Abstract: Systems and methods for dispensing a liquid or viscous material onto a substrate are disclosed herein. One exemplary method of positioning an applicator of a dispensing system to apply a liquid or viscous material to an electronic substrate includes generating a two-dimensional image of the electronic substrate using a camera communicatively connected to the dispensing system. Based on the two-dimensional image of the electronic substrate, a first set of one or more sub-regions of the electronic substrate having one or more components that protrude above the surface of the electronic substrate is identified. The method further includes using height information relating to the one or more sub-regions having the one or more components to determine a control program for the dispensing system to position the applicator relative to the electronic substrate and dispense the liquid or viscous material onto the electronic substrate.

Abstract: A fluid dispensing system and a method of controlling a fluid dispensing system are disclosed. The fluid dispensing system includes a source of a fluid, a dispensing nozzle, and a spray system. The spray system supplies fluid from the source of fluid to the dispensing nozzle using system parameters for the spray system. The spray system and dispensing nozzle are configured to dispense the fluid as a stream or spray as an actual fluid pattern according to one or more first system parameters that are intended to produce a first fluid pattern. A camera is configured to capture one or more images of the actual fluid pattern dispensed from the dispensing nozzle. A controller is operatively connected to the spray system and the camera.

Abstract: System and methods for calibrating a coating system are disclosed. Initially, a material is dispensed using an applicator of the coating system for a predetermined time period. A characteristic of the dispensing of the material for the predetermined time period is then determined. The characteristic of the dispensing of the material is compared to a predetermined range and it is determined that the characteristic of the dispensing of the material is outside of the predetermined range. In response, a velocity of the applicator, a pulse rate of the applicator, a temperature of the material, a pressure of the material supplied to the applicator, or a fan width of the applicator is adjusted to change the characteristic of the dispensing of the material.

Abstract: A fluid dispensing system and a method of controlling a fluid dispensing system are disclosed. The fluid dispensing system includes a source of a fluid, a dispensing nozzle, and a spray system. The spray system supplies fluid from the source of fluid to the dispensing nozzle using system parameters for the spray system. The spray system and dispensing nozzle are configured to dispense the fluid as a stream or spray as an actual fluid pattern according to one or more first system parameters that are intended to produce a first fluid pattern. A camera is configured to capture one or more images of the actual fluid pattern dispensed from the dispensing nozzle. A controller is operatively connected to the spray system and the camera.

Abstract: System and methods for calibrating a coating system are disclosed. Initially, a material is dispensed using an applicator of the coating system for a predetermined time period. A characteristic of the dispensing of the material for the predetermined time period is then determined. The characteristic of the dispensing of the material is compared to a predetermined range and it is determined that the characteristic of the dispensing of the material is outside of the predetermined range. In response, a velocity of the applicator, a pulse rate of the applicator, a temperature of the material, a pressure of the material supplied to the applicator, or a fan width of the applicator is adjusted to change the characteristic of the dispensing of the material.

Abstract: Systems and methods for dispensing a liquid or viscous material onto a substrate are disclosed herein. One exemplary method of positioning an applicator of a dispensing system to apply a liquid or viscous material to an electronic substrate includes generating a two-dimensional image of the electronic substrate using a camera communicatively connected to the dispensing system. Based on the two-dimensional image of the electronic substrate, a first set of one or more sub-regions of the electronic substrate having one or more components that protrude above the surface of the electronic substrate is identified. The method further includes using height information relating to the one or more sub-regions having the one or more components to determine a control program for the dispensing system to position the applicator relative to the electronic substrate and dispense the liquid or viscous material onto the electronic substrate.

Abstract: System and methods for applying a liquid coating to a substrate are disclosed herein. One exemplary method includes a flow control routine in which the velocity of an applicator, or other parameter affecting the amount of material applied to the substrate, is iteratively adjusted. The amount of the adjustment performed in each iteration is tracked. When the sum of the adjustments by the flow control routine exceeds a predetermined threshold, a fan width control routine is initiated in which the fan width of the stream of material applied by the applicator is adjusted.

Abstract: An applicator for dispensing a liquid conformal coating material onto a substrate. The applicator includes a body assembly with a liquid flow passage having a liquid inlet adapted to receive the coating material and a liquid outlet. A valve seat is positioned between the liquid flow passage and the liquid outlet. A valve stem is mounted in the body assembly for reciprocating movement between an open position and a closed position. The valve stem includes a first end and a second end. The first end of the valve stem engages the valve seat in the closed position to stop flow of the liquid coating material through the outlet and disengages from the valve seat in the open position to allow flow of the liquid coating material through the outlet. A valve actuating mechanism is operative to move the valve stem from the open position to the closed position and is further operative to move the valve stem from the closed position to the open position.

Abstract: Systems and methods for applying liquid coating materials to a substrate, such as an electronic component or circuit board. A control system of a coating system controls an applicator and a robot moving the applicator to apply the liquid coating material to the substrate in accordance with the information contained in a coating program. The control system determines a volume of liquid coating material actually dispensed onto the substrate during the coating program, and compares the dispensed volume to a desired dispensed volume of liquid coating material to produce an error signal representing the difference between the calculated and desired volume values. The control system uses the error signal to change the dispensed volume of liquid coating material on a subsequent substrate by a future coating program.

Abstract: An applicator for dispensing a liquid conformal coating material onto a substrate. The applicator includes a body assembly with a liquid flow passage having a liquid inlet adapted to receive the coating material and a liquid outlet. A valve seat is positioned between the liquid flow passage and the liquid outlet. A valve stem is mounted in the body assembly for reciprocating movement between an open position and a closed position. The valve stem includes a first end and a second end. The first end of the valve stem engages the valve seat in the closed position to stop flow of the liquid coating material through the outlet and disengages from the valve seat in the open position to allow flow of the liquid coating material through the outlet. A valve actuating mechanism is operative to move the valve stem from the open position to the closed position and is further operative to move the valve stem from the closed position to the open position.

Abstract: Systems and methods for applying liquid coating materials to a substrate, such as an electronic component or circuit board. A control system of a coating system controls an applicator and a robot moving the applicator to apply the liquid coating material to the substrate in accordance with the information contained in a coating program. The control system determines a volume of liquid coating material actually dispensed onto the substrate during the coating program, and compares the dispensed volume to a desired dispensed volume of liquid coating material to produce an error signal representing the difference between the calculated and desired volume values. The control system uses the error signal to change the dispensed volume of liquid coating material on a subsequent substrate by a future coating program.

Abstract: Systems and methods for applying liquid coating materials to a substrate, such as an electronic component or circuit board. A control system (18, 24, 26) of a coating system (10) controls an applicator (16) and a robot (14) moving the applicator (16) to apply the liquid coating material to the substrate (12) in accordance with the information contained in a coating program. The control system (18, 24, 26) determines a volume of liquid coating material actually dispensed onto the substrate (12) during the coating program, and compares the dispensed volume to a desired dispensed volume of liquid coating material to produce an error signal representing the difference between the calculated and desired volume values. The control system (18, 24, 26) uses the error signal to change the dispensed volume of liquid coating material on a subsequent substrate by a future coating program.

Abstract: A first embodiment includes a control system which operates a spray gun to apply an even coating of flux to a circuit board or a plurality of different length circuit boards irrespective of the speed that the circuit board(s) move through a coating chamber. In a second embodiment, the control system pulses the spray gun on and off with a pulsing pattern that coats a plurality of zones of a circuit board with spray patterns of different length and thickness.

Abstract: A first embodiment includes a control system which operates a spray gun to apply an even coating of flux to a circuit board or a plurality of different length circuit boards irrespective of the speed that the circuit board(s) move through a coating chamber. In a second embodiment, the control system pulses the spray gun on and off with a pulsing pattern that coats a plurality of zones of a circuit board with spray patterns of different length and thickness.

Abstract: Apparatus and methods for dispensing droplets of liquid or viscous material are disclosed. A valve is opened to dispense a stream of the heated liquid or viscous material through an elongated orifice of a nozzle. The stream of material being dispensed from the elongated orifice is broken into droplets by rapidly closing the valve. Furthermore, a method for varying the height of a droplet of liquid or viscous material is disclosed by which two or more droplets combine to form a droplet of a desired height. A method for applying a plurality of droplets of material onto a substrate so that the droplets flow together to form a uniform film of desired thickness and shape is also disclosed. A second embodiment of the invention relates to dispensing apparatus with a heater assembly removably attached to the dispenser housing.

Abstract: Apparatus and methods for a system and process for applying a flux coating to a circuit board by pulsing an airless spray gun on and off to achieve excellent circuit board through-hole penetration and uniform film thickness. An overspray collection system is provided which reduces overspray and increases material utilization and transfer efficiency. A gun positioning mechanism, which can be automated, accurately locates the gun relative to the circuit board.

Abstract: Apparatus and methods for a system and process for applying a flux coating to a circuit board by pulsing an airless spray gun on and off to achieve excellent circuit board through-hole penetration and uniform film thickness. An overspray collection system is provided which reduces overspray and increases material utilization and transfer efficiency. A gun positioning mechanism, which can be automated, accurately locates the gun relative to the circuit board.

Abstract: A film coater for applying a coating material to selected areas on a target substrate, such as a printed circuit board, having a vented dispenser body with a plunger moveable therein between an open and closed position. A flow of pressurized air which moves the plunger to the open position is controlled by a valve carried by the dispenser body, and a plurality of springs return the plunger to the closed position. The number of return springs is selected to provide a variable biasing force so that movement of the plunger is controlled to eliminate or at least significantly reduce hammering, tapering and drooling, particularly when the dispenser is operated intermittently.

Abstract: Apparatus and methods for spray coating selected areas of a circuit board with an insulative coating material without coating regions of the circuit board to be left uncoated. A liquid spray device emits the coating material and an air assist attachment connected to the liquid spray device directs jets of air into impinging relation with the coating material emitted therefrom to transform the coating material into an atomized, shaped spray pattern for coating the selected areas. The air assist attachment can be disabled so that the spray device transforms the coating material into a non-atomized, shaped spray pattern for coating selected areas without coating regions of the circuit board to be left uncoated.

Abstract: Apparatus and process for curing conformal coatings on circuit boards being conveyed through a curing chamber within a UV oven. Warm air, exhausted from a lamp housing containing UV lamps for curing the coatings, is directed into a flash zone chamber through which the coated circuit boards are conveyed prior to entering the UV oven for flashing volatile constituents from the coatings and raising the temperature of the circuit boards.