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Contact force–based method for controlling the dispensing volume of ultra-micro-adhesive

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Abstract

With the rapid development of precision micro-manufacturing technology, the connection and assembly processes of precision micro-devices have placed higher demands on the volume and precision of micro-dispensing technology. In the dispensing process, the adhesive dispensing volume is crucial to the bonding quality. In this paper, based on the analysis of the composition of critical contact force and the mechanism of action, a method was proposed to control the ultra-micro-adhesive dispensing volume at pL level. Firstly, a mathematical model describing the change of droplet size and critical contact force during the extrusion of adhesive was established, which provided a theoretical basis for analyzing the mapping relationship between contact force and adhesive dispensing volume. Then, the mathematical models describing the droplet initial volume, dispensing volume, and transfer ratio were derived. Based on this, a mechanism and method to control the volume of dispensing to the substrate by contact force control to trigger the liquid bridge pull-off action was developed. The critical contact force was detected in real time to determine the changing state of the process of adhesive contacting the substrate, and used as the basis for triggering the stretching stage of the liquid bridge, and then achieved the prediction and control of the adhesive dispensing volume. In this paper, a series of experimental studies were conducted on the method of controlling the adhesive dispensing volume through contact force by embedding a micro-force sensor with high resolution into the dispensing system. The experiments were conducted with the critical contact force in the range of 0.5–4.5 mN. The results showed that the increase of the critical contact force was approximately linear with the increase of the adhesive dispensing volume. The deviation rate of the dispensing volume under the same critical contact force was less than 1.7%, and the average deviation rate of the overall adhesive dispensing volume was about 0.6%, so it was basically possible to precisely control the adhesive dispensing volume at the pL level by changing the contact force. This study revealed the composition and variation mechanism of contact force, and the proposed method for controlling the adhesive dispensing volume have significant value and potential in the micro-assembly of viscous ultra-microfluids and other applications.

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Data availability

The data that support the funding of this study are available within the article.

Abbreviations

U :

Descending speed of the pipetting needle

α 1 :

Contact angle before squeezing

α 2 :

Contact angle after squeezing

S a-s :

Contact area between extruded adhesive and substrate

F c :

Contact force

\(\overrightarrow{u}\) :

Squeeze flow rate of adhesive

p :

Pressure

h i :

Initial distance

α i :

Squeeze contact angle

r i :

Contact radius

u r :

Velocity distribution function

\({\Delta p}_{L}\) :

Laplace pressure

d :

Pipetting needle diameter

l 1 :

Curved surface radius of the droplet

A :

Curvature circle of the initial droplet

b :

Distance from the center of circle A to the tip of the pipetting needle

V 1 :

Initial volume of adhesive droplet

V 3 :

Adhesive dispensing volume

w :

Height of the side of the adhesive point

l 2 :

Curved surface radius of the adhesive point

h 1 :

Distance before squeezing between needle tip and substrate

h 2 :

Distance after squeezing between needle tip and substrate

r 1 :

Contact radius before squeezing

r 2 :

Contact radius after squeezing

ρ :

Adhesive density

t :

Squeezing time of adhesive

\(\overrightarrow{f}\) :

Body force

μ :

Adhesive viscosity

P(r):

Pressure distribution function

p c :

Constant

\(\gamma\) :

Surface tension

R 1 /R 2 :

Principal radius of curvature of meniscus surface tension

ε :

Adhesive thickness on the surface of the pipetting needle

δ :

Contact angle formed between the tip of the pipetting needle and the droplet

D :

Curvature circle of liquid bridge

k :

Radius of curvature circle D

V 2 :

Volume of liquid bridge

m :

Adhesive point radius

β :

Contact angle between the adhesive-point and the substrate

η :

Transfer ratio

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Funding

This work was supported by the National Natural Science Foundation of China (No. 52175428), Liaoning Revitalization Talents Program (Grant No. XLYC2007072), and Joint Fund of Science & Technology Department of Liaoning Province and State Key Laboratory of Robotics of China (Grant No. 2020-KF-12–07).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shenyang University of Technology, Shenyang, 110870, China

    Huifang Liu, Ying Chen, Xi Chen & Shenhui Jiang

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  1. Huifang Liu
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  2. Ying Chen
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Contributions

H.L. (corresponding author) contributed to conceptualization, project administration, funding acquisition, and methodology. Y.C. contributed to investigation, data analysis, and writing original draft preparation. X.C. helped in control system debugging and data validation. S.J. contributed to data processing and software application.

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Correspondence to Huifang Liu.

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Liu, H., Chen, Y., Chen, X. et al. Contact force–based method for controlling the dispensing volume of ultra-micro-adhesive. Int J Adv Manuf Technol 121, 5015–5033 (2022). https://doi.org/10.1007/s00170-022-09624-z

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  • DOI: https://doi.org/10.1007/s00170-022-09624-z

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