Reusable Nozzle Hub Design for Underfill Dispensing
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Solution Overview
Problem
Current nozzle designs for underfilling electronic devices with viscous liquids face issues such as high pressure drop, poor heat transfer, and permanent connections, which restrict liquid flow and are costly to produce, especially for small sizes and complex shapes, leading to limited industry adoption.
Innovation Solution
A novel separable nozzle hub design that allows for tool-less connection and removal of nozzle cores, made from thermally efficient materials like copper alloys, providing increased structural rigidity and reducing waste by enabling core replacement, while allowing for standard tool usage and improved thermal energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a modified hypodermic needle is used for nozzle construction, then the nozzle can be easily manufactured and assembled, but the pressure drop across the nozzle becomes very high and liquid flow is restricted
Solution Approach 1:
The nozzle is divided into separate components: a reusable hub and a replaceable core. The core contains the fluid passage and can be independently optimized for flow characteristics, while the hub provides structural support and connection interfaces. This segmentation allows the core to be designed with optimal geometry for minimizing pressure drop without compromising manufacturing ease.
Solution Approach 2:
The invention changes the geometric parameters of the fluid passage within the core, transitioning from the constant diameter of a hypodermic needle to a contoured passage with varying diameter. The core features an enlarged proximal end and a tapered distal end, creating a more favorable flow profile that reduces pressure drop and improves liquid flow while maintaining ease of manufacture through molding processes.
2Ease of manufacture
If stainless steel or plastic materials are used for the nozzle, then the nozzle can be manufactured with standard materials, but heat transfer efficiency becomes poor
Solution Approach 1:
The nozzle system uses composite construction with the hub made from thermally conductive materials (such as metal alloys with copper, aluminum, or zinc) and the core made from molded material. This composite approach combines the thermal conductivity benefits of metal with the manufacturing advantages of molded components, achieving both ease of manufacture and improved heat transfer efficiency.
Solution Approach 2:
The invention applies different material properties to different parts of the nozzle system. The hub, which requires good heat transfer, is made from thermally conductive materials, while the core can be made from materials optimized for its specific functions. This local optimization of material properties allows each component to perform its function efficiently.
3Strength
If the hub and fluid path are permanently connected, then the connection is structurally sound, but the nozzle cannot be reused and costs increase
Solution Approach 1:
The nozzle system is segmented into a permanent reusable hub and a consumable core. The hub contains the connection interfaces and structural elements that remain in place, while the core contains the fluid passage and is replaced when worn or contaminated. This segmentation maintains strong connections where needed while enabling reuse of the valuable hub component.
Solution Approach 2:
The invention implements a discard-and-recover strategy where the core is discarded after use and the hub is recovered and reused. The hub is designed to be durable and reusable multiple times, while the core is designed as a consumable component. This approach reduces waste by recovering and reusing the more valuable hub component while accepting the core as a disposable element.
4Manufacturing precision
If custom machining is used to create precise nozzle geometries, then the nozzle performance can be optimized, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The invention replaces complex mechanical machining processes with molding processes for manufacturing the core. The core geometry, which requires precise contours and transitions, is created through injection molding or similar molding processes that can produce complex shapes directly from molds. This substitution of manufacturing methods achieves high manufacturing precision without the cost and complexity of custom machining.
Solution Approach 2:
The hub is designed as a universal component that can accommodate different core types and configurations. The standardized hub interface and structure allow the same hub to be used with various cores, reducing the need for custom machining for each application. This universality simplifies manufacturing while maintaining the ability to optimize core geometry for specific performance requirements.
Data Source
AI summary
A novel hub design that enables removal of nozzle core for disposal while the hub is retained for reuse. The reusable hub provides a cost advantage over a one-piece metal design, enabling the use of a dispensing system that is of high quality and low cost to proliferate the use of the technology in the industry. Using this method, a nozzle hub dispensing system has a very favorable impact on the environment, 90% less hazardous waste with a reusable hub system, as only the lightweight cores are disposed. This nozzle hub provides a positive locking, tool-less mechanical connection of nozzle core to hub, which offers a financial advantage over competitive products.