Conductive Ball Mounting Head With Downward Gas Flow Distribution
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Solution Overview
Problem
Existing cyclone heads struggle to efficiently mount small and light-weight conductive balls in mounting recesses of a mask due to the conductive balls floating upward in the chamber, and the uneven distribution of balls leads to reduced productivity in the conductive ball mounting process.
Innovation Solution
A head assembly with a central chamber surrounded by parallel first and second wall members, connected by connection members, and equipped with inclined main nozzles and guide recesses to control the flow of compressed gas, ensuring conductive balls are evenly distributed and directed towards the mounting recesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a cylindrical cyclone head structure is used to generate fast whirlwind-type air flow, then the conductive balls can be moved in the chamber, but the conductive balls float upward instead of moving toward the mounting recesses, reducing mounting efficiency
Solution Approach 1:
The patent inverts the conventional cyclone head structure by changing from a cylindrical vertical configuration to a rectangular horizontal configuration. The air flow direction is reversed from upward whirlwind to horizontal flow that pushes conductive balls downward toward the mounting recesses. This inversion resolves the floating upward problem while maintaining effective ball movement and distribution.
Solution Approach 2:
The patent transitions from a single-dimensional vertical cyclone flow to a multi-dimensional horizontal flow system. The rectangular chamber creates three-dimensional air flow patterns that distribute balls not only horizontally but also vertically downward toward the mask, improving both distribution uniformity and mounting efficiency.
2Device complexity
If a cylindrical cyclone head is used, then the structure is simple, but the conductive balls concentrate at the center rather than being evenly distributed, degrading productivity
Solution Approach 1:
The patent segments the single cylindrical chamber into multiple rectangular chambers with separate air flow paths. This segmentation allows independent control of air flow in different regions, enabling even distribution of conductive balls across the entire mask surface rather than concentration at a single center point, thereby improving productivity.
3Quantity of substance
If the size and weight of conductive balls are reduced, then more balls can be mounted in a unit area, but the balls float upward in the chamber making mounting difficult
Solution Approach 1:
The patent applies anti-weight principle by using horizontal air flow pressure to counteract the gravitational effect on lightweight conductive balls. The compressed air flow provides an opposing force that prevents small, light balls from floating upward uncontrollably, enabling effective mounting of high-quantity small balls without the floating problem.
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 head assembly effectively and accurately mounts small and light-weight conductive balls in all mounting recesses of a mask, significantly improving productivity by ensuring even distribution and efficient alignment of the conductive balls with the mounting recesses.
Implementation Method 1
a first main nozzle extending along a lengthwise direction of the first wall member on a lower portion of the first wall member so as to eject a compressed gas to a lower side in the central chamber; and a second main nozzle extending along a lengthwise direction of the second wall member on a lower portion of the second wall member so as to eject a compressed gas to a lower side in the second wall member
Data Source
AI summary
According to a head assembly for mounting conductive balls of the disclosure, a gas flow for moving the conductive balls in a downward direction is formed in a chamber, and thus, small and light-weight conductive balls may be effectively mounted in mounting recesses of a mask. Also, because the head assembly for mounting the conductive balls is operated in the manner of inducing the conductive balls to move in a direction in which the mounting recesses are formed, the conductive balls may be rapidly and thoroughly mounted in the plurality of mounting recesses formed in the mask.