Molten Solder Injection Head Venting to Prevent Dripping
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Solution Overview
Problem
In high-density packaging applications, especially for fine pitch interconnects and 2.5D or 3D and mobile devices, controlling solder interconnect properties and preventing electro-migration (EM) is challenging due to the small size of solder bumps, which leads to issues with material handling and process productivity, particularly with molten solder injection systems.
Innovation Solution
An injection apparatus with a tank and a head body having a surface for contacting substrates, featuring an opening part that allows gas flow, enabling smooth evacuation and filling of material without dripping, even when covered by the substrate, using a slit-like opening and connected members that facilitate gas flow to prevent material loss and maintain productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the opening part is covered by the substrate to inject material, then material injection into substrate holes is achieved, but material dripping from the opening part occurs
Solution Approach 1:
The patent extracts the gas flow path from the material flow path by providing a separate gas introduction hole that communicates with the opening part independently from the material supply channel. This allows gas to be introduced to prevent material dripping while maintaining precise material injection control.
Solution Approach 2:
The patent introduces gas as an intermediary substance through the gas introduction hole to prevent material from dripping. The gas acts as a barrier or carrier that allows the opening part to be covered by the substrate for injection while preventing uncontrolled material flow.
2Manufacturing precision
If the opening part is covered by the substrate, then material can be injected into substrate, but gas trapped in the opening part causes incomplete material transfer
Solution Approach 1:
The patent extracts the gas venting function from the material injection system by providing a dedicated gas introduction hole that is separate from the material supply channel. This allows trapped gas to be efficiently removed without complicating the material injection mechanism.
Solution Approach 2:
The patent introduces gas into the opening part before or during material injection to preemptively remove trapped air. This preliminary gas introduction ensures complete material transfer by preventing air pockets from interfering with the filling process.
3Ease of operation
If a hole is formed in the head body for gas flow, then gas can escape, but the hole may be clogged by material
Solution Approach 1:
The patent segments the gas flow path from the material flow path by providing a separate gas introduction hole positioned independently from the material supply channel and opening part. This segmentation ensures gas can flow freely without risk of material clogging the gas path.
Solution Approach 2:
The patent positions the gas introduction hole at a different spatial location and orientation relative to the material flow path. The gas hole is configured to communicate with the opening part from a different dimension, preventing material from entering and clogging the gas flow channel while still allowing effective gas introduction.
4Productivity
If the injection apparatus is lifted up from substrate after injection, then the process can continue, but material may drip from the opening part
Solution Approach 1:
The patent introduces gas into the opening part before lifting the injection apparatus from the substrate. This preliminary gas introduction ensures that any remaining material is prevented from dripping during the lifting operation, allowing continuous process operation without material loss.
Solution Approach 2:
The patent uses gas as an intermediary substance that remains in the opening part after material injection. This gas acts as a protective barrier during the lifting operation, preventing material from dripping while allowing the apparatus to be moved to the next position.
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 effectively prevents material dripping and maintains process productivity by allowing gas flow through the opening part, enabling efficient transfer of molten solder, thus minimizing downtime and ensuring consistent chip package interaction and EM performance.
Implementation Method 1
each of the at least one member includes a porous member that allows the gas to flow therethrough while separating the gas from the material
Data Source
AI summary
An injection apparatus for injection material is disclosed. The injection apparatus includes a tank for storing material. The injection apparatus further includes a head body that has a surface for contacting a substrate and an opening part opened at the surface for discharging the material in fluid-communication with the tank. The injection apparatus further includes a member connected to the opening part, in which the member allows gas to flow into and flow out from the opening part.