Rheological Sensor Feedback for Electronic Assembly Printing
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Solution Overview
Problem
Existing manufacturing processes for electronic assemblies face challenges in maintaining exactness of the predefined layout due to fluctuations in external parameters like temperature and humidity, leading to variations in the rheological behavior of printing media, which affect the quality of printed products.
Innovation Solution
A method that involves measuring rheological properties of the printing medium during the printing process, using a computer-implemented rheological model to determine optimal printing parameters, and automatically adjusting these parameters to maintain consistent quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of individual printing steps are carried out sequentially in series production, then productivity is improved, but manufacturing precision deteriorates due to parameter drift and environmental fluctuations
Solution Approach 1:
The patent implements a feedback mechanism where rheological properties of the printing medium are measured in real-time during the printing process. These measurements are fed back to automatically adjust printing parameters, ensuring consistent print quality across all substrates in the series production run despite environmental fluctuations or material property changes.
Solution Approach 2:
The patent introduces dynamic adjustment of printing parameters based on real-time rheological measurements. Instead of using fixed printing parameters throughout the production run, the system continuously adapts parameters such as printing speed, pressure, or temperature according to the currently measured rheological state of the printing medium, thereby maintaining manufacturing precision while sustaining high productivity.
2Manufacturing precision
If printing parameters are optimized at the beginning of a production shift, then manufacturing precision is improved, but reliability deteriorates as parameters drift away from optimal values over time
Solution Approach 1:
The system continuously monitors rheological properties during the production process and uses this feedback to maintain optimal printing parameters throughout the entire production shift. This eliminates the parameter drift problem by constantly adjusting settings based on actual material state, ensuring both high print quality and process reliability.
Solution Approach 2:
The system performs self-adjustment of printing parameters based on automated rheological measurements without requiring manual intervention. The automated adjustment mechanism maintains optimal printing conditions throughout the production shift, ensuring consistent reliability and print quality without operator involvement.
3Ease of operation
If automated adjustment of printing parameters is implemented, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical adjustment of printing parameters with an automated control system that uses rheological measurements to dynamically adjust parameters. This substitution of manual operation with automated measurement and control simplifies ease of operation while the added complexity is confined to the measurement and control subsystem.
Solution Approach 2:
The system automatically measures rheological properties and adjusts printing parameters without operator intervention. This self-service capability greatly improves ease of operation, and while it adds measurement and control components, the automation eliminates the need for skilled operators and manual adjustment mechanisms.
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
This approach ensures high-quality printing results by continuously optimizing printing parameters, reducing downtimes, and increasing throughput while maintaining high process quality, even with changes in environmental conditions or printing layout.
Implementation Method 1
at least one rheological property of the printing medium is repeatedly measured within the printing device using a process rheometer
Implementation Method 2
a layer of printing medium is applied in a structured manner onto a substrate using a printing device
Data Source
AI summary
The invention relates to a method for producing electronic assemblies (10) which comprises the following steps: a) depositing a fluid printing medium (160) in a structured manner by means of a printing device (100), - step a) being carried out multiple times consecutively in a sequence of individual printing steps ai), b) measuring at least one rheological characteristic of the printing medium (160) inside the printing device (100), - step b) being carried out in a repeated sequence of individual measurement steps bn) during the individual printing steps ai) and/or between the individual printing steps ai), c) providing a rheological model (M) for the sequence of individual printing steps ai), - the rheological model (M) using the repeatedly measured rheological characteristic as a variable input parameter, d) determining a favourable value for at least one selected printing parameter with the aid of the rheological model (M) in accordance with the currently measured rheological characteristic and e) automatically setting the determined favourable value for the at least one selected printing parameter. The invention further relates to a production plant which is designed to carry out this method.