Systems and methods related to ablation during manufacture of radio-frequency modules

Abstract

Disclosed are systems and methods related to removal of materials by techniques such as ablation during manufacture of radio-frequency (RF) modules. Such modules can be manufactured in an array on a panel, and an overmold structure can be formed on the panel. In some situations, it can be desirable to remove a portion of an upper surface of the overmold to, for example, better expose upper portions of shielding wirebonds. In some embodiments, an ablation system can include a blasting apparatus configured to provide a stream of ablating particles to a blasting region. A first transport section that moves a panel through the blasting region can be separate from a second transport section that feeds or removes the panel to or from the first transport section. Such a configuration can substantially isolate the second transport section from the stream of ablating particles.

What is claimed is: 
     
         1 . A system for ablating a panel having electronic modules formed thereon, the system comprising:
 a blasting apparatus configured to provide a stream of particles to a blasting region;   a first transport section configured to move the panel through the blasting region and receive the stream of particles to thereby allow removal of a surface of the panel; and   a second transport section configured to move the panel to or from the first transport section such that the second transport section is substantially isolated from the stream of particles.   
     
     
         2 . The system of  claim 1  wherein the second transport section is a loading transport section that moves the panel to the first transport section. 
     
     
         3 . The system of  claim 2  further comprising a third transport section configured to unload the panel from the first transport section such that the third transport section is substantially isolated from the stream of particles. 
     
     
         4 . The system of  claim 3  wherein each of the first, second and third transport sections includes a conveyor belt driven by one or more pulleys. 
     
     
         5 . The system of  claim 4  wherein the conveyor belt for the first transport section is configured to withstand repeated exposure to the stream of particles. 
     
     
         6 . The system of  claim 4  wherein the conveyor belt for the first transport section is perforated with a plurality of openings, the openings dimensioned to allow the conveyor belt to support the panel and to allow at least some of the particles sprayed in the blasting region to fall through. 
     
     
         7 . The system of  claim 4  wherein the conveyor belt for the first transport section is sufficiently conductive to provide a desired electrostatic discharge (ESD) protection property. 
     
     
         8 . The system of  claim 4  wherein the conveyor belt for the first transport section is configured to be resiliently soft to absorb impact energy of the stream of particles without having parts of the conveyor belt ablated off. 
     
     
         9 . The system of  claim 3  further comprising at least one tracking sensor for each of the first, second, and third transport sections, the tracking sensor configured to facilitate tracking movement of the panel. 
     
     
         10 . The system of  claim 9  further comprising an input assembly configured to allow automated feeding of a plurality of panels in series to the loading transport section. 
     
     
         11 . The system of  claim 10  wherein the input assembly includes a magazine configured to hold the plurality of panels. 
     
     
         12 . The system of  claim 9  further comprising an output assembly configured to allow automated receiving of a plurality of panels in series from the unloading transport section. 
     
     
         13 . The system of  claim 10  wherein the output assembly includes a magazine configured to hold the plurality of panels. 
     
     
         14 . The system of  claim 9  wherein each of the first, second, and third transport sections is provided with an input tracking sensor and an output tracking sensor configured to detect entry and exit of the panel into and out of the respective transport section. 
     
     
         15 . The system of  claim 14  wherein the first transport section is further provided with an activation sensor configured to activate or deactivate operation of the blasting apparatus. 
     
     
         16 . The system of  claim 9  further comprising a controller configured to control operation of the system based at least in part on signals from the tracking sensors. 
     
     
         17 . A method for ablating a panel having electronic modules formed thereon, the method comprising:
 transporting the panel through an input section;   transporting the panel received from the input section through a blasting section that includes a blasting region where a stream of particles is provided to yield an ablated panel; and   transporting the ablated panel received from the blasting section through an output section, each of the input section and the output section being substantially isolated from the stream of particles.   
     
     
         18 . The method of  claim 17  wherein the transporting of the panel through the input section, the transporting of the panel through the blast section, and the transporting of the panel through the output section are controlled by a processor. 
     
     
         19 . The method of  claim 18  wherein the method is performed automatically for a plurality of panels.