Visible-Light Flux Detection by Optical Attenuation on Substrates
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Solution Overview
Problem
Automated optical inspection systems struggle to detect clear flux due to its transparent nature, lack of contrasting color, and absence of solid material, leading to increased manufacturing risks and costs when alternative methods are employed.
Innovation Solution
Utilizing visible range image sensors and line-scan cameras to model clear flux as a natural passive optical attenuator, detecting clear flux by quantifying the attenuation rate of visible light based on the amount of flux on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional optical inspection methods are used, then the inspection system is simple and low-cost, but clear flux cannot be detected due to its transparent nature
Solution Approach 1:
The patent changes the inspection parameter from visual appearance to optical attenuation properties. By measuring how much visible light is absorbed or attenuated by the flux layer, the system can detect clear flux even though it is transparent and lacks contrasting color. This parameter change enables detection of previously undetectable clear flux without requiring complex additional hardware.
Solution Approach 2:
The patent replaces traditional mechanical or visual inspection methods with optical measurement. Instead of relying on solid material presence or color contrast, the system uses visible light attenuation measurements to detect flux, substituting a simpler optical field-based approach for complex mechanical or chemical detection methods.
2Measurement precision
If alternative detection methods are employed to detect clear flux, then detection capability is improved, but manufacturing costs increase
Solution Approach 1:
The patent utilizes the inherent optical properties of clear flux (its ability to attenuate visible light) for self-detection. The flux material's own physical property of absorbing light serves as the detection mechanism, eliminating the need for expensive external markers, dyes, or complex detection systems. This self-service approach achieves accurate detection while keeping manufacturing costs low.
3Reliability
If clear flux is used to facilitate soldering, then soldering performance is improved, but detection and quality control become difficult
Solution Approach 1:
The patent introduces visible light as an intermediary medium to detect flux presence. By shining visible light through the flux layer and measuring the attenuation, the system creates an indirect detection pathway that overcomes the difficulty of directly observing clear flux. This intermediary approach enables reliable quality control while maintaining the use of clear flux for soldering.
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
Enhances process margins and yield without significantly increasing costs, allowing for efficient detection and adjustment of clear flux application, thereby optimizing manufacturing processes.
Implementation Method 1
model clear flux as a natural passive optical attenuator, detecting clear flux by quantifying the attenuation rate of visible light
Data Source
AI summary
Systems, apparatus, articles of manufacture, and methods are disclosed to detect transparent flux with visible light. An example apparatus includes interface circuitry to communicate with an image sensor and programmable circuitry to at least one of instantiate or execute machine-readable instructions. Additionally, the example programmable circuitry is to cause the image sensor to capture reflected light off of a substrate, the reflected light being visible. The example programmable circuitry is also to, based on a level of attenuation of the reflected light relative to projected light projected onto the substrate, determine at least one of a presence or a property of transparent flux on the substrate.