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Analysis of the production process of plastic-coated electronic components
Together with Continental, CADFEM investigated and optimized the production process of sensor elements with multiple plastic overmoulding (bare die packaging).

Simulation on behalf of Continental

Branch : Automotive supplierSpecialist field: Structural mechanics

On behalf of Continental, CADFEM investigated the production process of plastic-coated sensor elements with extensive simulations.

Summary

Task

The production process of sensor elements with multiple plastic overmoulding (bare die packaging) was investigated. Of particular interest was the behaviour of the thermoelastic anisotropic materials including the fibre orientation of the short fibre reinforced injection moulding sheathing.

Solution

CADFEM worked through the individual process steps of the manufacturing process using simulation technology. The associated heating and cooling processes as well as the shrinkage and distortion that occurred were analyzed.

Customer benefits

Together with CADFEM, Continental has developed a method for FE simulation of the production process of electronic components with multiple plastic covers. With this method, predictions about the functionality and robustness of sensor elements could be investigated at an early stage.

Project Details

Task

Together with Continental, CADFEM investigated the production process of sensor elements with multiple plastic overmoulding (bare die packaging) in order to optimise it. For this purpose, it was necessary to analyze the process influences on the overmolded sensor elements, which are placed with their electrical contacts on a carrier. Of particular interest was the behaviour of the thermoelastic anisotropic materials including the fibre orientation of the short fibre reinforced injection moulding sheathing.


Customer Benefit

Together with CADFEM, Continental has developed a method for FE simulation of the production process of electronic components with multiple plastic covers. The following points were particularly highlighted:

  1. the integration of thermoelastic anisotropic material including the fiber orientation of the short fiber reinforced injection molded sheathing
  2. the transfer of residual stresses and distortion of injection moulding simulations to the mechanical model by temperature mapping.
  3. the determination of the influence of distortion and shrinkage from the individual production steps on the electronic components by switching elements on and off.

This enabled predictions to be made at an early stage on the functionality and robustness of sensor elements, taking into account the influences of the manufacturing process, in order to optimize it and compare it with other manufacturing techniques.


Solution

The individual process steps of the manufacturing process were carried out by simulation and the associated heating and cooling processes as well as the shrinkage and warpage were analysed. This also included the heating up for the curing of the adhesive, casting, reaction resin and overmoulding as well as the subsequent cooling down to room temperature. The temperature distribution as well as the fibre orientation for the injection moulding sheathing were determined from the filling simulation. By coupling the injection moulding analysis with the  FEM calculation, these data were used for the structural-mechanical calculation of strain and stress. The homogenization of the short fiber reinforced model led to representative volume elements with anisotropic properties. The material data of this injection-moulded sheathing was determined for three load directions (0°/45°/90°) and for their temperature dependence on the basis of tensile specimens.


Enterprise Account Manager

Products applied in the project