Conductive Ball Mounting Head With Downward Gas-Flow Nozzles
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Solution Overview
Problem
Existing conductive ball mounting technologies, such as the cyclone head, face challenges in efficiently and accurately mounting small and lightweight conductive balls in mounting recesses of a mask due to inefficient distribution and directional issues, leading to reduced productivity and increased time requirements.
Innovation Solution
A head assembly with a parallel wall structure and inclined nozzles that utilize controlled compressed gas flows to guide conductive balls into mounting recesses, ensuring even distribution and efficient mounting across a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a cylindrical cyclone head structure is used to generate whirlwind-type air flow, then conductive balls can be accommodated in the chamber, but the conductive balls move in a horizontal direction parallel to the mask surface rather than toward the mounting recesses, reducing mounting efficiency
Solution Approach 1:
The patent inverts the traditional cylindrical cyclone head structure into a flat plate structure with the chamber formed between the upper and lower plates. This inversion changes the air flow pattern from horizontal whirlwind to vertical downward flow, directing conductive balls toward the mask surface and mounting recesses, thereby resolving the directional mismatch problem
Solution Approach 2:
The patent uses compressed air nozzles to generate controlled air flows that guide conductive balls into the mounting recesses. The air flow system is optimized to create vertical downward movement rather than horizontal circulation, ensuring balls are propelled toward the mask surface for efficient mounting
2Ease of operation
If a cylindrical cyclone head is used, then conductive balls can be supplied to the chamber, but the balls concentrate at the center of the head rather than being evenly distributed, degrading productivity when mounting on large area masks
Solution Approach 1:
The patent segments the single centralized air flow into multiple distributed nozzles arranged across the chamber. This segmentation distributes the conductive balls across a wider area of the mask surface simultaneously, preventing center concentration and enabling parallel mounting operations that improve productivity for large area masks
Solution Approach 2:
The patent transitions from a centralized vertical axis (cylindrical) to a distributed planar arrangement (flat plate with multiple nozzles). This dimensional change spreads the ball supply across the horizontal plane, achieving even distribution across the mask surface and eliminating the bottleneck of center concentration
3Quantity of substance
If the size and weight of conductive balls are reduced to tens or hundreds of micrometers, then substrate integration increases, but the balls float upward in the chamber like a tornado instead of moving toward the mask, making efficient mounting difficult
Solution Approach 1:
The patent counteracts the upward floating tendency of lightweight conductive balls by introducing downward-directed air flows from the nozzles. The air flow pressure and direction are controlled to overcome buoyancy and gravitational effects, forcing even the smallest balls to move downward toward the mask surface for accurate mounting
Solution Approach 2:
The patent changes the physical parameters of the air flow system - using controlled pressure, velocity, and direction of air jets from multiple nozzles - to effectively manipulate the movement of ultra-fine conductive balls. By adjusting these parameters, the system maintains control over ball trajectory despite their reduced mass that would otherwise cause upward floating
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 enhances the productivity and accuracy of mounting small and lightweight conductive balls by ensuring they are evenly distributed and directed into recesses, reducing the time required for the process.
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.