Digital Dispense Device Multi-Mode Fluid Droplet Control

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Solution Overview

Problem

Existing methods for dispensing fluids onto or into substrates lack the ability to accurately control the volume of fluid deposited in specific areas, which is critical for applications such as medical sample analysis and micro-circuit manufacturing, and are often limited by fixed shapes and volumes, requiring either manual operation or expensive automated devices.

Innovation Solution

A method that involves selecting fixed spot size target areas and calculating the required number of droplets to achieve precise fluid deposition, allowing for dynamic adjustment of spot sizes to maximize fluid density and efficiency, combining static and dynamic dispensing techniques to accommodate varying fluid volumes and shapes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional inkjet printing is used for fluid dispensing, then the device complexity is low and ease of operation is good, but the manufacturing precision and control over fluid volume are insufficient

Engineering Contradiction:

Improvefluid volume control precisionVSAvoiddispensing system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system dynamically switches between static dispensing mode (for high volume requirements) and dynamic scanning dispensing mode (for high precision requirements). The ejection head can remain stationary over a target area or move across multiple target areas, allowing the same device to adapt to different precision and volume requirements without changing hardware configuration.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters including droplet volume, number of droplets, target area size, and ejection head movement speed to achieve different dispensing modes. By adjusting these parameters, the system can provide either high volume dispensing or high precision dispensing as needed.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If fixed shape target areas are used for dispensing, then the manufacturing precision is improved, but the adaptability to different application requirements deteriorates

Engineering Contradiction:

Improvedroplet placement precisionVSAvoidtarget area shape flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system allows dynamic selection of target area shapes and sizes based on application requirements. The control system can define arbitrary target areas with different geometries (circles, rectangles, irregular shapes) and adjust the dispensing pattern accordingly, rather than being limited to fixed predetermined shapes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The dispensing process is segmented into multiple passes when needed, allowing complex target area shapes to be filled by dividing them into smaller dispensable units. This enables precise dispensing into arbitrarily shaped areas by breaking down the overall target into manageable segments.

Inventive Principle:

Principle #1Segmentation

3Productivity

If manual dispensing methods are used, then the adaptability to different volumes and shapes is good, but the productivity and time consumption are poor

Engineering Contradiction:

Improvedispensing speedVSAvoidsample preparation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system maintains continuous dispensing action by automatically moving the ejection head between target areas and adjusting operational parameters without requiring manual intervention. The automated control ensures continuous fluid ejection and head movement, maximizing productivity and eliminating idle time associated with manual repositioning and setup.

Inventive Principle:

Principle #20Continuity of useful action

4Quantity of substance

If high volume fluid dispensing is required, then the quantity of substance is sufficient, but the manufacturing precision and area coverage control are insufficient

Engineering Contradiction:

Improvefluid volume depositedVSAvoidarea coverage precision

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts the number of passes, droplet spacing, and ejection head movement parameters to achieve both high volume deposition and precise area coverage control. By coordinating multiple dispensing passes with automated head movement, the system can distribute large volumes of fluid uniformly across target areas while maintaining precise boundary control.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11820140B2Dispense modes for multi-mode capable device

Publication Date: 2023.11.21 BRADY WORLDWIDE INC

AI summary

A system and method for ejecting one or more fluids from a digital dispense device. The method includes selecting a) fixed target areas and total fluid volumes for the target areas of the substrate; b) a predetermined droplet volume for the target areas; c) calculating a required number of droplets for the target areas; d) determining a maximum number of droplets per pixel based on the target areas; e) calculating a number of droplets per pass of an ejection head over the target areas; f) modifying one or more dimension of the target areas to create modified target areas; g) selecting and centering the modified spot size target areas in the target areas; and h) depositing fluids in the modified target areas while scanning the ejection head over the modified target areas.