Apparatus and method for producing or processing a product or sample

An apparatus and method are provided for producing a plurality of products or processing a plurality of samples via dispensing. The apparatus and method provide real-time monitoring of the products/samples and can provide real-time control. The apparatus and method can monitor the liquid both before and after it has been added to a carrier substrate. The apparatus and method can provide monitoring of each product/sample that is processed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to the manufacture or processing of products or samples. More particularly, the present invention relates to an apparatus and process for manufacturing or processing a product or sample by dispensing.

2. Description of Related Art

Manufacturing processes often require the combination of different materials, such as solder onto a printed circuit board or an active agent onto a pharmaceutical substrate. Various methods have been developed for the combining of such materials. For example, soldering methods have been developed for connecting integrated circuit chips to the printed circuit board. One such method includes applying a small amount of solder to the bottom surface of the chip, aligning the solder with a bond pad on the surface of the printed circuit board, and heating the solder until it reflows. Another such method includes applying solder to bonding pads on the printed circuit board and then bonding electrical components to the printed circuit boards by positioning the components over the solder and by heating and reflowing the solder. In other methods, chips are bonded to a patterned layer of solder created by applying a thin layer of solder paste to a printed circuit board through holes in a stencil, leaving a selected solder pattern on the printed circuit board.

Such methods suffer from drawbacks as to efficiency and quality. Accordingly, there is a need for an apparatus and process for manufacturing products via dispensing that reduces or eliminates these manufacturing and quality control drawbacks of the contemporary devices and techniques.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a more efficient process and/or apparatus for manufacturing or processing products or samples that comprise a dispensed component.

It is another object of the present invention to provide such a process and/or apparatus that provides real-time process monitoring.

It is yet another object of the present invention to provide such a process and/or apparatus that provides real-time feedback and control of the process and product quality.

It is still another object of the present invention to provide such a process and/or apparatus that provides monitoring of each of the products or samples that are manufactured or processed.

It is yet still another object of the present invention to provide such a process and/or apparatus that minimizes or eliminates off-line quality control inspection and facilitates real-time release of the products.

It is yet a further object of the present invention to provide such a process and/or apparatus that facilitates change over to production of a different product.

These and other objects and advantages of the present invention are provided by a monitoring system for a machine that produces a plurality of products by dispensing droplets of liquid on one or more carrier substrates. The monitoring system comprises an inspection system having a microprocessor, a first camera or video/digital recording device (herein referred to as “camera”) in communication with the microprocessor and a trigger operably connected to the first camera. The inspection system determines an amount of the liquid that is being added to each of the carrier substrates. The trigger actuates the first camera to obtain a first image of each of the droplets in-flight. The microprocessor determines the amount of the liquid based upon the first image.

In another aspect, an apparatus for producing a plurality of products is provided. Each of the plurality of products has a carrier substrate and a dispensed liquid thereon. The apparatus comprises a dispensing system for dispensing the dispensed liquid as a droplet onto each of the carrier substrates and a monitoring system comprising an inspection system that determines an amount of the dispensed liquid that is being added to each of the carrier substrates by the dispensing system. The inspection system comprises a microprocessor, a camera or video/digital recording device (herein referred to as “camera”) in communication with the microprocessor and a trigger operably connected to the first camera. The trigger actuates the first camera to obtain a first image of the droplet in-flight. The microprocessor determines the amount of the dispensed liquid based upon the first image.

In another aspect, an apparatus for producing a plurality of products that each have a carrier substrate and a dispensed liquid is provided. The apparatus comprises a dispensing system that adds the dispensed liquid to each of the carrier substrates; and a monitoring system that performs real-time monitoring of the dispensing system to determine an amount of the dispensed liquid on each of the carrier substrates.

In another aspect, a monitoring system for a machine that produces a plurality of products is provided where the plurality of products each have a carrier substrate and a dispensed liquid. The monitoring system comprises a confirmation system operably connected to the machine that determines an amount of the dispensed liquid that has been added to each of the carrier substrates by the machine. The confirmation system performs optical profilometry on each of the carrier substrates to determine the amount of the dispensed liquid.

In another aspect, a machine which produces a plurality of products where each has a carrier substrate and a dispensed liquid is provided. The machine comprises a dispensing system for adding the dispensed liquid to each of the carrier substrates and a confirmation system for determining an amount of the dispensed liquid that has been added to each of the carrier substrates. The confirmation system performs optical profilometry on each of the carrier substrates to determine the amount of the dispensed liquid.

In another aspect, a method of monitoring a machine is provided. The machine produces a plurality of products by dispensing a droplet of liquid on a carrier substrate. The method comprises actuating a camera based upon dispensing of the droplet; obtaining a first image of the droplet in-flight; and determining a volume of the droplet based upon the first image.

In another aspect, a method of producing a plurality of products that each have a carrier substrate and a dispensed liquid thereon is provided. The method comprises dispensing the dispensed liquid as a droplet onto each of the carrier substrates; and determining an amount of the dispensed liquid that is being added to each of the carrier substrates by the dispensing system by obtaining a first image of the droplet in-flight and determining the amount of the dispensed liquid based upon the first image.

Each of the carrier substrates can continue to move along the apparatus as the inspection system determines the amount of the dispensed liquid. The monitoring system may further comprise a confirmation system having a probe that performs spectroscopy on the dispensed liquid that has been added to each of the carrier substrates. Each of the carrier substrates can continue to move along the apparatus as the probe performs spectroscopy. The spectroscopy may be taken from the group consisting of near infrared, mid-infrared, ultraviolet/visible, fluorescence, laser-induced fluorescence, Raman, terahertz, and any combinations thereof.

The monitoring system can further comprise a confirmation system having a second camera that obtains a second image of the dispensed liquid on each of the carrier substrates. The confirmation system determines a position of the dispensed liquid for each of the carrier substrates based on the second image. Each of the carrier substrates may continue to move along the apparatus as the second camera obtains the second image.

The apparatus can further comprise a temperature conditioning system that changes the temperature of the dispensed liquid to facilitate its formation on the carrier substrate. The temperature conditioning system may monitor environmental parameters for each of the carrier substrates, wherein the environmental parameters are taken from the group consisting of temperature, air-flow rate, humidity, radiation, product surface temperature, and any combinations thereof.

The apparatus can further comprise a printing system for applying an identification marker to each of the carrier substrates. The printing system may have a third camera for obtaining a third image of the identification marker for inspection. Each of the carrier substrates can continue to move along the apparatus as the third camera obtains the third image.

The apparatus can further comprise a control system for performing real-time control of the dispensing system based on the real-time monitoring. The real-time control may comprise adjusting an amount of dispensing from the dispensing system. The dispensing system may have a nozzle, wherein the real-time control comprises adjusting a position of the nozzle with respect to each of the carrier substrates thereby adjusting the position of the dispensed liquid on each of the carrier substrates. The confirmation system can perform optical profilometry on each of the carrier substrates to determine the amount of the dispensed liquid. Each of the carrier substrates may continue to move along the apparatus as the optical profilometry is performed.

This application is related to the following applications which have been filed contemporaneously herewith and the disclosures of which are hereby incorporated by reference in their entirety: APPARATUS AND METHOD FOR PHARMACEUTICAL PRODUCTION, Ser. No 11/148,919; APPARATUS AND METHOD FOR PRODUCING A PHARMACEUTICAL PRODUCT, Ser. No. 11/148,894; PHARMACEUTICAL PRODUCT, Ser. No. 11/149,100; APPARATUS FOR PRODUCING A PHARMACEUTICAL PRODUCT, Ser. No. 11/148,920; and METHOD FOR PRODUCING A PHARMACEUTICAL PRODUCT, Ser. No. 11/149,022.

Other and further objects, advantages and features of the present invention will be understood by reference to the following:

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, and in particularFIGS. 1through3, a preferred embodiment of the apparatus or machine of the present invention is shown and generally referred to by reference numeral10. The machine10has a plurality of components that are operably connected to manufacture a product or process a sample, and preferably a batch of products or samples, as will be described later in greater detail. A batch is a quantity of product, which has been produced or processed during a defined cycle, such as, for example, a fixed number or one or more runs over a fixed time period. The machine10has various components arranged along a straight or substantially straight line. However, the present invention contemplates other arrangements and positionings of the various components, such as, for example, in circular or rectangular paths. While the exemplary embodiment describes the manufacture of a product via dispensing, the present invention contemplates other processes being performed by the machines described herein, such as, for example, testing or processing of samples via dispensing.

The arrangement and positioning of the components of machine10provide a smaller footprint for space savings, as well as providing a more efficient and ergonomic machine that facilitates operation. Machine10can have components stacked on each other or at differing heights to take advantage of vertical space, as well as facilitating operation, such as, for example, enabling the use of gravity in the process performed by the machine.

The machine10has a loading system100, a holding system200, a conveyor system300, a dispensing system400, a coating system600, a printing system700, a product acception-rejection system800, and a control system900. Each of these systems100through900are operably connected to each other to efficiently and ergonomically provide products that are ready for packaging, and which have each undergone real-time monitoring, and preferably real-time feedback and adjustment or control.

The machine10delivers the product, which is a combination of a substrate1000and a liquid2000. As will be described later in greater detail, the liquid2000is dispensed by dispensing system400in the form of a droplet2100(shown inFIG. 3) that is dispensed onto the substrate1000. It should be understood that the liquid2000can have a variety of properties, such as, for example, low-viscosity, high-viscosity, such that the term liquid is not intended to be limiting. The liquid2000can be anything that is dispensable onto the substrate1000, such as, for example, solder onto an IC chip or a therapeutic active agent onto a carrier tablet. One of ordinary skill in the art could utilize the present invention for processing a variety of substrates1000with a variety of liquids2000. Additionally, the dispensing of liquid2000onto substrate1000is not limited to droplets2100, but can also include other flow patterns, such as, for example, a partial or continuous stream. It should be further understood that the present disclosure contemplates the substrate1000being a variety of substances upon which the liquid2000can be dispensed and having a variety of properties. Such a substance for substrate1000may also include another liquid.

The droplet2100is dispensed onto the outer surface or substantially along the outer surface of the substrate1000, such as, for example, solder that is heated and then dispensed onto the substrate. The substrate1000, the liquid2000and the resulting product undergo real-time monitoring, feedback and adjustment, which improve quality control.

In the preferred embodiment shown inFIG. 1, loading system100has a loading container or hopper110in communication with a loading chute120. Hopper110is preferably movable so that one or more substrates1000can be loaded into the hopper and then the hopper can be moved into communication with the loading chute120. Loading chute120is in communication with holding system200and conveyor system300so that the substrates1000can be moved from the hopper110into the holding system200for movement along and through machine10by way of conveyor system300.

The hopper110and loading chute120can use various devices and methods, such as, for example, powered wheels or wedges, powered belts, or gravity, to move each of the substrates1000into their designated positions in holding system200. In machine10, a portion of loading system100is preferably disposed above a portion of conveyor system300to take advantage of gravity, in combination with a mechanical loading device.

In the preferred embodiment, holding system200has a plurality of holding members or trays210with substrate positions220having a size and shape that allows for holding of each of the substrates1000. Preferably, each of the holding trays210is rectangular, and the substrate positions220are arranged in an array of equi-distantly spaced rows and columns. As will be explained later, this array facilitates operation of the dispensing system400in adding the droplets2100to the substrates1000. However, the present invention contemplates the use of other structures and methods for securing each of the substrates1000and the resulting products as they travel along machine10.

One of ordinary skill in the art can vary the sizes, capacities and shapes of the holding trays210and the substrate positions220to accommodate different shapes and/or sizes of substrates1000and to increase efficiency. Additionally, the holding trays210may simply be a mechanism for temporarily connecting the substrate1000with the conveyor system300so that the substrate travels along the machine10, such as, for example, a large substrate receiving multiple dispensings thereon.

Holding system200tracks individual substrates1000by their designation in each of the substrate positions220. This allows machine10to perform various real-time monitoring, feedback and adjustment activities upon each of the substrates1000, droplets2100and products, and also to make determinations as to whether each of the substrates, droplets or resulting products have met the quality control standards that are designated for a particular product. The tracking of each of the substrates1000, droplets2100and/or products throughout the process carried out by machine10, allows for acceptance or rejection during the process. The present invention also contemplates tracking of unacceptable substrates1000for removal by acception-rejection system800based on the real-time monitoring.

Various tracking or identification methods can be used by holding system200for each of the substrates1000. In the preferred embodiment of machine10, holding trays210have a bar code230that can be scanned to provide identification and information to control system900, and which can also be used to track and monitor the individual substrates1000, droplets2100and/or products throughout the process. As will be discussed later in greater detail, the data compiled throughout the process is stored by control system900. The data is based upon the individual substrates1000, droplets2100and/or products, as opposed to contemporary quality control methods that use batch-sampling.

In the embodiment of machine10, holding system200positions each of the substrates1000so that dispensing system400can add the droplet2100to the outer surface of the substrate, which is facing away from the holding tray210. The present invention contemplates the dispensing system400also adding the droplet2100to the opposing outer surface of the substrate1000. This would allow for a greater capacity of liquid2000being carried by the substrate1000(on both of its outer surfaces).

Dispensing onto both sides of the substrate1000would also provide the ability for different liquids2000, to be dispensed upon a single substrate, such as, for example, where the different liquids are incompatible and cannot be mixed together in liquid form or where the different liquids cannot be layered on top of each other. The present invention contemplates dispensing system400adding one or more different liquids2000to substrates1000through layering, through depositing on opposing outer surfaces and/or both. The present invention also contemplates dispensing system400adding a plurality of different liquids2000to substrates1000, where the liquids are simultaneously on one or both of the outer surfaces of the substrate.

Machine10can also be used to re-process the substrates1000any number of times through the dispensing system400in order to add each of the different liquids2000. Machine10may have additional dispensing systems400in series that will add each of the different liquids2000to the substrates1000.

Holding system200can alternatively provide for dispensing the liquid2000(or different liquids) on both sides of the substrates1000by providing dispensing system400with access to both sides of the substrate. Examples of such alternative methods of dispensing include, but are not limited to, inverting holding tray210so that each of the substrates1000are transferred into a second holding tray210so that the opposing outer surfaces are now facing away from the second holding tray or using a holding tray that holds each of the substrates around their perimeters or outer circumferences so that both outer surfaces are simultaneously accessible.

The flipping or inverting of each of the carrier substrates1000or their holding tray210can be done near the end of the process so that the opposing outer surface is re-processed by the same components or a second set of components could be added to machine10to continue the process with respect to the opposing outer surface. Additionally, the inverting of each of the substrates1000or their holding tray210, can be done by holding system200to allow for other operations or processes to be performed on the opposing outer surface, such as, for example, coating or printing on both sides of the products.

Conveyor system300provides for movement of holding trays210along machine10and through the various stages or systems of the machine. In the preferred embodiment of machine10, conveyor system300provides for movement of holding trays210along a substantially horizontal path. However, the present invention contemplates movement of the holding trays210in other directions, such as, for example, in a vertical path, where spacial economy, the use of gravity or other reasons suggest or dictate such a direction of movement.

Conveyor system300has a drive conveyor310. Drive conveyor310is controlled by control system900, shown inFIG. 1, and is preferably variable speed. Holding trays210are preferably removably connected to drive conveyor310. Holding trays210are securely connected to the drive conveyor310so that each of the substrate positions220remains constant with respect to the drive conveyor in order to provide accuracy in dispensing and monitoring of the substrates1000, droplets2100and products. In the preferred embodiment of machine10, drive conveyor310is a circulating conveyor belt that traverses the length of machine10and, more preferably, is a serial real-time communications system drive unit. However, the present invention contemplates other types and methods of moving the holding trays210, such as, for example, parallel drive chains, tracks, belts or wheels to which the holding trays can be removably connected.

The present invention also contemplates the use of a number or series of holding trays210that are pivotally secured to each other to form a belt-like structure or tray belt, which can be operably connected to the drive conveyor310. Machine10can have a plurality of tray belts with different sizes and/or shapes of substrate positions220to accommodate different sizes and/or shapes of substrates1000. The tray belt is a length or line of holding trays210that is connectable at opposing ends to form a loop. When the holding trays210are to be replaced for different products, the tray belt is fed along the drive conveyor310and then secured at its opposing ends to form the belt along the machine10. To expedite the connection of the second tray belt to drive conveyor310, the second tray belt can preferably be connected to the end of the first tray belt that is being removed, as that first tray belt is driven along and off of the drive conveyor.

The present invention also contemplates the use of any number of drive conveyors310. For example, different systems of machine10can have independent drive conveyors310that allow for independent control of the speed of the drive conveyors, such as, for example, to more rapidly remove the products from the end of the process. In such an alternative embodiment, control system900would preferably control the various independent drive conveyors310, and be able to coordinate their movement.

In the preferred embodiment, dispensing system400provides for the addition of the liquid2000to each of the substrates1000, and provides for real-time monitoring, feedback and adjustment. To dispense the liquid2000, dispensing system400has a gantry410that laterally spans above and across drive conveyor310, and is longitudinally movable with respect to the drive conveyor. The movement of gantry410, including speed and position, is controlled by control system900.

The gantry410has a dispensing module420movably connected thereto. The dispensing module420is movable along the longitudinal axis of the gantry410, which laterally traverses across the drive conveyor310. The movement of the dispensing module420, including speed and position, is also controlled by the control system900.

Based upon the movement of the gantry410, and its own movement with respect to the gantry, the dispensing module420is capable of movement along X and Y axes with respect to the drive conveyor310and the holding trays210. Additionally, the present invention contemplates movement of the gantry410, the dispensing module420, and/or both, along a Z-axis with respect to the drive conveyor310and the holding trays210. The movement of the dispensing module420allows it to accurately dispense the droplet2100on each of the substrates1000that are in the array of substrate positions220on holding tray210. Control system900can also adjust the movement of the dispensing module420and the gantry410to accommodate different sizes and shapes of holding trays210, as well as different arrays of substrate positions220on the holding trays.

The use of the gantry410to move the dispensing module420along X and Y axes (and the Z axis if desired), provides for smooth movement and accurate alignment of the dispensing module with each of the substrates1000. This is especially significant in the preferred embodiment of machine10where the drive conveyor310continues to move the holding tray210through the dispensing system400as the droplets2100are being dispensed. The continuous movement of each of the substrates1000along machine10as the dispensing step is occurring speeds up the manufacturing process. Additionally, smooth continuous movement of the holding tray210and the substrates1000thereon, as opposed to dispensing onto the substrates via indexing or discontinuous movement, provides for less wear and tear on the machine10and its components, particularly the drive conveyor310. Dispensing module420preferably moves in an X-like path to accurately dispense on each of the substrates1000. The size and shape of the X-like path depends upon the dispensing speed and the spacing of substrate positions220, as shown inFIGS. 2aand2b. It should be further understood by one of ordinary skill in the art that the dispensing module420can be moved along alternative paths that preferably allow for continuous movement of the substrates1000during dispensing.

The accuracy of the alignment of the dispensing module420with each of the substrates1000, and the efficiency of the movement of the module, is facilitated by the use of the rectangular array of substrate positions220along holding tray210and the control of the movement of the module and gantry410in a rectangular coordinate system. However, the present invention contemplates the use of other structures and methods that could also be used to move the dispensing module420with respect to each of the substrates1000, as the drive conveyor310continues to move through the dispensing system400, such as, for example, a multiple axis robotic arm and/or along different coordinate systems.

In the preferred embodiment of machine10, the dispensing system400has a pair of dispensing modules420connected to gantry410. The use of more than one dispensing module420provides for increased speed and efficiency in dispensing of the liquid2000. Additionally, the use of more than one dispensing module420would allow the dispensing system400to add different liquids2000to a substrate1000without cleaning or replacing the module, such as, for example, in layering or on opposing outer surfaces through re-processing the substrate back through the dispensing system.

Dispensing module420dispenses a desired amount of liquid2000onto the substrate1000. In the preferred embodiment of machine10, the dispensing module420has a pump425, a flow cell or meter430, and a dispensing head435. The present invention contemplates a single dispensing module420that has duplicate components, such as, for example, a pump425and a flow cell430that are in fluid communication with a pair of dispensing heads435, and/or other combinations or numbers of components for any number of dispensing modules.

The pump425is connected to a liquid source440. In the preferred embodiment of the machine10, the liquid source440is a movable container445that is connected to the pump425via removably connectable conduit447, so that the liquid2000can be quickly and efficiently replaced. The liquid source440can have a heater (not shown) to facilitate flow of the liquid2000from the container445to the pump425, such as, for example, where the liquid is a solder or other type of material that is generally in a solid state at room temperature.

The present invention contemplates the use of a liquid source440with replaceable cartridges, containers or canisters (not shown) that can be easily inserted in, or connected to, the liquid source. For lower amounts of the liquid2000to be dispensed, having a liquid source440that is held in replaceable cartridges, containers or canisters is especially useful for facilitating operation of machine10.

The pump425is preferably a metered, positive displacement pump (shown inFIGS. 2cthrough2f), which causes the dispensing head435to dispense a single droplet2100. The metered, positive displacement pump425is controlled by the control system900, and facilitates the accuracy and control of dispensing a single droplet2100of the desired size so that the proper amount of liquid2000is added to the substrate1000. However, the present invention contemplates the use of other types of pumps, such as, for example, a time-pressure pump or reciprocating piston pump connected to a dispensing module that can provide the same degree of accuracy and speed in adding the liquid2000to the substrate1000.

Pump425has a motor module4250and a piston module4280, as shown inFIGS. 2eand2f. The motor module4250has a motor4255, a connection port4260and an adjustment mechanism4265. The piston module4280has a piston assembly4285and a cylinder4290. When the piston module4260is operably connected to the motor module4250through connection port4260, the piston on piston assembly4285is driven which imparts both reciprocating and rotary motion to the piston. The magnitude of the piston stroke is manually adjustable by the adjustment mechanism4265. The present invention contemplates automatic adjustment through use of the real time monitoring, feedback and control as described herein.

Pump425, as controlled by the control system900, can skip select substrate positions220, where the substrates1000contained therein have been designated as rejected. Machine10provides for inspection of the substrates1000before they undergo the dispensing process described above. In the preferred embodiment, the substrate inspection is performed by a camera426and gantry assembly (not shown), which provide images of each of the substrates1000for inspection by control system900.

Alternative inspection devices and methods can be used which determine the condition of the substrate, as well as ensure that it is properly positioned in substrate position220. Selective dispensing by pump425improves efficiency by not wasting any liquid2000on any substrates1000that have already been deemed to not meet the required tolerances of the products or are not properly positioned for receiving the droplet2100.

The pump425is connected to the flow cell430. The flow cell430determines the amount of liquid2000contained in container445that is going to be dispensed through the dispensing head435, which will be used in the real-time monitoring of the droplets2100.

The dispensing head435has a dispensing nozzle450(shown inFIG. 2d) through which the pressurized, metered amount of liquid2000is dispensed, and forms the droplet2100. The droplet2100dispenses onto the outer surface of the substrate1000.

Nozzle450provides for exact amounts of liquid2000being dispensed. The liquid2000is preferably dispensed by a very precise, positive displacement, piston pump425that pumps the liquid through tubing to the nozzle450. The proper selection of liquid composition, viscosity, the materials of construction and orifice size of the nozzle450are significant and/or critical parameters to the reproducibility of droplets formed.

Nozzle450can also be made from a hydrophobic material and/or have a hydrophobic coating to facilitate formation and dispensing of droplet2100by compensating for liquid vehicle composition/formulation and surface tension.

In an alternative embodiment shown inFIG. 2g, nozzle450has an internal plunger4510that is retracted to allow the exact amount of liquid2000to enter the dispensing chamber4520under pressure of pump425. Preferably, plunger4510is spring-loaded by a spring4530, or other biasing device, and can be retracted by air pressure, such as, for example, by a solenoid driven pressure source. The liquid2000is dispensed as a result of the retraction of the plunger4510. Under automatic control, the time that the plunger4510is in the open position, the pressure maintained on the reservoir of liquid and the vehicle composition are significant and/or critical parameters to the reproducibility of the droplets formed.

Chamber4520is preferably selectively sealed so that the chamber and liquid2000contained therein remain under pressure. A heater4540may be utilized to facilitate the ejection process. Nozzle450may have a micro-adjuster4550or other adjustment mechanism, manual or automatic (such as being controlled by control system900with real-time monitoring, feedback and control), that provides for adjustment of the amount of liquid2000that is allowed to exit the dispensing chamber4520. Nozzle4560may be a co-axial air exhaust4560that further facilitates dispensing of liquid2000.

The dispensing system400uses a pump and nozzle assembly to form and dispense the droplet2100. This is advantageous due to the accuracy of the components as described above, and the ability to perform real-time monitoring of their activities. Also, the dispensing system400, through use of nozzle450, can preferably provide a spherical or substantially spherical droplet2100, which reduces or prevents splashing and overspray. Additives can be provided to liquid2000to facilitate dispensing where appropriate.

The dispensing system400, and the use of a liquid2000and droplet2100that are dispensed onto the substrate1000, is advantageous over contemporary systems and processes in that the production facilities or sites where the machine10is located can centrally process the liquid. This reduces the steps of the production, such as eliminating off-site production and delivery, which decreases production time and saves on costs. Where harmful compounds are being used in the liquid2000, this is especially advantageous in reducing the handling of the compounds by the workers.

Dispensing system400can alternatively have a nozzle-plate assembly4600(a portion of which is schematically represented inFIGS. 2hthrough2j) to form and dispense the droplet2100. The assembly4600has a plate4610with an aperture or nozzle opening4620therethrough. The plate4610is capable of movement with respect to the supply of liquid2000, as indicated by arrows4630. Such movement includes, but is not limited to, vibration of the plate4610in order to actuate the dispensing. The liquid2000is dispensed through nozzle opening4620when the plate4610is selectively moved towards the supply of the liquid.

As shown inFIG. 2i, the size of nozzle opening4620can be adjusted or changed to provide for a range of different sizes or volumes for droplet2100. The ability to accurately size very small openings in plate4610and the dispensing dynamics of the assembly4600allow for dispensing of very small amounts of liquid2000. As shown inFIG. 2j, a number of nozzle openings4620can also be used in the plate4610so that array dispensing can be done.

Nozzle-plate assembly4600is advantageous due to its minimization of components so that there are fewer materials in contact with the liquid2000. The dispensing operation of the assembly4600is reliable since there are no narrow channels and the design is insensitive to air entrapment. Dispensing through the movement of plate4610makes the assembly4600easy to load and easy to clean. Dead volume for the supply of liquid2000is minimized or eliminated due to the planar or substantially planar shape of plate4610.

The present invention further contemplates the use of other structures and methods of dispensing the liquid2000onto the substrate1000, such as, for example, by a pad-printing device where the liquid2000is loaded into the ink cartridge.

Dispensing system400has a dispensing inspection system460that provides real-time monitoring of each droplet2100that is to be added to the substrates1000. In the preferred embodiment of the machine10, dispensing inspection system460uses high-speed imaging of the droplet2100to determine the volume of the droplet. Dispensing inspection system460has a high-speed camera465, preferably a digital camera, that is connected to gantry410and which is able to take a high-speed image470(shown inFIG. 3) of each droplet2100. In the preferred embodiment of machine10, two high-speed, preferably digital, cameras465are used, which correspond to each of the two dispensing modules420.

The image470of the droplet2100is preferably taken in-flight after the droplet has left the nozzle450but before it makes contact with substrate1000. The machine10uses a laser detector to trigger the camera465to obtain the image470due to the high speed of the droplet2100(shown generally inFIG. 2d). However, the present invention contemplates the use of other triggering devices and methods for triggering camera465and obtaining image470.

Image470is used by the control system900to calculate a volume of each of the droplets2100. The calculated volume of the droplet2100is used to determine the amount of liquid2000that is being dispensed onto the substrate1000. Any amount of liquid2000that does not meet tolerances will be marked with an error code by control system900so that the substrate1000having that particular droplet2100can be rejected.

Where larger amounts of liquid2000are required in a product, dispensing module420may dispense a number of droplets2100or a stream of liquid. Dispensing inspection system460still has the ability to capture the image470of the stream of liquid2000, and the volume calculations can be made therefrom.

Dispensing system400has a temperature conditioning system475that performs cooling/heating/drying of the droplet2100on the substrate1000depending upon the particular liquid2000that has been dispensed, such as, for example, solder may be subjected to cooling to transform it to its solid state while a therapeutic active agent may be subjected to drying to form a film on a carrier tablet. In the preferred embodiment of the machine10, temperature conditioning system475has a temperature conditioner480and temperature conditioner sensors or monitors482(not shown in detail). The temperature conditioner480provides a temperature change to the droplet2100and substrate1000, such as, for example, heating, cooling and/or air flow. Various components can be used for temperature conditioner480, such as, for example, an oven, refrigeration/cooling device and/or fan. The temperature conditioner sensors482monitor the conditions or environmental parameters of each of the dispensed droplets2100and substrates1000to ensure that the products meet the required tolerances.

Conditions, such as, for example, temperature, air-flow and humidity are monitored by the temperature conditioner sensors482, and a number of such sensors are used to account for any variance along the temperature conditioner480. The data gathered by the sensors is provided to control system900for evaluation of the quality of the substrates1000and droplets2100in each of the holding trays220.

In the preferred embodiment, the drying conditions are monitored for the entire holding tray220, and error codes can be assigned to the individual substrates1000and droplets2100contained therein, based upon a holding tray being affected by a condition of the temperature conditioner480that does not meet the required tolerances. Alternatively, portions of trays can be monitored for drying conditions by placing more sensors482in the temperature conditioner480in strategic positions. Additionally, the present invention contemplates the monitoring of other conditions or criteria related to the temperature conditioning process, such as, for example, conditions that may be more significant to particular products.

The present invention also contemplates temperature conditioner480being an infrared (IR) temperature conditioner and/or having a combination of IR, convection, conduction and/or microwave heating. Temperature conditioning system475can include sensors to detect conditions, such as, for example, the surface temperature of the substrates1000, or IR radiation. Temperature conditioning system475may also include a sensor for turning on the temperature conditioner, such as, for example, a photo-cell triggered by holding trays210entering the temperature conditioner480. Additionally, temperature conditioner480can be utilized for heating of the substrate1000to cause reflow, such as for dispensed solder.

Dispensing system400has a dispensing confirmation system500that provides real-time monitoring, feedback and adjustment for the liquid2000that has been added to the substrate1000. In particular, the dispensing confirmation system500monitors the positioning of the liquid2000on the substrate1000and the amount of the liquid contained thereon. Additionally, the dispensing confirmation system500can monitor for other substances, such as, for example, identifying contaminants present on the substrate1000, as well as the amount of such other substances.

The data obtained by the dispensing confirmation system500is provided to the control system900. The control system900will assign error codes to individual substrates1000and their liquids2000that do not meet the required tolerances of the product.

In the preferred embodiment of the machine10, dispensing confirmation system500has a gantry510(similar to gantry410described above) with a pair of charge coupled device (CCD) cameras520that obtain images525of each of the substrates1000. The images525are provided to control system900for a determination of the position of the liquid2000with respect to the substrate1000. For example, the position of solder on an IC chip can be analyzed via image525to determine the strength of the bond, as well as short circuits or the potential risk of short circuits.

Dispensing confirmation system500can also have a probe530(shown inFIG. 2) that is used for determining the amount, type and/or distribution of the liquid2000on the substrate1000. In the preferred embodiment of machine10, the probe530uses chemical imaging to determine the amount of the liquid2000present on the substrate1000. The present invention contemplates dispensing confirmation system500providing other analysis for the liquid2000, such as, for example, mechanical stress, crystallinity, crystal orientation, composition, crystal phase, and/or doping.

Probe530has components that carry out chemical imaging on each of the substrates1000in holding tray210, such as, for example, fiber optics, focal plane array (FPA) detectors, and/or charge coupled device (CCD) detectors. Additionally, liquid crystal tunable filters can be used as wavelength selectors for the chemical imaging. The chemical imaging provides good penetration into the liquid2000and upper surface of the substrate1000for an accurate measurement of the quantity of the liquid.

In the preferred embodiment of machine10, probe530uses a focal plane array detector to obtain a signal from every point in the sample area. The sample area preferably includes the entire holding tray210so that all of the substrates1000are being simultaneously measured, which further improves the efficiency of the process. The focal plane detector is able to obtain simultaneous spectral information at every frequency for the sample area. Probe530can rapidly and non-destructively measure the liquid2000for various characteristics including, but not limited to, amount, formulation and/or distribution, as well as monitor or detect other substances contained in or on the substrate1000.

The present invention contemplates the use of various methods and devices for determining the presence, type, distribution, amount or other characteristics of a particular liquid2000on the substrate1000, such as, for example, spectroscopy and/or chemical imaging utilizing Raman and UV reflectance, and various other types of imaging, chemical imaging and/or spectroscopy, such as, for example, UV/visible absorption, fluorescence, laser-induced fluorescence, luminescence, photoluminescence, terahertz, NIR and mid-IR. The present invention contemplates the use of various devices or components that facilitate the use of spectroscopy and/or chemical imaging for analysis of the products, such as, for example, lasers (e.g., pulse lasers), beam splitters, water-vapor free environments (e.g., nitrogen shrouds), optical delays (e.g., variable optical delays), antennas and/or semi-conductors. The present invention contemplates the use of room temperature solid state detectors and/or pulsed time-gated techniques and components. The present invention contemplates the use of techniques for analysis of the products that are non-ionizing, non-invasive, non-destructive and/or require low power.

The present invention contemplates the use of any regions of the electromagnetic spectrum which allow for analysis of the substrate1000and liquid2000, as well as various techniques and sources for excitation in using the particular type of spectroscopy. The present invention also contemplates the use of other techniques and components for digital imaging to allow for use of chemical imaging of the substrate1000and liquid2000. It should be further understood that dispensing confirmation system500also contemplates the use of surrogate detection in any of the spectral ranges.

The coating system600of machine10provides for a coating (not shown) to be placed on the substrate1000and/or over the liquid2000, or some portion thereof. The coating2300may be a sealant or a protective layer. Coating system600has a coating device610, a coating source620and a coating dryer630(if necessary depending upon the particular coating being used). The coating device610transfers the coating to the upper surface of the substrate1000. A pad-printing device can be used for coating device610and is advantageous because of its efficient transfer of the coating to the substrate without any waste, e.g., no overspray. Alternative devices can also be used, such as, for example, a spray device (not shown) or ink jet device to spray the coating upon the substrate1000. The spray device could also be movably connected to gantry615to pass over each of the substrate positions220. The present invention contemplates the use of other devices and methods for applying a coating to the substrate1000, such as, for example, an ultrasonic atomizer. The coating system600can use intermittent, low volume atomized sprayers to locally apply the coating over the all or a portion(s) of the surface of substrate1000. The sprayer may use volumetric pumps to intermittently supply coating materials. A two fluid air-liquid atomization sprayer may also be used to generate a fine spray.

In the preferred embodiment of machine10, coating device610is connected to or is positioned adjacent to the machine10to coat an array of substrates with each reciprocating stroke. Coating device610can be movably connected to a gantry615or other similar device to facilitate movement of the coating device with respect to the holding tray220. The holding tray220continues to move as the coating is being applied by the coating device610. However, the present invention contemplates the use of other devices and methods of positioning the coating device610with respect to each of the substrate positions220so that the coating is accurately applied.

The coating device610is releasably connected to the coating source620. In the preferred embodiment of the machine10, the coating source620is a movable container625that is connected to the coating device610via removably connectable conduit627, so that the coating can be quickly and efficiently replaced.

As described above with respect to the dispensing of the substrate1000in layers or on opposing sides, the coating system can provide the necessary coating depending upon how the liquid2000has been added to the substrate, such as, for example, on both sides or between layers. This can facilitate the use of higher volumes of liquid2000.

Coating dryer630can be used to perform drying of the coating (where appropriate) that has been applied to the substrate1000and/or over the liquid2000. The coating dryer630preferably has an oven640and oven sensors650(not shown in detail). The oven640provides heat and air flow to the coating. The oven sensors650, similar to the temperature conditioner sensors482discussed above, monitor the drying conditions of the coatings to ensure that the products meet the required tolerances.

The printing system700of machine10provides an identification marker on the substrate1000. The printing system700preferably has a pad-printing device710that transfers the marker to the substrate1000and a pair of cameras720that obtain an image730of each of the identification markers to verify the quality of the image. Unacceptable substrates1000will be identified by the control system900for subsequent rejection by system800.

In the preferred embodiment of machine10, pad-printing device710and cameras or digital/video recording devices720are movably connected to a gantry735(similar to gantries410,510and615) to facilitate movement of the pad-printing device with respect to the holding tray210that continues to move as the identification marker is being applied. However, the present invention contemplates the use of other devices and/or methods, for positioning the pad-printing device710or alternative device with respect to each of the substrate positions220for accurate application of the identification markers, such as, for example, lasermarking, inkjet or rotogravure. Each of the marker images730is provided to control system900for inspection and to determine if the printed identification marker meets the required tolerances of the products. Also, the present invention contemplates machine10having an ink dryer (not shown), such as, for example, an oven, that applies heat and/or air-flow to the identification marker to dry it.

The acception-rejection system800provides products that have undergone real-time monitoring and adjustment for quality control to ensure that each of the products meets the required tolerances. Based upon the real-time monitoring being continuously performed at various stages of the process by machine10, control system900has designated each and every product as either acceptable or rejected.

Acceptable products pass through to the delivery area (not shown in detail), preferably under bias that is selectively controlled by the control system900, while rejected product drop into a scrap area, preferably under the force of gravity. However, the present invention contemplates the use of other structures and methods of separating those products that are designated by control system900as acceptable from those products that have been designated by the control system as rejected.

The control system900coordinates and synchronizes the various stages and systems of the machine10. In the preferred embodiment, control system900is a distributed process control system that has a number of microprocessors910that control the different systems of machine10. The microprocessors are preferably coordinated through a workstation920. However, the present invention contemplates other types of system control including central and regional control, such as, for example, a single microprocessor910controlling all of the systems or similar systems being controlled by one of several microprocessors910.

The microprocessors910and workstation920are in communication with each other, preferably through a network930using an Ethernet switch935, which allows for the real-time monitoring, feedback and adjustment of the process being performed by the machine10. The present invention contemplates the use of other structures and methods for communication, such as, for example, hardwiring. The control system900also has an archive microprocessor or historian940, which is used to centrally store the large amount of data that is compiled for each and every product that is processed by the machine10. However, the present invention contemplates other methods of storage of the process data, such as, for example, microprocessors910individually storing the data that they have compiled.

The control system900preferably has a number of monitors950that provide displays of the data, portions of the data, summaries of the data, and/or calculations and conclusions based upon the data, so that the workers can monitor and/or adjust the process as it is occurring. More preferably, the monitors950, through use of the various microprocessors910and/or workstation920, can selectively display the data, portions of the data, summaries of the data, calculations based upon the data, and conclusions based upon the data. Preferably, control system900records data for every product, which includes time, initial substrate status, droplet volume, temperature conditioner temperature, temperature conditioner humidity, temperature conditioner air flow, liquid location on substrate, liquid quantity and acceptability.

The present invention also contemplates dispensing inspection system460utilizing optical profilometry for real-time monitoring and feedback control. The components utilized by dispensing inspection system460to carry out the optical profilometry are known to one skilled in the art, such as, for example, a laser and camera. The technique of optical profilometry is especially useful for larger volumes of liquid2000, such as, for example, greater than 10 ul, where the dispensing system400is dispensing a stream, as opposed to the droplet2100.

For the optical profilometry technique, dispensing inspection system460performs a first scan of the substrate1000prior to dispensing of the liquid2000in order to obtain a first profile of the substrate. A second scan is then performed by the dispensing inspection system460to obtain a second profile of the substrate1000with the liquid2000thereon. The difference in the first and second profiles provides the measurement of the volume of liquid2000that has been dispensed onto the substrate1000. The present invention further contemplates the use of optical profilometry of the substrate1000after the liquid2000has been dried on the substrate. Also, the first profile may be based upon a predetermined value for the same substrates1000to expedite the process and eliminate the need for two scans.

The present invention also contemplates the use of the real-time monitoring to provide real-time feedback and adjustment to the conveyor and dispensing systems300and400, such as, for example, adjusting the speed for better positioning of the droplet2100on the substrate1000or adjusting the pump425and/or nozzle450to increase or decrease the volume of the droplet, which increases or decreases the amount of liquid2000that is ultimately dried on the substrate. The use of real-time monitoring of the droplet2100both before and after contact with the substrate1000, also would allow for more efficient accounting for any losses occurring during the process.

Referring toFIGS. 4,6and7, another embodiment of an apparatus or machine of the present invention is shown and generally referred to by reference numeral20. The machine20has components that are similar to the components described above with respect to the preferred embodiment ofFIG. 1and are similarly numbered, such as, conveyor system300, dispensing system400and control system900. Machine20is a scaled-down version of the preferred embodiment but still provides real-time monitoring for the process. Each of these systems300,400and900are operably connected to each other to efficiently and ergonomically provide products that have each undergone real-time monitoring, and, preferably, real-time feedback and adjustment.

Holding trays210are manually placed on drive conveyor310where the substrates1000begin their descent through machine20. Each holding tray210is identified through use of the bar code230on the tray and a scanner235. The holding trays210continue to move along machine20and pass through to the dispensing system400where a dispensing module420, which is mounted to gantry410, dispenses droplets2100on each of the substrates1000. Camera465takes an image of each droplet being dispensed and, in conjunction with the flow cell430, the real-time monitoring of the amount of liquid being dispensed occurs.

After passing through temperature conditioner480, where the liquid2000is formed on the outer surface or substantially along the outer surface of the substrate1000, each of the substrates undergoes real-time monitoring of the position and amount of the liquid. Camera520, which is mounted on gantry510, obtains an image525of each of the substrates1000and liquids2000thereon. The images525are processed by control system900for the location and quantity of the liquid2000.

Using spectroscopy, camera520captures the image525of the deposition spot left after dispensing and drying. Image analysis software uses gray scale to tabulate the number of pixels and relative intensity of the pixel to develop an image of the dried spot left behind. Based on this information, the amount of the liquid2000on the substrate1000is determined.

The holding tray210is then manually removed from the drive conveyor310. Data has been compiled for each product regarding dispensing position, quantity of liquid2000, and drying conditions. This data is used by control system900to provide a designation for each of the products as either acceptable or rejected. The machine20uses separate scanners235at different stages of the machine for identification of the individual substrates1000.

A second alternative embodiment of the apparatus of the present invention is shown inFIG. 5and is generally represented by reference numeral20′. Similar to the embodiment described above with respect toFIGS. 4,6and7, machine20′ is a scaled down version of the preferred embodiment of machine10shown inFIG. 1. Machine20′ has many features similar to machines10and20and such features are similarly numbered, such as, conveyor system300, and dispensing system400. Machine20′ exemplifies the modularity of the present invention as it includes the features of machine20and additionally has gantry510, which is readily available for connection with dispensing confirmation system500.

It should further be understood that some of the components and/or systems described with respect to machines10,20and20′ may not need to be utilized for certain products. For example, but not limited to, products that are highly regulated may require rigorous quality control. Control system900will synchronize the other systems based upon the lack of use of certain systems, which will further maximize the efficiency of the process, such as, for example, where drying of substrate1000and liquid2000is minimal or not required, the other activities can be greatly sped up.

The present invention contemplates machines10,20and20′, and the various components and systems therein, being modular. This will allow machines10,20and20′ to carry out only the necessary activities for particular products by removing selected unnecessary components, and will provide time saving, such as, for example, avoiding passing holding trays220through the coating temperature conditioner630where no coating is being applied.

The present invention contemplates the interchangeability of different components to perform the various activities of machines10,20and20′, such as, for example, probe530that performs chemical imaging being interchangeable with other probes that perform other types of analysis, such as, for example, spectroscopy and chemical imaging, such as, for example, utilizing Raman, UV reflectance, fluorescence, and/or terahertz. Machines10,20and20′ can utilize the type of analysis, and hence the components that perform that analysis, which are most efficient and accurate for a particular product. The present invention also contemplates control system900indicating which types of analysis and their corresponding components are to be used for a particular product.

The present invention further contemplates the process performed by machines10,20and20′ including a packaging step so that the end result is a product that is ready for shipping, especially where real-time release of products is utilized. The design and modularity of machines10,20and20′ facilitates the addition of a packaging step to the process (where appropriate).

Machines10,20and20′ also provide the ability to change production to a different product in a fraction of the time that it takes to make a similar adjustment to a contemporary machine. The cleaning of the machines10,20and20′ for a change of production to a different product requires only the cleaning of the dispensing module420, which can be quickly disassembled. Dispensing modules420are relatively low-cost which allows for their replacement rather than a time-consuming repair.

Machines10,20and20′ improve efficiency in manufacturing the products based upon the manufacturing steps as well as the quality control steps. The continuity of the process quickly and efficiently provides the products that are directly ready for packaging, without the need for any other quality control testing being performed on them. Also, machines10,20and20′ provide a process that can be run continuously without the need for stopping as in contemporary devices and techniques.

The real-time monitoring, feedback and adjustment of the present invention avoids unnecessary manufacturing steps (e.g., dispensing on rejected substrates) and provides quality control based on the individual properties of each of the substrates. The present invention is cost effective because it only discards the defective product identified by control system900, rather than discarding all of the products in a batch that has a significant number of defective substrates, as by contemporary methods of product sampling.

The present invention contemplates the use of individual systems or combinations of systems of machines10,20and20′ in combination with other devices, to provide one or more of the steps described herein. It should be further understood by one of ordinary skill in the art that the degree of real-time monitoring and/or feedback can be varied depending upon the particular product being manufactured and/or based upon other factors. For example, but not limited to, the machine10,20and20′ may only utilize the high-speed imaging for detection of whether the droplet2100has accurately been dispensed upon carrier substrate1000. Preferably, the volume calculation of dispensing inspection system460is also utilized to calculate the amount of liquid2000in the droplet2100. However, the use of contemporary quality control techniques is also contemplated, such as batch sampling. Also, the present invention contemplates the use of contemporary quality control techniques, such as, for example, batch sampling, in parallel with the real-time monitoring and/or feedback described herein for machines10,20and20′.

It should be further understood by one of ordinary skill in the art that the various devices, techniques and/or systems described herein for machines10,20and20′ can be utilized by themselves or in combination with one or more of the other systems of machines10,20and20′ or in combination with contemporary devices for manufacturing products. For example, but not limited to, the high-speed imaging and volume calculation of dispensing inspection system460may be followed by a contemporary batch sampling technique for quality control of the resulting products.

The video imaging and volume calculation of dispensing inspection system460provides versatile real-time monitoring and feedback control for the products. This type of quality control is not dependent on the particular formulation of the liquid2000, as opposed to some forms of chemical imaging which have such dependency.

It should also be noted that the terms “first”, “second”, “third”, “fourth”, “upper”, “lower”, and the like, are used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.

While the present invention has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment(s) disclosed as the best mode contemplated, but that the invention will include all embodiments falling within the scope of the appended claims.