METHOD AND DEVICE FOR JETTING DROPLETS
20170182578 ยท 2017-06-29
Assignee
Inventors
- Andreas Bergstrom (Stockholm, SE)
- Eric Eskang (Stockholm, SE)
- Johan Bergstrom (Stockholm, SE)
- Martin Dahlberg (Landvetter, SE)
Cpc classification
B05B12/082
PERFORMING OPERATIONS; TRANSPORTING
B41J2002/14483
PERFORMING OPERATIONS; TRANSPORTING
B41J2/14
PERFORMING OPERATIONS; TRANSPORTING
B05C5/0225
PERFORMING OPERATIONS; TRANSPORTING
B05C11/1034
PERFORMING OPERATIONS; TRANSPORTING
B23K3/0638
PERFORMING OPERATIONS; TRANSPORTING
B05C11/1007
PERFORMING OPERATIONS; TRANSPORTING
B23K3/0623
PERFORMING OPERATIONS; TRANSPORTING
H05K3/3489
ELECTRICITY
H05K2203/013
ELECTRICITY
B05C5/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23K3/06
PERFORMING OPERATIONS; TRANSPORTING
B05C5/02
PERFORMING OPERATIONS; TRANSPORTING
B05C11/10
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An ejector for jetting droplets of viscous media onto a substrate is disclosed. The ejector comprises a jetting nozzle having a nozzle space and a nozzle outlet, and an impacting device for impacting a volume of the viscous medium in the nozzle space such that droplets of viscous medium is jetted from the nozzle space through the nozzle outlet towards the substrate. The ejector also comprise a sensor arrangement arranged after the jetting nozzle in the jetting direction, wherein the sensor arrangement is adapted to detect a jetted droplet of viscous medium passing thereby.
Claims
1.-30. (canceled).
31. A method of jetting droplets of viscous medium onto a substrate, the method comprising the steps of: providing a jetting nozzle comprising a nozzle space and a nozzle outlet; providing a sensor arrangement after the jetting nozzle in the jetting direction; feeding said viscous medium into the nozzle space; impacting said viscous medium in the nozzle space, thereby jetting viscous medium from the nozzle space in the form of droplets through the nozzle outlet towards the substrate; monitoring a sensor parameter reflecting presence of viscous medium at the sensor arrangement; and generating a repair jetting program based on information detected by said sensor arrangement, wherein said repair jetting program is adapted to control an associated jetting process in order to jet a required amount of viscous medium onto required positions on said substrate, and wherein said associated, or supplemental, jetting process is performed in response to at least one of detection of missed shots, detection of droplets having a volume being outside a predetermined reference volume range, and/or detection of droplets having a velocity being outside a predetermined reference velocity interval.
32. The method according to claim 31, wherein said step of monitoring comprises: calculating at least one presence value (PV), said calculation including a comparison between at least one sensor value (SV) of said sensor parameter with at least one reference sensor value (SVref), thereby identifying the presence of viscous medium at the sensor arrangement.
33. The method according to claim 32, said method further comprising the step of: calculating a droplet value (DV), said calculation including a comparison between at least two presence values (PV) measured at different times, thereby identifying a droplet of viscous medium passing the sensor arrangement.
34. The method according to claim 32, said method further comprising the step of: calculating a droplet value (DV), said calculation including counting at least two presence values (PV) being equal to or exceeding reference presence value (PVref) representing presence of viscous medium at the sensor arrangement, said at least two presence values (PV) being measured at different times, thereby identifying a droplet of viscous medium passing the sensor arrangement.
35. The method according to claim 33, further comprising: monitoring a lapsed time parameter (LTP) reflecting a lapsed time from the impacting of said viscous medium in the nozzle space to the identifying of a droplet of viscous medium passing the sensor arrangement, said lapsed time parameter (LTP) including a time value (TV); calculating an impact droplet value (IDV), said calculation including comparing the time value (TV) with a reference time value (TVref), thereby verifying jetting of a droplet due to said impacting.
36. The method according to claim 33, further comprising: monitoring a droplet interval time parameter (DTP) reflecting a lapsed time between a first droplet of viscous medium passing the sensor arrangement and a second droplet of viscous medium passing the sensor arrangement, said droplet interval time parameter (DTP) including a droplet interval value (DIV); calculating an impact droplet value (IDV), said calculation including comparing the droplet interval value (DIV) with a reference droplet interval value (DIVref), thereby verifying jetting of droplet due to impacting of the impacting device.
37. The method according to claim 35, wherein the sensor arrangement comprises at least two sensor devices consecutively arranged in the jetting direction, the method further comprising the step of: calculating a droplet velocity value (DVV), said calculation including a comparison between at least a first presence value (PV) from at least a first sensor device, and at least a second presence value (PV) from at least a second sensor device, wherein the at least first and second presence values (PV) are measured at different times.
38. The method according to claim 35, wherein the sensor arrangement comprises at least two sensor devices consecutively arranged in the jetting direction, the method further comprising the step of: calculating a droplet length value (DLV), said calculation including a comparison between at least a first presence value (PV) from at least a first sensor device, and at least a second presence value (PV) from at least a second sensor device, wherein the a least first and second presence values (PV) are measured at different times.
39. The method according to claim 38, wherein the sensor arrangement further comprises at least two sensor devices arranged in a plane perpendicular to the jetting direction, the method further comprising the step of: calculating a droplet diameter value (DDIAV), said calculation including a comparison between at least two presence values (PV) from at least a first and a second sensor device, wherein the at least two presence values are measured at the same time; calculating a droplet length value (DLV), said calculation including a comparison between at least a first presence value (PV) from at least a first sensor device, and at least a second presence value (PV) from at least a second sensor device, wherein the at first and second presence values (PV) are measured at different times; and calculating a droplet volume value (DVOLV) based on said droplet length value (DLV) and said droplet diameter value (DDIAV).
40. The method according to claim 35, further comprising a step of: performing supplemental jetting of a droplet of viscous medium onto the substrate if a jetted droplet due to impact has not been verified.
41. The method according to claim 37, further comprising the step of: performing supplemental jetting of a droplet of viscous medium onto the substrate if said droplet velocity value (DVV) is below a droplet velocity reference value (DVVref).
42. The method according to claim 39, further comprising the step of: performing supplemental jetting of a droplet of viscous medium onto the substrate if said droplet volume value (DVOLV) is below a droplet volume reference value (DVOLVref).
43. The method according to claim 40, wherein the supplemental jetting is performed during the first jetting process.
44. The method according to claim 40, wherein the supplemental jetting is performed after the first jetting process.
45. The method according to claim 40, wherein the supplemental jetting is performed by an additional ejector.
46. The method according to claim 37, further comprising: increasing a strength of the impact of said viscous medium in the nozzle space if the droplet velocity value (DVV) is equal to or below a droplet velocity reference value (DVVref).
47. The method according to claim 37, further comprising: reducing the strength of the impact of said viscous medium in the nozzle space if the droplet velocity value (DVV) exceeds the droplet velocity reference value (DVVref);
48. The method according to claim 39, further comprising: increasing a feeding rate of the viscous medium into the nozzle space if the droplet volume value (DVOL) is equal to or below a droplet volume reference value (DVOLref).
49. The method according to claim 39, further comprising: reducing the feeding rate of the viscous medium into the nozzle space if the droplet volume value (DVOL) exceeds the droplet volume reference value (DVOLref).
50. The method according to claim 31, further comprising: providing a substrate sensor arrangement directed towards the substrate; monitoring a substrate sensor parameter (SSP) reflecting presence of viscous medium on the substrate, said substrate sensor parameter (SSP) including a substrate sensor value (SSV); calculating at least one substrate presence value (SPV), said calculation including a comparison between at least one substrate presence value (SPV) of said substrate sensor parameter (SSP) with at least one reference substrate presence value (SPVref), thereby identifying the presence of viscous medium on the substrate.
51. The method according to claim 31, wherein said generated repair jetting program is automatically generated.
52. The method according to claim 31, wherein said generated repair jetting program is executed by another, concurrently operating ejector.
53. The method according to claim 31, wherein said generated repair jetting program is executed by another, sequentially operating ejector.
54. A method for a jetting process for jetting droplets of viscous medium onto a substrate, the method comprising the steps of: providing a jetting nozzle comprising a nozzle space and a nozzle outlet; providing a sensor arrangement after the jetting nozzle in the jetting direction; feeding said viscous medium into the nozzle space; impacting said viscous medium in the nozzle space, thereby jetting viscous medium from the nozzle space in the form of droplets through the nozzle outlet towards the substrate; monitoring a sensor parameter reflecting presence of viscous medium at the sensor arrangement; and modifying a jetting program which controls a printing process, wherein said modifying of said jetting program is performed during said printing process by adding one or several additional shots to said jetting program in response to said monitoring of said sensor parameter by the detection of at least one of missed shots, droplets having a volume being outside a predetermined reference volume range, and/or droplets having a velocity being outside a predetermined reference velocity.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] The above, as well as additional objects, features and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of embodiments of the present invention. Reference will be made to the appended drawings, on which:
[0059]
[0060]
[0061]
[0062]
[0063]
[0064]
[0065] All the figures are schematic, not necessarily to scale, and generally only show parts which are necessary in order to elucidate the invention, wherein other parts may be omitted or merely suggested.
DETAILED DESCRIPTION
[0066] With reference to
[0067] The ejector 1 comprises an impacting device, which in this implementation includes a piezoelectric actuator 7 and a plunger 6, which is connected to the piezoelectric actuator 7. The plunger 6 is axially movable while slidably extending through a bore in bushing 8. Cup springs 9 are provided to resiliently balance the plunger 6 against the assembly housing 10, and for providing a preload for the piezoelectric actuator 7. An eject control unit (not shown) applies a drive voltage intermittently to the piezoelectric actuator 7, thereby causing an intermittent extension thereof, and hence a reciprocating movement of the plunger 6 with respect to the assembly housing 10, in accordance with solder pattern printing data.
[0068] Furthermore, the ejector 1 comprises an essentially plate shaped jetting nozzle 2 operatively directed against the substrate 23, onto which droplets 22 of viscous medium are to be jetted. In the jetting nozzle 23, there is provided a nozzle space 3 and a nozzle outlet 4 through which the droplets 22 are jetted towards the substrate 23. The nozzle outlet 4 is located at one end, a lower portion, of the nozzle 2. The nozzle space 3 is arranged for receiving viscous medium, which is forced through the nozzle space 3 and out of the nozzle outlet 4 upon an impact by the plunger 6 of the impacting device.
[0069] The impacting device in form of a plunger 6 comprises a piston portion which is slideably and axially movably extending through a piston bore, an impact end surface 11 of said piston portion of the plunger 6 being arranged close to said nozzle 2.
[0070] In other implementations of the technology disclosed using a different type of ejector(s), the plunger comprising a piston may be replaced by another type of impacting device such as e.g. a membrane or diaphragm, which may or may not also comprise an ejector control unit adapted to apply a drive voltage intermittently to a piezoelectric actuator in accordance with what is mentioned above.
[0071] All these impacting devices have in common that they are configured to provide for a non-contact jetting process to form and shoot droplets of a viscous medium from a jetting nozzle onto a substrate by quickly generating a pressure impulse by the reciprocating movement, or vibrating movement, of the impacting device, e.g. a plunger, membrane or diaphragm.
[0072] The impacting devices of the one or more ejector(s) used in connection with the technology disclosed may move from a starting position towards an end position (which may or may not be close to the nozzle of the ejector) during a time period of about 1-50 microseconds in order to shoot individual droplets having a deposit volume of between about 100 pL and about 30 nL, e.g. about 10 nL or within the size range 5-15 nL. The speed of the impacting device for impacting the jetting nozzle with a pressure impulse may be between about 5 m/s and about 50 m/s.
[0073] Hence, the one or more ejector(s) used in connection with the technology disclosed may be configured to shoot droplets having a deposit volume with a certain size or size range, e.g. 5-15 nL, 1-5 nL or 10-20 nL. As mentioned above, the volume of each individual droplet to be jetted onto the workpiece may be between about 100 pL and about 30 nL and the dot diameter for each individual droplet may be between about 0.1 mm and about 1.0 mm.
[0074] The upper surface of the nozzle 2 is positioned opposite to the impact end surface. Axial movement of the plunger 6 towards the nozzle 2, said movement being caused by the intermittent extension of the piezoelectric actuator 7, will cause a rapid pressurization and jetting through the nozzle outlet 4 of any viscous medium contained in the nozzle space.
[0075] Viscous medium is supplied to the nozzle space 3 a supply container, via a feeder 12. The feeder 12 comprises an electric motor (not shown) having a motor shaft 13 partly provided in a tubular bore, which extends through the ejector housing 10 to an outlet port communicating with the nozzle space. An essential portion of the rotatable motor shaft, or feed screw 13, is surrounded by a tube 14, made of an elastomer or the like, arranged coaxially therewith in the tubular bore, the threads of the rotatable feed screw 13 making sliding contact with the innermost surface of the tube. An electronic control signal provided by a supply control unit (not shown) to the motor causes the feed screw 13 to rotate a desired angle, or at a desired rotational speed. Viscous medium captured between the threads of the rotatable feed screw 13 and the inner surface tube are then made to travel from the inlet port to the nozzle space 3 in accordance with the rotational movement of the feed screw 13, thereby feeding viscous medium into the nozzle space 3.
[0076] A sensor arrangement 5 is arranged after the jetting nozzle 2, as seen in the direction of the jetted droplet 22, such that the path of the jetted droplet 22 intersects a sensor field 17 controlled by the sensor arrangement 5. Thus, the droplet 22 passing by the sensor arrangement 5 may cause a disturbance of the sensor controlled field 17 such that a presence of viscous medium may be detected.
[0077] With reference to
[0078]
[0079] With reference to
[0080] A similar arrangement as described with reference to
[0081] It will however be appreciated that the sensor arrangement 5 may comprise a plurality of sensor devices consecutively arranged in the jetting direction, which may be integrated with a vacuum washer 24 or not integrated with the same.
[0082] Turning now to
[0083] With reference to
[0084] The jetting program for a specific machine, or a plurality of machines that will use the same jetting program, may be generated as follows. First the operator, working on the computer 53 where the software program has been loaded, on basis of the CAD data for a substrate, assigns the components that are to be places on the substrate to the machine by means of the software program. Component data about the components, such as their extension, regarding the housing as well as the leads, if any, and their position on the substrate, is comprised in the substrate data. By opening the machine interface for the present machine on the computer, the operator may begin the procedure of generating data for the jetting program based on the substrate data.
[0085]
[0086] A repair jetting program, in which printing errors such as e.g. missed shots and droplets having a volume below a predetermined value, may be generated similarly to the jetting program as described with reference to
[0087] With reference to
[0088] According to this embodiment, a jetting nozzle 2 comprising a nozzle space 3 and a nozzle outlet 4 is provided 102. After the jetting nozzle 2, in the jetting direction, a sensor arrangement 5 is provided 103, which e.g.
[0089] comprises an optical sensor device 17, 18. Viscous medium, such as e.g. solder paste, is fed 106 into the nozzle space 3 and impacted 108 by an impacting device such that the viscous medium is jetted from the nozzle space 3 in the form of droplets 22 through the nozzle outlet 4 towards the substrate 23. The method further comprises a step of monitoring 110 a sensor parameter reflecting presence of viscous medium at the sensor arrangement 5.
[0090] As shown in
[0091] In the next step, a droplet value (DV), identifying a droplet of viscous medium passing the sensor arrangement, is calculated 114 by e.g. comparing at least two presence values (PV) measured at different times. This may for example be achieved by comparing two presence values consecutively registered by the same sensor device. A first PV representing presence of viscous medium, followed by a second PV representing absence of viscous medium, may e.g. indicate that a droplet was passing the sensor device. The calculation may also comprise a comparison of several presence values in order to improve the reliability of the identification and to reduce noise of the measurements.
[0092] It will also be realised that passage of a droplet may be identified in several other ways readily understood by a person skilled in the art. For example, the droplet value may be calculated 114 by counting at least two presence values (PV) being equal to or exceeding a reference presence value representing presence of viscous medium at the sensor arrangement.
[0093] Further, the passing droplet may be verified as a jetted droplet, i.e. an intentional droplet passing the sensor arrangement due to an impact of the impacting device. This may be achieved by monitoring 116 a lapsed time parameter (LTP) and calculating 118 an impact droplet value (IDV). The lapsed time parameter reflects a lapsed time from the impacting 108 of the impacting device to the identifying 114 of a droplet passing by the sensor arrangement, and the impact droplet value may be calculated 118 by comparing a time value (TV) of the lapsed time parameter (LTP) with a reference time value (TVref). A relatively low time value may e.g. indicate that the passing droplet is passing the sensor arrangement due to the recent impact, whereas a relatively high time value may indicate that the droplet is not passing the sensor arrangement due to the impact.
[0094] As shown in
[0095] By using at least two sensor devices consecutively arranged in the jetting direction, both a droplet velocity value (DVV) and a droplet length value (DLV) may be calculated 120, 122. The droplet velocity value (DVV), obtained by comparing a first presence value (PV) from a first sensor device with a second presence value (PV) from a second sensor device, may be used together with a third presence value from either one of the sensor devices to determine the droplet length value (DLV). The first presence value may e.g. represent a front of the droplet, and the third presence value, e.g. obtained from the first sensor device, an end of the droplet. Based on the time interval between the passing of the front and the end of the droplet with the droplet velocity value (DVV), the lengthi.e. the distance between the front and the endof the droplet may be calculated 122.
[0096] A sensor arrangement further comprising at least two sensor devices arranged in a plane perpendicular to the jetting direction. By comparing two presence values (PV) from a first and a second sensor device arranged in a plane perpendicular to the jetting direction, wherein the two presence values, the diameter of the droplet may be calculated as a droplet diameter value (DDIAV). A droplet volume value (DVOLV) may then be calculated 126 based on the droplet diameter value (DDIAV) and the droplet length value (DLV).
[0097] Supplemental jetting 128 of a droplet of viscous medium onto the substrate may be performed if a jetted droplet due to impact has not been verified 118, if the jetted droplet has a too low velocity, or if the jetted droplet has a too low volume. The additional jetting 128 may e.g. be performed in a separate, correcting printing process, or performed dynamically during the jetting the jetting process.
[0098] If the calculated 120 droplet velocity is below a reference droplet velocity value, a step of increasing 130 a strength of the impact of the viscous medium may be performed so as to increase the droplet velocity. Correspondingly, a step of increasing 132 the strength to the impact may performed in response to the calculated 120 droplet velocity being equal to or exceeding the reference droplet velocity value. The adjustment 130, 132 of the impact strength may e.g. be achieved by modifying the applied voltage to the piezoelectric actuator connected to the piston.
[0099] In response to a droplet volume value being too low or high, compared with a reference droplet volume value, the method may comprise a step of increasing 134 or decreasing 136, respectively, the feeding rate of the viscous medium into the nozzle space. This may e.g be performed by adjusting the speed of the electric motor operating the feeding screw.
[0100] Finally,
[0101] It will be appreciated that any one of the embodiments described above with reference to
[0102] As outlined above, the method illustrated by
[0103] While specific embodiments have been described, the skilled person will understand that various modifications and alterations are conceivable within the scope as defined in the appended claims.