Pellet Loader Separator for IC Molding Double Pickup

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Solution Overview

Problem

Conventional transfer molding processes experience downtime and productivity loss due to double pellet transfer issues caused by pellet sticking between top and under pellets in the pellet dispenser, leading to multiple pellets being transferred into mold cavities.

Innovation Solution

A pellet separator tool is introduced to move top pellets laterally relative to under pellets, breaking adhesion forces and ensuring only the top pellets are transferred to the mold cavities, thereby preventing double pellet pickup.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the pellet dispenser uses a spring force to transfer top pellets into receiving positions, then the pellet transfer operation is automated and efficient, but pellet sticking between top pellets and under pellets causes double pellet transfer into mold cavities

Engineering Contradiction:

Improvepellet transfer efficiencyVSAvoidsingle pellet transfer accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The pellet transfer system is segmented into distinct functional zones: the pellet dispenser with magazine, the pellet separator with laterally moving separator member, and the tablet lifter with pellet stopper. This segmentation allows the separator member to independently break adhesion between top pellets and under pellets, ensuring only single pellet transfer to the stopper while maintaining automated efficiency

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator member acts as an intermediary element between the pellet dispenser and tablet lifter. It laterally moves to insert between the top pellet and under pellet, breaking their adhesion force. This intermediary action prevents double pellet sticking without disrupting the overall automated transfer mechanism, resolving the contradiction between efficiency and accuracy

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If double pellet transfer occurs, then the molding process can continue operating, but system downtime and productivity loss occur due to stopping the molding machine for removal of extra pellets

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidsystem downtime for clearing double pellets

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The separator member performs preliminary action by laterally moving to break the adhesion force between top pellets and under pellets before the pellet transfer occurs. This preliminary separation prevents double pellet sticking at the source, eliminating the need for subsequent stopping and clearing operations, thus maintaining continuous productivity without time loss

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The separator member applies preliminary anti-action by disrupting the harmful adhesion force between pellets before it can cause double pellet transfer. This preventive measure counteracts the sticking tendency in advance, ensuring continuous operation without the need for corrective stopping and clearing actions

Inventive Principle:

Principle #9Preliminary anti-action

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 pellet separator effectively reduces pellet sticking, preventing double pellet transfers and maintaining continuous operation by ensuring only single pellets are loaded into mold cavities, thus enhancing productivity and system efficiency.

Implementation Method 1

breaking the adhesion force between the top pellets and under pellets to generally eliminate, or at least significantly reduce, the occurrence of multiple pellet pickup

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

The tablet lifter then transfers the pellets received into a mold of a molding section

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

where the mold compound is melted by the application of heat and pressure to a fluid state

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 4

where the mold compound is melted by the application of heat and pressure to a fluid state

Methodology Applied

Scientific EffectHeat and pressure: Heating

Implementation Method 5

The liquefied mold compound is then forced by a plunger into runners connected between the plunger and molding cavities

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS8297472B2Pellet loader with pellet separator for molding IC devices

Publication Date: 2012.10.30 TEXAS INSTRUMENTS INC

AI summary

A pellet loading apparatus includes a tablet pusher including a support surfaces including a pusher mechanism coupled thereto for vertical movement upon actuation. A tablet holder on the tablet pusher includes locations framed by sidewall members aligned in the vertical direction that form columns having open tops for holding a pellet stacks of mold component pellets. A pellet separator having a solid portion and apertures is sized to fit around a portion of a top mold pellet in the pellet stacks. The pellet separator includes a pellet drive for lateral moving the top mold pellets relative to under pellets so that after lateral movement the top mold pellets are laterally offset from the under pellets. A tablet lifter includes a pellet stopper having receiving positions for receiving top mold pellets upon receipt after a transfer actuation of the pusher mechanism.