Multi-Unit Dispensing Gantry for Viscous Substrate Deposition
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Solution Overview
Problem
Existing dispensing systems for viscous materials on electronic substrates face limitations in throughput due to the need for multiple machines and increased manufacturing space, as well as challenges in accurately positioning multiple dispensing units for high-throughput applications.
Innovation Solution
A dispensing apparatus with a common gantry system that supports multiple dispensing units, allowing for simultaneous operation and precise positioning using a vision system to align substrates and adjust the distance between units, enabling efficient dispensing on multiple substrates with reduced footprint and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple independent dispensing systems are used to increase throughput, then production rate is improved, but manufacturing space and system complexity increase
Solution Approach 1:
The patent combines multiple dispensing units (first and second dispensing units) onto a single shared gantry structure, allowing them to operate simultaneously on different substrates while occupying the same physical space. This merging approach enables increased throughput without proportionally increasing manufacturing footprint, as the dispensing units share common support infrastructure and operational space.
Solution Approach 2:
The patent arranges dispensing units in a vertical or multi-layer configuration on the gantry, utilizing the Z-axis dimension rather than only horizontal expansion. By positioning dispensing units at different heights or vertical levels, the system achieves multi-substrate capability without requiring proportional horizontal space expansion, effectively transitioning from 2D to 3D space utilization.
2Productivity
If multiple independent dispensing systems are used to increase throughput, then production rate is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple dispensing units onto a single gantry with shared control systems, positioning, and support structures. This consolidation reduces the number of independent systems required, simplifying overall system architecture while maintaining multi-substrate dispensing capability and high throughput.
Solution Approach 2:
The gantry structure serves multiple functions: it supports and positions multiple dispensing units, provides common motion control, and enables coordinated operation across different substrates. This multi-functionality reduces the need for separate dedicated systems, thereby reducing overall device complexity while achieving high productivity.
3Productivity
If multiple dispensing units are positioned on a common gantry, then throughput is improved, but positioning accuracy becomes more difficult
Solution Approach 1:
The patent incorporates a vision system that provides real-time feedback on substrate positions and dispensing unit locations. This feedback mechanism enables dynamic adjustment and calibration of positioning, ensuring accurate material deposition even when multiple units operate simultaneously on the same gantry, thereby maintaining manufacturing precision while achieving high throughput.
4Device complexity
If a single dispensing system is used, then device complexity is reduced, but throughput is limited
Solution Approach 1:
The patent segments a single dispensing system into multiple independent dispensing units that can operate simultaneously on different substrates or different locations on the same substrate. Each unit functions independently but is coordinated through a shared control system, thereby multiplying throughput while maintaining the simplicity of a unified system architecture.
Solution Approach 2:
The patent extends a single gantry system into the vertical dimension, allowing multiple dispensing units to be positioned at different heights or vertical levels. This three-dimensional arrangement enables simultaneous operation on multiple substrates stacked vertically or arranged in layers, increasing throughput without requiring proportional horizontal expansion or additional independent systems.
Data Source
AI summary
A dispensing apparatus includes a frame, a support coupled to the frame to receive electronic substrates, a first dispensing unit to dispense viscous material, a second dispensing unit to dispense viscous material, and a gantry coupled to the frame. The gantry includes a first Z drive mechanism to support the first dispensing unit and lower the first dispensing unit toward a first electronic substrate pattern when performing a dispense operation, and a second Z drive mechanism to support the second dispensing unit and lower the second dispensing unit toward a second electronic substrate pattern when performing a dispense operation. The second Z drive mechanism may be adjusted relative to the first Z drive mechanism a predetermined distance. A controller controls a dispense operation of the first dispensing unit on the first electronic substrate pattern and a dispense operation of the second dispensing unit on the second electronic substrate pattern.