Stencil Printer Dispenser Merging Functions
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Solution Overview
Problem
Current surface-mount circuit board manufacturing processes face inefficiencies due to the need for separate machines for printing and dispensing viscous materials, leading to increased space requirements and manual interventions for defect rectification, which disrupts the production line flow.
Innovation Solution
A combination stencil printer and dispenser that integrates a print head for depositing viscous material, a cleaning assembly for removing excess material, and a dispenser for on-the-fly correction of defects, all controlled by a centralized system to streamline the process and reduce interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate machines are used for printing and dispensing viscous materials, then each machine can be optimized for its specific function, but space requirements increase and production line flow is disrupted
Solution Approach 1:
The patent combines a stencil printer and a dispenser into a single integrated machine, allowing both printing and dispensing functions to be performed in one location. This eliminates the need for separate machines, reduces space requirements, and maintains continuous production line flow by eliminating interruptions for manual interventions between printing and dispensing operations.
Solution Approach 2:
The integrated machine performs multiple functions (printing viscous material through stencil and dispensing material for defect correction) within a single device. The system can switch between printing mode and dispensing mode, allowing one machine to replace what would traditionally require two separate specialized machines.
2Ease of manufacture
If separate machines are used for printing and dispensing, then each machine can operate independently, but manual interventions increase and space requirements increase
Solution Approach 1:
The patent merges the printing and dispensing functions into a single machine footprint, significantly reducing the space required compared to having two separate machines. The integrated design allows both functions to share common components such as the substrate support, positioning systems, and control mechanisms.
3Reliability
If separate machines are used for printing and dispensing, then each machine can be specialized, but production efficiency decreases due to interruptions
Solution Approach 1:
The integrated machine enables continuous production by allowing printing and dispensing operations to occur in sequence without removing the substrate from the machine. The system can complete printing operations, then immediately perform defect inspection and dispensing corrections all within one continuous cycle, eliminating interruptions and improving overall production efficiency.
Solution Approach 2:
The system incorporates inspection capabilities that provide feedback on the printed material, allowing the dispenser to correct defects in real-time. This closed-loop approach ensures high production efficiency by preventing defective products from moving through the line and allows for immediate correction without stopping production.
4Adaptability or versatility
If manual interventions are used for defect rectification, then flexibility is maintained, but production line flow is disrupted and time is lost
Solution Approach 1:
The integrated dispenser system enables the machine to correct its own defects automatically. When inspection systems detect printing defects, the dispenser can immediately re-apply material to correct the issue without requiring manual intervention. This self-service capability maintains production line flow and eliminates time loss associated with manual defect rectification.
Data Source
AI summary
A combination stencil printer and dispenser includes a frame, a movable stencil coupled to the frame, a substrate support coupled to the frame to support a substrate in a print position, and a print head coupled to the frame to deposit and print viscous material over the stencil. The combination stencil printer and dispenser further includes a dispenser mounted on the movable stencil to dispense viscous material on the substrate when the substrate is in the print position. In other embodiments, the dispenser can be mounted on a stencil wiper or on an independent gantry provided within the combination stencil printer and dispenser.