Photometric Pre-Connection Layer Control for Sinter Joint Reliability
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Solution Overview
Problem
Sinter connections in power semiconductor modules are prone to process instabilities, leading to faulty connections that can result in mechanical instability and inadequate thermal performance, necessitating a method to prevent or identify such faults to avoid field failures.
Innovation Solution
A method involving the formation of a pre-connection layer with a certain amount of liquid on a connection partner, where photometric measurements are performed to determine fluid content-dependent parameters, allowing for real-time evaluation and termination of the process when parameters are within a desired range, ensuring reliable connection formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sintering process is performed to form connections between semiconductor devices and substrates, then mechanical stability and thermal performance are improved, but process instabilities cause faulty connections
Solution Approach 1:
The patent applies preliminary action by performing a pre-connection process that forms a pre-connection layer with controlled liquid content before the final sintering step. This pre-treatment ensures proper material distribution and eliminates excess liquid that could cause defects during sintering, thereby preventing faulty connections before they occur.
Solution Approach 2:
The patent implements feedback control by using photometric measurements to continuously monitor the liquid content in the pre-connection layer during the pre-connection process. The measured parameters are evaluated and fed back to adjust process conditions, ensuring the liquid content remains within the desired range and preventing process instabilities.
2Manufacturing precision
If photometric measurements are performed to monitor liquid content in pre-connection layer, then connection quality is improved, but process complexity increases
Solution Approach 1:
The patent replaces complex mechanical or chemical analysis methods with photometric measurements to monitor liquid content. This optical approach uses light interaction with the pre-connection layer to determine liquid content based on optical properties, simplifying the monitoring system while maintaining high measurement precision.
Solution Approach 2:
The patent exploits color or optical property changes in the pre-connection layer that occur as liquid content changes during the pre-connection process. By measuring these optical variations photometrically, the system can non-invasively and simply track the liquid content without requiring complex analytical equipment.
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
This approach enables the reliable identification and prevention of faulty sinter connections, enhancing mechanical stability and thermal performance by ensuring precise control over the connection process, thereby reducing the risk of field failures.
Implementation Method 1
performing a pre-connection process, thereby removing liquid from the pre-connection layer
Implementation Method 2
performing photometric measurements while performing the pre-connection process, wherein performing the photometric measurements comprises determining at least one photometric parameter of the pre-connection layer, wherein the at least one photometric parameter changes depending on the fluid content of the pre-connection layer
Data Source
AI summary
A method for forming a connection between two connection partners includes: forming a pre-connection layer on a first surface of a first connection partner, the pre-connection layer including a certain amount of liquid; performing a pre-connection process, thereby removing liquid from the pre-connection layer; performing photometric measurements while performing the pre-connection process, wherein performing the photometric measurements includes determining at least one photometric parameter of the pre-connection layer, wherein the at least one photometric parameter changes depending on the fluid content of the pre-connection layer; and constantly evaluating the at least one photometric parameter, wherein the pre-connection process is terminated when the at least one photometric parameter is detected to be within a desired range.