Dispense Tip Outlet Resizing for Ultra-Fine Fluid Dispensing
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Solution Overview
Problem
Existing methods for manufacturing dispense tips are limited in their ability to produce outlets smaller than those achievable by the smallest available machining tools or die casts, hindering precision in dispensing operations.
Innovation Solution
A method involving positioning the output end of the dispense tip's neck against a die surface, inserting a punch into the input end of the neck, and applying an external force to deform the neck, reducing the outlet hole diameter from a first diameter to a second diameter that is less than the first.
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 processes are simple and reliable, but the outlet diameter cannot be reduced below the limits of available tools
Solution Approach 1:
The manufacturing process is divided into two distinct stages: first forming the basic tip structure with a relatively large outlet hole using conventional machining or die casting, then separately reducing the outlet hole diameter through a second deformation process. This segmentation allows each stage to be optimized independently, achieving small outlet dimensions without requiring ultra-precise initial machining.
Solution Approach 2:
The outlet hole is pre-formed with a larger diameter using standard manufacturing techniques, and the reduction to the final small diameter is achieved as a subsequent action. This preliminary formation allows the use of reliable conventional processes for the bulk material shaping, while the final precision is achieved through controlled deformation.
2Measurement precision
If the outlet hole diameter is reduced to dispense smaller fluid volumes, then dispensing precision is improved, but the manufacturing capability is exceeded by available tools
Solution Approach 1:
The outlet hole diameter parameter is changed through mechanical deformation rather than through tool removal. By applying compressive force to the tip material, the outlet hole diameter is reduced from its initial machined size to the final smaller dimension, bypassing the limitation of minimum drill or die cast sizes.
Solution Approach 2:
The conventional mechanical removal process (drilling, milling, or die casting) is replaced with a mechanical deformation process. Instead of using a cutting tool to remove material to create the small outlet hole, the tip material is deformed plastically to reduce the hole diameter, substituting one mechanical process for another that overcomes the tool size limitation.
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
This approach enables the formation of dispense tips with outlet holes of smaller diameters than previously possible, enhancing precision and control in dispensing small volumes of fluid materials.
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, to reduce the diameter of the hole at the output end of the neck
Data Source
AI summary
A dispense tip for low-volume dispensing is formed according to a process. The process comprises forming a hole through a length of a neck formed of a body of material; forming an inlet hole at a distal end of the hole, the inlet hole having a first inner diameter; forming an outlet hole at a distal end of the inlet hole, the outlet hole having a second inner diameter less than the first inner diameter, a first inner taper transitioning the inlet hole from the first inner diameter to the second inner diameter; forming an outer taper having a width that decreases along a longitudinal axis of the length of the hole in a direction of a distalmost end of the outlet hole; and reducing a width of an opening at the distalmost end of the outlet hole to a third inner diameter that is less than the second inner diameter.