High-Speed Pen Tip Dispensing for Uniform Lines and Dots
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Solution Overview
Problem
Current dispensing technologies face challenges in precisely dispensing high viscosity materials at high speeds, particularly in achieving uniform line height and width, and in starting and stopping the dispensing process smoothly on non-flat, fragile electronic devices, with limitations in feature size control and material waste.
Innovation Solution
A modified pen tip dispensing system with a hydrophobic surface and mechanical vibrator, featuring a square or rectangular orifice, and multiple nozzles, allows for precise control of the writing gap and increased throughput by maintaining a predetermined distance above the substrate, reducing material interaction and enhancing flow of viscous materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If pen tip dispensing is used to produce continuous line patterns, then superior continuity is achieved, but precise feature size control is lost due to variable writing gap
Solution Approach 1:
The patent replaces the mechanical contact-based writing gap control with a non-contact ultrasonic vibration field. The ultrasonic transducer generates vibrations that couple through the pen tip to modulate material flow and deposition, eliminating the need for precise mechanical gap control while maintaining line continuity and feature size precision.
Solution Approach 2:
The patent changes the operating parameters by introducing ultrasonic vibration frequency and amplitude as control variables. By modulating these parameters, the system achieves precise control over line width and height without relying on mechanical writing gap adjustments, thus resolving the contradiction between continuity and precision.
2Manufacturing precision
If writing gap is reduced to control line height uniformity, then manufacturing precision improves, but device complexity increases due to precise gap control requirements
Solution Approach 1:
The patent eliminates the complex mechanical gap control system by substituting it with ultrasonic vibration-based non-contact dispensing. The ultrasonic transducer generates vibrations that directly control material deposition characteristics without requiring precise mechanical positioning, thereby simplifying the device while maintaining line height uniformity.
3Productivity
If dispensing speed is increased to meet production rate requirements, then productivity improves, but material flow control and line uniformity deteriorate
Solution Approach 1:
The patent employs periodic ultrasonic vibrations at high frequency to modulate material flow during dispensing. This periodic action allows the system to maintain precise control over line uniformity even at high dispensing speeds, as the vibrations continuously regulate material deposition in a rhythmic manner that prevents flow instability.
Solution Approach 2:
The patent utilizes mechanical vibration from the ultrasonic transducer to enhance material flow control during high-speed dispensing. The vibrations prevent material stagnation and ensure consistent flow rates, allowing the system to achieve both high productivity and line uniformity simultaneously.
4Loss of substance
If material viscosity is increased to reduce material waste, then loss of substance decreases, but material flow through the orifice becomes difficult
Solution Approach 1:
The patent applies mechanical vibration from the ultrasonic transducer to the pen tip, which generates vibrational energy that reduces the effective viscosity of high-viscosity materials during dispensing. This allows the material to flow more easily through the orifice at controlled rates, preventing waste while maintaining adequate flow speed for production requirements.
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 precise placement and smooth start/stop of dispensed lines with controlled line height and width, increased travel velocity, and reduced material waste, accommodating non-flat surfaces and high viscosity materials, while minimizing material adherence to the pen tip.
Implementation Method 1
A mechanical vibrator on the pen tip to enhance the flow of more viscous particle loaded materials will be described
Implementation Method 2
An addition of a hydrophobic surface on the pen tip to promote a clean start and stop without material clinging to the pen tip will be described
Data Source
AI summary
A method for depositing a material on a substrate includes providing an apparatus with at least one material dispenser. The method further includes positioning the pen tip at a predetermined writing gap where the predetermined writing gap is a distance of more than 75 micrometers above the substrate. The method also provides for controlling velocity of the flow of material through the outlet and dispense speed based on dispensed line height and dispensed line width parameters. An apparatus for depositing a material on a substrate is also provided which may have one or more mechanical vibrators, a pen tip with a hydrophobic surface, or multiple nozzles and pen tips on a single pump.