Tape Preform Positioning Apparatus for Layered Heater Manufacturing
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Solution Overview
Problem
The manual positioning of thick film tape preforms on resistive device substrates is inefficient and unreliable, particularly in applications where speed and precision are crucial, such as in the manufacturing of layered resistive devices like heaters or load resistors.
Innovation Solution
A method involving a positioning apparatus with grabber arms and a controller to translate and position the tape preform around the substrate, ensuring accurate placement and subsequent application of pressure, temperature, and time to adhere the tape securely, utilizing a bladder press for uniform pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual positioning of tape preform is used, then ease of operation is improved, but productivity and reliability deteriorate
Solution Approach 1:
The positioning device automatically positions the tape preform onto the substrate without requiring manual intervention. The device uses self-contained mechanisms including a holder to grasp the tape preform, a positioning member with engagement features that automatically align with substrate features, and a pressing member that applies pressure to secure the tape in place, thereby eliminating the need for manual positioning while maintaining operational simplicity
Solution Approach 2:
The patent replaces the manual mechanical positioning system with an automated positioning device that uses mechanical components actuated by a control system. The positioning device translates and rotates components automatically to position the tape preform, substituting human-operated mechanical processes with automated mechanical systems controlled by signals from a controller
2Device complexity
If manual positioning of tape preform is used, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The positioning device incorporates self-aligning features where the positioning member automatically engages with corresponding features on the substrate through translation and rotation. The pressing member automatically applies pressure to secure the tape preform, creating a self-contained system that reliably positions and secures the tape without manual intervention, thereby improving reliability while maintaining manageable device complexity
Solution Approach 2:
The positioning device incorporates a controller that receives signals from sensors detecting the position and state of the tape preform and positioning components. The controller automatically adjusts the translation and rotation of the positioning member and the pressing force applied by the pressing member based on feedback signals, ensuring reliable positioning and securing of the tape preform while maintaining controlled device complexity
3Productivity
If automated positioning device is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The positioning device is divided into distinct functional modules: a holder module that grasps the tape preform, a positioning member module that translates and rotates to position the tape, and a pressing member module that secures the tape. Each module can be independently controlled and adjusted, allowing the system to achieve high productivity through automation while managing complexity through modular design
Solution Approach 2:
The positioning device is designed to handle various tape preforms and substrate types using the same basic mechanism. The holder can grasp different tape configurations, the positioning member can translate and rotate to accommodate different positioning requirements, and the pressing member can adjust pressure for different materials, providing universal functionality that improves productivity without proportionally increasing device complexity
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 method enhances the speed and reliability of tape positioning on resistive device substrates, ensuring uniform adhesion and thickness, thereby improving the manufacturing efficiency of layered resistive devices.
Implementation Method 1
utilizing a bladder press for uniform pressure distribution
Implementation Method 2
translating at least one of a positioning device, the resistive device substrate, and the tape preform relative to each other
Data Source
AI summary
A method of positioning a tape preform as a layer onto a resistive device substrate during the manufacture of a layered resistive device is provided. The method includes locating the tape preform in a predetermined position and translating one or more of the following relative to each other until a portion of the positioning device engages the tape preform: a positioning device, the resistive device substrate, and the tape preform. The method also includes continuing the translation until the tape preform engages the resistive device substrate and continuing the translation such that components of the positioning device progressively translate around the resistive device substrate and subsequently position the tape preform onto the resistive device substrate. In some forms, the method includes using a controller and/or applying a predetermined cycle of temperature, pressure, and time to the substrate and tape preform.