Multi-Actuator Encapsulation Press for Pressure Alignment Control
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Solution Overview
Problem
The existing encapsulation methods for electronic components on carriers face challenges in maintaining dimensional accuracy and risk of carrier damage due to inadequate control over pressure distribution and external loads during the encapsulation process.
Innovation Solution
A press system with intelligent control and controllable actuators that dynamically adjust pressure distribution based on real-time displacement sensor feedback, allowing for precise control of mould part alignment and pressure distribution, even under changing external loads, to prevent carrier damage and ensure accurate encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single drive system is used to move press parts, then the device complexity is low, but the manufacturing precision of encapsulated components deteriorates due to inability to control pressure distribution
Solution Approach 1:
The drive system is segmented into multiple independent actuators (at least two) that can individually control different regions of the press parts. This segmentation allows independent adjustment of pressure distribution across different zones, enabling precise control of mould part alignment and encapsulation pressure, thereby resolving the contradiction between maintaining simple device structure and achieving high manufacturing precision.
Solution Approach 2:
The drive system transitions from a static, uniform pressure application to a dynamic, adaptive pressure distribution system. The intelligent control continuously adjusts the actuation of individual actuators based on real-time feedback from displacement sensors, allowing the system to adapt pressure distribution to compensate for variations in external loads and maintain precise dimensional control throughout the encapsulation process.
2Reliability
If uniform pressure is applied during encapsulation, then the device complexity is low, but the reliability of the process deteriorates due to risk of carrier damage under varying external loads
Solution Approach 1:
Displacement sensors are integrated to provide real-time feedback on the position and alignment of press parts and mould parts. The intelligent control system processes this feedback information and dynamically adjusts the actuation of individual actuators to maintain optimal pressure distribution. This closed-loop feedback mechanism enhances process reliability by preventing excessive or uneven pressure that could damage carriers, while adapting to varying external loads during encapsulation.
Solution Approach 2:
The system dynamically changes the pressure parameters applied at different locations on the press parts based on real-time conditions. By independently controlling the actuation force, position, and timing of each actuator, the system adapts pressure distribution to compensate for variations in external loads, carrier properties, and encapsulation progress, thereby preventing carrier damage while maintaining process reliability.
3Manufacturing precision
If mould parts are tightly clamped to prevent leakage, then the manufacturing precision is improved, but the reliability deteriorates due to increased risk of carrier damage
Solution Approach 1:
The pressure application is localized and differentiated across different regions of the press parts and mould parts. Individual actuators apply pressure selectively to specific zones, allowing tight clamping and precise alignment at the mould-part interfaces where leakage prevention is critical, while applying reduced or distributed pressure to areas where carrier damage risk is concerns. This localized quality control enables simultaneous achievement of high alignment precision and carrier protection.
Data Source
AI summary
The invention relates to a press for encapsulating electronic components mounted on a carrier, comprising: at least two press parts displaceable relative to each other, a drive system for the displacement of the press parts, and an intelligent control adapted to control the drive system of the press parts wherein the drive system comprises at least two individual controllable actuators, the intelligent control further connects to plural displacement sensors for detecting the relative displacement of the press parts, and wherein the intelligent control is adapted to control the actuators of the drive system dynamically over time based on the measured values detected with the displacement sensors. The invention also relates to an actuator set to convert a prior art press into a press according to the present invention as well as to a method for encapsulating electronic components mounted on a carrier.