USP_20100078496_Methods and systems for ultrasonic spray shaping (1063673), страница 3
Текст из файла (страница 3)
Prior to components being soldered to a PCB the boardmust be coated With ?ux. This is often done by spraying the?ux onto the PCB. The PCB is placed on a conveyor and thegas streams to create the spray pattern led to non-uniformityin the spray pattern if there is a slight difference in pressure,?oW or direction of one of the gas streams. The Impact SprayShaping Assembly of the present invention uses only a singlegas stream for spray shaping and thus avoids this issue. Thisleads to a more consistent pattern over extended productionspray noZZle reciprocates perpendicular to the motion of thePCB. Air atomiZing noZZles, noZZles Which use high velocityair to break apart (atomiZe) the liquid, have, here to for, oftenruns.
The pattern produced by the Impact Spray Shapingbeen used in this application. The Impact Spray ShapingAssembly of the present invention provides signi?cantImpact Spray Shaping Assembly pattern is produced by aimprovements over air atomiZing noZZles in this and otherapplications. The ori?ce siZes in air atomiZing noZZles aresmall, relative to ultrasonic noZZles, due to the high velocityrequired to atomiZe liquid.
The small ori?ces easily clog. ThisAssembly is unique in the fact that it is not produced by tWoblended gas streams meeting at a centraliZed location. Thesingle gas stream and thus does not require tWo or moreindividual streams of entrained atomiZed drops to meet andproduce a uniform pattern.[0033]Other ultrasonic devices, not noZZles, have beenused in the spray ?uxing of PCBs. These prior art devices useleads to non-uniform coverage or no coverage if the ori?cesside liquid feed apparatus, Which is prone to clogging.
Theyclog fully. The liquid feed ori?ce in the ultrasonic noZZle isalso use multiple gas streams to entrain the atomiZed drops tolarge, relative to the ori?ce in an air atomiZing noZZle. Thisproduce the desired spray pattern. These ultrasonic devicesproduce a spray pattern equal or only slightly greater than thealone leads to reduced clogging during operation, but theultrasonic vibration in the noZZle virtually eliminates thepossibility of clogging in the ultrasonic noZZle. The ori?ce inthe Impact jet Which supplies the gas stream for spray shapingis also large relative to the spray shaping ori?ces associatedWith an air atomiZing noZZle.
The ori?ce in the Impact jet canpattern Width of the atomiZed liquid. The Impact Spray Shaping Assembly of the present invention has the ability to produce a pattern Width many times the Width of the ultrasonicplume. The Impact Spray Shaping Assembly is unique in thefact that it has a single gas delivery and a single liquid delivApr. 1,2010US 2010/0078496 A1ery. Other ultrasonic and air atomiZing devices require multiple liquid and gas delivery in order to produce and atomizedspray suitable to coat PCBs With ?ux. The Impact SprayShaping Assembly of the present invention is unique in itsability to spray in any orientation. This alloWs the ImpactSpray ShapingAssembly to be orientatedperpendicular to theconveyor carrying the PCB through the ?uxing chamber tothe Wave solder machine.
Other, prior art ultrasonic devicesWith liquid side feed apparatus must be located on a horizontal plane or the liquid being delivered through the side feedapparatus is not distributed uniformly on the atomiZing surface. This causes the spray pattern to be non-uniform andproduces an unacceptable coating. Due to the use of an ultrasonic noZZle With a central liquid feed ori?ce to the atomiZingsurface the ultrasonic spray plume is not affected by theorientation of the Impact Spray Shaping Assembly of thepresent invention.[0034] There have thus been provided neW and improvedultrasonic spray shaping assemblies, components thereof,and methods for using the assemblies.
In accordance With thepresent invention, the ultrasonic spray shaping assemblyincludes jet block and impact jet components to receive andredirect a single gas stream, Whereby to use the single gasstream to shape an ultrasonic spray plume in a desired shape,particularly into a desired Width of the plume. Modi?cationsto the components, such as relative positioning, canbe used toeasily alter the shape of the spray plume. The present invention can be fabricated in a compact, light-Weight design. It hasmany applications, including but not limited to, the deposition of ?ux onto a printed circuit board.[0035] While the invention has been shoWn and describedWith respect to particular embodiments, it is not thus limited.Numerous modi?cations, changes and enhancements, Withinthe scope of the invention, Will noW occur to the reader.[0036] The many features and advantages of the inventionare apparent from the detailed speci?cation, and thus, it isintended by the appended claims to cover all such featuresand advantages of the invention Which fall Within the truespirit and scope of the invention.
Further, since numerousmodi?cations and variations Will readily occur to thoseskilled in the art, it is not desired to limit the invention to theexact construction and operation illustrated and described,and accordingly, all suitable modi?cations and equivalentsmay be resorted to, falling Within the scope of the invention.4. The apparatus of claim 3 and further including a blockfor positioning the hydraulic noZZle relative to the ultrasonicnoZZle.5. The apparatus of claim 1 further including a productcomprising ?ux deposited upon a printed circuit board.6. The apparatus of claim 1 further including a productcomprising a suspension of transparent conductive oxide(TCO) to be sprayed on in layers on a thin ?lm solar cell.7.
The apparatus of claim 1 further including a productcomprising solder bus ?ux for the production of silicon solarcells.8. The apparatus of claim 1 further including a productcomprising phosphoric doping material to be used in apyrolysis production of fuel cells9. The apparatus of claim 1 further including a product tocoat Proton Exchange Membranes With a catalyst ink ontona?on membranes.10. The apparatus of claim 9 in Which the catalyst is ink iscarbon black.11.
The apparatus of claim 1 further including a product tocoat a bread With a preservative.12. The apparatus of claim 1 further including a product tocoat a bread With an egg Wash.13. A method for shaping the plume of an ultrasonic sprayto deposit ?ux on a printed circuit board, comprising:receiving a gas stream input and a liquid ?ux stream input;converting the liquid ?ux stream to an ultrasonic ?uxspray; shaping the gas stream;directing the gas stream relatively perpendicular to theultrasonic ?ux spray to control a plume shape of theultrasonic ?ux spray; anddirecting, using the assembly, the ultrasonic ?ux spray ontoa printed circuit board, Whereby to deposit the ?ux uponthe printed circuit board.14.
A method for shaping the plume of an ultrasonic sprayto deposit material on a fuel cell, comprising:receiving a gas stream input and a liquidphosphoric dopingmaterial stream input; converting the liquid phosphoricdoping material stream to an ultrasonic phosphoric doping material spray; shaping the gas stream;directing the gas stream relatively perpendicular to theultrasonic phosphoric doping material spray to control aplume shape of the ultrasonic phosphoric doping mateWhat is claimed is:1. An apparatus for shaping the plume of an ultrasonicspray, comprising:a body including a gas stream input and a liquid streaminput;an ultrasonic noZZle connected to the body for receiving theliquid stream and converting the liquid stream to anultrasonic spray; andan assembly connected to the body for receiving and shaping the gas stream and directing the gas stream relativelyperpendicular to the ultrasonic spray to control a plumeshape of the ultrasonic spray.2.
The apparatus of claim 1 Wherein the assembly includesa hydraulic noZZle for receiving, shaping and redirecting thegas stream to impact the ultrasonic spray and control theplume shape of the ultrasonic spray.3. The apparatus of claim 2 Wherein the hydraulic noZZlecomprises a ?at fan hydraulic noZZle.rial spray; anddirecting, using the assembly, the ultrasonic phosphoricdoping material spray onto a fuel cell ?rst surface,Whereby to deposit the phosphoric doping material uponthe fuel cell ?rst surface.15. The method of claim 14 in Which the stream material isa catalyst inks and the fuel cell’s ?rst surface is a ProtonExchange Membrane.16. The method of claim 13 in Which the stream material isa transparent conductive oxide and the printed circuit board isa thin ?lm solar cell.17.
A means for shaping the plume of an ultrasonic spray todeposit a material on a surface, comprisesreceiving means for a gas stream input and a liquid streaminput;means for converting the liquid stream to an ultrasonicspray;means for shaping the gas stream;US 2010/0078496 A1Apr. 1, 20105means for directing the gas stream relatively perpendicularto the ultrasonic spray to control a plume shape of theultrasonic spray; andmeans for directing, using the assembly, the ultrasonicspray onto a surface, Whereby to deposit the liquidstream upon the surface.18. The apparatus of claim 2 in Which the ?at fan is madeform brass, stainless steel or Te?on.19. The apparatus of claim 3 in Which the block is stainlesssteel3 Te?on or enalyte,*****.
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