Conductive Ball Removal Using Adhesive Sheet Transfer

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Solution Overview

Problem

Existing methods for removing surplus conductive balls from a mask used in semiconductor device mounting are inefficient, as they either fail to remove all balls reliably or cause scattering, leading to potential short-circuits and incomplete removal.

Innovation Solution

A conductive ball removing method and apparatus that uses a sheet member with a contacting mechanism to adhere surplus conductive balls onto the sheet, ensuring they are removed without scattering, by adjusting the gap between the sheet and the mask to be smaller than the ball diameter and using air pressure or elastic forces to secure the sheet in close proximity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If brush or air blow methods are used to remove surplus conductive balls, then removal speed is improved, but removal reliability deteriorates due to incomplete removal or scattering

Engineering Contradiction:

Improveremoval speedVSAvoidremoval reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A sheet member is introduced as an intermediary between the mask and the external environment. The sheet member contacts the mask surface and transfers surplus conductive balls from the mask to itself, preventing direct scattering while enabling reliable removal. This mediator approach resolves the contradiction by providing a controlled transfer mechanism that maintains both speed and reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the direct mechanical action of brushes or air blows with a controlled sheet-based transfer mechanism. Instead of using forceful mechanical means that cause scattering, the sheet member gently contacts and transfers balls through controlled movement, achieving reliable removal without the harmful scattering effects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If brush methods are used continuously, then removal efficiency is improved, but conductive balls enter into the brush fibers causing incomplete removal

Engineering Contradiction:

Improveremoval efficiencyVSAvoidcomplete removal

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent extracts the conductive balls from the mask surface and transfers them to the sheet member, which then carries them away from the system. By separating the removal function from the mask surface and using the sheet as a temporary holding medium, the system ensures complete removal without balls getting trapped in brush fibers.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The sheet member serves as an intermediary that temporarily holds conductive balls during transfer. This mediator prevents direct interaction between balls and brush fibers, eliminating the problem of balls entering and becoming trapped in the brush structure while maintaining continuous removal capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If air blow methods are used, then removal speed is improved, but conductive balls scatter causing potential short-circuits

Engineering Contradiction:

Improveremoval speedVSAvoidscattering and short-circuits

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The sheet member acts as a mediator that captures conductive balls directly from the mask surface and transports them to a collection area. This controlled transfer mechanism eliminates scattering entirely, as balls are moved through direct contact rather than being blown through the air, preventing short-circuit hazards while maintaining efficient removal speed.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the air blow mechanism with a sheet-based contact transfer system. Instead of using pneumatic force that causes scattering, the sheet member physically contacts and transports balls in a controlled manner, eliminating the harmful scattering effect while preserving removal efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures complete and reliable removal of surplus conductive balls without scattering, preventing short-circuits and improving the accuracy of semiconductor device mounting processes.

Implementation Method 1

making the sheet member close to the mask by air pressure from the contacting mechanism

Methodology Applied

Scientific EffectAir pressure: Pressure Increase

Implementation Method 2

The conductive balls are removed in such a manner that the conductive balls are adhered onto the sheet member

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7866533B2Conductive ball removing method, conductive ball mounting method, conductive ball removing apparatus, and conductive ball mounting apparatus

Publication Date: 2011.01.11 SHINKO ELECTRIC IND CO LTD

AI summary

In a method of removing conductive balls that are left on a mask provided on a substrate having pads thereon, the method includes: (a) making a sheet member close to the mask using a contacting mechanism such that a gap between the sheet member and the mask is set small than a diameter of the conductive balls. The conductive balls are removed in such a manner that the conductive balls are adhered onto the sheet member.