Dual-Dispensing Apparatus for Simultaneous Substrate Alignment
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Solution Overview
Problem
Existing dispensing systems for viscous materials on electronic substrates face limitations in throughput due to the rate of material dispensing, alignment accuracy, and the need for multiple machines, which increases costs and space requirements.
Innovation Solution
A dual-dispensing apparatus with a common gantry system that includes two non-contact dispensing units, a vision system for alignment, and independent Z drive mechanisms to adjust the dispensing units' positions based on fiducial markers, allowing simultaneous dispensing on multiple substrates with precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single dispensing system is used, then device complexity and cost are reduced, but productivity is limited by the throughput capability of one dispense pump assembly
Solution Approach 1:
The patent combines multiple dispense pump assemblies (first and second dispensing units) into a single integrated system sharing a common gantry, frame, and controller. This merging approach enables simultaneous dispensing on multiple substrates, thereby increasing productivity while avoiding the complexity of operating completely separate dispensing systems.
Solution Approach 2:
The system divides the dispensing function into separate dispensing units (first and second dispensing units) that can operate independently on different substrates or substrate regions. Each unit has its own pump assembly and nozzle, allowing parallel operation to increase throughput while maintaining individual control for precision.
2Productivity
If multiple dispensing systems are used to increase throughput, then productivity is improved, but device complexity, space requirements, and operational costs increase
Solution Approach 1:
Multiple dispensing units are merged into a single physical platform sharing common infrastructure (frame, gantry, controller), which reduces the overall space footprint compared to having separate dispensing systems while maintaining the productivity benefits of multiple simultaneous dispensing operations.
3Productivity
If multiple dispensing systems are used to increase throughput, then productivity is improved, but operational costs and maintenance requirements increase
Solution Approach 1:
The system merges multiple dispensing units under a single controller and shared infrastructure, reducing operational costs by having one operator manage the system, simplifying maintenance through shared components, and reducing training requirements compared to operating multiple independent dispensing systems.
4Manufacturing precision
If non-contact dispensing is used, then manufacturing precision is improved through better alignment accuracy, but device complexity increases due to vision system requirements
Solution Approach 1:
The vision system acts as an intermediary between the dispensing units and the substrates, capturing images to determine precise substrate positions and orientations. This intermediary system enables accurate alignment and positioning without requiring physical contact during the alignment process, thereby improving manufacturing precision.
Data Source
AI summary
A dispensing apparatus includes a frame, a support coupled to the frame, a gantry coupled to the frame, a first dispensing unit coupled to the gantry, a second dispensing unit coupled to the gantry, and an imaging system coupled to one of the frame and the gantry. The imaging system may be configured to capture at least one image of a first pattern and a second pattern, with the second pattern being identical to the first pattern. The dispensing apparatus further includes a controller configured to verify whether the first pattern and the second pattern are properly positioned on the support with respect to one another based on the at least one captured image to permit simultaneous dispense operations of the first dispensing unit on the first pattern and the second dispensing unit on the second pattern. Other embodiments and methods of dispensing are further disclosed.