Desmear Module Separating Element for Particle Isolation
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Solution Overview
Problem
Existing desmear modules in horizontal galvanic or wet-chemical process lines face challenges in efficiently removing manganese dioxide particles generated during the desmear process, particularly due to their high density and tendency to agglomerate, leading to increased processing interruptions and costs, especially with the increasing flexibility of modern substrates.
Innovation Solution
A desmear module design featuring a separating element, such as a non-permeable or permeable liquid weir, positioned between two liquid areas within the module, effectively keeps desmear particles from reaching the intake area of the immersion pump, allowing for continuous processing and reducing the volume of desmear treatment liquid required, thus minimizing particle circulation and prolonging the treatment liquid bath life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large desmear container volume is provided to prevent particles from reaching the pump intake, then particle contamination is reduced, but the cost of the process increases
Solution Approach 1:
The desmear container is segmented into two distinct liquid areas by a separating element: a first liquid area where desmear particles are generated and accumulate, and a second liquid area containing the pump intake. The separating element (such as a baffle or weir) physically divides the container to prevent particles from the first area from reaching the pump in the second area, thereby protecting the pump while maintaining a reduced overall liquid volume.
2Ease of manufacture
If the horizontal processing line is stopped to clean the desmear container, then desmear particles are removed, but processing efficiency decreases
Solution Approach 1:
The separating element extracts and isolates the particle-containing first liquid area from the pump-intake second liquid area. This extraction creates a physical barrier that prevents particle migration to the pump, eliminating the need to stop the processing line for pump protection purposes. The system continuously operates with particles confined to the first area while the pump draws clean liquid from the second area.
3Reliability
If complex automatic cleaning procedures are installed to avoid processing interruptions, then maintenance can be performed continuously, but the cost and complexity of the processing line increases
Solution Approach 1:
The separating element acts as an intermediary structure between the particle-generating first liquid area and the pump-intake second liquid area. This passive physical barrier automatically prevents particle contamination without requiring active cleaning mechanisms, sensors, or control systems. The separator performs the protective function continuously through its static presence, eliminating the need for complex automatic cleaning procedures while maintaining pump reliability.
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
The solution enables efficient mechanical removal of desmear particles, reducing processing interruptions, lowering operational costs, and allowing for a smaller immersion pump, while maintaining high product quality and requiring less desmear treatment liquid, thus enhancing the economic efficiency of the process.
Implementation Method 1
a separating element, such as a non-permeable or permeable liquid weir, positioned between two liquid areas within the module, effectively keeps desmear particles from reaching the intake area of the immersion pump
Implementation Method 2
there are generated large amounts of desmear particles by the chemical reaction of the desmear chemical with resin residues... which are known to agglomerate on the bottom of the respective desmear container... due to the high density of the suspension of manganese dioxide particles
Data Source
AI summary
A desmear module for a horizontal galvanic or wet-chemical process line for metal, in particular copper, deposition on a substrate to be treated for a removal of precipitates comprising a desmear container connectable to a desmear unit, a pump and at least a first liquid connection element for connecting said pump with the desmear unit, wherein said pump is in conjunction with said desmear unit by said at least first liquid connection element; and wherein a treatment liquid level is provided inside the desmear module, which is above an intake area of the pump; wherein the desmear module further comprises at least a first liquid area, at least an adjacent second liquid area comprising the intake area of the pump, and at least a first separating element arranged between said at least first liquid area and said at least second liquid area.