1. Field of Invention
The present invention relates generally to stencil cleaning methods and apparatus, and more particularly to a stencil cleaning apparatus that consistently and evenly applies a fluid, such as solvent, on a web material prior to the web material being placed in a position to clean the stencil.
2. Discussion of Related Art
In a typical surface-mount circuit board manufacturing operation, a stencil printer is used to print solder paste onto a circuit board having a pattern of pads or some other conductive surface onto which solder paste will be deposited. The circuit board is automatically fed into the stencil printer and one or more small holes or marks on the circuit board, called fiducials, is used to properly align the circuit board with the stencil or screen of the stencil printer prior to the printing of solder paste onto the circuit board. Once a circuit board has been properly aligned with the stencil in the printer, the circuit board is raised to the stencil, solder paste is dispensed onto the stencil, and a wiper blade (or squeegee) traverses the stencil to force the solder paste through apertures formed in the stencil and onto the board. As the squeegee is moved across the stencil, the solder paste tends to roll in front of the blade, which desirably causes mixing and shearing of the solder paste so as to attain desired viscosity to facilitate filling of the apertures in the screen or stencil. The solder paste is typically dispensed onto the stencil from a standard cartridge.
In some prior art stencil printers, any excess solder paste remaining under the squeegee after it has fully traversed the stencil remains on the stencil when the squeegee is returned to its initial position for printing on a second circuit board. Usually, as the squeegee passes the solder paste over the stencil, minute amounts of solder paste seep through the apertures to accumulate at the bottom side of the stencil. This presents various problems, such as the solder paste being inadvertently disposed on the unintended areas of the circuit boards. Also, as the solder paste hardens, it complicates the alignment procedure of a circuit board with the stencil. Therefore, it is highly desirable to remove the excess solder paste that forms on the bottom of the stencil.
U.S. Pat. No. 5,918,544 to Doyle represents one prior art stencil printer having a well-known method and apparatus for cleaning the bottom of the stencil. Doyle discloses a wiping system that is positioned near the vicinity of the stencil and moves beneath the stencil from one end of the stencil to the other end. As the stencil wiper system moves beneath the stencil, it wipes off excess solder paste at the bottom of the stencil.
Specifically, the stencil wiper system includes a paper supply roller containing a roll of paper, a take-up roller, a pair of paper guide rollers, a hollow solvent tube with numerous small openings formed along the length of the tube, and a vacuum plenum for removing excess moisture and hardened solder paste from the paper as it travels underneath the stencil.
During a cleaning operation, a paper winder motor rotates the take-up roller to draw paper from the paper supply roller, which passes paper through the pair of paper guide rollers. The hollow solvent tube is located between the paper guide rollers and is filled with solvent by a solvent pump, which causes the solvent tube to squirt solvent through its numerous holes onto the paper as it passes the solvent tube. The solvent impregnated paper is passed to the vacuum plenum, which holds the paper in place as the stencil moves over the paper, thereby cleaning the stencil.
A disadvantage to the system described in Doyle is that solvent may be applied to the paper in an inconsistent and uneven fashion. Specifically, since the pressure of the solvent closer to the solvent source, which is typically introduced at one end of the solvent tube, is far greater than the pressure at the other (opposite) end of the solvent tube, the solvent has a tendency to more completely impregnate the paper closer to the solvent source and barely wet the paper at the other end of the solvent tube. The result is that the more fully solvent impregnated portion of the paper cleans the stencil more effectively than the portion of the paper having less solvent. Another result is that too much solvent may be delivered to the portion of paper close to the solvent source thereby resulting in an excessive amount of solvent being applied to the stencil.
Embodiments of the invention provide improvements to stencil cleaning apparatus, such as those described above.
A first aspect of the invention is directed to a stencil wiper apparatus for wiping a stencil of a stencil printer. The apparatus includes a material supply assembly having a supply roller to deliver a roll of material, a take-up roller to receive the material, and a drive to move the material across the stencil between the supply roller and the take-up roller. The apparatus further includes a fluid delivery assembly to wet the material. The fluid delivery assembly includes: an outer tube constructed and arranged to engage the material and to deliver fluid to the material; an inner tube positioned within the outer tube, the inner tube being constructed and arranged to deliver fluid to the outer tube; and a fluid delivery source to deliver fluid to the inner tube.
In another aspect of the present invention, the outer tube has a length and a plurality of openings positioned along the length of the outer tube to wet the material along the width of the material. The inner tube has a length and a plurality of openings positioned along the length of the inner tube. The openings of the outer tube are formed in the outer tube in a position proximate to the material as material engages the outer tube. The openings of the inner tube are formed in the inner tube in a position generally opposite the plurality of openings of the outer tube.
In another aspect of the invention, the apparatus further includes a wiper blade assembly spaced between the fluid delivery assembly and the take-up roller of the material supply assembly. The wiper blade assembly moves the material between a first position in which the material is spaced away from the stencil and a second position in which the material engages the stencil.
In still another aspect of the present invention, a method for wiping a stencil of a printing machine includes: (a) delivering a roll of material having a width across the stencil; (b) evenly applying fluid on the material across the width of the material; and (c) placing the material in a position proximate to the stencil.
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
This invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
For purposes of illustration, embodiments of the present invention will now be described with reference to a stencil printer used to print solder paste onto a circuit board. One skilled in the art will appreciate, however, that embodiments of the present invention are not limited to stencil printers that print solder paste onto circuit boards, but rather, may be used in other applications requiring dispensing of other viscous materials such as glues and encapsulents. Further, stencil printers in accordance with embodiments of the present invention are not limited to those that print solder paste on circuit boards, but rather, include those used for printing other materials on a variety of substrates. Also, the terms “screen” and “stencil” may be used interchangeably herein to describe a device in a printer that defines a pattern to be printed onto a substrate.
The second plate 24 is movably coupled to the frame 12 such that the second plate 24 can move with respect to the frame 12 along an x axis, the x axis also being defined by the coordinate axis system 26. As described below in further detail, the movements of the first and second plates 20, 24 allow the dispensing head 18 to be placed over the stencil 16 and moved across the stencil 16 to allow printing of solder paste onto a circuit board.
Stencil printer 10 also includes a conveyor system having rails 28 for transporting a circuit board 30 to a printing position in the stencil printer 10. The stencil printer 10 has a number of pins 32 positioned beneath the circuit board 30 when the circuit board is in the dispensing position. The pins 32 are used to raise the circuit board 30 off of the rails 28 to place the circuit board in contact with, or in close proximity to, the stencil 16 when printing is to occur.
The dispensing head 18 is configured to receive two standard three ounce or six ounce solder paste cartridges 34 that provide solder paste to the dispensing head 18 during a printing operation. Each of the solder paste cartridges 34 is coupled to one end of a pneumatic air hose. As readily understood by those skilled in the art, the dispensing head 18 could be adapted to receive other standard, or non-standard, cartridges. The other end of each of the pneumatic air hoses is attached to a compressor that under the control of the controller 14 provides pressurized air to the cartridges 34 to force solder paste to flow from the cartridges into the dispense head 18 and onto the stencil 16. Mechanical devices, such as piston, may be used in addition to, or in place of, air pressure to force the solder paste from the cartridges into the dispensing head. The controller 14 is implemented using a personal computer having a Microsoft DOS or Windows NT operating system with application specific software to control the operation of the stencil printer 10.
The stencil printer 10 operates as follows. A circuit board 30 is loaded into the stencil printer 10 using the conveyor rails 28. The dispensing head 18 is then lowered in the z direction until it is in contact with the stencil 16. Pressurized air is provided to the cartridges 34 while the dispensing head 18 is moved in the x direction across the stencil 16. The pressurized air forces solder paste out the cartridges 34 and creates pressure on the solder paste in the dispensing head 18 forcing solder paste from the dispensing slot of the dispensing head through apertures in the stencil 16 and onto the circuit board 30. Once the dispensing head 18 has fully traversed the stencil 16, the circuit board 30 is lowered back onto the conveyor rails 28 and transported from the printer 10 so that a second circuit board may be loaded into the printer. To print on the second circuit board, the dispensing head 18 is moved across the stencil 16 in the direction opposite to that used for the first circuit board. Alternatively, a squeegee arm could swing in to contain the solder paste in the dispenser 18, and the dispenser 18 can then be lifted in the z direction and moved back to its original position to prepare to print on the second circuit board using a similar direction stroke.
After one or more applications of the solder paste to the circuit boards 30, excess solder paste accumulates at the bottom of the stencil and a stencil wiper apparatus, generally indicated at 36, of the present invention moves beneath the stencil 16 to remove the excess solder paste.
Turning now to
The stencil wiper apparatus 36 further includes a fluid delivery assembly, generally indicated at 56, and a wiper blade assembly 58 having a vacuum plenum for removing excess moisture and hardened solder paste from the paper as it travels underneath the stencil 16. A wiper blade driver 60 of the wiper blade assembly 58 moves the web W between a first position in which the paper is spaced away from the stencil to a second position in which the paper engages the stencil. Arrow A in
During a cleaning operation, the paper winder motor 54 of the web material driver 52 rotates the paper supply roller 44, which passes paper over the guide roller 48. Between the paper guide roller 48 and the take-up roller 50, there is the fluid delivery assembly 56 that is filled with solvent by a solvent pump, which is constructed to squirt solvent onto the paper as it passes over the fluid delivery assembly 56. The solvent impregnated paper is passed to the wiper blade assembly 58, which holds the paper in place as the stencil 16 moves over the paper, thereby cleaning the stencil.
The fluid delivery assembly 56 of the present invention is designed specifically for consistently and evenly wetting the paper. As shown in
After wetting the paper, a wiper blade 70 of the wiper blade assembly 58 engages the wetted paper to clean the underside of the stencil 16. The vacuum plenum of the wiper blade assembly 58 removes particles from the web of paper W so as not to contaminate the printing operation. A more detailed description of the vacuum plenum can be found in the related application entitled SELF-CONTAINED VACUUM MODULE FOR STENCIL WIPER ASSEMBLY. The wiper blade driver 60 extends and retracts the wiper blade 70 between the second and first positions in response to control signals from the controller 14. The web material driver 52 advances the web of paper W from left to right (as shown in
Referring specifically to
Referring to now
The solvent source 68 delivers solvent to the inner tube 76 of the fluid delivery assembly 56. The solvent captured within the inner tube 76 escapes through a plurality of relatively small openings 84 formed along the length of the inner tube 76. As illustrated in
The operation of the stencil wiper apparatus 36 is as follows. The stencil wiper apparatus 36 (or the stencil 16, as the case may be) is brought into position so that the stencil wiper apparatus 36 can clean the underneath of the stencil 16. The controller 14 activates the web material driver 52 to move the web of paper W across the outer solvent tube 72 of the fluid delivery assembly 56 and the wiper blade assembly 58. Simultaneously, the controller 14 activates the solvent source 68 to deliver solvent to the web of paper W (via the inner tube 76 to the outer tube 72) and activates the wiper blade driver 60 to engage the wiper blade 70 of the wiper blade assembly 58 against the web of paper W and stencil 16. The stencil wiper apparatus 36 is moved across the underneath of the stencil 16 to effect cleaning of the stencil. Alternatively, the stencil 16 can be moved across the stencil wiper apparatus 36. Excess material wiped away from the stencil 16 is removed by the vacuum plenum of the wiper blade assembly 58. The stencil wiper apparatus 36 of the present invention is far more effective in cleaning the underneath of the stencil in that solvent is applied to the web of paper W more evenly than with prior art fluid delivery assemblies.
The improved stencil wiper apparatus 36 of the present invention is particularly adaptive in retrofitting existing prior art solvent tubes that require replacement due to their ineffectiveness in evenly wetting the paper. Specifically, by simply replacing the solvent tube, such as the solvent tube 62 illustrated in
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.
This application relates to U.S. patent application Ser. No. ______ entitled SELF-CONTAINED VACUUM MODULE FOR STENCIL WIPER ASSEMBLY (Attorney Docket No. M2010-700019) by Joseph Perault, William Claiborne and Thomas LeClair, filed on even date herewith, and U.S. patent application Ser. No. ______ entitled METHODS AND APPARATUS FOR CHANGING WEB MATERIAL IN A STENCIL PRINTER (Attorney Docket No. M2010-700119) by Joseph Perault, Randy Peckham, Gary Freeman and Frank Marszalkowski, filed on even date herewith. Both of these related applications are incorporated herein by reference.