Tape Reel Chip Counter Using Fluorescent X-Ray Imaging
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Solution Overview
Problem
Conventional chip counters are burdensome and costly due to the use of large-area detectors for counting semiconductor chips on tape reels, which increases manufacturing costs and is inefficient for varying reel sizes.
Innovation Solution
A chip counter design that uses a sealed housing with an X-ray tube, a fluorescent intensifying screen, and a camera, where an X-ray beam shielding member, including lead glass and beam shielding plates, blocks X-ray beams from reaching the camera, allowing for image processing without an expensive detector, enabling precise counting of semiconductor chips across various reel sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a detector is used to receive and image X-ray beams for counting semiconductor chips, then measurement precision is improved, but manufacturing cost increases sharply
Solution Approach 1:
The patent uses a fluorescent screen to convert X-ray signals into visible light images, creating a visual copy of the chip positions that can be captured by a standard camera. This replaces the expensive detector while maintaining the ability to image and count chips accurately through optical copying of the X-ray interaction patterns.
Solution Approach 2:
The patent substitutes expensive, durable detectors with inexpensive components: a fluorescent screen and a standard camera. While these components are less durable than detectors, their low cost makes the overall system more economical, especially for applications where the equipment may be relocated or upgraded frequently.
2Adaptability or versatility
If a large-area detector is used to cover larger tape reel diameters, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The fluorescent screen and camera combination serves multiple functions: it can detect X-rays from chips, create visible images, and accommodate various tape reel sizes by adjusting the screen size or camera position. This universal approach replaces specialized large-area detectors with a flexible, multi-functional system that adapts to different reel diameters without proportionally increasing cost.
Solution Approach 2:
The system allows dynamic adjustment of the fluorescent screen and camera configuration to accommodate different tape reel sizes. Rather than requiring a fixed large-area detector for maximum reel sizes, the dynamic arrangement of smaller, cheaper components can be adjusted to match the actual reel diameter being used, reducing cost for smaller applications.
3Reliability
If the camera is exposed to direct X-ray beams, then the imaging function is compromised, but device complexity increases with shielding components
Solution Approach 1:
The fluorescent screen acts as an intermediary between the X-ray source and the camera. It absorbs the X-ray energy and converts it to visible light, which the camera can detect without damage. This intermediary layer protects the camera from direct X-ray exposure while still enabling the imaging function through the converted light signal.
Solution Approach 2:
The patent converts the potentially harmful direct X-ray exposure into a beneficial process by using the fluorescent screen to transform X-ray energy into visible light. The X-rays that would otherwise damage the camera are instead used to excite the fluorescent screen, creating the light image that the camera captures. This converts a harmful effect into the basis of the imaging mechanism.
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 configuration reduces manufacturing costs by eliminating the need for a large-area detector, protects the camera from X-ray damage, and allows for accurate counting of semiconductor chips on tape reels of varying sizes without increasing costs.
Implementation Method 1
allowing an X-ray beam emitted from an X-ray tube (20) inside the housing (10) to be transmitted through the tape reel (1) and react with a fluorescent intensifying screen (60)
Implementation Method 2
receiving and image-processing, by a computer (80), an image obtained by capturing the fluorescent intensifying screen (60) using a camera (70) positioned behind the fluorescent intensifying screen (60), wherein the chip counter includes an X-ray beam shielding member (100) blocking the X-ray beam directed to the camera (70)
Data Source
AI summary
The present invention relates to a chip counter, which transmits an X-ray beam through a tape reel around which a tape having a plurality of semiconductor chips mounted in a row therein is wound, acquires an image scattered or diffracted by the semiconductor chips, and processes the acquired image, so as to count the number of the semiconductor chips, wherein: the X-ray beam transmitted through the tape reel (1) is sensed by a fluorescent intensifying screen (60); a fluorescent light emitted from the fluorescent intensifying screen (60) according to the sensing of the X-ray beam is captured by a camera (70), so that the number of the semiconductor chips is counted from an image in which the semiconductor chips are displayed by a dotted image; and the camera (70) is protected by an X-ray beam shielding member (100: 110; 120; and 130).