Dispense System
Systems and methods for locating and eliminating and/or minimizing non-functional nozzles of dispense systems are described.
1 . An apparatus comprising:
a dispense head including a plurality of nozzles;
a fluid supply connected to the dispense head;
a processor; and
memory coupled to the processor, the memory including computer-readable instructions executable by the processor to identify a non-functional nozzle of the plurality of nozzles.
2 . The apparatus of claim 1 , wherein the memory includes additional computer-readable instructions executable by the processor to:
collect data related to droplets of fluid dispensed from one or more of the plurality of nozzles; and
determine whether at least one nozzle of the plurality of nozzles is non-functional based on the data collected.
3 . The apparatus of claim 1 , further comprising a vision system to provide one or more images of a pattern of droplets of fluid dispensed onto a substrate via one or more of the plurality of nozzles, and wherein the memory includes additional computer-readable instructions executable by the processor to identify the non-functional nozzle by comparing the one or more images of the pattern of droplets of the fluid dispensed onto the substrate with a prescribed drop pattern.
4 . The apparatus of claim 1 , further comprising a sensor that detects fluid egressing from one or more of the plurality of nozzles.
5 . The apparatus of claim 1 , further comprising one or more diagnostic sensors to provide data related to activation of one or more of the plurality of nozzles, wherein each of the one or more diagnostic sensors is associated with a respective nozzle.
6 . The apparatus of claim 1 , further comprising a gravimetric system to monitor changes in mass of fluid dispensed from one or more of the plurality of nozzles.
7 . The apparatus of claim 1 , wherein the fluid supply comprises a main supply reservoir and a refilling reservoir, and wherein a filter is coupled between the main supply reservoir and the refilling reservoir.
8 . The apparatus of claim 7 , further comprising a nitrogen gas supply connected to the main supply reservoir and to the refilling reservoir, wherein the nitrogen gas provides force to move fluid between the main supply reservoir, the refilling reservoir, the dispense head, the filter, or a combination thereof.
9 . One or more computer-readable media including computer-readable instructions that, when executed by a processor, perform acts comprising:
providing an indication that at least one nozzle of a plurality of nozzles of a fluid dispense system is non-functional;
determining a fluid dispense scheme to compensate for the at least one non-functional nozzle; and
modifying operation of the fluid dispense system according to the fluid dispense scheme.
10 . The one or more computer-readable media of claim 9 , wherein the acts further comprise identifying the at least one non-functional nozzle by identifying an error in a pattern of droplets dispensed by the plurality of nozzles when compared with a prescribed drop pattern, and wherein the prescribed drop pattern comprises a grid having rows including drop locations and empty locations.
11 . The one or more computer-readable media of claim 10 , wherein the acts further comprise activating a first set of the plurality of nozzles to dispense fluid according to the prescribed drop pattern, and wherein the first set of the plurality of nozzles includes the at least one non-functional nozzle, and wherein the fluid dispense scheme includes activating a second set of the plurality of nozzles to dispense the fluid to cover drop locations of the prescribed drop pattern that include an amount of the fluid that is less than a threshold amount.
12 . The one or more computer-readable media of claim 10 , wherein the acts further comprise activating a first plurality of nozzles of a first dispense head and a second plurality of nozzles of a second dispense head to dispense fluid according to the prescribed drop pattern, wherein the first plurality of nozzles includes the at least one non-functional nozzle, and wherein the fluid dispense scheme includes modifying operation of the second plurality of nozzles to dispense fluid in drop locations of the prescribed drop pattern that received an amount of the fluid that is less than a threshold amount.
13 . The one or more computer-readable media of claim 10 , wherein the acts further comprise identifying at least one row of the prescribed drop pattern comprised of empty locations, and, wherein the fluid dispense scheme includes modifying operation of the plurality of nozzles, such that the at least one non-functional nozzle is associated with a respective row of the prescribed drop pattern comprised of empty locations.
14 . The one or more computer-readable media of claim 10 , wherein the acts further comprise identifying at least one row of the prescribed drop pattern with a minimal number of drop locations, and wherein the fluid dispense scheme includes modifying operation of the plurality of nozzles such that the at least one non-functional nozzle is associated with a respective row of the prescribed drop pattern that includes the minimal number of drop locations.
15 . The one or more computer-readable media of claim 10 , wherein each row of the prescribed drop pattern is associated with a respective nozzle, and the fluid dispense scheme includes modifying the prescribed drop pattern by removing a respective row of the prescribed drop pattern associated with the at least one non-functional nozzle.
16 . The one or more computer-readable media of claim 10 , wherein the acts further comprise activating the plurality of nozzles during multiple passes of a substrate to dispense fluid to the substrate, and wherein the fluid dispense scheme includes modifying operation of the plurality of nozzles during at least one of the multiple passes in order to dispense the fluid to a row of the prescribed drop pattern associated with the at least one non-functional nozzle.
17 . The one or more computer-readable media of claim 10 , wherein the fluid dispense scheme includes identifying one or more empty locations of the prescribed drop pattern adjacent to a drop location of the prescribed drop pattern associated with the at least one non-functional nozzle and modifying operation of the plurality of nozzles by dispensing the fluid to at least one of the empty locations adjacent to the drop location of the prescribed drop pattern associated with the at least one non-functional nozzle.
18 . A method comprising:
identifying, by a lithographic system, that at least one of a plurality of nozzles of a fluid dispense system of the lithographic system is non-functional;
performing maintenance on one or more nozzles of the fluid dispense system in response to identifying the at least one non-functional nozzle;
determining whether the maintenance fixed the at least one non-functional nozzle; and
replacing a dispense head of the fluid dispense system when the maintenance fails to fix a threshold number of non-functional nozzles.
19 . The method of claim 18 , further comprising:
determining whether a fluid dispensed by the fluid dispense system is to be changed; and
replacing one or more reservoirs of the fluid dispense system when the fluid is to be changed to another fluid with a different formulation.
20 . The method of claim 18 , wherein performing maintenance on the one or more nozzles of the fluid dispense system includes purging the dispense head with nitrogen gas, purging the dispense head by dispensing fluid through nozzles of the dispense head, wiping the dispense head with a wipe, vacuum wiping the dispense head, disconnecting the dispense head from the fluid dispense system, or a combination thereof.