Ring-Shaped Plastic Frame Casting in Rotor Disk Recess
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Solution Overview
Problem
Existing methods for casting plastic frames in rotor disks of double-sided machining machines fail to precisely control the dimensions and arrangement of the plastic frames, leading to axially asymmetrical frames and deviations in semiconductor wafer dimensions due to material shrinkage and casting method parameters.
Innovation Solution
A device and method that utilize ring-shaped mold inserts and a mold core with casting channels to precisely control the dimensions and position of the plastic frame, allowing for flexible adjustment of the frame's thickness and alignment relative to the rotor disk, using a mold volume that compensates for material shrinkage and includes features like feeders to prevent cavity formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional casting methods are used to produce plastic frames in rotor disks, then the manufacturing process is simple, but the dimensions and arrangement of the plastic frames cannot be precisely controlled
Solution Approach 1:
The mold is divided into two separate parts: a mold body that forms the basic recess structure and a removable mold insert that defines the precise plastic frame geometry. This segmentation allows the complex precision requirements to be isolated in the insert while keeping the overall mold structure manageable and reusable.
Solution Approach 2:
A mold insert acts as an intermediary element between the mold body and the plastic frame. The insert is placed within the recess and provides the precise geometric constraints for the plastic frame, serving as a mediator that transfers the precision requirements from the design to the actual casting process.
2Manufacturing precision
If conventional casting methods are used, then the manufacturing process is straightforward, but axially asymmetrical plastic frames are produced with deviations in semiconductor wafer dimensions
Solution Approach 1:
The mold insert is prepared in advance with the precise geometric features and positioning elements before the casting process. This preliminary preparation ensures that when the plastic frame is cast, it automatically achieves the correct alignment and dimensions without requiring complex real-time adjustments or post-processing.
Solution Approach 2:
The conventional mechanical alignment methods are replaced by a geometric constraint system using the mold insert. The insert's precise geometry and its interaction with the mold body create automatic alignment through geometric constraints rather than relying on mechanical positioning adjustments.
3Manufacturing precision
If material shrinkage is not compensated, then the casting process is simple, but dimensional deviations occur in the plastic frame
Solution Approach 1:
The mold insert is designed in advance with compensation features that account for material shrinkage. The insert geometry is pre-calculated to compensate for shrinkage, so that when the plastic frame is cast and cools, it achieves the desired final dimensions without requiring complex real-time compensation mechanisms.
Solution Approach 2:
The mold insert geometry is adjusted based on material shrinkage parameters. By changing the dimensions of the insert relative to the desired final frame dimensions, the design compensates for shrinkage effects. This allows the system to adapt to material properties without adding complex control mechanisms.
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 solution enables precise control of plastic frame dimensions, reducing thickness deviations to ±5 μm or less, ensuring optimal semiconductor wafer dimensions and improved machining results by minimizing injection pressure and promoting homogeneous crystallization for enhanced dimensional stability.
Implementation Method 1
One end of the mold terminates in a mold volume provided for the plastic frame and the other end is connectable to a supply for plastified plastic
Implementation Method 2
using a mold volume that compensates for material shrinkage
Implementation Method 3
promoting homogeneous crystallization for enhanced dimensional stability
Data Source
AI summary
A method for casting a ring-shaped plastic frame comprises providing two mold parts, wherein at least one of the two molds parts includes at least one ring-shaped seat. Positioning a rotor disk between the two mold parts where the rotor disk comprises at least one annular recess. Engaging a mold core with at least a portion of each of the two mold parts. The mold core comprises at least one casting channel configured to attach at one end to a supply of plastified plastic. Inserting at least one mold insert into the at least one ring-shaped seat. A mold volume is defined by the at least one mold insert, the mold core and an edge of the at least one annular recess, wherein the mold volume is configured to fluidly connect with the at least one casting channel to receive plastified plastic to form a plastic frame.