Tilt-Rotate Dispenser Flow Control for 3D Edge Deposition
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Solution Overview
Problem
Existing dispensing systems for viscous materials on electronic substrates lack precise control, especially when dispensing near corners or edges, as they are limited by vertical orientation and lack the ability to tilt and rotate, making it difficult to accurately deposit material in hard-to-reach areas.
Innovation Solution
A dispensing system with a gantry assembly that supports a dispensing unit capable of tilting and rotating, controlled by a controller to move in x, y, and z axes, and adjust angle and speed, allowing for precise dispensing of viscous materials along a three-dimensional path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the dispensing unit is limited to vertical orientation and movement along x, y, z axes, then the system structure is simpler, but the ability to accurately deposit material in hard-to-reach areas such as corners and edges is insufficient
Solution Approach 1:
The dispensing unit is transformed from a static vertical orientation to a dynamic configuration that can tilt and rotate. The tilt mechanism allows the dispensing unit to angle toward corners and edges, while rotation enables positioning from different angular approaches, making the system adaptable to complex substrate geometries without requiring multiple fixed dispensing stations
Solution Approach 2:
The dispensing unit gains rotational degree of freedom around the z-axis in addition to tilting. This rotational capability allows the nozzle to approach the substrate from different angular directions, effectively adding a rotational dimension to the traditionally three-dimensional linear movement, enabling access to corner and edge areas that are geometrically challenging
2Manufacturing precision
If the dispensing unit moves at variable speed, then the system is easier to control for different dispensing patterns, but maintaining constant speed is required for precise material deposition
Solution Approach 1:
The control system continuously monitors the dispensing unit's position, tilt angle, and rotation angle, and adjusts the material flow rate in real-time based on these parameters. This feedback mechanism ensures that even when speed or orientation changes, the material deposition remains precise by dynamically compensating for variations in dispensing conditions
3Manufacturing precision
If the nozzle is positioned closer to the substrate for better precision, then material deposition accuracy improves, but the risk of contamination and difficulty in maintaining constant distance increases
Solution Approach 1:
The z-axis position of the dispensing unit is dynamically adjusted based on the substrate surface topology and the required dispensing pattern. The control system continuously maintains the optimal nozzle-to-substrate distance by coordinating z-axis movement with tilt and rotation adjustments, ensuring both precision and contamination prevention through real-time position optimization
Data Source
AI summary
A dispensing system includes a frame, a support coupled to the frame, a dispensing unit configured to dispense viscous material, and a gantry assembly coupled to the frame. The gantry assembly includes a gantry configured to support the dispensing unit and to move the dispensing unit in x-axis, y-axis and z-axis directions and a tilt and rotate subassembly configured to tilt and rotate the dispensing unit. The dispensing system further includes a controller configured to control dispensing unit and the gantry assembly to perform a dispense operation on the electronic substrate. The controller is configured to control the dispensing unit to dispense material from the nozzle of the dispensing unit at a flow rate configured to deposit a desired amount or density of material on the electronic substrate along a three-dimensional path.