PCB Unit Unloading and Dual-Side Washing to Reduce Sawing Damage

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Solution Overview

Problem

The processing of printed circuit boards (PCBs) faces significant waste and rejection issues due to damage during sawing and detritus from the sawing process, leading to higher material costs and longer manufacturing paths, with existing methods only cleaning and deburring one side of the PCBs during the sawing cycle.

Innovation Solution

A method and system that involves washing and deburring both sides of PCB units by initially receiving them with a bump face down, flipping them to expose a ball face, and then washing and deburring both sides, along with an IC unit unloading system using a chute with varying channels to facilitate efficient lateral movement and sorting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If only one side of PCB is washed and deburred during sawing cycle, then processing time is reduced, but rejection rate increases due to damage and detritus on the other side

Engineering Contradiction:

Improveprocessing speedVSAvoidrejection rate

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The washing and deburring process is segmented into two separate operations: first washing/deburring the initial side, then flipping the PCB to wash/deburr the opposite side. This segmentation ensures both sides receive proper treatment without compromising processing efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flipper performs preliminary action by positioning the PCB in the correct orientation before the washing unit processes the opposite side, ensuring that both sides are systematically treated in sequence during the same processing cycle

Inventive Principle:

Principle #10Preliminary action

2Productivity

If sawing process is performed on PCB, then PCB units are separated, but damage and detritus are caused on the PCB surfaces

Engineering Contradiction:

Improveseparation efficiencyVSAvoidsurface damage and detritus

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The washing and deburring unit converts the harmful detritus and burrs generated during sawing into removable contaminants that are systematically eliminated through washing and mechanical deburring actions, transforming the harmful byproduct into a manageable cleaning process

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

Washing and deburring is performed as a preliminary action immediately after sawing while the PCB is still in position, preventing detritus from drying or causing further damage before removal

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11706875B2Unit unloading system

Publication Date: 2023.07.18 ROKKO SYST PTE LTD

AI summary

An IC unit unloading system including a chute and a drawer. The chute has a plurality of channels each arranged to receive a unit. The drawer is arranged to move along the chute and has a gate with a unit contact face proximate a top surface of the chute. The contact face is arranged to draw the units along the respective channel as the drawer moves along the chute, and to allow the units to slide laterally across the contact face from a first pitch of each channel to a second pitch. A method for washing a plurality of PCB units, the method comprising the steps of: receiving a plurality of PCB units, said PCB units arranged with a bump face projecting downwards; washing the bump face of the PCB units, then; flipping the PCB units so as to project the ball face downwards, then; washing the ball face.