Substrate Nip Feeding With Force Release to Prevent Compression
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Solution Overview
Problem
Existing methods for applying a substance pattern to fragile substrates, such as semiconductor wafers, risk damaging or breaking the substrates during the transfer process due to compression forces applied at the nip.
Innovation Solution
A system and method where the transport conveyor ceases applying force to the substrate upon engagement with the nip, ensuring the substrate is gripped without additional compression, using a trailing edge engagement and controlled velocity to prevent breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transport conveyor continues applying force to advance the substrate towards the nip upon engagement, then the substrate can be reliably fed into the nip, but the substrate may be compressed and damaged
Solution Approach 1:
The transport conveyor is configured to preemptively stop applying force before the substrate fully engages with the nip, preventing the harmful compression effect from occurring in the first place. This anticipatory action eliminates the need for complex force modulation during engagement.
Solution Approach 2:
The system dynamically adjusts the force application by the transport conveyor based on the engagement state with the nip. The conveyor transitions from an active force-applying state to a passive state upon engagement, allowing the nip to grip the substrate without additional compressive forces.
2Manufacturing precision
If the substrate is gripped firmly in the nip for effective pattern transfer, then the substance pattern can be accurately transferred, but fragile substrates may break due to the gripping force
Solution Approach 1:
The substrate is pre-positioned and aligned before entering the nip, ensuring that the gripping action occurs at the optimal location. This preliminary positioning allows the nip to grip the substrate effectively without requiring excessive force that could cause breakage.
Solution Approach 2:
The system changes the velocity parameter of the substrate as it passes through the nip, matching the web velocity to ensure synchronous movement. This velocity synchronization maintains firm contact for accurate pattern transfer while avoiding differential forces that could fracture fragile substrates.
3Manufacturing precision
If the substrate velocity is matched to the web velocity through the nip, then the substance pattern transfers accurately, but the substrate may be compressed by continuous transport conveyor force
Solution Approach 1:
The harmful element (continuous force application by the transport conveyor) is extracted or removed at the critical moment of nip engagement. By taking out the force application, the system achieves velocity matching for accurate pattern transfer without the harmful compressive stress.
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
Reduces substrate breakage during pattern transfer, maintaining integrity and enhancing productivity by minimizing compressive forces, particularly effective for fragile substrates.
Implementation Method 1
a transport conveyor for advancing a substrate towards the nip for the substrate to be gripped in the nip and frictionally driven through the nip at the same velocity, as the web
Data Source
AI summary
A system is disclosed for transferring a substance pattern to a substrate. The system comprises a nip defined between a roller and an opposing surface, a web carrying the substance pattern driven to pass the nip with a predetermined velocity, and an endless conveyor for transporting the substrate towards the nip, the substrate passing through the nip at the same time, and with the same speed, as the web in order for the substance pattern to be transferred from the web to the substrate. Upon gripping of the substrate by the nip, no further force is applied by the transport conveyor, thereby avoiding compression of the substrate. The endless transport conveyor can be formed with at least one projection configured to engage a trailing edge of the substrate and can be driven to push the substrate towards the nip with a velocity less than the velocity of the web.