Curing Base-plate inspection Carbon printing Drying Terminal pad printing Drying Sealing paste printing Curing Phosphor paste printing Drying Grid bonding paste printing Grid bonding assembly Curing Manufacturing Flow Chart (1)

13 Substrate insulation inspection Substrate cutting Frame, mesh Hydrogen treatment Terminal forming Filament anchor welding Filament welding Getter welding Mount check Final assembly Sealing Exhausting Getter flashing Baking Aging Lead cutting Lead brushing Soldering In-process inspection Lead forming Labelling External inspection Out going inspection Shipping Packaging Manufacturing Flow Chart (2)

14 Phosphor is a generic term. Chemically Phosphor is mainly a mixture of zinc and zinc oxides (zno:zn) Phosphors are available in 17 different colours. Most commonly specified is green because it has greatest luminance (>2000 cd/sq m) longest lifetime – 30,000 hours to ½ brightness cost – high volume reduces cost can be filtered to produce range of effects wavelength of 550nm A word about Phosphor

15 Quality Management Systems Futaba Corporation holds Certificates issued for the following systems: ISO 9001 / ISO 9002 Quality Management ISO Environment Management ISO TS Extended Automotive QA Requirements

16 It is the quality goal of Futaba Corporation to continuously improve its product acceptance in PPM level, and finally reach the ultimate goal of: Innovation, quality and dependability will continue to be hallmarks of our growth and Futabas commitment to quality in all aspects of operations is the base for our position of market leadership Our Quality Policy

17 Reliability Testing (1) Test ItemTest Conditions Life Vibration fatigue High temperature operation Temperature Cycling Heater Cycling Lighted for 1000 hours at room temperature, rated voltage applied. Lighted, 4.4G acceleration, 2000 cpm vibration, applied for 4 hours in the X plane and 2 hours each in the Y and Z planes. Lighted, for 96 hours at +85° ± 2ºC. Lighted subject to the specified test conditions as shown, for 5 cycles. 30 mins15 mins30 mins 15 mins 85°C °C °C Filament voltage at 120% of the rated voltage and cycles without voltage applied to anode and grid. 10 seconds5 seconds Functional / Durability

18 Reliability Testing (2) Test ItemTest Conditions High temperature Storage Thermal Shock Humidity (Steady State) Unlighted, for 72 hours at +85° ± 2ºC. Unlighted subject to the specified test conditions as shown, for 5 cycles. 30 mins5 mins30 mins 5 mins 85°C °C °C Unlighted, subject to a relative humidity of 90 to 95%, at a temperature of 40° ± 2ºC, for 96 hours. Environmental Test Low temperature StorageUnlighted, for 72 hours at -40° ± 3ºC.

19 Reliability Testing (3) Test ItemTest Conditions Vibration (1) Shock Solderability Unlighted, 1.5mm total excursion, 10 – 55Hz frequency. Sweep time cycle 1 minute. Vibration applied for 2 hours in each X, Y and Z planes. Unlighted, 100G maximum acceleration, 6 ms duration, half sine wave 3 times in each X, X, Y, Y and Z, Z planes (18 times in total in unlighted state). Immerse in a 230° ± 5ºC solder pot for 5 seconds. Physical Characteristics Vibration (2) Unlighted, 4G acceleration, 55 – 200 Hz frequency. Sweep time cycle 10 minutes. Vibration applied for 2 hours in each X, Y and Z planes. Resistance to Soldering HeatImmerse in a 280° ± 5ºC solder pot for 30 ± 2 seconds. Terminal Strength Attach 250g weight to leads. Bend leads through 90° and then return to original position, 3 cycles.

20 Thank you for your attention!


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