Automated Masking System with Flexible Press Tool
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Solution Overview
Problem
Conventional masking and de-masking processes for electronic devices are time and labor intensive, and lack repeatability and consistency, especially when applying protective coatings that can damage subcomponents like ports and openings.
Innovation Solution
An automated masking system and method that includes a substrate loading apparatus, multiple masking material application stations (tape, hot glue, and grease) with X-Y table motion, and a conveyor system for precise application, along with an automated system for removing bubbles from tape masks and masking materials using a press tool with a flexible head and robotic arm, and a removal tool with heating elements for efficient de-masking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated masking material application is implemented, then productivity and consistency are improved, but device complexity increases
Solution Approach 1:
The automated masking system is divided into separate functional modules: substrate loading apparatus, multiple masking material application stations (tape, hot glue, grease), conveyor system, and de-masking station. Each module performs a specific function and can be independently controlled, which manages the overall system complexity while achieving high productivity through automation.
Solution Approach 2:
The automated masking system is designed to handle multiple types of masking materials (tape, hot glue, grease) and process multiple substrates sequentially. The system uses a universal conveyor apparatus that can transport various substrate types through different masking stations, allowing one system to perform multiple masking functions rather than requiring separate systems for each material type.
2Manufacturing precision
If multiple masking material application stations are used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Different masking material application stations are used for different regions or types of masking requirements on the substrate. The tape application station applies tape to specific areas, the hot glue station applies adhesive masking to other areas, and the grease station applies grease-based masking. Each station is optimized for its specific masking material and application requirements, achieving high precision for each local masking need.
Solution Approach 2:
The masking material application stations use dispensing apparatus that move relative to the substrate in repeatable motions, with the substrate moving automatically between stations. This dynamic positioning system allows precise control of masking material placement at each station while maintaining flexibility to accommodate different substrate sizes and masking patterns.
3Productivity
If automated substrate movement is implemented, then productivity is improved, but ease of operation decreases
Solution Approach 1:
The substrate loading apparatus automatically loads substrates onto the conveyor system, and the conveyor apparatus automatically transports substrates between masking stations without manual intervention. The system performs self-service substrate handling operations, which maintains ease of operation by eliminating the need for operators to manually handle each substrate while significantly improving productivity through continuous automated processing.
4Manufacturing precision
If press tool with flexible head is used for bubble removal, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The press tool uses a flexible head made of compliant material that can conform to the substrate surface and tape mask geometry. This flexible head allows the press tool to apply uniform pressure across the tape mask to remove bubbles while adapting to different substrate shapes and tape configurations, achieving high manufacturing precision without requiring a complex rigid positioning system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system streamlines the masking and de-masking process, ensuring precise application and removal of masking materials, improving efficiency and consistency, reducing labor costs, and protecting sensitive subcomponents during the application of protective coatings.
Implementation Method 1
The removal tool includes a heating element. The method further includes applying heat to the masking material during removal of the masking material.
Implementation Method 2
The press tool includes a spring buffer structure. The method includes pressing the press tool against the tape mask to remove formed bubbles from the tape mask.
Data Source
AI summary
An automated masking system includes a substrate loading apparatus designed to hold a plurality of substrates, a first masking material application station designed to automatically apply a first masking material to a portion of the substrate, and a second masking material application station designed to automatically apply a second masking material to a portion of the substrate, the second masking material being different than the first masking material. The system includes a first dispensing apparatus and a second dispensing apparatus that move relative to the substrate in a repeatable motion. The substrate moves automatically from the first masking material application station to the second masking material application station.