Apparatus, carrier and method for manufacturing display patch

Abstract

An apparatus includes a carrier, an aperture, and a motion platform. The carrier is configured to secure a substrate. The orifice is configured to emit an aerosol jet. The motion platform is configured to move the carrier relative to the orifice with the orifice emitting a continuous aerosol jet to print a plurality of electrodes on the first major surface and edge surface of the substrate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under patent law to U.S. Provisional Application Serial No. 63 / 580798 filed on September 6, 2023, the contents of which are the basis for this application and are incorporated herein by reference in their entirety. Background Art

[0003] field

[0004] The present disclosure generally relates to methods and apparatus for making substrates with wrapped electrodes. More particularly, the present disclosure relates to methods and apparatus for making substrates with wrapped electrodes using an aerosol jet. Technical Background

[0006] Displays such as MicroLED displays include borderless, bezelless and / or tiled displays. Top-emitting MicroLED displays require a method to electrically interconnect the LEDs on the top surface of the substrate with a driver control board located behind the substrate. This can be achieved by using a flexible connector attached at the edge of the substrate. However, in the case of borderless, bezelless or tiled displays, it is not desirable to use a flexible connector attached to the top surface of the substrate. In this case, the flexible connector is either visible to the viewer and needs to be hidden by the border, or the flexible connector takes up too much space between the tiles and hinders seamless tiling. One solution for electrically connecting the top surface of the display substrate to the driver control board is to utilize a wrap-around electrode.

[0007] Wrap-around electrodes can be manufactured around the edge of a substrate. This allows the electrode to take up less physical space and be less noticeable. Wrap-around electrodes have been demonstrated on borderless, bezel-less, and tiled displays. Such electrodes can include different materials and can be manufactured through methods such as printing, vacuum deposition, flexible bonding, and electroplating. Methods are being developed to improve the electrical performance and reliability of wrapped electrodes through material and process improvements. Summary of the invention

[0008] Some embodiments of the present disclosure relate to an apparatus for manufacturing a display patch. The apparatus includes a carrier, an orifice, and a motion platform. The carrier is configured to fix a substrate. The orifice is configured to emit an aerosol jet. The motion platform is configured to move the carrier relative to the orifice while the orifice emits a continuous aerosol jet to print a plurality of electrodes on a first main surface and an edge surface of the substrate.

[0009] Other embodiments of the present disclosure relate to a carrier for manufacturing a display patch. The carrier includes a first carrier portion configured to contact a first major surface of a substrate. The first carrier portion includes a plurality of first magnets and a plurality of second magnets. The plurality of first magnets are configured to detachably couple the first carrier portion to a motion platform of an apparatus for manufacturing the display patch. The plurality of second magnets are configured to fix the substrate to the first carrier portion.

[0010] Other embodiments of the present disclosure are directed to a method for manufacturing a display patch. The method includes: emitting a first continuous aerosol jet from an orifice. The method includes: depositing a first portion of a first electrode on a first major surface and an edge surface of a substrate by the first continuous aerosol jet emitted from the orifice. The method includes: depositing a first portion of a second electrode on the first major surface and the edge surface of the substrate by the first continuous aerosol jet emitted from the orifice.

[0011] The apparatus and methods disclosed herein enable high-volume electrode printing (e.g., highly accurate, highly repeatable, and short stroke motions). The apparatus provides zero friction printing strokes, greatly reduced friction indexing strokes, longer equipment life, increased accuracy (e.g., about + / - 5 microns), and faster printing speeds compared to previous solutions.

[0012] Additional features and advantages will be set forth in the detailed description that follows and, in part, will be apparent to those skilled in the art from the description or by practice of the embodiments as described herein, including the subsequent detailed description, claims, and accompanying drawings.

[0013] It should be understood that both the above summary and the following detailed description are exemplary only and are intended to provide an overview or framework for understanding the nature and characteristics of the claims. The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. The accompanying drawings illustrate one or more embodiments and together with the description explain the principles and operation of the various embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 is a perspective view of an exemplary substrate;

[0015] Figure 2 is a perspective view of electrode deposition on a substrate positioned at an angled orientation relative to a deposition orifice;

[0016] Figure 3 is a side cross-sectional view of a portion of a substrate having a wrapped electrode deposited thereon;

[0017] Figure 4is a perspective view of an exemplary apparatus for printing a plurality of wrapped electrodes on a substrate;

[0018] Figure 5 yes Figure 4 A perspective view of an exemplary carrier of the device;

[0019] Figure 6 yes Figure 5 A perspective view of an exemplary carrier portion of a carrier of;

[0020] Fig. 7A is a perspective view of an exemplary carrier and an exemplary alignment fixture for positioning a substrate within the carrier, Figure 7B is a partial side view of an exemplary carrier and an exemplary alignment fixture;

[0021] Figure 8 is a perspective view of another exemplary carrier and another exemplary alignment fixture for positioning a substrate within the carrier;

[0022] Fig. 9 is a partial cross-sectional view of an exemplary carrier portion coupled to a motion platform;

[0023] Fig.10 yes Figure 4 A partial side view of the device;

[0024] Fig.11 yes Figure 4 a side cross-sectional view of the device; and

[0025] FIG. 12A to FIG. 12D is a flow chart of an exemplary method for manufacturing a display tile. DETAILED DESCRIPTION

[0026] Reference will now be made in detail to embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used to represent the same or similar parts in all the accompanying drawings. However, the present disclosure may be implemented in many different forms and should not be considered to be limited to the embodiments described herein.

[0027] Ranges may be expressed herein as from "about" one particular value and / or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation by using the antecedent "about," it is understood that the particular value forms another embodiment. It will be further understood that each of the endpoints in a range is meaningful relative to and independent of the other endpoint.

[0028] Directional terms used herein—eg, up, down, right, left, front, back, top, bottom, vertical, horizontal—are made with reference only to the drawings in which they are drawn and are not intended to imply an absolute orientation.

[0029] Unless otherwise expressly stated, it is not intended that any method set forth herein be interpreted as requiring that its steps be performed in a particular order, or requiring a particular orientation of any device. Thus, in the absence of a method claim actually reciting the order in which its steps are to be followed, or any device claim actually reciting an order or orientation for individual components, or in the absence of additional specific statements in the claim or description that the steps are to be limited to a particular order, or a particular order or orientation for components of the device, it is not intended to infer an order or orientation in any respect. This applies to any possible non-expressive basis for interpretation, including: logical matters regarding the arrangement of steps, operational flow, order of components, or orientation of components; clear meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in this specification.

[0030] As used herein, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" component includes aspects having two or more such components unless the context clearly dictates otherwise.

[0031] Reference now Figure 1 , depicting a perspective view of an exemplary substrate 100. The substrate 100 includes a first major surface 102, an opposite second major surface 104 (located on a side of the substrate 100 opposite to the first major surface) extending in a direction generally parallel to the first major surface 102, and an edge surface 106 extending between the first major surface 102 and the second major surface 104 and extending in a direction generally perpendicular to the first major surface 102 and the second major surface 104.

[0032] In certain exemplary embodiments, the substrate 100 may include a glass substrate including a glass material such as aluminosilicate, alkali aluminosilicate, borosilicate, alkali borosilicate, aluminoborosilicate, alkali aluminoborosilicate, soda lime, or other suitable glass. Non-limiting examples of commercially available glasses suitable for use as the glass substrate 100 include EAGLE GLASS from Corning Incorporated. Lotus TM , Iris TM and Glass. The substrate 100 may have a thickness within a certain range, for example, from about 0.1 mm to about 2 mm, between the first major surface 102 and the second major surface 104. The substrate 100 may have a refractive index within a certain range, for example, between about 1.5 and 2.4.

[0033] Figure 2 2 is a perspective view of electrode deposition on substrate 100 positioned at an angle relative to deposition orifice 204. Figure 2 As shown, a plurality of contact pads 110 are arranged on the main surface of the substrate 100, and at least a portion of a plurality of electrodes 112 are deposited on the contact pads 110, the main surface of the substrate 100, and the edge surface. The substrate 100 may then be rotated or flipped to allow at least a portion of the plurality of electrodes 112 to be deposited on the opposite main surface and edge surface of the substrate 100. In certain exemplary embodiments, a mask 114 including an edge 115 indicated by a dotted line may be applied on a portion of the main surface to prevent deposition where deposition is not desired on the main surface. In addition, the substrate 100 may include a reference 116, which may be used to initially position the substrate 100 relative to the orifice 204 before depositing the electrode 112. For example, electrode deposition in which the substrate can be oriented at various angles relative to the deposition orifice is disclosed in WO2019079253, the entire disclosure of which is incorporated herein by reference. The deposition of such electrodes may be achieved by various techniques, including but not limited to printing seed layer plating, direct printing, laser induced metallization, pen dispensing, and aerosol jets.

[0034] Embodiments disclosed herein include those in which the electrode is deposited on the substrate by an aerosol jet. For example, aerosol jet deposition is described in US20090061077, the entire disclosure of which is incorporated herein by reference. This deposition includes using an aerosol jet to form an annular propagating jet, the jet including an outer sheath flow and an inner carrier flow carrying an aerosol. In the aerosol jet process, the aerosol flow preferably enters the print head directly after the aerosolization process, or enters the print head after passing through the heater assembly, and is guided toward the print head orifice along the axis of the device. The mass flux can be controlled by an aerosol carrier gas mass flow controller. Inside the print head, the aerosol flow can be collimated by an orifice of about 0.1 mm in size. Then, the emitted particle flow can be combined with an annular sheath gas, the function of which is to eliminate the blockage of the nozzle and focus the aerosol flow. The carrier gas and the sheath gas can, for example, include dry nitrogen, compressed air or an inert gas, one or more of which can be modified to include solvent vapor. For example, when the aerosol is formed from an aqueous solution, water vapor may be added to the carrier gas or sheath gas to prevent evaporation of the droplets.

[0035] The sheath gas can then enter through the sheath air inlet below the aerosol inlet and form an annular flow with the aerosol flow. As with the aerosol carrier gas, the sheath gas flow rate can also be controlled by a mass flow controller. The mixed flow is discharged from the nozzle through an orifice pointing to the target at a high speed (e.g., about 50 meters per second) and then hits the target. This annular flow focuses the aerosol flow onto the target and allows printing features with a size less than, for example, about 1 micron. A print pattern can be created by moving the target relative to the print head and / or moving the print head relative to the target. Examples of commercially available aerosol jet print heads, devices, and systems include those available from Optomec Inc.

[0036] Electrical traces (e.g., electrodes) may be formed using a multi-step process to extend from the first major surface 102 of the substrate 100 to the second major surface 104 of the substrate opposite to the first major surface, the multi-step process comprising multiple non-contact aerosol jets using conductive nanoparticle ink. The nanoparticle ink may be atomized using a venturi atomization process and a carrier gas as described above. The gas may then be focused into a small deposition stream and deposited onto one side of the substrate 100. The focal height from the orifice 204 may be large enough so that the orifice 204 may be printed on the top and edge surfaces of the substrate 100 when the substrate 100 is held at a specified angle. Once the nanoparticle ink is dry, the substrate 100 may be flipped over and printing may continue on the other side of the substrate to connect or create an electrical trace (e.g., electrode) that wraps around the edge between the first major surface 102 and the second major surface 104 of the substrate. The finished portion may then undergo a thermal cycle to bond the nanoparticle ink to the surface of the substrate 100.

[0037] Figure 3 1 is a side cross-sectional view of a portion of a substrate 100 having a wrapped electrode 112 deposited thereon. Specifically, the electrode 112 extends along the first major surface 102, the edge surface 106, and a portion of the second major surface 104 of the substrate 100 while contacting the contact pad 110. Although the edge region of the substrate 100 is shown as having a rectangular cross-section, the embodiments disclosed herein include embodiments in which the edge region of the substrate 100 has other cross-sections, including but not limited to embodiments including a curved or angled (e.g., chamfered) region (not shown). The electrode 112 may include a conductive material, such as a conductive metal material, including, for example, at least one material selected from silver or copper.

[0038] Figure 4 It is used to print a plurality of wrapped electrodes (e.g., Figure 3112). In certain exemplary embodiments, the apparatus 200 can be used to manufacture a display patch. The apparatus 200 includes a carrier 202, a print head 252 including an orifice 204, and a motion platform 210. The carrier 202 is configured to fix the substrate 100, as described below with reference to Figures 5 to 8 The orifice 204 is configured to emit an aerosol jet to deposit electrical traces (e.g., electrodes) on the substrate 100. The motion platform 210 is configured to move the carrier 202 relative to the orifice 204. In some embodiments, the motion platform 210 is configured to move the carrier 202 relative to the orifice 204 while the orifice 204 emits a continuous aerosol jet to deposit electrical traces (e.g., electrodes) on the first major surface 102 ( Figure 3 ) and edge surface 106 ( Figure 3 ) to print a plurality of electrodes on the second major surface 104 of the substrate 100. In some embodiments, the motion platform 210 is configured to move the carrier 202 relative to the orifice 204 when the carrier 202 is flipped and the orifice 204 emits a continuous aerosol jet to print a plurality of electrodes on the second major surface 104 ( Figure 3 ) and print multiple electrodes on the edge surface 106.

[0039] exist Figure 4 In the illustrated exemplary apparatus 200, the motion platform 210 may include a plurality of air bearings 212; a first non-contact linear motor 214; a second non-contact linear motor 216; a third non-contact linear motor 254 (hidden behind the plate and in Figure 4 210 ); a plurality of flexures 220, 222, 224, and 256; a plurality of encoders 226, 228, and 258, a print head tower 250; and an optical system 240. The carrier 202 floats on a plurality of air bearings 212. In certain exemplary embodiments, the plurality of air bearings 212 include vacuum preloaded air bearings to provide a rigid and flat bearing to allow frictionless transport between the bearings and the carrier 202. The carrier 202 is removably coupled to the flexures 220 of the motion platform 210. The flexure 220 also floats on the plurality of air bearings 212 and is coupled to the flexure 224 by two decoupled flexures 222. The flexures 220, 222, and 224 couple the carrier 202 to a first non-contact linear motor 214 and a second non-contact linear motor 216.

[0040] The first non-contact linear motor 214 moves the carrier 202 relative to the orifice 204 along an index stroke axis 232 (e.g., a first axis). The second non-contact linear motor 216 moves the carrier 202 relative to the orifice 204 along a print stroke axis 230 (e.g., a second axis) that is perpendicular to the index stroke axis 232. In certain exemplary embodiments, the orifice 204 is stationary while printing a plurality of electrodes (e.g., 112) on the substrate 100. In some embodiments, the print head tower 250 is configured to position the orifice 204 relative to the substrate 100. The third non-contact linear motor 254 can be used to incorporate a small vertical print head stroke along the nozzle motion axis 234 parallel to the aerosol jet emitted from the orifice 204 into the printing process to maintain an offset between the orifice 204 and the substrate 100 when the aerosol jet wraps around the edge of the substrate 100. By using a smaller vertical print head stroke, the uniformity of the electrical traces can be further improved. The printhead tower 250 includes a flexure 256 (eg, a rotational flexure configured to provide parallel motion) that couples the printhead 252 and orifice 204 to a non-contact linear motor 254 to achieve vertical printhead strokes.

[0041] In certain exemplary embodiments, the non-contact linear motors 214, 216, and 254 are frictionless and coupled with air bearing supports and flexures as described herein to provide zero friction motion along the print stroke axis 230 and the nozzle motion axis 234 and extremely low friction motion along the index stroke axis 232. In certain exemplary embodiments, each non-contact linear motor 214, 216, and 254 includes a coil and a magnetic track, wherein the coil is straddled on the magnetic track. The encoder 226 may be used to provide feedback to control the positioning of the substrate 100 relative to the orifice 204 along the print stroke axis 230. The encoder 228 may be used to provide feedback to control the positioning of the substrate 100 relative to the orifice 204 along the index stroke axis 232. The encoder 258 may be used to provide feedback to control the positioning of the orifice 204 relative to the substrate 100 along the nozzle motion axis 234.

[0042] The flexure 220 (e.g., a rotational flexure configured to provide parallel motion) used to connect the carrier 202 to the motion platform 210 limits the flatness errors of the substrate 100 and / or the carrier 202 that may be caused by the motion platform 210. The flexure 222 (e.g., a rotational flexure configured to provide parallel motion) is a disconnected flexure that connects the flexure 220 to the flexure 224. The flexure 224 (e.g., a rotational flexure configured to provide parallel motion) is a flexure plate for printing stroke bearings. The flexure 224 is straddled on the linear guide 225 along the index stroke axis 232 via a ball bearing bracket 229. The flexure 224 provides a repeatable frictionless bearing with a theoretically infinite life. Due to the highly repeatable and short stroke nature of the motion used to print the wrapped electrode, the flexure 224 provides an increased service life compared to traditional contact bearings. Flexure 256 accommodates short and repeated vertical motion strokes of print head 252. Flexure 256 provides a repeatable frictionless bearing with increased service life compared to conventional bearings. Additional flexures (such as encoder flexure 227 of encoder 226) can be used to limit any non-axial forces transmitted to encoders 226, 228, and 258. Encoder flexures can also act as weak links in the event of motion collisions and / or failures.

[0043] The optical system 240 is configured to calibrate the orifice position 204 each time the orifice 204 as part of the print head 252 is replaced. The optical system 240 is also configured to calibrate the orifice position 204 based on the reference 116 ( Figure 2 ) The substrate 100 is positioned relative to the orifice 204 (eg, by moving the carrier 202 that holds the substrate 100). Fig.10 The optical system 240 is further described.

[0044] In operation, the carrier 202 can be moved into and out of a continuous aerosol jet emitted from the orifice 204 to print a plurality of electrical traces (e.g., electrodes) on the major and edge surfaces of the substrate 100. The print head 252 is turned on at the beginning of printing and remains on during printing. When the substrate leaves the aerosol jet path, the substrate 100 is indexed to the next electrical trace, thereby eliminating the need for ink blocking. In this way, run time and ink flow uniformity are maximized. In addition, motion errors associated with the print head 252 due to its cantilever mounting design are eliminated.

[0045] The starting position of the substrate 100 is outside the aerosol jet path, and the substrate is indexed to the correct starting position (e.g., based on the reference 116). Each of the printed electrical traces is the result of two print strokes (one to drive the substrate into the aerosol jet path, and another to pull the substrate out of the aerosol jet path without moving in the indexing direction). Due to this printing strategy, a rapid acceleration control is used to accelerate the substrate to the correct printing speed, control the printing speed, decelerate to zero as quickly as possible because the substrate is still under the aerosol jet path, accelerate back to the printing speed in the opposite direction, and control the printing speed when the substrate leaves the aerosol jet path, and then decelerate back to zero during the next indexing move. The device 200 is designed to minimize the moving mass, thereby improving the ability to accelerate and decelerate rapidly.

[0046] In some embodiments, a mask (eg, Figure 2 114) to allow the substrate to move in the aerosol jet path while preventing ink from being deposited on the substrate where it is not intended and / or desired. By using a mask, printing time can be further reduced by eliminating double printing strokes for each electrical trace.

[0047] Figure 5 is connected to Figure 4 A perspective enlarged view of an exemplary carrier 202 of a motion platform 210 of an apparatus 200. Figure 5 As shown, the motion platform 210 includes a plurality of magnets 260 (as part of the flexure 220) to removably couple the carrier 202 to the motion platform. In addition, the motion platform 210 includes a plurality of V-shaped members 262 configured to receive the kinematic ball-end adjusters (e.g., Figure 6 306) to position the carrier 202 relative to the flexure 220, as will be further described below.

[0048] The carrier 202 may include a first carrier portion 300a and a second carrier portion 300b. In certain exemplary embodiments, the first carrier portion 300a and the second carrier portion 300b are identical, such as Figure 6 The first carrier portion 300a and the second carrier portion 300b are symmetrical so that once the substrate 100 is fixed in the carrier 202, the carrier can be rotated and flipped to enable printing on the top and bottom sides of both long edges of the substrate. In other examples, as described below with reference to Figure 8 As further described, the carrier 202 may include a single carrier portion 300 and a plurality of magnets to secure the substrate 100 to the single carrier portion 300 .

[0049] Reference again Figure 5 and Figure 6 The first carrier portion 300a is configured to contact the first major surface (eg, Figure 1 The first carrier portion 300a includes a plurality of first magnets 302a (in Figure 5 Not visible in , but in Fig. 7A ) and a plurality of second magnets 304 (shown in Figure 5 Not visible in , but in Figure 6 20). The plurality of first magnets 302a of the first carrier portion 300a are configured to removably couple the first carrier portion 300a to the motion platform 210 via the flexure 220. The first carrier portion 300a is removably coupled to the flexure 220 by positioning the first plurality of magnets 302a opposite to the corresponding plurality of magnets 260 of the flexure 220. The plurality of kinematic adjusters 306a of the first carrier portion 300a (in Figure 5 Not visible in , but in Fig. 7A ) is configured to adjust the positioning of the first carrier portion 300a relative to the motion platform 210 (eg, relative to the flexure 220) by engaging the V-shaped member 262.

[0050] The second carrier portion 300 b is configured to contact a second main surface (eg, Figure 1 The second carrier portion 300b includes a plurality of third magnets 304 (in Figure 5 Not visible in , but in Figure 6 ), the plurality of third magnets are opposite to the plurality of second magnets 304 of the first carrier portion 300a to fix the substrate 100 between the first carrier portion 300a and the second carrier portion 300b. The second carrier portion 300b further includes a plurality of fourth magnets 302b, which are configured to detachably couple the second carrier portion to the motion platform 210 through the flexure 220 when the carrier 202 is flipped over to print electrodes on the second main surface and edge surface of the substrate 100.

[0051] Fig. 7A is a perspective view of an exemplary carrier 202 and an exemplary alignment fixture 400 for repeatedly positioning a substrate 100 within the carrier 202, Figure 7B2 is a partial side view of an exemplary carrier 202 and an exemplary alignment fixture 400. In some examples, a first polyimide film interposer can be added between the first carrier portion 300a and the first major surface of the substrate, and a second polyimide film interposer can be added between the second carrier portion 300b and the second major surface of the substrate to protect the substrate. The alignment fixture 400 includes a precision machined dowel 402 and two precision machined dowels 410. In certain exemplary embodiments, the dowels 402 and 410 are polyetheretherketone (PEEK) dowels.

[0052] The dowel 402 includes a first portion 404 configured to contact the first carrier portion 300a (e.g., within a groove of a short side of the first carrier portion 300a), a second portion 406 configured to contact the substrate 100, and a third portion 408 configured to contact the second carrier portion 300b (e.g., within a groove of a short side of the second carrier portion 300b). The first portion 404 and the third portion 408 have the same radius so that the side surface of the first carrier portion 300a is aligned with the side surface of the second carrier portion 300b. The radius of the second portion 406 is smaller than the radius of the first portion 404 and the third portion 408 so that the substrate 100 extends into the groove on the side surface of each of the first carrier portion 300a and the second carrier portion 300b. The dowel 402 sets an offset between the short edge of the substrate 100 and each short side surface of the first carrier portion 300a and the second carrier portion 300b. Different dowels 402 with different radii for the first portion 404 , the second portion 406 , and the third portion 408 may be used to support different offsets between the carrier 202 and the substrate 100 .

[0053] like Figure 7B As best illustrated, each dowel 410 includes a first portion 412 configured to contact the first carrier portion 300a (e.g., on the long side of the first carrier portion 300a), a second portion 414 configured to contact the substrate 100, and a third portion 416 configured to contact the second carrier portion 300b (e.g., on the long side of the second carrier portion 300b). The first portion 412 and the third portion 416 have the same radius so that the side surface of the first carrier portion 300a is aligned with the side surface of the second carrier portion 300b. The radius of the second portion 414 is smaller than the radius of the first portion 412 and the third portion 416 so that the substrate 100 extends beyond the side of each of the first carrier portion 300a and the second carrier portion 300b. Each dowel 410 sets an offset between the long edge of the substrate 100 and each long side surface of the first carrier portion 300a and the second carrier portion 300b. Different dowels 410 with different radii for the first portion 412 , the second portion 414 , and the third portion 416 may be used to support different offsets between the carrier 202 and the substrate 100 .

[0054] Figure 8 2 is a perspective view of another exemplary carrier 203 and another exemplary alignment fixture 500 for repeatably positioning the substrate 100 within the carrier 203. The carrier 203 includes the substrate 100 as previously described and with reference to FIG. Figure 6 The illustrated carrier portion 300 and a plurality of third magnets 320 (e.g., coated magnets for preventing damage to the substrate 100) are shown. Each third magnet 320 is configured to be arranged on a second major surface of the substrate 100, the second major surface being opposite to the first major surface, and to be aligned with a corresponding second magnet 304 ( Figure 6 ) to fix the substrate 100 to the carrier portion 300. In some examples, a polyimide film interposer may be added between the carrier portion 300 and the main surface of the substrate to protect the substrate. When the electrode is printed on one main surface and the edge surface of the substrate 100, but not printed on the other main surface of the substrate, the carrier 203 may be used instead of the carrier 202.

[0055] The alignment fixture 500 includes independently adjustable stops 502, 504, 506, 508, 510, and 512 to align the substrate 100 with the carrier portion 300. The independently adjustable stop 502 is configured to contact the short side surface of the carrier portion 300, and the independently adjustable stop 504 is configured to contact the short edge of the substrate 100 to align the short edge of the substrate relative to the short side surface of the carrier portion 300. The independently adjustable stops 508 and 510 are configured to contact the long side surface of the carrier portion 300, and the independently adjustable stops 506 and 512 are configured to contact the long edge of the substrate 100 to align the long edge of the substrate relative to the long side surface of the carrier portion 300.

[0056] The independently adjustable stops 502, 508 and 510 may include a kinematic plane and a kinematic adjuster 306 ( Figure 6 ) . The independently adjustable stops 504, 506 and 512 can be machined PEEK stops to set the position of the substrate 100 and reduce the possibility of damage to the substrate 100. This embodiment can be suitable for incorporating a vacuum to hold the substrate 100 to the carrier portion 300. In this case, the alignment fixture 500 and the substrate / carrier configuration can be used to print electrodes wrapped on both major surfaces of the substrate.

[0057] Fig. 9is a partial cross-sectional view of an exemplary carrier portion 300 coupled to the motion platform 210. Magnets 302 of the carrier portion 300 correspond with magnets 260 of the flexure 220 of the motion platform 210 to removably couple the carrier portion 300 to the motion platform 210. Kinematic ball-end adjusters 306 of the carrier portion 300 engage with the V-shaped members 262 of the flexure 220. The kinematic ball-end adjusters 306 can be adjusted to change the positioning of the carrier portion 300 relative to the flexure 220 of the motion platform 210.

[0058] Fig.10 yes Figure 4 2 is a partial side view of the apparatus 200, illustrating the optical system 240 and the carrier 202. The optical system 240 includes a camera 602, a first adjustment mechanism 604, and a second adjustment mechanism 606. The optical system 240 is mounted to the print head tower 250 so that the camera 602 is perpendicular to the major surface of the substrate 100 to provide optimal image quality. The first adjustment mechanism 604 (e.g., a micrometer adjustment) can be adjusted to calibrate the positioning of the camera 602 along a camera axis (e.g., an axis perpendicular to the major surface of the substrate 100) relative to the substrate 100. The second adjustment mechanism 606 (e.g., a micrometer adjustment) can be adjusted to calibrate the positioning of the camera 602 along an axis perpendicular to the camera axis (e.g., an axis parallel to the major surface of the substrate 100) relative to the substrate 100.

[0059] The optical system 240 is used to calibrate the print head 252 each time the print head is replaced ( Figure 4 ) and thus calibrate the position of the orifice 204. In certain exemplary embodiments, the calibration routine includes printing a reference (e.g., Figure 2 116 in the image), and then the printed fiducial is moved under the camera 602, and the center of the fiducial is accurately located within the field of view using the camera. Once the center of the fiducial is found, the position within the field of view in pixels can be converted to machine coordinates and microns to accurately indicate the location where the aerosol jet impacts the substrate 100. The optical system 240 can also be used to locate the substrate 100 where the electrode is to be printed by referencing the existing fiducial position on the substrate. In certain exemplary embodiments, the calibration and alignment process using the optical system 240 results in a printing accuracy greater than about + / - 5 microns.

[0060] Fig.11 yes Figure 42 is a side cross-sectional view of an apparatus 200, illustrating a motion platform 210 including a print head tower 250. The print head tower 250 can be mounted on a linear track 270 to enable the orifice 204 to be positioned relative to the substrate 100 along an axis perpendicular to the aerosol jet. The print head tower 250 can include an adjustment mechanism 272 (e.g., a micrometer adjustment) that can be adjusted during initial setup of the apparatus 200 to precisely optimize the position of the print head 252 and therefore the orifice 204 relative to the substrate 100.

[0061] FIG. 12A to FIG. 12D is a flow chart of an exemplary method 700 for manufacturing a display patch. In certain exemplary embodiments, the method 700 may be as previously described and referenced. Figures 4 to 11 The method 700 can be used to print a wrapped electrode 112 on a substrate 100, such as Figure 3 exemplified. like Fig. 12A As illustrated at 702 in , method 700 may include: emitting a first continuous aerosol jet from an orifice (e.g., 204). At 704, method 700 may include: depositing a first portion of a first electrode (e.g., first electrode 112) on a first major surface (e.g., 102) and an edge surface (e.g., 106) of a substrate (e.g., 100) by the first continuous aerosol jet emitted from the orifice. At 706, method 700 may include: depositing a first portion of a second electrode (e.g., second electrode 112 adjacent to first electrode 112) on the first major surface and edge surface of the substrate by the first continuous aerosol jet emitted from the orifice.

[0062] In some embodiments, such as Fig. 12B exemplified, Fig. 12A Step 706 of method 700 may also include method 706a. At 708, method 706a may include: moving the substrate away from the first continuous aerosol jet emitted from the orifice after depositing the first portion of the first electrode (e.g., by moving the carrier 202 away from the orifice 204 along the print stroke axis 230 by the non-contact linear motor 216). At 710, method 706a may include: moving the substrate relative to the orifice (e.g., by moving the carrier 202 along the index stroke axis 232 parallel to the carrier 202 by the non-contact linear motor 214) with the substrate away from the first continuous aerosol jet emitted from the orifice. At 712, method 706a may include: moving the substrate into the first continuous aerosol jet emitted from the orifice to deposit the first portion of the second electrode (e.g., by moving the carrier 202 toward the orifice 204 along the print stroke axis 230 by the non-contact linear motor 216). In the described embodiment, each electrode is printed using a double printing stroke, one printing stroke from the edge of the substrate towards the center of the substrate and one printing stroke returning to the edge of the substrate.

[0063] In some embodiments, such as Fig. 12C exemplified, Fig. 12A Step 706 of method 700 may also include method 706b. At 714, method 706b may include: moving a masked portion (e.g., 114) of a substrate (e.g., 100) into a first continuous aerosol jet emitted from an orifice after depositing the first portion of the first electrode (e.g., by moving the carrier 202 toward the orifice 204 along the print stroke axis 230 by the non-contact linear motor 216 so that the aerosol jet impacts the masked portion 114 of the substrate 100). At 716, method 706b may include: moving the substrate relative to the orifice (e.g., by moving the carrier 202 along the index stroke axis 232 parallel to the carrier 202 by the non-contact linear motor 214) with the masked portion of the substrate in the first continuous aerosol jet emitted from the orifice. At 718, method 706b may include moving an unmasked portion of the substrate into the first continuous aerosol jet emitted from the orifice to deposit a first portion of the second electrode (e.g., by moving the carrier 202 away from the orifice 204 along the print stroke axis 230 by the non-contact linear motor 216). In the described embodiment, the mask on the substrate enables the substrate to be moved in the path of the aerosol jet and prevents undesired and / or unwanted printing on the substrate. By using a mask on the substrate, printing time can be reduced by eliminating double print strokes for each electrode.

[0064] like Fig.12D As illustrated at 720 in , method 700 may further include: flipping the substrate (e.g., by detaching carrier 202 from motion platform 210, flipping carrier 202, and reconnecting carrier 202 to motion platform 210). At 722, method 700 may further include: emitting a second continuous aerosol jet from the orifice. At 724, method 700 may further include: depositing a second portion of the first electrode on a second major surface (e.g., 104) and an edge surface (e.g., 106) of the substrate (e.g., 100) by the second continuous aerosol jet emitted from the orifice, wherein the second major surface is opposite to the first major surface (e.g., 102) and the edge surface extends between the first major surface and the second major surface. At 726, method 700 may further include: depositing a second portion of the second electrode on the second major surface and the edge surface of the substrate by the second continuous aerosol jet emitted from the orifice.

[0065] It will be apparent to those skilled in the art that various modifications and changes may be made to the various embodiments of the present disclosure without departing from the spirit and scope of the present disclosure. Therefore, it is intended that the present disclosure covers such modifications and changes as long as they fall within the scope of the appended claims and their equivalents.

Claims

1. A device for manufacturing a display patch, the device comprising: a carrier configured to hold a substrate; an orifice configured to emit an aerosol jet; as well as A motion platform is configured to move the carrier relative to the orifice when the orifice emits a continuous aerosol jet to print a plurality of electrodes on the first major surface and the edge surface of the substrate.

2. The apparatus of claim 1, wherein the motion platform comprises a plurality of air bearings on which the carrier floats.

3. The apparatus of claim 1, wherein the motion platform comprises a non-contact linear motor to move the carrier relative to the aperture.

4. The apparatus of claim 3, wherein the motion platform includes a flexure coupling the carrier to the non-contact linear motor.

5. The apparatus of claim 1, wherein the motion platform comprises a plurality of magnets to detachably couple the carrier to the motion platform.

6. The apparatus of claim 1, wherein the motion platform is configured to move the carrier along a first axis and a second axis perpendicular to the first axis.

7. The device of claim 1, further comprising: An optical system is configured to calibrate the aperture position each time the aperture is changed.

8. The apparatus of claim 7, wherein the optical system is further configured to position the substrate relative to the orifice based on a fiducial on the substrate prior to printing the plurality of electrodes.

9. The apparatus of claim 1, wherein the orifice is stationary while printing the plurality of electrodes.

10. The device of claim 1, further comprising: A printhead tower is configured to position the orifice relative to the substrate.

11. The apparatus of claim 10, wherein the printhead tower includes a non-contact linear motor to move the orifice relative to the substrate.

12. The apparatus of claim 11, wherein the printhead tower includes a flexure coupling the aperture to the non-contact linear motor.

13. A carrier for manufacturing a display patch, the carrier comprising: A first carrier portion, the first carrier portion being configured to contact the first main surface of the substrate, the first carrier portion comprising: a plurality of first magnets configured to removably couple the first carrier portion to a motion platform of an apparatus for manufacturing the display patch; and A plurality of second magnets are configured to secure the substrate to the first carrier portion.

14. The carrier of claim 13, wherein the first carrier portion further comprises a plurality of first kinematic adjusters configured to adjust a positioning of the first carrier portion relative to the motion platform.

15. The vector according to claim 13, further comprising: A plurality of third magnets, each third magnet being configured to be arranged on a second major surface of the substrate, the second major surface being opposite to the first major surface and opposite to a corresponding second magnet of the plurality of second magnets, to secure the substrate to the first carrier portion.

16. The vector according to claim 13, further comprising: A second carrier portion, the second carrier portion being configured to contact a second main surface of the substrate opposite to the first main surface, the second carrier portion comprising: a plurality of third magnets, the plurality of third magnets being opposite the plurality of second magnets to secure the substrate between the first carrier portion and the second carrier portion; and A plurality of fourth magnets are configured to removably couple the second carrier portion to the motion platform.

17. A method for manufacturing a display patch, the method comprising: emitting a first continuous aerosol jet from the orifice; depositing a first portion of a first electrode on a first major surface and an edge surface of a substrate from the first continuous aerosol jet emitted from the orifice; as well as A first portion of a second electrode is deposited on the first major surface and the edge surface of the substrate by the first continuous aerosol jet emitted from the orifice.

18. The method of claim 17, wherein depositing the first portion of the second electrode comprises: after depositing the first portion of the first electrode, moving the substrate away from the first continuous aerosol jet emitted from the orifice; moving the substrate relative to the orifice with the substrate moving away from the first continuous aerosol jet emitted from the orifice; as well as The substrate is moved into the first continuous aerosol jet emitted from the orifice to deposit the first portion of the second electrode.

19. The method of claim 17, wherein depositing the first portion of the second electrode comprises: after depositing the first portion of the first electrode, moving the masked portion of the substrate into the first continuous aerosol jet emitted from the orifice; moving the substrate relative to the orifice with the masked portion of the substrate in the first continuous aerosol jet emitted from the orifice; as well as An unmasked portion of the substrate is moved into the first continuous aerosol jet emitted from the orifice to deposit the first portion of the second electrode.

20. The method of claim 17, further comprising: turning over the substrate; emitting a second continuous aerosol jet from the orifice; depositing a second portion of the first electrode on a second major surface and an edge surface of the substrate from the second continuous aerosol jet emitted from the orifice, wherein the second major surface is opposite the first major surface and the edge surface extends between the first major surface and the second major surface; as well as A second portion of the second electrode is deposited on the second major surface and the edge surface of the substrate by the second continuous aerosol jet emitted from the orifice.

Images