Ink-jet printing adhesive layer leveling method based on contour iterative compensation

Abstract

The invention discloses a method for leveling an ink-jet printing adhesive layer based on contour iterative compensation. The method comprises the following steps: S100, obtaining contour data of the surface of a base material; s200, carrying out preprocessing on the obtained contour data; s300, the contour data obtained through scanning are leveled; s400, thickness compensation is conducted on the thickness data of the printing area, and compensation matrix data is generated; s500, performing thickness data compensation on the printing canvas to generate a new printing canvas; and S600, the printed sample is subjected to thickness scanning, contour form data of the surface of the sample are obtained, whether the flatness of the rubber surface is within the specification or not is judged, and if not, the step S400 is executed. According to the method, through active digital compensation based on accurate measurement, the influence of the base material morphology and the spraying hole difference can be fundamentally offset, and the accuracy of the product quality is improved. And the adhesive layer flatness which is difficult to achieve by a traditional method is achieved.

Description

Technical Field

[0001] This invention relates to the field of inkjet printing technology, and in particular to a method for smoothing inkjet printing adhesive layers based on contour iteration compensation. Background Technology

[0002] Inkjet printing technology, especially the printing of functional inks (such as conductive adhesives, insulating adhesives, and optical adhesives), has been widely used in high-end manufacturing fields such as microelectronic packaging, printed electronics, and biosensors. In these applications, the surface smoothness of the printed adhesive layer (or film) is a key indicator that directly affects the electrical performance, optical performance, and reliability of the product.

[0003] However, existing technologies struggle to achieve high-flatness adhesive layer printing, primarily due to two fundamental problems: ① Inherent inconsistencies in inkjet systems: Due to manufacturing tolerances, wear, or localized blockages, the individual nozzles in the printhead exhibit differences in droplet volume and flight direction. This results in the printed adhesive layer displaying fixed thickness streaks related to the nozzle location, even on an absolutely flat substrate, i.e., "uneven adhesive layer thickness."

[0004] ② Unevenness of the printing substrate surface: The substrates used in actual production (such as wafers, FPC flexible circuit boards, glass substrates, OLED / LCD display panels) may have global warping, local depressions or protrusions, and micro-roughness. Inkjet printing replicates this underlying morphology, resulting in an uneven surface of the printed adhesive layer, i.e., "substrate morphology reproduction".

[0005] Limitations of existing technology: ① Single nozzle calibration: The nozzle volume difference is calibrated by an ink droplet observer, but this only solves the first problem and cannot cope with changes in substrate morphology.

[0006] ② Passive process optimization: The current mainstream method is to "hope" that the ink will level itself by adjusting the ink formulation (such as adding leveling agents), increasing the number of printing passes (multi-pass), or heating the substrate. This method is passive, inefficient, and often ineffective for high-viscosity functional inks or complex morphologies.

[0007] ③ Lack of closed-loop feedback: Existing technology lacks the ability to quantitatively measure the finished product after printing and feed the data back to the printing system to guide the next printing, thus failing to achieve precise "targeted" compensation.

[0008] Therefore, there is an urgent need in this field for an innovative solution that can proactively, accurately, and adaptively compensate for both nozzle differences and substrate morphology to obtain an adhesive layer with ultra-high flatness. Summary of the Invention

[0009] The technical problem solved by this invention is to provide a method for smoothing inkjet printing adhesive layers based on contour iteration compensation that can fundamentally "counteract" the influence of substrate morphology and nozzle differences to achieve a smooth adhesive layer.

[0010] The technical solution adopted by this invention to solve its technical problem is: a method for smoothing inkjet printing adhesive layer based on contour iteration compensation, comprising the following steps: S100: Obtain the contour data of the substrate surface; S200: Preprocess the acquired contour data and proceed to step S300 or step S400; S300: Level the contour data obtained from the scan; S400: Performs thickness compensation on the thickness data of the printed area and generates compensation matrix data; S500: Compensates for the thickness data of the printed canvas, generates a new printed canvas, and prints a sample. S600: Perform a thickness scan on the printed sample to obtain the contour morphology data of the sample surface and determine whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, return to step S400.

[0011] Furthermore, in step S100, acquiring the contour data of the substrate surface specifically involves: scanning the surface of the substrate to be printed using a contact or non-contact thickness scanner to acquire high-precision two-dimensional or three-dimensional contour data, denoted as a matrix. .

[0012] Furthermore, in step S200, the acquired contour data is preprocessed, specifically by using Gaussian filtering or median filtering algorithms to eliminate random noise and high-frequency spikes introduced during the measurement process.

[0013] Furthermore, in step S300, the contour data obtained by scanning is leveled. Specifically, the inclined substrate surface data is fitted to an ideal plane using a plane fitting algorithm, and the inclined surface of the substrate is subtracted from the original data to obtain local undulation data after removing the global tilt. For special printing substrates with originally tilted surfaces, this step can be omitted.

[0014] Furthermore, the plane fitting algorithm is the least squares method.

[0015] Furthermore, in step S400, thickness compensation is performed on the thickness data of the printing area, and compensation matrix data is generated. In step S500, thickness compensation is performed on the printing canvas to generate a new printing canvas, and a sample is printed. Specifically, the compensated target printing canvas... From the original design canvas The compensation matrix data is obtained by subtracting the corrected substrate contour data: ; in, The compensation coefficient is settable, and the initial value of K is 1.

[0016] Furthermore, in step S600, the printed sample is thickness-scanned to obtain the contour morphology data of the sample surface. Specifically, the same or higher-precision thickness scanner used in step S100 is used to scan the surface of the cured adhesive layer to obtain the actual adhesive layer contour. .

[0017] Furthermore, in step S600, it is determined whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, the process returns to step S400, specifically: calculating the flatness index of the adhesive surface and determining whether it meets the preset specifications. If it does not meet the requirements, one of the following two compensation methods can be selected: ① Adjusting the compensation coefficient based on the surface data obtained in S100. ① Return to step S400 to generate a new printing canvas for reprinting; ② Use the adhesive surface data obtained in S600, and return to step S400 to generate new compensation matrix data. And adjust the compensation coefficient A new canvas is generated for reprinting.

[0018] The present invention also discloses a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the above-described method for smoothing inkjet printing adhesive layers based on contour iteration compensation.

[0019] The present invention also discloses a computer device, including a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other through the communication bus; wherein: The memory is used to store computer programs; The processor is configured to execute the steps of the above-described method for inkjet printing adhesive layer planarization based on contour iteration compensation by running a program stored in the memory.

[0020] The beneficial effects of this invention are: 1. Achieve ultra-high flatness: Through active, precise measurement-based digital compensation, the influence of substrate morphology and nozzle differences can be fundamentally "counteracted", achieving a level of adhesive layer flatness that is difficult to achieve with traditional methods: improving flatness from ±10μm to within ±2μm.

[0021] 2. Integrated solution: It innovatively unifies substrate morphology compensation and nozzle uniformity compensation in a single mathematical model, thus solving two core problems simultaneously.

[0022] 3. Intelligence and Adaptability: An "iterative feedback" mechanism has been introduced, which enables the system to learn and optimize itself, and can automatically adapt to different ink characteristics, printhead conditions and substrate types.

[0023] 4. Improved Yield and Reduced Costs: By precisely controlling ink deposition, the number of defective products due to poor flatness is reduced, thus improving production yield. At the same time, this solution lowers the stringent requirements for the initial flatness of the substrate, broadens the range of raw material choices, and reduces production costs.

[0024] 5. Digitalization and predictability: The entire process is highly digitalized, which makes the printing results "predictable and calculable", providing key technical support for realizing Industry 4.0 level intelligent manufacturing. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the surface contour acquisition in step S100 of this application embodiment.

[0026] Figure 2 This is a schematic diagram of the data preprocessing in step S200 of this application embodiment.

[0027] Figure 3 This is a schematic diagram of the contour leveling process in step S300 of this application embodiment.

[0028] Figure 4 This is a schematic diagram of the thickness compensation of the canvas in step S400 of the embodiments of this application.

[0029] Figure 5 This is a schematic diagram of the thickness scan of the printed sample in step S600 of this embodiment.

[0030] Figure 6 This is a flowchart illustrating the method for smoothing inkjet printing adhesive layers based on contour iteration compensation according to an embodiment of this application. Detailed Implementation

[0031] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0032] like Figure 6 As shown, embodiments of this application disclose a method for inkjet printing adhesive layer planarization based on contour iteration compensation, comprising the following steps: S100: Obtain the contour data of the substrate surface; S200: Preprocess the acquired contour data and proceed to step S300 or step S400; S300: Level the contour data obtained from the scan; S400: Performs thickness compensation on the thickness data of the printed area and generates compensation matrix data; S500: Compensates for the thickness data of the printed canvas, generates a new printed canvas, and prints a sample. S600: Perform a thickness scan on the printed sample to obtain the contour morphology data of the sample surface and determine whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, return to step S400.

[0033] It should be explained that since step S300 is not a necessary step, you can choose whether to perform step S300 or proceed directly to step S400.

[0034] The above-mentioned method, through proactive, precise measurement-based digital compensation, can fundamentally "counteract" the influence of substrate morphology and nozzle differences, achieving a smoothness of the adhesive layer that is difficult to achieve with traditional methods: improving the smoothness from ±10μm to within ±2μm. At the same time, this method innovatively unifies substrate morphology compensation and nozzle uniformity compensation in a single mathematical model, solving two core problems simultaneously. In addition, this method also introduces an "iterative feedback" mechanism, enabling the system to learn and optimize itself, and automatically adapt to different ink characteristics, printhead conditions, and substrate types.

[0035] In this embodiment, as Figure 1 As shown, in step S100, obtaining the contour data of the substrate surface specifically involves: scanning the surface of the substrate to be printed using a contact or non-contact thickness scanner to obtain high-precision two-dimensional or three-dimensional contour data, denoted as a matrix. .

[0036] Specifically, the non-contact thickness scanner can be a laser confocal microscope, a white light interferometer, or a spectral confocal sensor, while the contact thickness gauge can be a high-precision column-type thickness gauge or a probe profilometer. Before scanning, the substrate needs to be pre-treated to remove dust, oil, and other impurities attached to the surface to avoid interference with the acquisition of contour data, thereby obtaining real, high-precision three-dimensional contour data.

[0037] In this embodiment, as Figure 2 As shown, in step S200, the acquired contour data is preprocessed, specifically by using Gaussian filtering or median filtering algorithms to eliminate random noise and high-frequency spikes introduced during the measurement process.

[0038] Specifically, the purpose of this step is to purify the original contour data, providing reliable input for subsequent leveling and compensation. Gaussian filtering, through weighted averaging, can effectively smooth high-frequency noise while preserving the overall trend of the contour. Median filtering has a stronger suppression effect on isolated outliers (such as burrs). Appropriate filtering algorithms and parameters can be selected according to the actual noise characteristics of the substrate surface. The signal-to-noise ratio of the preprocessed contour data is significantly improved, laying the foundation for subsequent accurate leveling.

[0039] In this embodiment, step S300 involves leveling the contour data obtained from the scan. Specifically, this involves fitting the tilted substrate surface data to an ideal plane using a plane fitting algorithm, and subtracting the tilted surface of the substrate from the original data to obtain local undulation data after removing the global tilt. .

[0040] Specifically, the plane fitting algorithm is the least squares method.

[0041] Specifically, the core of this step lies in eliminating the interference of the global tilt of the substrate caused by its placement or inherent characteristics on subsequent compensation calculations. The plane fitting algorithm uses the least squares method, which determines an optimal ideal plane equation by minimizing the sum of squared distances from the actual data points to the fitting plane.

[0042] In this embodiment, in step S400, thickness compensation is performed on the thickness data of the printing area, and compensation matrix data is generated. In step S500, thickness compensation is performed on the printing canvas to generate a new printing canvas, and a sample is printed. Specifically, the compensated target printing canvas... From the original design canvas The compensation matrix data is obtained by subtracting the corrected substrate contour data: ; in, It is a settable compensation coefficient, whose value can be positive, negative, or zero, used to precisely control the "strength" of compensation.

[0043] The initial value of K is 1.

[0044] Specifically, in the recessed areas of the substrate ( (If negative), this algorithm will increase the ink volume at that location (improving) ), to fill the depressions; in the raised areas ( If the value is positive, then reduce the amount of ink at that location (reduce the ink level). This achieves "digital leveling." Essentially, it involves performing a "reverse operation" on the substrate morphology in the digital world before printing.

[0045] In this embodiment, in step S600, the printed sample is thickness scanned to obtain the contour data of the sample surface, and it is determined whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, the process returns to step S400, which specifically involves using the same or higher precision thickness scanner as in step S100 to scan the surface of the cured adhesive layer to obtain the actual adhesive layer contour. Next, calculate the surface smoothness index of the adhesive layer to determine whether it meets the preset specifications. If it does not meet the specifications, choose one of the following two compensation methods: ① Adjust the compensation coefficient based on the surface data obtained from S100. ① Return to step S400 to generate a new printing canvas for reprinting; ② Use the adhesive surface data obtained in S600, and return to step S400 to generate new compensation matrix data. And adjust the compensation coefficient A new canvas is generated for reprinting.

[0046] Specifically, the flatness index of the adhesive layer surface can be calculated based on the global thickness range. Root mean square roughness Wait, then determine if the preset specifications are met. If not, ① adjust the compensation coefficient. For example, if there is still a depression, then increase the size. The value is adjusted to increase ink volume compensation in recessed areas; if a raised area appears, the value is decreased. ① Reduce ink output in raised areas; ② Obtain a new compensation data matrix based on the scanned surface. In conjunction with a new compensation coefficient K, the compensation accuracy is iteratively optimized through this dynamic adjustment.

[0047] For example: If the actual measured thickness of a film layer at a certain point I(x, y) is 30um, then ΔH = -20um. According to the formula Idesign = 50 + 1 * 20 = 70um, the initial set printing thickness for I(x, y) is 70um. When a new canvas is generated, the thickness at that point is set to 70um, and the thickness is measured again. If the thickness meets the requirements, no further compensation is needed. If it does not meet the requirements (assuming the actual measured thickness after adjustment is 60um), the thickness at that point is compensated again. There are two iterative compensation schemes (i.e., the two compensation schemes mentioned above): Compensation Method 1: Adjusting the Compensation Coefficient =0.67, ΔH remains unchanged at -20um, Idesign = 50+0.67*20=63.4um, that is, the printing thickness is set again to 63.4um; Compensation Method 2: Based on the results of the second scan, calculate ΔH' = 10µm and adjust the compensation coefficient accordingly. = -0.33, Idesign = 60 + 0.33*10 = 63.3um.

[0048] The two compensation methods yielded the same result.

[0049] In summary, the significance of the compensation coefficient K lies in controlling the intensity of compensation and preventing the compensation effect from being too strong or too weak.

[0050] It should be explained that the preset specifications have different requirements for different application scenarios. For example, for mobile phone cover plates, the adhesive layer thickness is 100um, and the thickness specification is 100±5um, that is, the global thickness range (the difference between the maximum and minimum thickness of the adhesive layer) Rr≤10um; for VR displays or perovskite printing, the specification requirement for a 25um film layer thickness is a mean square roughness Rq≤2.0um. Therefore, the preset specifications mentioned above need to be set according to the specific application scenario.

[0051] The present invention also discloses a computer-readable storage medium storing a computer program, which, when executed by a processor, implements the steps of the above-described method for smoothing inkjet printing adhesive layers based on contour iteration compensation.

[0052] The present invention also discloses a computer device, including a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other through the communication bus; wherein: The memory is used to store computer programs; The processor is configured to execute the steps of the above-described method for inkjet printing adhesive layer planarization based on contour iteration compensation by running a program stored in the memory.

[0053] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for smoothing inkjet printing adhesive layers based on contour iteration compensation, characterized in that, Includes the following steps: S100: Obtain the contour data of the substrate surface; S200: Preprocess the acquired contour data and proceed to step S300 or step S400; S300: Level the contour data obtained from the scan; S400: Performs thickness compensation on the thickness data of the printed area and generates compensation matrix data; S500: Compensates for the thickness data of the printed canvas, generates a new printed canvas, and prints a sample. S600: Perform a thickness scan on the printed sample to obtain the contour morphology data of the sample surface and determine whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, return to step S400.

2. The method for inkjet printing adhesive layer planarization based on contour iteration compensation as described in claim 1, characterized in that, In step S100, acquiring the contour data of the substrate surface specifically involves: scanning the surface of the substrate to be printed using a contact or non-contact thickness scanner to acquire high-precision two-dimensional or three-dimensional contour data, denoted as a matrix. .

3. The method for smoothing inkjet printing adhesive layer based on contour iteration compensation as described in claim 2, characterized in that, In step S200, the acquired contour data is preprocessed, specifically by using Gaussian filtering or median filtering algorithms to eliminate random noise and high-frequency spikes introduced during the measurement process.

4. The method for smoothing inkjet printing adhesive layer based on contour iteration compensation as described in claim 3, characterized in that, In step S300, the contour data obtained by scanning is leveled. Specifically, the inclined substrate surface data is fitted to an ideal plane using a plane fitting algorithm, and the inclined surface of the substrate is subtracted from the original data to obtain local undulation data after removing the global tilt. .

5. The method for inkjet printing adhesive layer planarization based on contour iteration compensation as described in claim 4, characterized in that, The plane fitting algorithm is the least squares method.

6. The method for smoothing inkjet printing adhesive layer based on contour iteration compensation as described in claim 4, characterized in that, In step S400, thickness compensation is performed on the thickness data of the printing area, and compensation matrix data is generated. In step S500, thickness compensation is performed on the printing canvas to generate a new printing canvas, and a sample is printed. Specifically, the compensated target printing canvas... From the original design canvas The compensation matrix data is obtained by subtracting the corrected substrate contour data: ; in, The compensation coefficient is settable, and the initial value of K is 1.

7. The method for smoothing inkjet printing adhesive layer based on contour iteration compensation as described in claim 4, characterized in that, In step S600, the printed sample is thickness scanned to obtain the contour morphology data of the sample surface. Specifically, the same or higher precision thickness scanner used in step S100 is used to scan the surface of the cured adhesive layer to obtain the actual adhesive layer contour. .

8. The method for inkjet printing adhesive layer planarization based on contour iteration compensation as described in claim 7, characterized in that, In step S600, it is determined whether the flatness of the adhesive surface meets the specifications. If it does not meet the requirements, the process returns to step S400, which specifically involves calculating the flatness index of the adhesive surface and determining whether it meets the preset specifications. If it does not meet the requirements, one of the following two compensation methods can be selected: ① Adjust the compensation coefficient based on the surface data obtained in S100. ① Return to step S400 to generate a new printing canvas for reprinting; ② Use the adhesive surface data obtained in S600, and return to step S400 to generate new compensation matrix data. And adjust the compensation coefficient A new canvas is generated for reprinting.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores a computer program that, when executed by a processor, implements the steps of the method for inkjet printing adhesive layer planarization based on contour iteration compensation as described in any one of claims 1 to 8.

10. A computer device, characterized in that, It includes a processor, a communication interface, a memory, and a communication bus, wherein the processor, the communication interface, and the memory communicate with each other through the communication bus; wherein: The memory is used to store computer programs; The processor is configured to execute the steps of the method for contour-iterative compensation-based inkjet printing adhesive layer planarization according to any one of claims 1 to 8 by running a program stored in the memory.

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