Classification of LED Packages for Quality Control by Discriminant Analysis, Neural Network and Decision Tree.

This study investigates supervised learning to improve LED classification. A hardware system for testing was built. The data for learning were acquired and then analyzed to show their characteristics. An LED was tested, and the results were categorized into three defective LED groups and one normal LED group. Before classification, electrical and optical data were examined to identify their characteristics. To find out the best way for quality control, an ensemble of methods was used. First, the discriminant analysis using the validation data achieved a 77.9% true positive rate for normal products, inadequate for quality control. Second, neural network-based learning boosted this rate to 97.8%, but the 2.2% false negative rate remained problematic. Finally, a binary decision tree was constructed, achieving a 99.4% true positive rate from just 14 splits, proving highly effective in product classification. The training time was measured as 8.1, 18.2 and 8.2 s for discriminant analysis, neural network and decision tree, respectively. This work has found the binary decision tree is advantageous considering both learning and classification efficiencies.

Expansion Injection Molding Process Using Clamping Force for Melt Compression.

Melt expansion followed by compression has been utilized for high-speed filling. In general, this technology was developed for a machine level. Recently, mold-level technology has been tried. In this study, an expansion injection molding process was examined, which included compressing a polymer melt through cylinder action facilitated by the movement of the platen, followed by the expansion of the polymer melt into a mold cavity. A mold system including temperature control and valve actions, similar to hot runner systems, was designed and built. The test results show good filling when the injection pressure was high. Simulations were also carried out, highlighting consistent pressure and filling trends, while revealing limitations tied to the characteristics of the state model. This research indicates promise for expansion injection molding through platen compression but emphasizes the need for the seamless integration of valve action with the injection molding machine for large-scale production.

Numerical Simulation of Deformation in Hot Runner Manifold.

This study simulated the deformation of a hot runner manifold and nozzle assembly during operation, aiming to address potential leaks and premature failure. Both thermal and mechanical models were used simultaneously to accurately capture system behavior. A simplified set of boundary conditions was proposed for efficient problem-solving. Analysis of the simulation results revealed that thermal deformation posed a risk of catastrophic failures and leaks. Deformation from melt pressure was relatively small compared to thermal loading, not exceeding 12%. The study provided design recommendations based on the simulation findings, guiding the development of hot runner systems for improved reliability.

Data Communication Based on MQTT in a Polymer Extrusion Process.

This work aims at building a flexible data communication structure for a polymer processing machine by employing a publisher-subscriber based protocol called Message Queuing Telemetry Transport (MQTT), which is operated over TCP/IP. Even when using conventional equipment, processing data can be measured and recorded by various devices anywhere through an Internet communication. A message-based protocol allows flexible communication that overcomes the shortcomings of the existing server-client protocol. Multiple devices can subscribe to the processing data published by source devices. The proposed method facilitates data communication between multiple publishers and subscribers. This work has implemented a system that publishes data from the equipment and additional sensors to a message broker. The subscribers can monitor and store the process data relayed by the broker. The system has been deployed and run for a film extrusion line to demonstrate the effectiveness.

Rapid Numerical Estimation of Pressure Drop in Hot Runner System.

To determine dimensions in the hot runner systems, given a material, it is necessary to predict the pressure drop according to them. Although modern injection molding simulators are able to evaluate such pressure drops, they are expensive and demanding to be employed as a design utility. This work develops a computer tool that can calculate a pressure drop from the sprue to the gate assuming a steady flow of a generalized Newtonian fluid. For a four drop hot runner system, the accuracy has been verified by comparing the obtained results with those by a commercial simulator. This paper presents how to utilize the proposed method in the hot runner design process.

High-Throughput Synthesis of Liposome Using an Injection-Molded Plastic Micro-Fluidic Device.

For mass production of liposomes, we designed a plastic micro-channel device on the basis of 5 µm of micro-nozzle array forming T-junction with 100 µm depth of micro-channel. A micro-channel unit for synthesizing liposomes consisted of two micro-nozzle arrays for mixing two solutions as well as delivery and recovery channels for supplying solutions and collecting liposome suspension. The number of micro-nozzles was approximately 2400 for a micro-channel unit, and seven units were applied independently on a micro-channel plate. The plastic micro-channel plate was injection-molded for mass production using a micro-channel stamper previously fabricated by UV lithography and nickel electroforming process. A plastic cover plate with seven pairs of inlet and outlet ports was machined by mechanical milling and drilling and was assembled with a micro-channel plate using a holder to form a liposome synthesizing device. Flow and mixing of solutions in the micro-channels were tested using colored water to check the micro-fluidic characteristics of the device. Finally, a L-α-phosphatidylcholine (SOY PC) liposome was synthesized using EtOH solution of SOY PC (95%) and saline (0.85% NaOH solution) to find that the liposomes were around 230 and 260 nm in diameter, depending on the flow rate of the lipid solution.

Optimal Dummy Pattern Design Method for PWB Warpage Control Using the Human-Based Genetic Algorithm.

In this work, a method that minimizes printed wiring board (PWB) warpage by dummy pattern design is proposed. This work suggests that dummy patterns are placed on a preset discretized location in the PWB to reduce the warpage. On each discretized candidate area, the dummy pattern can be set or unset. The warpage is numerically simulated based on direct modeling of the as-is PWB patterns to evaluate the warpage alongside the dummy pattern design set. The optimal pattern that minimizes warpage is determined using the human-based genetic algorithm where the objective function is evaluated by the structural simulation. The optimization method is realized in a spreadsheet that allows scripting language with which the input and output files of the simulation tool can be modified and read. Two different cases have been tested and the results show that the method can determine the optimal dummy patterns. The measured and simulated deflections agree well with each other. Moreover, it has been shown that certain dummy pattern designs that should reduce the warpage can be sought by the optimization.

Enhancement of struvite purity by re-dissolution of calcium ions in synthetic wastewaters.

Although it is widely known that the presence of Ca ions inhibits the nucleation and growth of struvite, which consists of NH4(+), PO4(3-), and Mg(2+), there is a lack of knowledge on actual Ca contents in struvite co-precipitates at various N and P concentrations and the corresponding effects on the sizes of the precipitates. Therefore, to address this challenge, this study designed synthetic wastewaters including the variety of N and P concentrations, and conducted batch experimental reactions with each wastewater to investigate Ca precipitation and size distributions of the precipitates. The molar ratio of Mg:P:N was confined to 1:1:7, while the initial Ca(2+) concentrations were chosen to be 30-60 mg/L, which are typical Ca concentrations in real wastewaters. The result of the batch experiments confirmed that the presence of Ca caused smaller solids than struvite as indicated in previous studies, and there was competition between Ca-phosphate and Mg-N- PO4 (struvite) reactions, as expected. At the beginning of the experiment (∼1 min), fast Ca-phosphate precipitation was dominant because free Ca and P ions were quickly removed while Mg and N concentrations gradually reduced. However, as the nucleation and crystal growth processes elapsed, dissolved Mg and N concentrations continuously decreased, but dissolved Ca concentrations could rise again at high N and P concentration conditions. The interesting phenomenon is that such increases of Ca concentrations probably results from the thermodynamic energy differences between struvite and Ca-phosphate formations. A high thermodynamic driving force of struvite precipitation could drive the re-dissolution of Ca-ions from the Ca-phosphate compounds with low saturation states. This result is expected to be applied for increasing the struvite purity by the Ca re-dissolution through the thermodynamic spontaneity without additional energy input.

Effects of electron beam irradiation and temperature on the treatment of swine wastewater using an ion exchange biological reactor.

Swine wastewater was treated using an ion exchange biological reactor (IEBR). Organic matter and nutrient in swine wastewater were pre-treated by electron beam irradiation. The optimal dose for solubilization of organic matter in swine wastewater ranged from 20 kGy to 75 kGy. The carbohydrates, proteins, and lipids were investigated as proteins and lipids mainly contained the solubilized organic matter. The solubilization of organic matter in swine wastewater was affected by the combination effects of temperature and dose. The maximum chemical oxygen demand (COD) and ammonia removal efficiencies were 74.4% and 76.7% at a dose of 0 kGy under room temperatures (23.0°C). The removal of ammonia was significantly affected by low temperature (15.3°C). On the other hand, the removal of phosphorus was not a function of electron beam irradiation or temperature because struvite is one of the main removal mechanisms under anoxic conditions.

Antibiotic resistance in bacteria isolated from freshwater aquacultures and prediction of the persistence and toxicity of antimicrobials in the aquatic environment.

The occurrence of antibiotic-resistant bacteria isolated from freshwater aquaculture effluents was investigated. The bacterial strains were collected from four different freshwater aquaculture effluents (catfish, trout, eel, and loach). Based on sequence of 16S rRNA, a total of 20 bacterial strains was isolated and one half of the isolated bacteria were Aeromonas sp. The antimicrobial sensitivity test was performed using the disc diffusion method. Individual antibiotic-resistant bacteria to antimicrobials were 41.7% and multiple antibiotic resistant bacteria were 58.3%. The disinfection of antibiotic-resistant bacteria by electron beam (E-beam) irradiation was carried out using an electron accelerator. Antibiotic-resistant bacteria were effectively disinfected by E-beam irradiation. The isolated bacteria were completely disinfected at a dose of less than 2 kGy. The persistence and toxicity of each antimicrobial in the aquatic environment was estimated due to the human health and ecosystems. In order to estimate the persistence and toxicity of antimicrobials in the aquatic environment, two quantitative structure activity relationship (QSAR) models were used. The persistence and toxicity of each antimicrobial were influenced on its hydrophobicity. In addition, QSAR models showed that isoelectric point and hydrogen bonding acceptor are key parameters to estimate the persistence and toxicity of antimicrobials in the aquatic environment.

Interface analysis of embedded chip resistor device package and its effect on drop shock reliability.

In this study, the drop reliability of an embedded passive package is investigated under JESD22-B111 condition. Chip resistors were buried in a PCB board, and it was electrically interconnected by electroless and electrolytic copper plating on a tin pad of a chip resistor without intermetallic phase. However tin, nickel, and copper formed a complex intermetallic phase, such as (Cu, Ni)6Sn5, (Cu, Ni)3Sn, and (Ni, Cu)3Sn2, at the via interface and via wall after reflow and aging. Since the amount of the tin layer was small compared with the solder joint, excessive intermetallic layer growth was not observed during thermal aging. Drop failures are always initiated at the IMC interface, and as aging time increases Cu-Sn-Ni IMC phases are transformed continuously due to Cu diffusion. We studied the intermetallic formation of the Cu via interface and simulated the stress distribution of drop shock by using material properties and board structure of embedded passive boards. The drop simulation was conducted according to the JEDEC standard. It was revealed that the crack starting point related to failure fracture changed due to intermetallic phase transformation along the via interface, and the position where failure occurs experimentally agrees well with our simulation results.