Multi-Format Vacuum Table for Flattening Warped Component Panels
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Solution Overview
Problem
Existing methods for handling electronic components of varying formats in manufacturing processes require manual plate changes, lead to warpage and damage due to mechanical clamping, and involve cumbersome and complex clamping mechanisms.
Innovation Solution
A multi-format vacuum table with a base plate structure and lip seals that define portions, utilizing suction arrangements and interconnected channels for controlled vacuum application, eliminating the need for manual plate changes and complex clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual plate changes are used to handle different component formats, then each format can be accommodated, but the process time increases and clean room requirements may be violated
Solution Approach 1:
A single vacuum table surface is designed to accommodate multiple component formats through a universal hole pattern system. The table includes arrays of holes that can be selectively connected to vacuum sources to create custom vacuum zones for different panel sizes and shapes, eliminating the need for multiple dedicated master plates while maintaining format-specific vacuum distribution
Solution Approach 2:
The vacuum table surface is divided into multiple independently controllable vacuum zones. Each zone can be activated or deactivated separately through selective connection of hole arrays to vacuum sources, allowing the system to adapt to different component formats by activating only the necessary zones rather than requiring physical plate changes
2Force
If mechanical clamps are applied to flatten warped panels, then flattening force is applied, but contact stress concentrates and may break brittle panels
Solution Approach 1:
Instead of mechanical clamps, the system uses distributed vacuum pressure applied through multiple suction points across the panel surface. This pneumatic approach distributes the flattening force uniformly across the entire panel area, eliminating contact stress concentration at discrete clamp points that could cause brittle panel breakage
Solution Approach 2:
The vacuum distribution system uses flexible vacuum distributors or bellows that can conform to the panel surface, providing uniform pressure distribution. These flexible elements adapt to warped panel surfaces and maintain consistent vacuum contact across the entire area, preventing stress concentration
3Adaptability or versatility
If adjustable format clamps are used to accommodate various panel sizes, then format versatility is achieved, but the mechanism becomes complicated
Solution Approach 1:
A single vacuum table with a universal hole pattern serves multiple format requirements. The table can accommodate different panel sizes and shapes by selectively activating different combinations of vacuum zones, eliminating the need for multiple adjustable clamp mechanisms for each format
Solution Approach 2:
The complex mechanical clamp adjustment system is replaced with a simplified vacuum distribution system. Instead of mechanically adjusting clamp positions for different formats, the system uses selective activation of vacuum zones through fluid control, replacing mechanical complexity with simpler pneumatic control
4Reliability
If master plates are used for each panel format, then vacuum coverage is optimized, but the sandwiched structure causes additional warpage
Solution Approach 1:
The vacuum table surface is segmented into multiple independent vacuum zones that can be selectively activated. This allows the vacuum to be applied directly to the panel surface through appropriately sized and positioned hole arrays, eliminating the intermediate master plate layer that causes warpage while maintaining optimized vacuum coverage for each format
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 efficient flattening and support of various component formats without warpage or damage, simplifying the process and maintaining consistent vacuum force distribution.
Implementation Method 1
a vacuum table for supporting and flattening an electronic component
Implementation Method 2
a plurality of lip seals operatively coupled to the base plate structure and extending upwardly beyond the top surface of the base plate structure
Data Source
AI summary
A vacuum table for supporting and flattening an electronic component includes a base plate structure comprising a top surface defining a plurality of suction arrangements. The vacuum table also includes a plurality of lip seals operatively coupled to the base plate structure and extending upwardly beyond the top surface of the base plate structure, the plurality of lip seals arranged to define a plurality of portions of the vacuum table, wherein each of the plurality of portions of the vacuum table includes at least one of the plurality of suction arrangements therein.