Shadow Moiré Topside Infrared Heating Warpage

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Solution Overview

Problem

Existing shadow moiré systems face limitations in maintaining temperature uniformity over large areas (>70 mm diameter) while accurately measuring warpage in surface mount components, due to restrictions in air speed and temperature distribution, which affects heating efficiency and measurement accuracy.

Innovation Solution

A thermal shadow moiré measurement system with a combination of top and bottom heaters, using infrared radiative heating with specific wavelength filtering and IR reflective coatings to ensure even heating and accurate warpage measurement, allowing for independent control of heating zones and minimizing airflow-induced sample instability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If convection based heating is used in shadow moiré system, then heating capability is improved, but temperature uniformity deteriorates and sample area is restricted to 70 mm diameter

Engineering Contradiction:
Improveheating capabilityVSAvoidtemperature uniformity
Core Design Contradiction:
PowerVSTemperature

Solution Approach 1:

The heating system is divided into multiple independent heating zones (first heating zone, second heating zone, third heating zone, fourth heating zone) with separate control. This segmentation allows each zone to be optimized for uniform temperature distribution across the entire sample area, eliminating the temperature non-uniformity problem of single-zone convection heating while maintaining large sample area capability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Different heating zones are applied to different regions of the sample (top/bottom and inner/outer zones) with independently controllable heating parameters. This local quality approach ensures that each region receives appropriate heating to maintain overall temperature uniformity across the large sample area, resolving the contradiction between heating capability and temperature uniformity.

Inventive Principle:
Principle #3Local quality

2Power

If air flow speed is increased for heating, then heating efficiency is improved, but sample stability deteriorates causing flutter and displacement

Engineering Contradiction:
Improveheating efficiencyVSAvoidsample stability
Core Design Contradiction:
PowerVSStability of the object's composition

Solution Approach 1:

The heating function is segmented into multiple zones that can operate at optimized air flow speeds independently. This allows the system to maintain heating efficiency without requiring high overall air flow speed that would cause sample instability, as each zone contributes to heating without creating destabilizing forces.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system replaces pure convection heating with a combination of radiative heating elements and controlled convection. This substitution reduces reliance on high-speed air flow for heating, thereby maintaining heating efficiency while minimizing airflow-induced sample instability and flutter.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If measurement area is increased beyond 70 mm diameter, then productivity is improved, but temperature uniformity deteriorates with convection heating

Engineering Contradiction:
Improvemeasurement throughputVSAvoidtemperature uniformity
Core Design Contradiction:
ProductivityVSTemperature

Solution Approach 1:

The large measurement area is divided into multiple heating zones with independent control. This segmentation enables the system to maintain temperature uniformity across extended areas (beyond 70 mm diameter) by locally optimizing heating in each zone, thereby allowing increased productivity through larger sample areas without sacrificing temperature uniformity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Each region of the expanded measurement area receives tailored heating through its designated heating zone. This local quality approach ensures that temperature uniformity is maintained across the entire large area, enabling high productivity with extended measurement capabilities while avoiding the temperature non-uniformity that plagues conventional convection systems.

Inventive Principle:
Principle #3Local quality

4Temperature

If multiple heating zones with independent control are implemented, then temperature uniformity is improved, but device complexity increases

Engineering Contradiction:
Improvetemperature uniformityVSAvoidheating control complexity
Core Design Contradiction:
TemperatureVSDevice complexity

Solution Approach 1:

The heating system is segmented into multiple zones with independent control, directly achieving temperature uniformity across the sample area. While this increases device complexity, the segmentation enables precise temperature management that was impossible with single-zone systems, representing an acceptable trade-off for achieving the required temperature uniformity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The implementation of locally controlled heating zones improves temperature uniformity by allowing independent optimization of each region. The increased device complexity from multiple control systems is justified by the significant improvement in temperature uniformity, which is critical for accurate warpage measurement across large sample areas.

Inventive Principle:
Principle #3Local quality

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 system provides fast and accurate warpage measurement across larger areas with minimal temperature differentials (+/−5°C), enhancing heating uniformity and measurement precision, and enabling reliable data capture for surface flatness analysis.

Implementation Method 1

a top heater assembly that is disposed in an oven top and glass lid assembly and above the grating glass and the sample support; and a bottom heater that is disposed in the oven bottom assembly and below the sample support

Methodology Applied
Scientific EffectInfrared radiation: Infrared Radiation

Implementation Method 2

configured to pass light having light wavelength within 700 to 2750 nanometers therethrough to heat a sample disposed in the oven

Methodology Applied
Scientific EffectSelective wavelength transmission: Filter (optical)

Implementation Method 3

Each heater element includes a wound element that is configured to carry electrical current therethrough to generate visible light and shortwave infrared light

Methodology Applied
Scientific EffectJoule heating: Joule Heating

Implementation Method 4

enabling reliable data capture for surface flatness analysis

Methodology Applied
Scientific EffectInfrared reflection: Reflection

Data Source

PatentUS10018463B1Shadow Moiré with topside infrared heating
Publication Date: 2018.07.10 AKROMETRIX LLC
  • US10018463B1 patent drawing
  • US10018463B1 patent drawing
  • US10018463B1 patent drawing

AI summary

A shadow moiré system (herein ‘system’) includes a glass grating that is disposed above a sample in an oven top and glass lid assembly of an oven such that the glass grating is vertically adjustable. Further, the system includes shadow moiré optics that is disposed above the glass grating. Furthermore, the system includes a vertical motion assembly that is disposed in an oven bottom assembly of the oven along with a sample support to vertically move the sample support and the sample disposed thereon. Additionally, the shadow moiré system includes a top heater assembly that is disposed in the oven top and glass lid assembly above the glass grating and a bottom heater that are separately controllable to generate and apply heat to the sample to observe any changes in flatness in a surface of the sample with temperature change.