Injection Head Gas Venting to Prevent Material Dripping
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Solution Overview
Problem
In high-density packaging applications, especially for 2.5D or 3D and mobile devices, the small size of solder bumps poses challenges in controlling solder interconnect properties and electro-migration performance, and existing technologies struggle to prevent material dripping during the injection process, which degrades productivity.
Innovation Solution
An injection apparatus with a tank and a head body having an opening part that allows gas flow, enabling smooth evacuation of material without dripping, even when covered by a substrate, using a slit-like opening and gas flow members to transfer material back to the tank, thereby maintaining process productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the opening part is covered by the substrate during material injection, then the material can be discharged onto the substrate, but the material cannot be transferred back to the tank without causing dripping
Solution Approach 1:
A gas flow member is introduced as an intermediary element between the opening part and the tank. This member allows gas to flow through it, creating a controllable gas flow path that enables material transfer back to the tank without direct contact or opening the opening part, thus preventing material dripping while maintaining discharge control
Solution Approach 2:
The invention utilizes gas flow (pneumatics) through the gas flow member to control material movement. By introducing gas flow, the material can be transferred back to the tank in a controlled manner without causing dripping, resolving the contradiction between material discharge and material recovery
2Object-generated harmful factors
If the opening part is opened to transfer material back to the tank, then material dripping can be prevented, but process productivity is degraded due to extended downtime
Solution Approach 1:
The gas flow member serves as a mediator that enables material transfer without requiring the opening part to be opened. The gas flow creates a pathway for material to return to the tank while the opening part remains covered, thus preventing dripping without interrupting the process and maintaining productivity
Solution Approach 2:
The gas flow member is pre-configured and connected to the opening part before the injection process. This preliminary setup allows immediate material transfer back to the tank after discharge without requiring additional steps to open or modify the opening part, thereby preventing dripping while maintaining continuous operation and high productivity
3Object-generated harmful factors
If a hole is formed in the head body for gas flow, then material transfer is enabled, but the hole may be clogged by material
Solution Approach 1:
The gas flow member can be implemented as a porous structure that allows gas to pass through while its pore size and material properties prevent solder or other injection materials from penetrating and clogging the flow path. This enables reliable material transfer capability without the risk of hole clogging
Solution Approach 2:
The gas flow member can be designed as a disposable or easily replaceable component with a simple structure (such as a porous plate or membrane) that is inexpensive to manufacture. If it becomes clogged or degraded, it can be quickly replaced without affecting the entire injection apparatus, maintaining system reliability while enabling material transfer
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 effectively prevents material dripping and maintains high productivity by allowing gas flow through the opening part, ensuring efficient transfer and minimizing downtime during the injection process, especially when handling molten solder at high temperatures.
Implementation Method 1
the at least one member is configured to allow gas to flow into and flow out from the opening part for discharging the material
Implementation Method 2
each of the at least one member includes a porous member that allows the gas to flow therethrough while separating the gas from the material
Data Source
AI summary
An injection apparatus for injection material is disclosed. The injection apparatus includes a tank for storing material. The injection apparatus further includes a head body that has a surface for contacting a substrate and an opening part opened at the surface for discharging the material in fluid-communication with the tank. The injection apparatus further includes a member connected to the opening part, in which the member allows gas to flow into and flow out from the opening part.