Mold Chase Demagnetization for Uniform Magnetic Mold Compounds
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Solution Overview
Problem
During the molding process for magnetic mold compounds on integrated circuit devices, the mold chase, made of metal, becomes magnetized, leading to irregular distribution of metal fillers due to magnetic fields, which compromises the functionality and appearance of IC packages.
Innovation Solution
A mold system with a gaussmeter and demagnetizer is used to detect and cease operations when magnetic fields exceed a threshold, and demagnetize the mold chase to maintain uniform distribution of metal fillers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the mold chase is made from metal (e.g., chrome) for structural strength and durability, then the mold machine can perform heating and clamping operations effectively, but the mold chase becomes magnetized during the molding process, causing magnetic fields that attract metal fillers and result in irregular distribution in the magnetic mold compound
Solution Approach 1:
The mold chase is demagnetized before the molding process begins and periodically during operation. This preliminary action removes residual magnetism that would otherwise cause metal filler attraction and irregular distribution, ensuring uniform dispersion of metal particles in the magnetic mold compound while maintaining the structural integrity of the metal mold chase
Solution Approach 2:
A gaussmeter is used to detect and monitor magnetic field strength in the mold chase during the molding process. When the detected magnetic field exceeds a predetermined threshold, the system automatically triggers demagnetization. This feedback mechanism ensures that metal filler distribution remains uniform by continuously monitoring and correcting magnetic field conditions
2Productivity
If the molding process continues without interruption to maintain productivity, then production efficiency is improved, but magnetic fields accumulate in the mold chase causing irregular metal filler distribution and compromising product quality
Solution Approach 1:
The gaussmeter continuously monitors magnetic field strength during the molding process. When the magnetic field exceeds a predetermined threshold, the controller automatically pauses the molding process and activates the demagnetizer. This feedback-controlled approach allows the system to maintain high productivity by only interrupting operations when necessary, while ensuring uniform metal filler distribution through timely demagnetization
Solution Approach 2:
The molding process operates in periodic cycles, alternating between molding operations and demagnetization intervals. The gaussmeter detects when magnetic field levels require intervention, triggering periodic demagnetization events. This periodic action maintains productivity by minimizing interruptions while preventing magnetic field accumulation that would cause irregular metal filler distribution
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 system ensures uniform distribution of metal fillers in the magnetic mold compound, preventing irregularities that affect IC package performance and appearance.
Implementation Method 1
detecting magnetic fields in a mold chase of the mold machine via a gaussmeter
Implementation Method 2
the mold chase is demagnetized via a demagnetizer
Implementation Method 3
The lower mold chase is heated to a temperature to transform the magnetic mold compound from the powder state to a liquid state
Data Source
AI summary
A system and method of demagnetizing a mold machine for forming a magnetic mold compound of electronic devices is provided. The method includes performing a molding process with a mold machine to form a magnetic mold compound on electronic devices and detecting magnetic fields in a mold chase of the mold machine via a gaussmeter. The molding process of the mold machine is ceased responsive to determining that a strength of at least one detected magnetic field exceeds a threshold and the mold chase is demagnetized via a demagnetizer.