Integrated Stencil Printer Dispenser for Viscous Material Defect Correction
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Solution Overview
Problem
In surface-mount circuit board manufacturing, existing stencil printers and dispensers often require manual intervention to correct printing errors, leading to interruptions in the production line and reduced efficiency due to the separation of print and dispense operations, as well as inefficiencies in cleaning and inspection processes.
Innovation Solution
A combination stencil printer and dispenser that integrates a print head, a cleaning assembly, and a dispenser, allowing for simultaneous printing, cleaning, and inspection of viscous materials on a substrate, with a controller managing the movement mechanisms for efficient operation and real-time defect correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate stencil printer and dispenser operations are used, then each device can be optimized for its specific function, but production line efficiency decreases due to manual intervention and interruptions
Solution Approach 1:
The patent combines the stencil printer and dispenser into a single integrated device, allowing both printing and dispensing operations to be performed simultaneously on the same substrate without manual intervention. The printer head and dispenser are co-located and coordinated by a single controller, eliminating the need to transfer substrates between separate devices and reducing production interruptions.
Solution Approach 2:
The integrated device performs multiple functions (printing and dispensing) through a single unified system. The printer head can both print viscous material through a stencil and dispense material directly, while the single substrate support and movement mechanism serve both operations, reducing device complexity despite increased functionality.
2Manufacturing precision
If manual intervention is used to correct printing errors, then defect correction is possible, but production line interruptions increase and efficiency decreases
Solution Approach 1:
The integrated printer-dispenser system automatically detects and corrects printing defects without manual intervention. The dispenser can add material to correct under-filled areas or remove excess material directly at the print station, allowing the system to self-correct errors and maintain continuous production flow.
Solution Approach 2:
The system performs preliminary inspection and correction actions immediately after printing while the substrate is still in position. Vision systems detect defects and the dispenser applies corrective material before the substrate moves to the next processing stage, preventing defects from propagating through the production line.
3Reliability
If cleaning assembly moves under stationary stencil, then excess material is removed from stencil, but cleaning time and production cycle time increase
Solution Approach 1:
The cleaning assembly operates periodically rather than continuously, with the wiper engaging the stencil only at specific intervals or positions during substrate processing. The wiper removes excess material from the stencil surface at controlled moments, balancing cleanliness requirements with minimal interruption to the production cycle.
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 integrated solution enables on-the-fly defect correction and reduced production line interruptions by allowing for direct rework of printed circuit boards, improving cycle time performance and reducing material handling, thus enhancing the overall efficiency of the manufacturing process.
Implementation Method 1
a wiper assembly and a movement mechanism coupled to the frame and the wiper assembly to move the wiper assembly across the stencil
Implementation Method 2
a print head coupled to the frame to deposit and print viscous material over the stencil
Implementation Method 3
a dispenser coupled to the cleaning assembly to dispense viscous material on the substrate when the substrate is in the print position
Data Source
AI summary
A combination stencil printer and dispenser includes a frame, a 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. In one embodiment, the combination stencil printer and dispenser further includes a cleaning assembly coupled to the frame to wipe excess viscous material from a bottom surface of the stencil. The combination stencil printer and dispenser further includes a dispenser mounted on the cleaning assembly 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 movable stencil or on an independent gantry provided within the combination stencil printer and dispenser.