Changing the Game Rules with CO2 · 2011-01-28 · 73 atm, 31.1 c triple point 5.11 atm, -56.4 c 1 atm-78.5 c phase diagram for co 2 supercritical region dry ice 30 c 70 atm 5b atmospheric

IDEMA RELIABILITY SYMPOSIUM 2008

Changing the Game Changing the Game Rules with CORules with CO22

Clean Manufacturing Clean Manufacturing Solutions for the HDD Solutions for the HDD

IndustryIndustry

David JacksonDavid JacksonCool Clean TechnologiesCool Clean Technologies

May 15, 2008


After more than 20 years of development, CO2 cleaning technology today offers robust methods for precision cleaning components of high-tech products such as spacecraft, aircraft, lasers, electro-optical devices, sensors, integrated circuits, air bags, medical devices, and data storage devices.

Dry cleaning schemes:

• Composite Spray Cleaning• Centrifugal Immersion Cleaning • Supercritical Fluid Extraction• Atmospheric Plasma Treatment• Low Pressure Plasma Treatment• Hybrid Processes

CombinationalTreatments

COCO2 2 cleaning technologycleaning technology……


Advantages of COAdvantages of CO2 2 CleantechCleantech……

““CleanClean”” ProcessingProcessing……Cleans without producing environmentalwastes such as air pollution, spent solvents,rinse water, sludge and filters.

““LeanLean”” ProcessingProcessing……Reduces manufacturing wastes such as energy,space, time and manpower by modifying theproduction process.

““DryDry”” ProcessingProcessing……CO2 processes are similar to Freon 113 cleaning;parts remain dry during the cleaning process.


COCO22 is abundantis abundant……

South Pole - MarsA by-product of industrial and naturalprocesses such as refineries, CaCO3

wells, and bakeries.

A recyclable and renewable resource.

Major commercial uses include beveragecarbonation, fire extinguishing and welding.

MarsNASA Hubble

Space Telescope


Health and safetyHealth and safety……

Solvent Ozone DepletingPotential (ODP) OSHA PEL VOC

Carbon Dioxide None 5,000 ppm No

Perchloroethylene ~0 25 ppm YesCarbon Tetrachloride 1.10 2 ppm YesMethylene Chloride ~0 500 ppm YesTrichloroethylene ~0 50 ppm Yes

1,1,1-Trichloroethane 0.15 350 ppm Yesn-Propyl Bromide (nPB) ~0 100 ppm Yes

PEL – Permissible Exposure Limit

• CO2 is non-corrosive and non-toxic

• Recycled CO2 is not regulated by EPA (SNAP Alternative)and is not regulated under GW legislation


PR

ES

SU

RE

TEMPERATURE

CO2 (l)

CO2 (g)

CO2 (s)CRITICAL POINT73 atm, 31.1 C

TRIPLE POINT5.11 atm, -56.4 C

1 atm

-78.5 C

PHASE DIAGRAMFOR CO2

SUPERCRITICALREGION

DRY ICE

30 C

70 atm

5b ATMOSPHERICPLASMA

TREATMENTThe 4th StateCO2(p)

1a

4 EXTRACTIVECLEANING

SPRAY ORIMMERSIONCLEANING2

COCO22 cleaning agentscleaning agents……

SPRAY, JETCLEANING

3a

3bCDA

VACUUMPLASMA

TREATMENT

5a

1b


Composite COComposite CO22 spray cleaningspray cleaning……

Cleaning process and chemistry similar to spray cleaning with Freon 113.

Composite spray technology provides superior process control, cleaning performance and economy as compared to conventional “Snow”technology.


0

50

100

0 50 100

0

50

100

30%

70% 0%

CLEA

N DR

Y AI

R

ADDITIVE

CO2(s)

LEAN/FINEPARTICLECLEANING

COMPOSITION

P - 8

0 PS

IT-

150

DEG

. C

FINE PARTICLES

Technology differentiationTechnology differentiation……

Mass/Flow Control

Compositional ControlComposite CO2 Spray

Snow Spray


CO2 Crystals

• Structure - molecular crystal, angular, octahedron• Solvency - hydrocarbon-like chemistry• Impact Phenomenon - ablation and phase change (solid->liquid->gas)• Additives - can be modified with liquids, solids, vapor-phase additives• Compressibility - practically incompressible• Hardness - 0.3 Hm (8 Hv)• Particle Size - < 0.5 microns to > 500 microns, range adjustable (coarse/fine)• Impact Stress - up to 60 MPa, pressure/particle size/distance dependent

Composite COComposite CO22 cleaning spraycleaning spray……

SEMPhotomicrograph

1 μm Dilute CO2-CDA-AdditiveCompositions

Fine/CoarseLean/Rich


DENSITYg/ml

VISCOSITYmN-s/m2

SURFACETENSIONdynes/cm

SOLUBILITYMPa1/2

Freon 113

1.6 1.6

0.07 0.68

3 19.6

22 15

Carbon Dioxide

COCO22 (spray) compared to Freon 113(spray) compared to Freon 113……

Cohesion Energy

Shear Stress EnergyFd = (C) (ρ) (V2/2) (A)

δ = [(∆HV – RT)/V]1/2


Coaxial and Coaxial and CoandaCoanda sprayssprays……

CoaxialShort-range

CoandaLong-range


Spray Spray composition controlcomposition control……

Inert Gas

Particle SizeChemistry

Spray DensityTemperature

PressureDistance/Angle

Time

(Propulsion/Heat)

Additive(Chemical/Physical)

CO2

CleaningEnergy


CO2 COMPOSITE SPRAYCLEANING ENERGY

FINE

MEDIUM

COARSE

IMPACT SHEAR STRESS(MPa)

0.1 1 60

Shaved Ice andPellets

(100 - 500 MPa)

500

100

10

ULTRAFINE1

10

PAR

TIC

LE R

AN

GE

(mic

rons

)

CO2 Composite Sprays(0.01 - 60 MPa)

SnowSprays

(0.01 - 2 MPa)

Control ParametersCO2 Particle Size

CO2 Particle DensityPropellant Pressure

Propellant Temperature

Composite COComposite CO22 spray (mechanical) energyspray (mechanical) energy……


HDD applications for composite COHDD applications for composite CO22 sprayssprays……

Build-Clean (Prime)Rework/Reclaim

Production ToolingHSA

Spacers

MBA

• Partially-Assembled Devices• Tool Blocks• Fixtures


0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

Reclaim - NotCleaned

Wet Cleaning CO2 CompositeSpray

Cleaning Processes

MBAs

UCLSpec

Laboratory Testing Analysis/OptimizationCleaning Process Design

Cleaning System Design(Automation, Fixtures) Cleaning Recipe

DevelopmentCleaning System

Build

1 2 3

4 5 6

Application development processApplication development process……


HDD TEST FAILURE

CLEAN COMPONENTS

ASSEMBLY

HDD TEST

Reclaim Cleaning Process Flowchart

PARTIAL DISASSEMBLY

Application exampleApplication example……Reclaiming HDD ComponentsReclaiming HDD Components

• Dry cleaning • Processing partially assembled devices• High-capacity• Process repeatability• Small footprint• Less energy• Reduced labor

Value:

Reclaimed Covers


0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%



Cleaning Processes

MBAs

UCLSpec

Performance testing (manual)Performance testing (manual)……reclaim MBAsreclaim MBAsParticlesParticles

CO2 Feed: Lean Propellant Type: CDAPropellant Pressure: 80 PSIPropellant Temp: 185 CNozzle: CoaxialCapillary: Fine ParticleScan Type: Zig-ZagRate: ~100 mm/sDistance: ~2 inches

Typical pre-screeningspray parameters for

particle cleaning.


Performance testingPerformance testing……reclaim MBAsreclaim MBAsSilicones, NVR and IonsSilicones, NVR and Ions

F, Cl, NO2, Br, NO3, PO4, and SO4

<< 0.01 ug/cm2

No silicones0.00%5.00%

10.00%15.00%20.00%25.00%30.00%35.00%40.00%



Cleaning Process

Non-Volatile Residue(MBAs)

UCLSpec

FT-IR

IC


Latch

Before After

Application exampleApplication example……Prime Parts SupplierPrime Parts SupplierMagnetic Particle RemovalMagnetic Particle Removal

SEM 500x SEM 500x


Significant defect reduction

CompositeCO2

Spray

1stStamp

2ndStamp

3rdStamp

Blank

Application exampleApplication example……Prime Parts SupplierPrime Parts SupplierSuspension Cleaning During FormingSuspension Cleaning During Forming

CompositeCO2

Spray

CompositeCO2

Spray

Integrated into progressivestamping machine/process

Suspension


Cleaning cost comparisonCleaning cost comparison…… wet vs. drywet vs. dry

High capacity spray cleaning cell for MBA, cover and magnet reclaim operations.

Deionized Water(Immersion/Drying)

Composite CO2

(Spray)

$0.12-$0.13/part $0.01-$0.03/part

76% cost reduction (fully burdened)

Knoth et al, Automated CO2 Composite Spray Cleaning for HDD Parts, IDEMA Pacific Asia 2007 Conference, Singapore and Bangkok, Thailand, March 2007

8K–20K parts/day/cell


Meeting spec consistentlyMeeting spec consistently……

MBA Rework

Particle SizeChemistry

Spray DensityTemperature

PressureDistance/Angle

Time

KPVs

Automated CO2 Cleaning Process


COCO22 composite spray cleaning solutionscomposite spray cleaning solutions……

Automated/Capacity

Mobile/Clean-in-Place

Modular/Clean Integration

Hand Tools/Bench


• Mature – Technology has evolved over 20 years from simple snow gunsto high capacity systems using compositional sprays.

• Adaptable – Uniquely adapts to manufacturing processes and tools.

• Consistent – Known and stable process variables.

• Safe – no VOCs, no toxics, and no worker health hazards.

• Unregulated – Recycled CO2 is not an environmental hazard.

• Clean/Dry – Cleans like high pressure Freon 113 sprays.

• Lean – No waste, cellular, compact and efficient.

Changing the Game Rules with COChanging the Game Rules with CO22

WrapWrap--upup……


[email protected]: 661-803-0546

David Jackson

http://www.purco2.com

Precision Cleaning Division27636 Avenue Scott Unit CValencia, CA USA 91355

+1.661.775.5964

QuestionsQuestions……

PurCO2Clean…Pure & Simple.

Documents

Changing the Game Rules with CO2 · 2011-01-28 · 73 atm, 31.1 c triple point 5.11 atm, -56.4 c 1 atm-78.5 c phase diagram for co 2 supercritical region dry ice 30 c 70 atm 5b atmospheric