Artwork Submodule Correction for Fan-Out Panel Level Packages
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing processes for achieving electrical connections between electronic components in fan-out panel level packages are hindered by positioning tolerances, leading to time-consuming rerouting and rasterization, which limits production throughput and results in rejected components due to incorrect positioning.
Innovation Solution
A system and method for real-time error correction of predefined artwork during the recording process on a substrate using a substrate recording machine, involving offline preprocessing to divide the artwork into modules and tiles, allowing for lossless compression and online real-time error correction based on measured position coordinates, thereby minimizing data processing and transfer time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a completely new pattern is created for each substrate based on measured component positions, then proper electrical connection is achieved, but production throughput is limited due to time-consuming rerouting and rasterization
Solution Approach 1:
The patent pre-calculates and stores correction data for various possible component position deviations in advance. During production, the system only needs to retrieve the appropriate correction data based on measured positions and apply it directly to the existing artwork, eliminating the need for time-consuming rerouting and rasterization operations while maintaining accurate electrical connections
Solution Approach 2:
The patent divides the artwork into multiple independent modules, each associated with specific component positions and correction data. This segmentation allows the system to process and correct only the affected modules rather than regenerating the entire artwork, significantly reducing processing time while ensuring accurate electrical connections for positioned components
2Productivity
If electronic components are positioned with high speed using pick and place machines, then production throughput is improved, but positioning accuracy deteriorates due to speed limitations
Solution Approach 1:
The patent implements a feedback mechanism where the actual positions of placed components are measured and used to retrieve appropriate correction data. This closed-loop approach allows high-speed placement to continue while systematically compensating for positioning deviations through pre-calculated correction algorithms, maintaining both speed and accuracy
Solution Approach 2:
The patent changes the approach from attempting to maintain strict positioning tolerances to accepting a range of positions and using parameter-based correction. By storing correction data for various position scenarios and selecting the appropriate correction based on measured positions, the system accommodates high-speed placement variations while ensuring accurate electrical connections
3Productivity
If error correction is performed in real time during artwork recording, then production throughput is improved, but processing complexity increases
Solution Approach 1:
The patent performs the complex calculations of error correction in advance and stores the results in lookup tables. During real-time artwork recording, the system simply retrieves pre-computed correction data based on measured component positions, reducing real-time processing complexity while maintaining accurate error correction and improving throughput
Data Source
AI summary
A method for digital direct recording of an artwork representing electric connections of components on a substrate includes receiving data representing the artwork, analyzing the artwork representation to identify sections that are similar and sections that are unique and to identify locations of the components in the artwork, and dividing the artwork into modules corresponding to the identified sections, providing a set of unique modules and a set of redundant modules. The method also includes rasterizing each unique module to provide rasterized modules, dividing the rasterized modules into submodules, and receiving measurements representing positions of the components on the substrate. The method also includes receiving measurements representing the position of the substrate, calculating the differences between the measured positions of the components and the artwork positions of the components, calculating modifications for each of the sub modules to compensate for the differences, and recording the modified submodules onto the substrate to form a modified artwork on the substrate.