Dispense Tip Outlet Compression for Sub-Tool Diameter Openings
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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 outlet hole, reducing its diameter from a first to a second diameter, and optionally forming tapers between the inlet and outlet holes to create a continuous fluid path with precise dimensions.
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 straightforward, but outlet diameters cannot be reduced below the limits of the smallest available tools
Solution Approach 1:
A preliminary hole is formed through the dispense tip body and neck using conventional machining tools. This preliminary hole serves as a starting point that allows subsequent deformation processes to achieve smaller outlet diameters than could be directly machined, effectively decoupling the initial manufacturing step from the final precision requirement
Solution Approach 2:
The outlet hole diameter is changed by applying external force to deform the neck material, transforming the hole from a larger preliminary diameter to a smaller final diameter. This parameter change through deformation enables outlet sizes below the limits of conventional machining tools
2Manufacturing precision
If the outlet diameter is reduced to achieve smaller dispense patterns, then dispensing precision improves, but the risk of clogging increases
Solution Approach 1:
The neck region is given different properties than the body - specifically, the neck material is made malleable to allow deformation. This local quality difference enables the outlet to be shrunk to small diameters while the broader neck structure maintains sufficient strength and open passage to resist clogging
Solution Approach 2:
A tapered configuration is created in the outlet hole, with curved transitions from the preliminary cylindrical hole to the reduced-diameter outlet. This curvature eliminates sharp corners that could trap material, reducing clogging risk while maintaining small outlet dimensions for precision dispensing
3Manufacturing precision
If a preliminary hole is formed and then deformed to reduce diameter, then outlet sizes below machining limits are achieved, but additional manufacturing steps are required
Solution Approach 1:
Multiple functions are merged into the deformation step: the external force simultaneously reduces the hole diameter, creates the tapered configuration, and shapes the outlet opening. This consolidation achieves multiple precision requirements in a single operation, offsetting the added complexity of the preliminary hole formation step
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 dispensing of fluid patterns with diameters less than 0.004 inches, enhancing precision and reducing clogging, while maintaining accurate and reliable dispensing operations.
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
Implementation Method 2
cause the output end of the neck to deform under compression by the die surface, to reduce the diameter of the hole
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.