Viscous Fluid Dispensing with Integrated Flow Meter and Weigh Scale
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Solution Overview
Problem
Current viscous fluid dispensing systems face challenges in accurately controlling dot size, dispensed volume, and density variations, leading to inconsistencies in high productivity manufacturing processes, particularly in applications like flip chip technology and adhesive bonding, where precise amounts of viscous materials are required.
Innovation Solution
A computer-controlled non-contact jetting dispensing system that uses a flow meter and weigh scale to monitor and adjust dispensing parameters in real-time, ensuring accurate dispensing of viscous fluids by integrating gas flow meter output signals to determine volume and mass, and subsequently calculating density, allowing for precise control of dispensing parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known control loops are used to control dot size by varying supply pressure, valve on-time, and stroke length, then dot size control is achieved, but additional components such as weigh scales are required, introducing additional cost, time and reliability issues
Solution Approach 1:
The patent extracts the measurement function from separate weigh scales and integrates it into the dispenser system itself. The dispenser housing incorporates a measurement device that directly measures the dispensed material volume, eliminating the need for external weigh scales and associated complexity while maintaining dot size control precision.
Solution Approach 2:
The patent merges the measurement function with the dispenser structure by incorporating a measurement device within the dispenser housing. This integration combines the dispensing and measurement functions into a single unified system, reducing component count and simplifying the overall device architecture while maintaining control precision.
2Manufacturing precision
If calibration procedures separate from the manufacturing process are used, then dispensing accuracy is achieved, but productivity is reduced
Solution Approach 1:
The patent enables continuous measurement and control during the dispensing process itself, rather than requiring separate calibration procedures. The measurement device operates continuously alongside the dispensing action, allowing real-time adjustments without interrupting production flow, thereby maintaining both accuracy and productivity.
Solution Approach 2:
The patent implements a feedback mechanism where the measurement device continuously monitors dispensed material volume and provides real-time data to the control system. This feedback loop allows dynamic adjustment of dispensing parameters during operation, ensuring accuracy without requiring separate calibration steps that would interrupt production.
3Productivity
If viscous fluid dispensing is performed in high speed manufacturing environments, then productivity is improved, but accurate control of exact amount and location becomes more difficult
Solution Approach 1:
The patent replaces traditional mechanical measurement methods (weigh scales) with an integrated measurement system that operates at the fluid level. This substitution enables real-time measurement and control during high-speed dispensing, maintaining precision despite increased speed by using a measurement approach that is inherently suited to dynamic conditions.
Solution Approach 2:
The patent employs dynamic measurement and control that adapts to varying dispensing conditions in real-time. The integrated measurement device and feedback control system adjust to changes in flow rate, pressure, and speed during operation, maintaining accurate control of dispensed amount and location even in high-speed manufacturing environments where conditions are constantly changing.
Data Source
AI summary
Methods and systems of accurately dispensing a viscous fluid onto a substrate. In an embodiment, a method includes using an electronic flow meter device to produce electrical flow meter output signals and performing a responsive control function in a closed loop manner by adjusting at least one dispensing parameter to correct for a difference between an output data set and a reference data set. In another embodiment, a system includes a control operatively coupled to a gas flow meter device and to a weigh scale allowing for a density of an amount of viscous material to be determined. In another embodiment, a method includes using a control coupled to both a gas flow meter device and a weigh scale and performing a responsive control function in a closed loop manner by adjusting at least one dispensing parameter using gas flow meter output signals and weigh scale output signals.