Glass Composition Segmentation for Semiconductor Packaging
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Solution Overview
Problem
The semiconductor packaging industry faces challenges in manufacturing glass carriers with customized thermal expansion coefficients and other properties to meet the specific requirements of different manufacturers, as existing methods struggle to produce a single carrier substrate design that accommodates varying processing techniques.
Innovation Solution
A method involving the melting of a first glass composition in a melter, with a second glass composition added, allowing for the production of multiple glass articles with varying compositions and properties, including a first, intermediate, and final glass article, where the concentration of at least one component in the intermediate glass article is between that of the first and second glass compositions, enabling tailored thermal expansion coefficients and other properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single glass composition is used in the melter, then the manufacturing process is simple, but the ability to produce glass articles with different thermal expansion coefficients and properties is limited
Solution Approach 1:
The glass composition is segmented into multiple distinct compositions (first glass composition and second glass composition) with different concentrations of glass constituent components. Each composition is designed to produce glass articles with specific target properties, allowing the manufacturing system to accommodate different manufacturer requirements for thermal expansion coefficients and other properties.
Solution Approach 2:
The system dynamically switches between different glass compositions during continuous production. The melter transitions from producing glass articles from the first glass composition to producing glass articles from the second glass composition, enabling adaptability to different specifications without stopping production or changing the entire manufacturing system.
2Adaptability or versatility
If multiple glass compositions are produced in sequence, then different manufacturer requirements are met, but production time and process complexity increase
Solution Approach 1:
Both the first glass composition and second glass composition are prepared and available before production begins. The compositions are designed in advance with specific concentration ranges of glass constituent components to achieve target properties, eliminating the need for time-consuming formulation adjustments during production transitions.
Solution Approach 2:
The system maintains continuous production of glass articles by seamlessly transitioning between the first and second glass compositions. The melter continues operating without interruption, drawing glass articles from the molten glass state throughout the composition transition, ensuring uninterrupted useful action and minimizing production time losses.
3Manufacturing precision
If glass compositions with different concentrations are used, then tailored thermal expansion coefficients are achieved, but manufacturing precision control becomes more difficult
Solution Approach 1:
The system controls the thermal expansion coefficient by changing the concentration parameters of glass constituent components between the first and second glass compositions. Specific components are adjusted within defined concentration ranges to achieve target thermal expansion coefficients while maintaining manufacturing precision through systematic parameter management.
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
This approach allows for the production of glass articles with specific thermal expansion coefficients and other properties, such as Young's modulus, density, and surface quality, tailored to meet individual manufacturer requirements, enhancing compatibility with diverse semiconductor packaging processes.
Implementation Method 1
melting a first glass composition in a melter, the first glass composition comprising a combination of glass constituent components
Data Source
AI summary
Methods of producing a glass article include melting a first glass composition and feeding a second glass composition into the melter. Both glass compositions include the same combination of components but at least one component has a concentration that is different in each. At least three glass articles may be drawn from the melter, including: a first glass article formed from the first glass composition; at least one intermediate glass article composed of neither the first nor the second glass composition; and a final glass article not composed of the first glass composition. The concentration of the at least one component in the intermediate glass article may be between the concentration in the first and second glass compositions. The first glass article and final glass article may have differing values for certain properties, and the intermediate glass article may have an intermediate set of values for the same properties.