IC Leadframe Forming with Automatic Separation to Prevent Jams
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Solution Overview
Problem
Integrated circuit (IC) production machines experience jams due to improperly formed ICs that fail to pass through designated openings, leading to machine shutdowns and reduced efficiency, which increases production costs.
Innovation Solution
A component forming machine with a separation system that automatically separates properly formed ICs from unformed ICs using aperture-based, pneumatic, or gate-based techniques, integrated into or attachable to the forming machine, allowing formed ICs to pass through while retaining unformed ICs, thereby preventing jams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are processed through the forming machine without separation, then the machine can operate continuously, but unformed components cause jams and machine shutdowns
Solution Approach 1:
The separation system performs preliminary action by separating formed and unformed components immediately after the forming process, before the components enter the testing machine. This prevents unformed components from causing jams later in the process, maintaining both productivity and reliability.
Solution Approach 2:
The separation system extracts unformed components from the component stream by using a gate that detects component dimensions and directs only properly formed components through the opening to the testing machine, removing the harmful elements before they can cause problems.
2Reliability
If a separation system is added to the forming machine, then jams are prevented and reliability improves, but device complexity increases
Solution Approach 1:
The separation system is merged with the existing forming machine by integrating the gate and detection mechanisms into the forming machine's structure. This combines multiple functions (forming and separating) into a single system, improving reliability without proportionally increasing overall device complexity.
Solution Approach 2:
The separation system uses the component's own dimensional characteristics to automatically direct it to the appropriate path. The gate detects whether the component meets specifications and self-regulates the flow, eliminating the need for complex external control systems or manual intervention.
3Manufacturing precision
If manual inspection and separation of components is performed, then formed and unformed components can be distinguished, but labor time and production costs increase
Solution Approach 1:
The system replaces manual visual inspection and separation with an automated detection and sorting mechanism. The gate uses sensors to detect component dimensions and automatically directs components to the correct path, achieving high precision classification without manual labor or time loss.
Solution Approach 2:
The gate acts as an intermediary between the forming machine and the testing machine, automatically classifying components based on their dimensional characteristics. This intermediary system performs the classification function that would otherwise require manual inspection, maintaining precision while eliminating time loss.
Data Source
AI summary
An integrated circuit production method. In some examples, the method includes receiving a leadframe comprising a plurality of in-production ICs in a forming machine, singulating the plurality of in-production ICs, forming leads of at least some of the plurality of in-production ICs to comply with dimensions and tolerances corresponding to an intended form factor of the plurality of in-production ICs, and separating, automatically by the forming machine, formed ICs from unformed ICs after the forming.