Synchronous-to-Asynchronous Dispensing for Pattern Alignment
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Solution Overview
Problem
Existing dispensing systems for viscous materials on substrates, such as printed circuit boards, are limited by throughput capabilities, requiring multiple machines and significant manufacturing space, and struggle with accurate simultaneous dispensing on multiple patterns due to alignment and calibration challenges.
Innovation Solution
A method and apparatus that allows for synchronous and asynchronous dispensing modes, using multiple dispensing units with independent positioning and alignment, facilitated by a vision system and automatic adjustment mechanisms to ensure precise dispensing on multiple substrates or patterns, even when they are not perfectly aligned.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple dispensing units are used to increase throughput, then production efficiency is improved, but device complexity and manufacturing space requirements increase
Solution Approach 1:
The patent combines multiple dispensing units (first and second dispensing units) into a single integrated system that shares common components such as the controller, vision system, and gantry structure. This merging approach allows simultaneous dispensing on multiple substrates or patterns, increasing throughput while avoiding the complexity of completely separate dispensing systems.
Solution Approach 2:
The dispensing system is designed with multi-functional capability to perform both synchronous dispensing (when patterns are properly aligned) and asynchronous dispensing (when patterns are misaligned). The controller automatically selects the appropriate mode based on vision system analysis, making the system adaptable to different production scenarios without requiring multiple specialized machines.
2Productivity
If synchronous dispensing is performed on multiple patterns, then throughput is improved, but manufacturing precision deteriorates due to alignment and calibration challenges
Solution Approach 1:
The vision system performs preliminary analysis of the substrate patterns before dispensing operations begin. The controller uses this advance information to determine proper alignment and calculate necessary adjustments, ensuring that synchronous dispensing is only initiated when patterns are properly suited for simultaneous processing. This preliminary verification prevents precision errors before they occur.
Solution Approach 2:
The system incorporates a vision system that continuously monitors and provides feedback on pattern alignment and positioning. Based on this feedback, the controller automatically adjusts dispensing parameters or switches between synchronous and asynchronous modes, maintaining manufacturing precision while maximizing throughput capability.
3Manufacturing precision
If asynchronous dispensing mode is used to handle misaligned patterns, then manufacturing precision is maintained, but productivity decreases due to sequential processing
Solution Approach 1:
The system dynamically transitions between synchronous and asynchronous dispensing modes based on real-time vision system analysis of pattern alignment. When patterns are properly aligned, the system operates in synchronous mode for high-speed parallel processing. When misalignment is detected, it automatically switches to asynchronous mode to maintain precision, optimizing both productivity and manufacturing precision adaptively.
4Device complexity
If a single dispensing system is used, then device complexity is reduced, but productivity is limited by the throughput capability of one dispense pump assembly
Solution Approach 1:
The patent merges multiple dispensing units into a single integrated system that shares common infrastructure including the controller, vision system, gantry, and support structure. This approach provides the throughput capability of multiple independent systems while maintaining the simplicity and reduced complexity of a single unified platform.
Data Source
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AI summary
A method of dispensing material on multiple patterns or multiple substrates include delivering the patterns or substrates to a dispense position, acquiring data relative to the patterns or substrates, and determining whether the patterns or substrates are properly suited for simultaneous dispensing. If properly suited for simultaneous dispensing, the method includes performing simultaneous dispense operations on the patterns or substrates based on the acquired data in a synchronous mode of operation. If not properly suited for simultaneous dispensing, the method includes asynchronously performing one of (1) a first dispense operation on a first pattern of the at least two patterns and a second dispense operation on a second pattern of the at least two patterns, (2) a single dispense operation on one of the first pattern and the second pattern, and (3) no dispense operation.