Requirements of packaging plants for oil content in compressed air

In the packaging and production of electronic components, the cleanliness of compressed air directly affects product yield and reliability. Packaging plants have extremely strict requirements for the oil content of compressed air, mainly based on the following core requirements:

1. Core requirements

1. Ultra-low oil content standard
   The packaging process requires that the oil content in the compressed air must be controlled toextremely small level(Usually less than 0.01 mg/m3). Even a very small amount of oil mist may form residues on the surface of precision components, causing the following problems:
   • Risk of short circuit: Oil absorbs dust and forms a conductive film.
   • adhesive failure: Affects the adhesion of epoxy resin, silicone and other packaging materials.
   • optical pollution: Produce glare or haze in optical devices such as camera modules.
2. Oil-free technology path
   To meet the requirements, packaging factories usually useoil-free air compressor, and is equipped with a multi-stage filtration system:
   • pre-filter: Remove large oil droplets and impurities.
   • precision filtration: Absorb micron oil mist through activated carbon and fiber filter elements.
   • terminal filtration: Use ultra-efficient filter elements (such as 0.01 micron) to intercept nanoscale pollutants.

2. Potential risks of oil pollution

1. Direct harm to product
   • Risk of miniaturization of components: In chip packaging, oil may penetrate into micron lead gaps, causing electromigration or corrosion.
   • airtight failure: In products that require vacuum packaging such as MEMS sensors, the evaporation of oil will cause changes in chamber pressure.
2. Damage to production equipment
   • Plugged pneumatic components: The oil forms an adhesive layer on the inner wall of the solenoid valve and cylinder, causing the movement to be stuck.
   • Optical system pollution: In the visual positioning system of glue dispensers, crystal bonders and other equipment, oil mist will reduce the detection accuracy.

3. Quality control measures

1. Real-time monitoring system
   • deploymentOnline oil detectorContinuously monitor the oil mist concentration in the compressed air.
   • Collect gas samples regularly and passinfrared spectrum analysisorgravimetric methodConduct laboratory re-examination.
2. PM strategies
   • Filter life management: Replace the filter element in time according to the differential pressure sensor data to avoid penetrating leaks.
   • Compressor status monitoring: Early warning of abnormalities such as lubricating oil emulsification through vibration analysis and temperature monitoring.

4. Industry practice cases

A chip packaging factory once caused the following problems due to excessive oil content in compressed air:

• Increase in product rework rates: The packaging yield of a certain batch of BGA dropped by 15%, which was traced back to the source and found to be caused by emulsification of air compressor lubricating oil.
• Equipment shutdown losses: The glue dispenser needs to be shut down every week for cleaning due to blocked gas paths, and the annualized loss exceeds 2 million yuan.

By upgrading to an oil-free air compressor and adding a three-stage filtration system, the factory controlled the oil content below 0.003 mg/cubic meter, increased the product through-flow rate by 12%, and reduced the equipment failure rate by 80%.

conclusion

In the field of precision manufacturing, the cleanliness of compressed air is the “invisible line of defense” for quality control. By building an oil-free gas supply system and implementing full-link filtration and monitoring, the packaging factory can effectively avoid the risk of oil pollution and ensure product reliability and production continuity. With the development of advanced packaging technology, the control requirements for compressed air quality will continue to become stricter.