Dispense Tip Neck Compression for Sub-Tool Outlet Diameters
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Solution Overview
Problem
Conventional methods for manufacturing dispense tips are limited in producing outlets smaller than those achievable by the smallest available machining tools or die casts, restricting precision and control in dispensing operations for semiconductor applications.
Innovation Solution
A method involving positioning the output end of the dispense tip's neck against a die surface and applying an external force with a punch to deform the neck, reducing the outlet hole diameter from a first to a second diameter, and forming a continuous fluid path with inner and outer tapers to achieve precise fluid dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining tools or die casts are used to form dispense tip outlets, then manufacturing is feasible with standard processes, but the outlet diameter cannot be reduced below the limits of smallest available tools
Solution Approach 1:
The patent forms a preliminary larger-diameter hole through the neck using conventional machining or drilling, then subsequently reduces the diameter by deforming the neck walls inward. This preliminary action allows standard tools to create the initial hole, after which the outlet diameter is reduced below the tool size limit through controlled deformation processes.
Solution Approach 2:
The patent changes the physical state or dimensions of the neck material by applying external forces to deform the neck walls inward, reducing the outlet hole diameter from its initial larger size to a smaller final size. This parameter change enables outlet dimensions unachievable by direct conventional machining.
2Manufacturing precision
If the outlet diameter is reduced to achieve smaller dispense patterns, then dispensing precision is improved, but the risk of clogging increases
Solution Approach 1:
The patent creates a tapered geometry where the neck has different diameters at different locations - a larger inlet diameter and a smaller outlet diameter. This local quality variation allows the outlet to achieve small dimensions for precise dispensing while the larger upstream diameter maintains adequate flow capacity and reduces clogging risk.
Solution Approach 2:
The patent employs curved or tapered transition zones between the larger inlet and smaller outlet diameters, creating smooth transitions that prevent flow separation and reduce the likelihood of material accumulation and clogging at the outlet entrance.
3Ease of operation
If a tapered geometry is formed with inner and outer tapers, then material flow and pressure control are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent combines multiple functions into the single neck structure - the neck simultaneously serves as the fluid passage, the structural support element, and the geometry that provides both inner and outer tapers for flow control. This merging eliminates the need for separate components and simplifies the overall manufacturing process.
Solution Approach 2:
The neck structure is designed to perform multiple functions: it provides the fluid passage from inlet to outlet, structural support for the dispense tip, and the tapered geometry for flow control. This multi-functionality reduces the need for additional components and simplifies the overall device architecture.
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
Enables the creation of dispense tips with outlet diameters smaller than conventional limits, allowing for precise dot and line patterns with improved accuracy and reduced clogging, enhancing material flow and pressure control during dispensing.
Implementation Method 1
applying an external force to the neck to cause the output end of the neck to deform under compression by the die surface
Data Source
AI summary
A material dispense tip includes an elongated hole in an elongated neck that extends from an input end of the neck to an output end of the neck. The hole at the output end of the neck has a first diameter. The output end of the neck is positioned against a die surface. A punch is inserted into the hole at the input end of the neck. An external force is applied to the neck to cause the output end of the neck to be deformed under compression by the die surface, to reduce the diameter of the hole at the output end of the neck from the first diameter to a second diameter that is less than the first diameter.