Pattern manipulation for a jet valve dispenser

Abstract

A jet valve dispenser is configured to output individual, discrete drops of a material onto a target substrate. The jet valve dispenser includes a nozzle plate that supports a nozzle through which the material is emitted. The nozzle plate is configured to receive one or more flows of compressed gas and is configured to output the compressed gas to cause atomization of the dispensed drop of material.

Description

[0001] PATTERN MANIPULATION FOR A JET VALVE DISPENSER

[0002] CROSS-REFERENCE TO RELATED APPLICATION(S)

[0003] This application claims priority to U.S. Provisional Application No. 63 / 606,297 filed December 5, 2023 and entitled “PATTERN MANIPULATION FOR A JET VALVE DISPENSER,” the disclosure of which is hereby incorporated by reference in its entirety.

[0004] BACKGROUND

[0005] The present disclosure relates generally to non-contact dispensing. More particularly, this disclosure relates to pattern shaping for non-contact jet dispensing.

[0006] In some industries (e.g., semiconductor, electronics life sciences, etc.) viscous fluids are frequently dispensed. The demands to miniaturize in these industries require smaller and faster deposition of viscous fluids. Non-contact dispensing, often referred to as jet dispensing, is preferred for many reasons, some of which might be the ability to dispense drops while moving above a surface, the speed of drop formation, and the minute size and precision of the drops produced. Jetting as used herein refers to non-contact dispensing as compared to contact dispensing. Contact dispensing is the process where a fluid drop on the end of a dispensing tip comes into contact with the target substrate while still in contact with the dispensing tip so that the fluid drop “wets” or clings to the substrate and remains on the surface of the substrate as the dispensing tip pulls away.

[0007] Jet dispensers are configured to output discrete volumes of material with each dispense. Each dispense can be considered to apply a drop of material to the target substrate. The jet dispenser can have nozzles having different shapes and speed, pressure, and volume can be adjusted to manipulate the configuration of the drop that is applied to the target substrate. The jet dispenser can quickly dispense drops in succession such that the drops overlap to form a line or bead of the material.

[0008] SUMMARY

[0009] According to an aspect of the disclosure, a bottom plate for a non-contact jet valve dispenser includes a base plate having a plate body; an atomizing fitting extending out of the plate body from within an inlet bore formed in the plate body; and an atomization bore extending through the plate body between a first side of the plate body and a second side of the plate body, the atomization bore fluidly connected to the inlet bore to receive a first flow of compressed gas from the inlet bore.

[0010] According to an additional or alternative aspect of the disclosure, a jet valve dispenser includes a material supply configured to store a material; a hammer configured to be reciprocated on an axis; a diaphragm including a flexible body and a diaphragm pin, the diaphragm pin aligned with the hammer to be impacted by the hammer; a heater block; a nozzle plate connected to the heater block, the nozzle plate including a material fitting fluidly connected to the material supply to receive the material from the material supply, an atomization fitting configured to receive a first flow of compressed gas into the nozzle plate, and an atomization bore formed in the nozzle plate and fluidly connected to the atomization fitting to receive the first flow of compressed gas; and a nozzle supported by the nozzle plate, the nozzle fluidly connected to the material fitting to receive the material, wherein the nozzle is at least partially disposed within the atomization bore such that an exterior of the nozzle contacts the first flow of compressed gas within the atomization bore.

[0011] According to another additional or alternative aspect of the disclosure, a jet dispensing system includes a jet valve dispenser and a controller. The jet valve dispenser includes a material supply configured to store a material; a hammer configured to be reciprocated on an axis; a diaphragm including a flexible body and a diaphragm pin, the diaphragm pin aligned with the hammer to be impacted by the hammer; a heater block; a nozzle plate connected to the heater block, the nozzle plate including a material fitting fluidly connected to the material supply to receive the material from the material supply, an atomization fitting configured to receive a first flow of compressed gas into the nozzle plate, and an atomization bore formed in the nozzle plate and fluidly connected to the atomization fitting to receive the first flow of compressed gas; and a nozzle supported by the nozzle plate, the nozzle fluidly connected to the material fitting to receive the material, wherein the nozzle is at least partially disposed within the atomization bore such that an exterior of the nozzle contacts the first flow of compressed gas within the atomization bore. The controller operably connected to the jet valve dispenser, the controller configured to control operation of the jet valve dispenser based on at least one control parameter.

[0012] The present summary is provided only by way of example, and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of the present disclosure, including the entire text, claims, and accompanying figures.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is an isometric view of a jet dispensing system.

[0015] FIG. 2A is a simplified cross-sectional view showing a jet dispensing system in a load state. FIG. 2B is a simplified cross-sectional view showing a jet dispensing system in a dispense state.

[0016] FIG. 3 is an isometric view of a jet dispenser.

[0017] FIG. 4 is a partially exploded view of a jet dispenser.

[0018] FIG. 5 is a cross-sectional view of a jet dispenser with air assist.

[0019] FIG. 6 is an isometric view of a bottom plate.

[0020] FIG. 7A is a first isometric view of a base plate.

[0021] FIG. 7B is a second isometric view of a base plate.

[0022] FIG. 8A is a plan view of a shaping block.

[0023] FIG. 8B is an isometric view of a shaping block.

[0024] FIG. 9 is an exploded view of a bottom plate further showing a baffle tool.

[0025] FIG. 10 is a cross-sectional view of a bottom plate also showing a baffle tool.

[0026] FIG. 11 is a plan view showing material deposition on a substrate.

[0027] While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents embodiments by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale, and applications and embodiments of the present disclosure may include features and components not specifically shown in the drawings.

[0028] DETAILED DESCRIPTION

[0029] According to aspects of the present disclosure, a jet dispenser includes an air assist that interacts with the emitted material to form a spray pattern. The air assist includes compressed air that is configured to impinge on the dispensed material and cause the material to disperse into a desired pattern, such as a fan, cone, round pattern, etc. In some examples, the compressed gas, such as compressed air among other options, is emitted as multiple discrete outputs of compressed air. In such an example, the compressed air can include an atomization portion and a shaping portion. The atomization portion of the compressed air is configured to atomize the emitted material and complete the atomization of the pattern, preventing undesired tailing and providing for a smooth, even application. The shaping portion of the compressed air is configured to shape the spray into a desired pattern. The spray material is emitted through a nozzle and the compressed gas is emitted at locations about the nozzle. The atomization air is emitted throughout operation while the shaping air can be set by the user between no flow and a maximum flow. The air assist allows for emission and generation of wider and thinner swaths of material on a target substrate.

[0030] FIG. 1 is an isometric view of jet dispensing system 10. Jet dispensing system 10 includes controller 12, jet dispenser 14, and positioning table 16. A target substrate 18 is also shown. User interface 20 of controller 12 is shown.

[0031] Controller 12 is operably connected to other components of jet dispensing system 10, electrically or communicatively, to control operation of components of jet dispensing system 10. For example, controller 12 can be operatively connected to one or more of air supplies, positioning components for jet dispenser 14, positioning components of positioning table 16, etc. Controller 12 can be of any desired configuration for controlling operation of jet dispensing system 10 and can include control circuitry (e.g., one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), other equivalent discrete or integrated logic circuitry, etc.) and computer-readable memory. Controller 12 is configured to store executable code, implement functionality, and / or process instructions. Controller 12 is configured to perform any of the functions discussed herein, including controlling operation of any components referenced herein. Controller 12 can be of any suitable configuration for controlling operation of jet dispensing system 10, gathering data, processing data, etc. Controller 12 can include hardware, firmware, and / or stored software. Controller 12 can be of any type suitable for operating in accordance with the techniques described herein. While controller 12 is illustrated as a single unit, it is understood that controller 12 can be entirely or partially mounted on one or more circuit boards. In some examples, controller 12 can be implemented as a plurality of discrete circuitry subassemblies. In the example shown, a display screen, mouse, and keyboard are shown as forming the user interface 20 of controller 12, though it is understood that other components and / or combinations of components are possible.

[0032] Jet dispenser 14, which can also be referred to as a jet valve dispenser, is configured to output material onto the target substrate 18. Jet dispenser 14 is movable relative to the substrate 18. In some examples, jet dispenser 14 is movable in the Z-direction, towards and away from the positioning table 16, and is movable in the X-direction and Y-direction transversely relative to the positioning table 16. Positioning table 16 is configured to position the target substrate 18 relative to jet dispenser 14. In some examples, positioning table 16 is operable to shift the target substrate 18 in the X-direction and the Y-direction. Jet dispensing system 10 is configured to output discrete drops of material for application on the substrate. As discussed in more detail below, the jet dispensing system 10 includes an air assist that is configured to atomize the droplet into a spray pattern by way of atomization air. The air assist can further include shaping air that is configured to manipulate the spray pattern caused by the atomization air into a desired shape.

[0033] FIG. 2A is a simplified cross-sectional view showing jet dispenser 14 in a load state. FIG. 2B is a simplified cross-sectional view showing jet dispenser 14 in a dispense state. FIGS. 2A and 2B are discussed together. Nozzle plate 22, nozzle 24, heater block 26, material supply 28, supply hose 30, hammer 32, and diaphragm 34 of jet dispenser 14 are shown. Flexible body 36 and diaphragm pin 38 of diaphragm 34 are shown. Jet dispenser 14 operates similar to the jet dispensers disclosed and discussed in U.S. Pat. No. 10,099,238, assigned to Graco Minnesota Inc., the disclosure of which is hereby incorporated by reference in its entirety.

[0034] Nozzle plate 22 is fluidly connected to material supply 28 to receive flows of the material to be dispensed from material supply 28. Supply hose 30 extends between material supply 28 and nozzle plate 22. Nozzle 24 is supported by nozzle plate 22. The material is output from jet dispenser 14 through nozzle 24. In some examples, nozzle 24 is formed separately from nozzle plate 22 and assembled to nozzle plate 22. In the example shown, the nozzle 24 is formed separately form the nozzle plate 22 and mounted to the nozzle plate 22. It is understood, however, that in some examples, nozzle 24 can be integrally formed with nozzle plate 22. In some examples, the nozzle 24 and nozzle plate 22 can be monolithically formed.

[0035] Heater block 26 is configured to heat the nozzle plate 22 and thus the material flowing to nozzle 24 and within nozzle plate 22, which heating can affect the viscosity, and thus the quality, of the resultant drops of material dispensed from jet dispenser 14. Nozzle plate 22 is mounted to heater block 26.

[0036] Diaphragm 34 is disposed between heater block 26 and nozzle plate 22. The flexible body 36 of diaphragm 34 can be captured between nozzle plate 22 and heater block 26. The flexible body 36 of diaphragm can be mounted to heater block 26 and then secured in place by nozzle plate 22. Diaphragm pin 38 is supported by flexible body 36. Diaphragm pin 38 is configured to be contacted by hammer 32 and is configured to be driven into a seat. The momentum transferred to the material by the diaphragm pin 38 being driven by hammer 32 drives the material out of nozzle 24 as a drop of the material. Hammer 32 is configured to impact and displace diaphragm pin 38 to cause emission of drops of the material. In some examples, the hammer 32 is pneumatically displaced, though it is understood that other configurations are possible.

[0037] During operation, material flows from the material supply 28 to a chamber within nozzle plate 22. The hammer 32 is activated and displaces towards the diaphragm 34 to impact the diaphragm pin 38 and drive the diaphragm pin 38. The diaphragm pin 38 is displaced and causes emission of a drop of the material. The hammer 32 is reciprocated to cause emission of the multiple drops of the material.

[0038] FIG. 3 is an isometric view of jet dispenser 14. Nozzle plate 22, heater block 26, material supply 28, supply hose 30, jet pressure hose 40, material pressure hose 42, air assist hose 44, jet solenoid 46, and air assist solenoid 48 of jet dispenser 14 are shown.

[0039] Material supply 28 is configured to hold a supply of material for dispensing by jet dispenser 14. Material pressure hose 42 is fluidly connected to material supply 28 and is configured to pressurize material supply 28 to assist in flowing of material to nozzle plate 22. For example, material pressure hose 42 can be configured to supply compressed gas (e.g., compressed air among other options) to material supply 28. In some examples, the compressed gas provided to material supply 28 can act on a piston or other component that pushes on the material to assist in driving the material.

[0040] Heater block 26 is configured to heat the material flowing to nozzle 24, such as to affect the viscosity of the material. Heater 26 can heat nozzle plate 22 such that heat is transferred to and through nozzle plate 22, such as to the material and to the nozzle 24 itself. Nozzle plate 22 is mounted to heater block 26. Nozzle plate 22 is configured to receive flows of both material and compressed gas. Nozzle plate 22 is fluidly connected to material supply 28 by supply hose 30 to receive the material from material supply 28. The material flows within nozzle plate 22 to nozzle 24 for dispensing. Air assist hose 44 is fluidly connected to nozzle plate 22 and is configured to supply flow of compressed gas for flowing to nozzle plate 22. Air assist hose 44 can be connected to air assist solenoid 48 from which the assist air can flow to nozzle plate 22. The flow of assist air to nozzle plate 22 can be controlled via air assist solenoid 48. Air input hose 50 extends to nozzle plate 22 and is connected to nozzle plate 22 to provide compressed gas to nozzle plate 22.

[0041] Jet pressure hose 40 is configured to provide compressed gas for controlling operation of material dispensing. In the example shown, the jet pressure hose 40 is configured to provide pneumatic pressure for operating the hammer 32 to cause emission of the material. Jet solenoid 46 is configured to control flows of air to the hammer 32 to control actuation of the hammer 32 and thus dispensing of the material.

[0042] During operation, the controller 12 is used to set parameters for the jet dispenser 14 operation. The following parameters can be independently set on the controller 12: a) Fluid Pressure-applies a force to the material inside the material supply 28 to assist moving fluid into nozzle plate. Typical range between 10 -70 psi. b) Jet Pressure -Force applied to hammer 32. Typically the higher the jet pressure, the smaller the dot size. Typical range between 40-70psi. c) Refill(on timej-Amount of time hammer 32 is open for. Time input in milliseconds (ms), d) Dwell (off time) -Amount of time hammer 32 is closed for, allowing for fluid pressure to fill volume to material pressure setting. Time input in milliseconds (ms), e) Nozzle Temperature-adjusts the nozzle plate 22 temperature to adjust the viscosity of the material being dispensed so it flows through the nozzle 24 and allows for material to break off cleanly from the nozzle 24. Other parameters can be adjusted to achieve desired spray quality, such as: a) Hammer Gap - distance between the hammer 32 and diaphragm pin 38 to adjust the force acting on the material, b) Nozzle Size and Geometry -Nozzles come in various shapes (e.g., flat, 3mm capillary, 6mm capillary, 10mm capillary) and orifice sizes (e.g., 50pm up to 700pm) as well as ball geometry (e.g., 01.6mm and 03.0mm). c) Nozzle Distance -The nozzle distance often has a large role in the overall height of the bead and how the dot exits straight to the targeted surface.

[0043] When dispensing with assist air, an additional controllable parameter is the air pressure of the assist air. The atomizing air pressure used to create a spray pattern can have a large impact on the spray quality. If the pressure is too low, there may not be sufficient atomization of the spray pattern. If the pressure is too high, this can push material to the outside edges of the dispense pattern creating a thicker coating in that area.

[0044] When a dispense cycle is initiated, the fluid pressure acts on the material in the material supply 28 which causes the material to flow through the supply hose 30 to the nozzle plate 22. The jet pressure acts against the hammer 32 which forces the hammer 32 down, hitting the diaphragm pin 38. The diaphragm pin 38 transfers the motion through the material stream, dispensing a small dot or drop of material out through the nozzle 24. The jet dispenser 14 can be programmed to dispense separate dots or beads of material. For a bead dispense, the jet dispenser 14 still dispenses individual dots, but the dots overlap to form a solid bead of material.

[0045] It has been found that the following jet parameters have a large impact on spray pattern: A) Nozzle Size -The nozzle size plays the largest role in the volume of material if all other settings were the same. A 50pm nozzle produced a thinner coating compared to the 100pm nozzle.

[0046] B) Fluid Pressure -The fluid pressure has the next largest impact on the volume of material that is jetted. In conjunction with the refill / dwell time, this is one of the larger parameters that can be used to adjust the dot size.

[0047] C) Refill / Dwell (on / off) Time -The refill / dwell which also is referred to as on / off times help control the volume of material that is jetted. The refill / dwell time in conjunction with the fluid pressure plays the next largest impact on the volume of material that is jetted. The hammer 32 can be set to have a desired reciprocation rate, such as up to 300 Hz (up to 300 drops per second).

[0048] D) Z-Height-The distance from the substrate can have a large impact on the spray quality. If the distance to the substrate is too low, the atomizing air can distort the spray pattern.

[0049] E) Atomizing Air -The atomizing air pressure used to create a spray pattern has a large impact on the spray quality. If the pressure is too low, there may not be sufficient atomization of the spray pattern. If the pressure is too high, this can push material to the outside edges of the dispense pattern creating a thicker coating in that area. Typically as the atomizing air is increased, the pattern width is increased as well.

[0050] F) Material Surface -The material surface has an impact on the spray quality. When spraying on glass placards, which has a higher surface energy compared to aluminum foil, the atomizing air had a higher tendency to push out to the edges of the spray pattern; however, when spraying on the aluminum foil, it appears the spray pattern is fairly uniform across the entire dispense.

[0051] FIG. 4 is an exploded view of a portion of a jet dispenser 14. Nozzle plate 22, nozzle 24, heater block 26, and diaphragm 34 are shown. Nozzle plate 22 includes top plate 52 and bottom plate 54. Top plate 52 includes material fitting 56. Bottom plate 54 includes atomization fitting 58.

[0052] Diaphragm 34 is disposed between nozzle plate 22 and heater block 26. Diaphragm 34 is mounted to heater block 26 in the example shown. Top plate 52 and bottom plate 54 are assembled together to form nozzle plate 22. In the example shown, bottom plate 54 includes plate slot 60 that is configured to receive the top plate 52. As such, the top plate 52 can be recessed into the bottom plate 54 such that the nozzle plate 22 has a generally planar top surface for mounting to the heater block 26. Nozzle 24 is formed separately from top plate 52 and bottom plate 54 in the example shown. Nozzle 24 is captured between top plate 52 and bottom plate 54. Nozzle 24 includes dispense tip 62, which extends to a distal end including an outlet orifice out of which the material exits from jet dispenser 14. Nozzle 24 can extend at least partially through nozzle plate 22 in some examples.

[0053] With top plate 52 and bottom plate 54 assembled together, such as by fasteners, the nozzle 24 is captured and retained in position. Material fitting 56 extends from top plate 52. Material fitting 56 is configured to connect to a material supply hose, such as supply hose 30 (FIGS. 2A and 2B). Material enters into the nozzle plate 22 through the material fitting 56 and flows to the nozzle 24. Atomization fitting 58 extends from bottom plate 54. Atomization fitting 58 is configured to receive compressed gas into nozzle plate 22, such as from air input hose 50. It is understood that, in some examples bottom plate 54 can include multiple fittings for intake of compressed gas, such as atomization fitting 58 for intake of atomization air and a shaping fitting 98 for intake of shaping air.

[0054] FIG. 5 is a cross-sectional view of jet dispenser 14 with air assist. Nozzle plate 22, nozzle 24, heater block 26, hammer 32, and diaphragm 34 of jet dispenser 14 are shown. Top plate 52 and bottom plate 54 of nozzle plate 22 are shown. Material chamber 64 is formed within top plate 52 between nozzle 24 and diaphragm 34. Bottom plate 54 includes atomization fitting 58, atomization chamber 66, atomization passages 68, and outlet baffle 70.

[0055] Nozzle plate 22 is configured to receive flows of material and compressed gas. The material flows to material chamber 64 at least partially defined by top plate 52. Diaphragm 34 further defines material chamber 64. Diaphragm 34 can be displaced by hammer 32 impacting diaphragm pin 38. Diaphragm pin 38 extends fully through flexible body 36 of diaphragm 34 such that diaphragm pin 38 is configured to be contacted by hammer 32 and is configured to impact seat 72 to cause a dispense of material. Diaphragm pin 38 is supported by flexible body 36 such that flexible body 36 can withdrawn diaphragm pin 38 from seat 72 when hammer 32 is retracted and spaced from diaphragm pin 38. Hammer 32 is configured to reciprocate on axis DA to impact diaphragm 34 and cause emission of drops of the material.

[0056] Nozzle 24 is disposed between top plate 52 and bottom plate 54. Nozzle 24 can be considered to be captured or clamped between top plate 52 and bottom plate 54. Bottom plate 54 is connected to top plate 52. In some examples, bottom plate 54 is directly connected to top plate 52, such as by fasteners. Nozzle plate 22 is mounted to heater block 26. Heater block 26 can heat nozzle plate 22, through which heat can be transferred to nozzle 24 and the material and the compressed gas within nozzle plate 22.

[0057] Nozzle 24 projects within bottom plate 54 to dispense tip 62. Material exits from nozzle 24 though dispense tip 62. In the example shown, dispense tip 62 is recessed within bottom plate 54 such that dispense tip 62 does not project beyond bottom plate 54. Dispense tip 62 is recessed from bottom edge 74 of bottom plate 54. Recessing dispense tip 62 from bottom edge 74 causes the material to exit from nozzle 24 at a location still within and overlapped by bottom plate 54. The material thus exits from dispense tip 62 at a location where the atomization air is contained and can interact with the material exiting from dispense tip 62 to atomize the material.

[0058] Atomization fitting 58 extends from nozzle plate 22. In the example shown, atomization fitting 58 extends from bottom plate 54 of nozzle plate 22. Atomization fitting 58 can be a barbed fitting, among other options. Atomization fitting 58 is configured to connect to a hose to provide compressed gas to nozzle plate 22. Atomization chamber 66 is formed within bottom plate 54. Atomization chamber 66 is configured to receive compressed gas. Nozzle 24 is at least partially disposed within atomization chamber 66. Atomization passage 68 extends between and fluidly connects inlet bore 76 and atomization chamber 66. It is understood that bottom plate 54 can include one or more atomization passages 68 for providing atomization air to atomization chamber 66.

[0059] Atomization bore 67 is formed in nozzle plate 22, and specifically in bottom plate 54 of nozzle plate 22. The atomization bore 67 extends fully through the bottom plate 54. A shoulder 69 extends into the atomization bore 67. The shoulder 69 is configured to support the nozzle 24. Atomization bore 67 is disposed coaxially with hammer 32 on axis DA in the example shown. Nozzle 24 is disposed coaxially with hammer 32 on axis DA in the example shown.

[0060] Atomization chamber 66 can be considered to extend to bottom edge 74 of bottom plate 54. Atomization chamber 66 is formed in atomization bore 67. Baffle 70 is mounted in atomization bore 67. For example, baffle 70 can be threadedly connected to bottom plate 54 within atomization chamber 66. In some examples, baffle 70 is movable relative to atomization bore 67 along axis DA to readjust the position of baffle 70 and baffle orifice 82 relative to nozzle 24. Such adjustment can vary the axial distance between baffle orifice 82 and outlet orifice 84, which can affect the interaction of the atomization air with the material drop and change the resultant spray pattern. In the example shown, baffle 70 divides the atomization chamber 66 into an inner portion 78 and an outer portion 80. Baffle orifice 82 extends through baffle 70. Baffle orifice 82 is a smallest diameter portion of the atomization chamber 66 within the atomization bore 67. Baffle orifice 82 forms a smallest area portion of a flowpath for the compressed gas within the atomization bore 67. Baffle orifice 82 is disposed coaxially on axis DA, in the example shown. It is understood that baffles 70 having different sizes of baffle orifice 82 can be utilized to provide the desired atomization. In some examples, baffles 70 are removable and replaceable to provide a desired baffle orifice 82 size for the size of nozzle 24 actually being used. As such, the user is not required to utilize a new bottom plate 54 but can instead simply swap baffles 70 and nozzles 24.

[0061] Nozzle 24 can project through baffle orifice 82 such that dispense tip 62 is disposed in outer portion 80 of atomization chamber 66 and such that nozzle 24 outputs material within outer portion 80. Baffle 70 narrows towards baffle orifice 82 such that baffle orifice 82 forms a constriction for the atomization air to flow between inner portion 78 and outer portion 80. The constriction through baffle 70 can accelerate the atomization air and guide the atomization air towards the outlet orifice 84 of nozzle 24 through which the material is dispensed, providing for improved atomization and a high quality resultant spray pattern.

[0062] In the example shown, a surface of baffle 70 defining inner portion 78 narrows towards baffle orifice 82 and is sloped. The narrowing portion of baffle 70, including the inner surface 86, guides the atomization air to the baffle orifice 82 and can accelerate the atomization air though baffle orifice 82. In the example shown, a surface of baffle 70 defining outer portion 80 expands away from baffle orifice 82 and is sloped. The expanding portion of baffle 70, including the outer surface 88, allows for the atomization air to expand and can turbulate the flow as the atomization air moves out through outer portion 80, enhancing atomization of the material emitted from nozzle 24. let dispenser 14 provides significant advantages. let dispenser 14 is configured to emit discrete drops of material for each stroke of the hammer 32, which hammer 32 can also be referred to as a hammer piston. Jet dispenser 14 includes an air assist that is configured to atomize the drop of material prior to that material contacting the target substrate. The atomization air facilitates formation of wider and thinner tracks of material than generating the drops without the assisting air. Such a configuration is particularly effective for coating and reduces material cost required to cover larger surface areas. As shown below in FIG. 11, the atomization air facilitates formation of wider bands of material. FIG. 6 is an isometric view of a bottom plate 54 of a nozzle plate 22. In the example shown, bottom plate 54 is configured to emit flows of both atomization air and shaping air. Bottom plate 54 includes base plate 90 and shaping block 92. Support ridge 94, nozzle receiver 96, baffle 70, and atomization fitting 58 of base plate 90 are shown. Shaping fitting 98, shaping outlets 100, and shaping groove 102 of shaping block 92 are shown.

[0063] Bottom plate 54 is configured to modify the droplet shape of a droplet emitted from jet dispenser 14. In the example shown, bottom plate 54 is configured to emit both atomization air, for atomizing the droplet, and shaping air, for shaping the resultant atomized flow into a desired pattern. For example, the shaping air can be utilized to cause a wider or narrower fan of the material atomized by the atomization air.

[0064] In the example shown, base plate 90 is configured to handle flows of atomizing air and shaping block 92 is configured to handle flows of shaping air. Shaping block 92 is formed separately from and mounted to base plate 90 in the example shown. It is understood, however, that bottom plate 54 can be formed monolithically such that shaping block 92 and base plate 90 are integral and not detachable from each other.

[0065] Shaping block 92 is disposed on base plate 90. In the example shown, base plate 90 includes a projecting support ridge 94. The shaping block 92 mounts over the support ridge 94. Support ridge 94 extends into a locating groove 104 formed in shaping block 92 to prevent rotation of shaping block 92 relative to base plate 90. Mount bore 106 extends through shaping block 92. Mount bore 106 is configured to receive nozzle receiver 96 formed by a portion of base plate 90. Nozzle receiver 96 at least partially defines atomization chamber 66. Baffle 70 is mounted within nozzle receiver 96. Baffle orifice 82 extends through baffle 70.

[0066] Shaping groove 102 is configured to be oriented outward away from base plate 90. Shaping groove 102 extends fully laterally across shaping block 92 in the example shown. The shaping groove 102 is defined between side walls 114 that are sloped to expand the width of shaping groove 102 away from nozzle receiver 96. Shaping groove 102 is open such that shaping groove 102 does not restrict flow of atomization air and the atomized material drop.

[0067] Shaping outlets 100 are configured to emit shaping air for shaping of the atomized material. In the example shown, at least one shaping outlet 100 is formed through each side wall 114. The shaping outlets 100 are aligned with each other and baffle orifice 82. While bottom plate 54 is described as including shaping block 92, it is understood that not all examples are so limited. Base plate 90 can form the entirety of bottom plate 54 in examples in which shaping air is not needed or not desired.

[0068] During operation, atomization air is provided to bottom plate 54 through atomization fitting 58. As discussed above, the atomization air flows to an atomization chamber 66 and through baffle orifice 82 in baffle 70. Shaping air is provided to shaping block 92 through shaping fitting 98. The shaping air is emitted through shaping openings 100. The flow of shaping air can be controlled by the user to adjust a shape of the resultant spray pattern. The flows of shaping and atomization air are kept separate within bottom plate 54 and do not combine until after exiting from bottom plate 54.

[0069] FIG. 7 A is an isometric view of a first side of a base plate 90. FIG. 7B is an isometric view of a second side of base plate 90. FIGS. 7A and 7B are discussed together. Plate body 110, support ridge 94, top plate slot 60, nozzle receiver 96, and atomization fitting 58 of base plate are shown.

[0070] Base plate 90 is configured to receive flows of atomization air. Atomization fitting 58 extends from plate body 110. Support ridge 94 projects from a same side of plate body 110 as nozzle receiver 96, the first side 111 in the example shown. Support ridge 94 and nozzle receiver 96 are formed on an opposite side of plate body 110 from plate slot 60, which plate slot 60 extends into second side 113 of plate body 110. Support ridge 94 can at least partially define flowpaths for the atomization air. Support ridge 94 can further interface with shaping block 92 to locate shaping block 92 on base plate 90.

[0071] Nozzle receiver 96 projects away from plate body 110. Specifically, nozzle receiver 96 extends from first side 111 of plate body 110. Nozzle receiver 96 can be a cylindrical projection, among other options. Atomization chamber 66 is formed within nozzle receiver 96. The baffle 70 is not shown in FIGS. 7A and 7B for clarity. Various openings extend through plate body 110 and provide locations for fasteners to connect to a top plate 52 and to connect base plate 90 to heater block 26.

[0072] FIG. 8A is a plan view of a first side of shaping block 92. FIG. 8B is an isometric view of a second side of shaping block 92. FIGS. 8A and 8B are discussed together. Block body 112, shaping fitting 98, shaping outlets 100, mount bore 106, shaping groove 102, and locating groove 104 of shaping block 92 are shown. Shaping block 92 is configured to receive and output flows of shaping air.

[0073] Shaping fitting 98 extends from block body 112. Shaping fitting 98 is configured to connect to a supply hose that provides the shaping air to shaping block 92. Mount bore 106 extends through block body 112. Mount bore 106 is configured to receive nozzle receiver 96 with shaping block 92 mounted on base plate 90.

[0074] Locating groove 104 is formed on a first side of block body 112. Locating groove 104 extends partially across block body 112. Locating groove 104 extends between an edge of block body 112 and mount bore 106. Locating groove 104 is configured to receive support ridge 94 to locate shaping block 92 on base plate.

[0075] Shaping groove 102 is formed on a second side of block body 112 opposite the first side of block body 112. Shaping groove 102 extends fully across block body 112 such that each end of the shaping groove 102 is open. The side walls 114 of shaping groove 102 are sloped such that a width of shaping groove 102 narrows towards a base of shaping groove 102. Shaping outlets 100 are formed through block body 112. Shaping air is emitted through shaping outlets 100. In the example shown, shaping outlets 100 are formed through side walls 114 defining shaping groove 102. An opening extends through block body 112 offset from mount bore 106 and is configured to allow a fastener to pass through block body 112 to secure shaping block 92 to base plate 90.

[0076] FIG. 9 is an exploded view of a bottom plate 54 for a nozzle plate 22, further showing baffle tool 116 for installation, removal, or positional adjustment of the baffle 70. Base plate 90, shaping block 92, baffle 70, and baffle tool 116 are shown. Baffle 70 is removably mountable in atomization bore 67 formed in nozzle receiver 96. In the example shown, baffle 70 includes mount slots 122 formed into a distal face of baffle 70, the distal face oriented out of the atomization bore 67 and away from top plate 52. The mount slots 122 do not extend through or intersect with outer surface 88 of baffle 70. As such, the mount slots 122 do not affect flow of the atomization air after that atomizing air has exited through baffle orifice 82.

[0077] Baffle tool 116 includes handle 118 and prongs 120. Handle 118 is configured to be gripped by a user during installation, removal, or positional adjustment of baffle 70. Prongs 120 are configured to extend into mount slots 122 such that the user can torque baffle 70 by the prongs 120 being within the mount slots 122. Such a configuration allows the user to twist the baffle 70 such as for forming a threaded interface between baffle 70 and the interior of atomization bore 67.

[0078] FIG. 10 is a cross-sectional view of bottom plate 54 for a nozzle plate 22. FIG. 10 further shows baffle tool 116 for installation, removal, or positional adjustment of the baffle 70. Bottom plate 54 includes base plate 90 and shaping block 92. Nozzle 24 projects within bottom plate 54 to dispense tip 62. Material exits from nozzle 24 though outlet orifice 84 in dispense tip 62. In the example shown, dispense tip 62 is recessed within bottom plate 54 such that dispense tip 62 does not project beyond bottom plate 54. Recessing dispense tip 62 from bottom edge 74 causes the material to exit from nozzle 24 at a location still within and overlapped by bottom plate 54. The material thus exits from dispense tip 62 at a location where the atomization air is contained and can interact with the material exiting from dispense tip 62 to atomize the material.

[0079] Atomization fitting 58 extends from nozzle plate 22. In the example shown, atomization fitting 58 extends from bottom plate 54 of nozzle plate 22. Atomization fitting 58 is configured to connect to a hose to provide compressed gas to nozzle plate 22. Atomization chamber 66 is formed within bottom plate 54. Atomization chamber 66 is configured to receive compressed gas through atomization passage 68.

[0080] Atomization bore 67 is formed in nozzle plate 22, and specifically in bottom plate 54 of nozzle plate 22. The atomization bore 67 extends fully through the bottom plate 54. A shoulder 69 extends into the atomization bore 67. The shoulder 69 is configured to support the nozzle 24. Atomization bore 67 is disposed coaxially with hammer 32 on axis DA in the example shown. Nozzle 24 is disposed coaxially with hammer 32 on axis DA in the example shown. At least a portion of nozzle 24 extends through baffle orifice 82 in the example shown.

[0081] Baffle 70 is mounted in atomization bore 67. For example, baffle 70 can be threadedly connected to bottom plate 54 within atomization chamber 66. In some examples, baffle 70 is movable relative to atomization bore 67 along axis DA to readjust the position of baffle 70 and baffle orifice 82 relative to nozzle 24. Such adjustment can vary the axial distance between baffle orifice 82 and outlet orifice 84, which can affect the interaction of the atomization air with the material drop and change the resultant spray pattern. In the example shown, baffle 70 divides the atomization chamber 66 into an inner portion 78 and an outer portion 80. Baffle orifice 82 extends through baffle 70. Baffle orifice 82 is a smallest diameter portion of the atomization chamber 66 within the atomization bore 67. Baffle orifice 82 forms a smallest area portion of a flowpath for the compressed gas within the atomization bore 67.

[0082] In the example shown, a surface of baffle 70 defining inner portion 78 narrows towards baffle orifice 82 and is sloped. The narrowing portion of baffle 70, including the inner surface 86, guides the atomization air to the baffle orifice 82 and can accelerate the atomization air though baffle orifice 82. The inner surface 86 can be sloped fully annularly about the axis DA. In the example shown, a surface of baffle 70 defining outer portion 80 expands away from baffle orifice 82 and is sloped. The expanding portion of baffle 70, including the outer surface 88, allows for the atomization air to expand and can turbulate the flow as the atomization air moves out through outer portion 80, enhancing atomization of the material emitted from nozzle 24. The outer surface 88 can be sloped fully annularly about the axis DA.

[0083] In the example shown, baffle 70 includes mount slots 122 formed into a distal face of baffle 70, the distal face oriented out of the atomization bore 67 and away from top plate 52. The mount slots 122 do not extend through or intersect with outer surface 88 of baffle 70. As such, the mount slots 122 do not affect flow of the atomization air after that atomizing air has exited through baffle orifice 82.

[0084] In the example shown, baffle 70 includes baffle groove 124 formed on an exterior side of the baffle 70. The baffle groove 124 is configured to receive a seal, such as an o- ring seal, that seals between the exterior of baffle 70 and the interior of nozzle receiver 96 to prevent compressed gas leaking therebetween.

[0085] Base plate 90 is configured to handle flows of atomizing air and shaping block 92 is configured to handle flows of shaping air. Shaping block 92 is formed separately from and mounted to base plate 90 in the example shown. It is understood, however, that bottom plate 54 can be formed monolithically such that shaping block 92 and base plate 90 are integral and not detachable from each other.

[0086] Shaping passages 126 are formed in block body 112. Shaping passages 126 are fluidly connected to a passage that extends from shaping fitting 98 such that shaping passages 126 receive the compressed gas provided through shaping fitting 98. Plugs 128 are disposed in shaping passages 126 to prevent leakage of the compressed gas.

[0087] In the example shown, block grooves 130 are formed in mount bore 106. Block grooves 130 are each configured to receive a seal, such as an o-ring seal. The seals seal between the interior of mount bore 106 and the exterior of nozzle receiver 96 to prevent leakage of shaping air. As shown, the intersection between the shaping passages 126 and the upstream passage that receives compressed gas from shaping fitting 98 and provides the compressed gas to shaping passages 126 can be open to mount bore 106.

[0088] Shaping passages 126 are fluidly connected to shaping outlets 100 to provide compressed gas to shaping outlets 100. The compressed gas exits shaping outlets 100 and can interact with the atomized drop at a location downstream of baffle 70 and downstream of nozzle receiver 96. Baffle tool 116 includes handle 118 and prongs 120. Handle 118 is configured to be gripped by a user during installation, removal, or positional adjustment of baffle 70. Prongs 120 are configured to extend into mount slots 122 such that the user can torque baffle 70 by the prongs 120 being within the mount slots 122. Such a configuration allows the user to twist the baffle 70 such as for forming a threaded interface between baffle 70 and the interior of atomization bore 67.

[0089] With reference to each of the preceding figures, during operation there are multiple parameters that can be adjusted to control the quality of the resultant drop applied to the target substrate. The addition of assist air (atomization and, in some examples, shaping) provides for a higher quality pattern and can provide for wider and thinner stripes of material on the target substrate. As shown in FIG. 11, the material was applied in stripes A with the use of assist air and the material was applied in stripes B without the use of assist air. Stripes A are wider than stripes B and provide better coverage while also providing relatively flatter / thinner material deposition.

[0090] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. The particular offsets and ratios illustrated and described herein are offered only by way of example, not limitation. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

CLAIMS:

1. A bottom plate for a non-contact jet valve dispenser, the bottom plate comprising: a base plate having a plate body; an atomizing fitting extending out of the plate body from within an inlet bore formed in the plate body; and an atomization bore extending through the plate body between a first side of the plate body and a second side of the plate body, the atomization bore fluidly connected to the inlet bore to receive a first flow of compressed gas from the inlet bore.

2. The bottom plate of claim 1, further comprising: a baffle disposed within the atomization bore, wherein a baffle orifice is formed through the baffle.

3. The bottom plate of claim 2, wherein the baffle orifice is a smallest diameter portion of an atomization chamber within the atomization bore.

4. The bottom plate of any one of claims 2 and 3, wherein the baffle includes a first sloped side extending away from the baffle orifice.

5. The bottom plate of claim 4, wherein the baffle includes a second sloped side extending away from the baffle orifice.

6. The bottom plate of any one of claims 1-5, wherein a shoulder projects into the atomization bore, the shoulder configured to support a nozzle on the plate body.

7. The bottom plate of any one of claims 1-6, further comprising: a plate slot extending into the second side of the plate body and fully across a width of the plate body.

8. The bottom plate of any one of claims 1-7, further comprising: a nozzle receiver extending from the first side, the atomization bore at least partially formed in the nozzle receiver.

9. The bottom plate of claim 8, wherein the nozzle receiver is cylindrical.

10. The bottom plate of any one of claims 8 and 9, wherein a support ridge projects from the first side.

11. The bottom plate of claim 10, wherein the support ridge extends between the nozzle receiver and an edge of the plate body.

12. The bottom plate of any one of claims 10 and 11, wherein the inlet bore is at least partially disposed in the support ridge.

13. The bottom plate of any preceding claim, further comprising: a shaping block having a block body; a shaping fitting projecting from the block body; and a shaping flowpath within the block body and extending to at least one shaping outlet formed in the block body, the at least one shaping outlet configured to output a second flow of compressed gas received through the shaping fitting.

14. The bottom plate of claim 13, wherein the shaping block is removably connected to the base plate.

15. The bottom plate of any one of claims 13 and 14, wherein a mount bore extends fully through the block body, and wherein the atomization bore is at least partially disposed within the mount bore.

16. The bottom plate of any one of claims 13-15, wherein the at least one shaping outlet is disposed in a side wall of a shaping groove extending into the block body.

17. The bottom plate of claim 16, wherein the side wall is sloped.

18. A nozzle plate for a non-contact jet valve dispenser, the nozzle plate comprising: the bottom plate of any preceding claim; and a top plate connectable to the bottom plate, the top plate including a material fitting through which a material to be dispensed enters into the nozzle plate.

19. The nozzle plate of claim 18, further comprising: a nozzle captured between the top plate and the bottom plate, the nozzle at least partially disposed within the atomization bore.

20. A jet valve dispenser comprising: a material supply configured to store a material; a hammer configured to be reciprocated on an axis; a diaphragm including a flexible body and a diaphragm pin, the diaphragm pin aligned with the hammer to be impacted by the hammer; a heater block; a nozzle plate connected to the heater block, the nozzle plate comprising: a material fitting fluidly connected to the material supply to receive the material from the material supply;an atomization fitting configured to receive a first flow of compressed gas into the nozzle plate; and an atomization bore formed in the nozzle plate and fluidly connected to the atomization fitting to receive the first flow of compressed gas; and a nozzle supported by the nozzle plate, the nozzle fluidly connected to the material fitting to receive the material, wherein the nozzle is at least partially disposed within the atomization bore such that an exterior of the nozzle contacts the first flow of compressed gas within the atomization bore.

21. The jet valve dispenser of claim 20, wherein the flexible body is mounted to the heater block.

22. The jet valve dispenser of any one of claims 20 and 21, further comprising: a baffle disposed within the atomization bore, wherein a baffle orifice is formed though the baffle, and wherein the baffle orifice forms a smallest area portion of a flowpath for the first flow of compressed gas within the atomization bore.

23. The jet valve dispenser of claim 22, wherein the nozzle extends through the baffle orifice.

24. The jet valve dispenser of any one of claims 22 and 23, wherein the baffle orifice is disposed coaxially with the hammer.

25. The jet valve dispenser of any one of claims 20-24, further comprising: an air assist solenoid configured to control the first flow of compressed gas to the nozzle plate.

26. The jet valve dispenser of any one of claims 20-25, wherein the nozzle plate further comprises a shaping fitting configured to receive a second flow of compressed gas into the nozzle plate.

27. The jet valve dispenser of claim 26, wherein the nozzle plate includes at least one shaping outlet fluidly connected to the shaping fitting, the shaping outlet configured to emit the second flow of compressed gas from the nozzle plate.

28. The jet valve dispenser of claim 27, wherein the at least one shaping outlet is spaced axially away from the atomization bore.

29. The jet valve dispenser any one of claims 26-28, wherein the first flow of compressed gas and the second flow of compressed gas are fluidly separated at all locations within the nozzle plate.

30. A jet dispensing system comprising: a jet valve dispenser comprising: a material supply configured to store a material; a hammer configured to be reciprocated on an axis; a diaphragm including a flexible body and a diaphragm pin, the diaphragm pin aligned with the hammer to be impacted by the hammer; a heater block; a nozzle plate connected to the heater block, the nozzle plate comprising: a material fitting fluidly connected to the material supply to receive the material from the material supply; an atomization fitting configured to receive a first flow of compressed gas into the nozzle plate; and an atomization bore formed in the nozzle plate and fluidly connected to the atomization fitting to receive the first flow of compressed gas; and a nozzle supported by the nozzle plate, the nozzle fluidly connected to the material fitting to receive the material, wherein the nozzle is at least partially disposed within the atomization bore such that an exterior of the nozzle contacts the first flow of compressed gas within the atomization bore; and a controller operably connected to the jet valve dispenser, the controller configured to control operation of the jet valve dispenser based on at least one control parameter.

31. The jet dispensing system of claim 30, wherein the at least one control parameter includes a fluid pressure applied to the material in the material supply, a jet pressure applied to drive the hammer, a refill time, a dwell time, and a nozzle temperature.

32. The jet dispensing system of claim 30, wherein the at least one control parameter is a plurality of control parameters, the plurality of control parameters includinga fluid pressure applied to the material in the material supply, a jet pressure applied to drive the hammer, a refill time, a dwell time, and a nozzle temperature.

33. The jet dispensing system of any one of claims 30-32, wherein the at least one control parameter includes a pressure of the first flow of compressed gas.

34. The jet dispensing system of any one of claims 31-33, further comprising: a positioning table configured to support a target substrate, the positioning table configured to shift the target laterally and longitudinally; and wherein the jet dispenser is movable vertically, laterally, and longitudinally relative to the positioning table.

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