Laser Deposition Vacuum Shuttle for Precise Solder Paste Printing

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Solution Overview

Problem

Existing methods for applying solder paste in surface mount technology are prone to defects due to inaccuracies in depositing the correct amount of solder onto printed circuit board pads, which is critical for forming reliable electrical and mechanical connections.

Innovation Solution

A laser assisted deposition system with a vacuum shuttle and laser unit that prints individual dot-like portions of material onto a receiving substrate, using a vacuum channel to hold the donor substrate taut and sensors for precise alignment and positioning, enabling uniform and accurate deposition of viscous materials like solder paste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If screen-printing or jet printing is used to deposit solder paste, then the deposition process can be automated, but manufacturing precision deteriorates due to inaccuracies in depositing the correct amount of solder

Engineering Contradiction:

Improveautomation of solder paste depositionVSAvoidaccuracy of solder deposition amount

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical screen-printing or jet-printing systems with a laser-based deposition system. The laser assists in transferring material from the donor substrate to the receiving substrate with precise control over deposition amount, position, and volume, thereby maintaining high automation while significantly improving manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables precise control of deposition parameters including laser power, pulse duration, scanning speed, and material layer thickness. By dynamically adjusting these parameters, the system can deposit exact amounts of solder paste with high consistency, resolving the precision issue while maintaining automation.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If a vacuum shuttle is used to hold the donor substrate taut, then manufacturing precision improves through stable positioning, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracy of donor substrateVSAvoidcomplexity of vacuum shuttle system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The vacuum shuttle acts as an intermediary device between the donor substrate and the laser deposition system. It provides a simple yet effective mechanism to hold the thin donor substrate taut and stable during the laser scanning process, enabling high precision without requiring complex positioning systems. The shuttle's simplicity lies in using vacuum pressure rather than mechanical clamps or frames.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If laser assisted deposition is used for high-resolution printing, then manufacturing precision improves, but speed of deposition may deteriorate due to precise positioning requirements

Engineering Contradiction:

Improveresolution of material depositionVSAvoiddeposition speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system employs dynamic control of the laser scanning speed and positioning system to optimize both precision and speed. The vacuum shuttle and positioning mechanisms can rapidly accelerate and decelerate while maintaining stability, allowing high-speed scanning without sacrificing deposition precision. The system adapts its speed dynamically based on the required resolution and material properties.

Inventive Principle:

Principle #15Dynamics

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

Ensures high-resolution, high-speed printing of viscous materials with minimal size variations, improving the reliability and efficiency of surface mount assembly processes by maintaining precise control over the deposition process.

Implementation Method 1

The vacuum channel is fluidly coupled to a vacuum inlet for receiving a vacuum suction, thereby to engage the donor substrate and hold it taut against the bottom of the vacuum shuttle in operation

Methodology Applied

Scientific EffectVacuum suction: Vacuum

Implementation Method 2

The vacuum shuttle includes an open window through which the laser can irradiate the donor substrate

Methodology Applied

Scientific EffectLaser irradiation: Laser

Data Source

PatentUS12552179B2Large area laser printing system and method

Publication Date: 2026.02.17 REOPHOTONICS LTD

AI summary

Systems and methods for laser assisted deposition of a material includes a printing unit configured to print individual dot-like portions of a material from a donor substrate onto a receiving substrate, and a vacuum shuttle configured to be positionable in two or three dimensions between the printing unit and the donor substrate and to engage the donor substrate upon application of a vacuum to the vacuum shuttle. The printing unit may include a coating system and a laser. The vacuum shuttle includes a vacuum channel about its periphery and an open window through which the laser irradiates the donor substrate. The vacuum channel is fluidly coupled to a vacuum inlet for receiving a vacuum suction, thereby to engage the donor substrate and hold it taught against the bottom of the vacuum shuttle in operation. The vacuum shuttle may also include one or more distance measuring sensors and fiducial markers.