Variable-Volume Acoustic Dispensing Through Burst Calibration
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Solution Overview
Problem
Acoustic dispensing systems face challenges in precisely controlling the volume of dispensed drops due to factors like chemical composition, viscosity, temperature, and well geometry, limiting the ability to freely select drop volumes and increasing dispense time, especially for small volumes.
Innovation Solution
A method involving the creation of calibration functions that relate liquid level and burst value to allow selection of any drop volume within a specified range, using burst curves and calibration functions to determine the required burst parameters for precise drop volume control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If acoustic dispensing apparatus is carefully calibrated to dispense a specific drop volume, then manufacturing precision is improved, but device complexity and time consumption increase
Solution Approach 1:
The system performs preliminary calibration actions by pre-determining the relationship between burst parameters and drop volumes through calibration curves. This calibration data is stored and reused, eliminating the need for repeated calibration procedures while maintaining precise drop volume control.
Solution Approach 2:
The system changes the burst parameter (acoustic wave characteristics) to directly control drop volume. By establishing a calibration curve that maps burst parameters to drop volumes, the system can precisely adjust drop size by modifying the burst parameter without mechanical adjustments or recalibration.
2Manufacturing precision
If drop volume is fixed by calibration, then manufacturing precision is improved, but adaptability deteriorates
Solution Approach 1:
The system transitions from static fixed drop volumes to dynamic adjustable drop volumes. By using the calibration curve to map burst parameters to various drop volumes, the system can dynamically select and adjust drop sizes based on application requirements while maintaining precision through the established calibration relationship.
Solution Approach 2:
The system utilizes parameter changes in the burst characteristic to achieve different drop volumes. The calibration curve provides a systematic way to determine the appropriate burst parameter for any desired drop volume within the calibrated range, enabling flexible adaptation while preserving manufacturing precision.
3Manufacturing precision
If small drop size is used, then manufacturing precision for small volumes is improved, but productivity deteriorates due to increased number of drops required
Solution Approach 1:
The system dynamically adjusts drop size based on the required total volume and precision requirements. For applications requiring high precision at small volumes, the system can use smaller drops with optimized burst parameters. For applications where speed is more critical, larger drops can be selected, reducing the total number of dispensing operations while maintaining adequate precision through the calibration-based control.
Solution Approach 2:
The system changes the burst parameter to optimize the balance between drop size, precision, and dispensing speed. By referencing the calibration curve, the system can select the optimal burst parameter that achieves the desired precision for the target volume while minimizing the number of drops required, thereby improving overall productivity.
4Measurement precision
If multiple calibration functions are created for different liquid levels, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The calibration process is segmented into multiple liquid level ranges, with each segment having its own calibration function. This segmentation allows the system to achieve high measurement precision within each level range while managing complexity by organizing calibration data into discrete, manageable segments that can be selected based on the current liquid level.
Solution Approach 2:
The system changes the calibration function selected based on the measured liquid level. By storing multiple calibration functions corresponding to different liquid level ranges and automatically selecting the appropriate function based on the current level, the system achieves high measurement precision across varying conditions while managing complexity through parameter-based selection rather than complex real-time calculations.
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
Enables efficient and time-minimized dispensing by allowing selection of optimal drop volumes, reducing the number of drops needed to achieve the desired total volume and improving resolution and speed of the dispensing process.
Implementation Method 1
The acoustic wave can be focused by a lens 28 prior to propagating through a coupling medium 32 to optimize the energy of the acoustic wave or beam 20 upon the liquid/air interface (free surface) of a source liquid 40
Implementation Method 2
the wave is transmitted through a source liquid containment structure 44 where the wave comes to focus at or near the surface of the pool of source liquid 40, thereby causing a drop 60 of the source liquid 40 to be dispensed
Data Source
AI summary
A method that allows a user to dispense a desired volume of solution from an acoustic dispensing apparatus by allowing the user to select the drop volume to be dispensed. A typical drop volume is in the range of one to twenty-five nanoliters. The method comprises the steps of creating two or more burst curves that give the relationship between liquid level and burst value, using data from the burst curves to create two or more calibration functions, and using data from the calibration functions to create a dispensing data set that is used to set the burst parameter required to dispense the selected drop volume.