Liquid discharge device, method for manufacturing organic light-emitting device, and method for operating head

Abstract

To provide a technique advantageous for reducing positional deviation of a head which can be generated by moving a head including a discharge part for discharging liquid.SOLUTION: A liquid discharge device includes a lifting mechanism for lifting a support part for supporting a carriage holding a head for discharging liquid between a first height and a second height lower than the first height, a holding part for holding the carriage when the support part is positioned at the second height, and a positioning mechanism for positioning the carriage when the support part is positioned at the second height, wherein the holding part receives the carriage from the support part while the support part is lowered to the second height from the first height, and the support part receives the carriage from the holding part while the support part is raised to the first height from the second height.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a liquid ejection device, a method for manufacturing an organic light-emitting device, and a method for operating a head. [Background technology]

[0002] In recent years, attempts have been made to form patterns using inkjet devices in the manufacture of various functional elements. The technology of forming patterns using inkjet devices has the advantages of high material usage efficiency and being a non-vacuum process, which is advantageous for miniaturizing the manufacturing equipment. In recent years, the development of organic light-emitting devices (OLED devices) using organic electroluminescence (EL) elements has been actively promoted. As organic EL materials are expensive, the use of inkjet devices, which have excellent material usage efficiency, is expected.

[0003] As device production continues, the surface condition of the inkjet head (hereinafter, head) changes, and maintenance may be performed to return the surface condition to its original state. Head maintenance may be performed at a maintenance position different from the coating position. However, if the head is moved to the maintenance position, maintenance is performed, and then the head is returned to the coating position, misalignment of the head may occur. Also, if the head is moved from the coating position to another position for a purpose other than maintenance, and then returned to the coating position, misalignment of the head may occur.

[0004] Although not directly related to the present invention, Patent Document 1 describes an image forming apparatus having a lifting mechanism that raises and lowers a base member on which a plurality of recording heads that eject droplets are mounted. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2010-30270 A Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention provides an advantageous technique for reducing misalignment of a head that may occur when a head including an ejection unit that ejects liquid is moved. [Means for solving the problem]

[0007] One aspect of the present invention relates to a liquid ejection device comprising: a lifting mechanism that raises and lowers a support part that supports a carriage holding a head that ejects liquid, between a first height and a second height lower than the first height; a holding part that holds the carriage when the support part is located at the second height; and a positioning mechanism that positions the carriage when the support part is located at the second height, wherein the holding part receives the carriage from the support part while the support part descends from the first height to the second height, and the support part receives the carriage from the holding part while the support part rises from the second height to the first height. Effect of the Invention

[0008] According to the present invention, there is provided an advantageous technique for reducing misalignment of a head that may occur due to movement of a head including an ejection portion that ejects liquid. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view showing a configuration of a liquid ejection device according to a first embodiment. [Diagram 2] 5A to 5C are cross-sectional views each showing a schematic operation of the liquid ejection device according to the first embodiment. [Diagram 3] FIG. 2 is a cross-sectional view showing a first state of the liquid ejection device according to the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing a second state of the liquid ejection device according to the first embodiment. [Diagram 5] FIG. 4 is a top view showing a second state of the liquid ejection device according to the first embodiment. [Figure 6]3A and 3B are a top view and a front view showing one configuration example of a pressing mechanism of the liquid ejection device of the first embodiment. [Figure 7] FIG. 4 is a top view showing another example of the configuration of the pressing mechanism of the liquid ejection device according to the first embodiment. [Figure 8] FIG. 13 is a perspective view showing a first configuration example of a kinematic coupling that constitutes a positioning mechanism in a second embodiment. [Figure 9] FIG. 13 is a perspective view showing a second configuration example of a kinematic coupling that constitutes the positioning mechanism in the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] Hereinafter, the embodiments will be described in detail with reference to the accompanying drawings. Note that the following embodiments do not limit the invention according to the claims, and not all combinations of features described in the embodiments are essential to the invention. Two or more features among the multiple features described in the embodiments may be arbitrarily combined. Also, the same reference numbers are used for the same or similar configurations, and duplicated descriptions are omitted.

[0011] In this specification and the accompanying drawings, directions are described according to an XYZ coordinate system. In the XYZ coordinate system, the XY plane is a horizontal plane and the Z axis is parallel to the vertical direction. The position in the Z axis direction is also expressed as height.

[0012] 1, 2, 3, 4, and 5 show the configuration of a liquid ejection device 50 according to a first embodiment. First, the configuration of the liquid ejection device 50 will be exemplarily described with reference mainly to FIG. 1 and FIG. 2. The liquid ejection device 50 may be understood as an inkjet printer that ejects ink as a liquid. The liquid or ink can be selected from any substance that can be ejected. The liquid or ink can be, for example, an organic light-emitting material, but may also be other materials (for example, a pigment, a curable composition). The organic light-emitting material can be, for example, a solution containing a solute and a solvent for forming an organic film.

[0013] The liquid ejection device 50 may include a carriage 5 that holds one or more heads 1 that eject liquid. In the following, when the term "head 1" is used, it means one or more heads 1 unless the context is inconsistent. The liquid ejection device 50 may include a lifting mechanism 30 that raises and lowers a support unit 3 that supports the carriage 5 between a first height H1 and a second height H2. The lifting mechanism 30 may be supported by a main body frame 2. The second height H2 is lower than the first height H1. The liquid ejection device 50 may include a holder 6 that holds the carriage 5 when the support unit 3 is located at the second height H2. The holder 6 may hold the carriage 5 from below, for example. For convenience of explanation, FIG. 2 shows the support unit 3 located at the first height H1 and the carriage 5 supported by the support unit 3, as well as the support unit 3 located at the second height H2 and the carriage 5 held by the holder 6. In one example, the height of the support portion 3 may refer to the height of the surface of the support portion 3 that supports the carriage 5 .

[0014] When the support part 3 is located at the first height H1, the bottom end of the head 1 coincides with the first surface A. In this state, for example, maintenance of the head 1 can be performed, and this state is referred to as the first state. When the support part 3 is located at the second height H2 and the carriage 5 is held by the holder 6, the bottom end of the head 1 coincides with the second surface B. In this state, liquid can be ejected from the head 1, and this state is referred to as the second state. It may be understood that the head 1 held by the carriage 5 is raised and lowered between the first surface A and the second surface B by the lifting mechanism 30.

[0015] The liquid ejection device 50 may include a positioning mechanism 40 that positions the carriage 5 when the support unit 3 is located at the second height H2. The head 1 may be positioned by positioning the carriage 5 with the positioning mechanism 40. The holder 6 receives the carriage 5 from the support unit 3 while the support unit 3 is descending from the first height H1 to the second height H2. The holder 6 receives the carriage 5 from the holder 6 while the support unit 3 is ascending from the second height H2 to the first height H1.

[0016] The lifting mechanism 30 includes a drive mechanism that drives the carriage 5 (and the head 1 held by the carriage 5). The drive mechanism may include, for example, a ball screw 7 and a motor (rotary motor) 4. Alternatively, the drive mechanism may include a linear motor. The lifting mechanism 30 may rotate the screw shaft of the ball screw 7 by operating the motor 4 based on a command from a control unit (not shown), thereby lifting and lowering the support unit 3 fixed to the nut of the ball screw 7. The lifting mechanism 30 may include a position sensor that detects the position of the nut or the support unit 3, and may feedback-control the position of the support unit 3 based on the output of the position sensor. The lifting mechanism 30 may include multiple drive mechanisms. In the example of FIGS. 1 to 5, two support units 3 support the carriage 5 at its longitudinal ends, and the lifting mechanism 30 includes two drive mechanisms to drive the two support units 3, respectively.

[0017] FIG. 3 shows the liquid ejection device 50 in a first state. FIG. 4 shows the liquid ejection device 50 in a second state. The support unit 3 can support (restrain) the carriage 5 by frictional force. The support unit 3 can be connected to a movable part (e.g., a nut of the ball screw 7) of the lifting mechanism 30 (drive mechanism) via a buffer mechanism such as an elastic hinge. This is advantageous for reducing or preventing damage to the lifting mechanism 30 due to over-restraint. In addition, a stopper that restricts the movable range of the carriage 5 can be provided on the support unit 3 to prevent the carriage 5 supported by the support unit 3 from falling when an external force is applied to the carriage 5 due to an earthquake or the like. The liquid ejection device 50 can include a maintenance unit M that performs maintenance on the head 1 when the support unit 3 is located at the first height H1 and the carriage 5 is supported by the support unit 3.

[0018] During the transition from the first state (i.e., a state in which the support portion 3 is located at a first height H1) shown in FIG. 3 to the second state (i.e., a state in which the support portion 3 is located at a second height H2), the holder 6 receives the carriage 5 from the support portion 3. The carriage 5 can be held by the holder 6 in a form in which it sits on the holder 6. In the second state, the stopping accuracy of the carriage 5 can be suppressed to the natural vibration level of the structure consisting of the main body frame 2 and the carriage 5. The liquid ejection device 50 further includes a stage mechanism ST that moves the processing object (e.g., a substrate) S, and the head 1 can operate to eject liquid onto the processing object S while the carriage 5 is held by the holder 6.

[0019] 5 shows a top view of the liquid ejection device 50 in the second state. When the carriage 5 moves from the first state, in which liquid can be ejected from the ejection portion of the head 1 held by the carriage 5, to the second state for maintenance or the like, and then returns to the first state, the carriage 5 (head 1) may become displaced from its previous position. The positioning mechanism 40 is useful for reducing such positional deviations or for positioning the carriage 5 (head 1) at a target position (normal position). FIGS. 5 and 6 show examples of the configuration of the positioning mechanism 40.

[0020] The holding unit 6 may be configured to be able to hold the carriage 5 via air. When the carriage 5 is positioned by the positioning mechanism 40, the holding unit 6 may hold the carriage 5 via air. This allows the force required by the positioning mechanism 40 to move the carriage 5 to be reduced. After the carriage 5 is positioned by the positioning mechanism 40, the holding unit 6 may hold the carriage 5 without using air. The holding unit 6 may have a holding surface 61 that holds the held surface 51 of the carriage 5. When the carriage 5 is positioned by the positioning mechanism 40, the holding unit 6 may supply air to a space between the held surface 51 and the holding surface 61, and after the carriage 5 is positioned, the holding unit 6 may operate not to supply air to the space between the held surface 51 and the holding surface 61.

[0021] 5, the positioning mechanism 40 may include one or more pressing mechanisms 8 (8a, 8b, 8c, 8d) that apply a pressing force to the carriage 5 to position the carriage 5. The positioning mechanism 40 may include, for example, at least four pressing mechanisms 8 (8a, 8b, 8c, 8d). The two pressing mechanisms 8a and 8b may be arranged to press a first surface 55 of the carriage 5, and the two pressing mechanisms 8c and 8d may be arranged to press a second surface 56 of the carriage 5 (the surface opposite to the first surface 55).

[0022] 6(a) and 6(b) show a top view and a front view of the pressing mechanism 8 of one configuration example. The pressing mechanism 8 can be configured to press the carriage 5 with a pressing member 12. The pressing member 12 can be, for example, a roller. Configuring the pressing member 12 with a roller is advantageous for reducing friction between the carriage 5 and the pressing member 12 and improving positioning accuracy. The pressing mechanism 8 can include a slide mechanism 13 that allows the pressing member 12 to descend together with the carriage 5 in a state in which the carriage 5 is positioned. The slide mechanism 13 is advantageous for reducing friction between the carriage 5 and the pressing member 12 and improving positioning accuracy. The pressing mechanism 8 can include an actuator 10 that drives the pressing member 12.

[0023] A procedure for positioning the carriage 5 by the positioning mechanism 40 will be described by way of example with reference to Fig. 5. First, the pressing mechanisms 8a and 8b are operated to form a reference surface for positioning the first side surface 55 of the carriage 5 with their pressing members 12. Thereafter, the pressing mechanisms 8c and 8d are operated to press their pressing members 12 against the second side surface 56 of the carriage 5. As a result, the pressing members 12 are pressed against the carriage 5 by all of the pressing mechanisms 8a, 8b and 8c, 8d, and the carriage 5 is positioned.

[0024] All of the portions of the side surface of the carriage 5 that are pressed by the pressing members 12 of the pressing mechanisms 8a, 8b, 8c, and 8d may be flat. Alternatively, three of the portions of the side surface of the carriage 5 that are pressed by the pressing members 12 of the pressing mechanisms 8a, 8b, 8c, and 8d may be flat, and the remaining portion may be a V-shaped groove, as illustrated in Fig. 7. By pressing the four portions of the side surface of the carriage 5 with the pressing mechanisms 8a, 8b, 8c, and 8d, the carriage 5 can be positioned in the horizontal direction (X-axis direction, Y-axis direction) and with respect to rotation around the vertical direction (Z-axis).

[0025] As described above, by positioning the carriage 5 by the positioning mechanism 40 while the carriage 5 is held by the holding unit 6, it is possible to cancel any misalignment of the carriage 5 that occurs when the carriage 5 is raised and lowered by the lifting mechanism 30. Furthermore, when the carriage 5 is raised by the lifting mechanism 30, the support unit 3 receives the carriage 5, which has already been positioned by the positioning mechanism 40, from the holding unit 6, so that the head 1 is moved to the first surface A with guaranteed positional accuracy. Therefore, maintenance of the head 1 (for example, checking the state and restoring the state) can be performed with guaranteed positional accuracy.

[0026] The above embodiment relating to the operation of the liquid ejection device 50 has an aspect as an operation method for operating the carriage 5 holding the head 1 that ejects liquid. The operation method can include a step of lowering the support part 3 supporting the carriage 5 from a first height H1 to a second height H2, a step of the holder 6 receiving and holding the carriage 5 from the support part 3 while the carriage 5 is lowered from the first height H1 to the second height H2, a step of positioning the carriage 5 when the support part 3 is located at the second height H2, and a step of the support part 3 receiving the carriage 5 from the holder 6 while the support part 3 is raised from the second height H2 to the first height H1.

[0027] A liquid ejection device 50 according to a second embodiment will be described below. Matters not mentioned in the second embodiment may follow those of the first embodiment. In the second embodiment, the positioning mechanism 40 in the liquid ejection device 50 according to the first embodiment is configured using a kinematic coupling.

[0028] 8 shows a first configuration example of the kinematic coupling constituting the positioning mechanism 40 in the second embodiment. The kinematic coupling constrains six degrees of freedom between two rigid bodies. In the first configuration example, six degrees of freedom constraint is realized by one degree of freedom constraint between the sphere 100 and a flat surface 101, two degrees of freedom constraint between the sphere 100 and a V-shaped surface 102, and three degrees of freedom constraint between the sphere 100 and a conical surface 103.

[0029] 9 shows a second configuration example of the kinematic coupling constituting the positioning mechanism 40 in the second embodiment. In the second configuration example, six degrees of freedom constraint is realized by arranging two degrees of freedom constraints by the spheres 100 and the V-surfaces 102 at three locations.

[0030] Hereinafter, a manufacturing method for manufacturing an organic light-emitting device using the above-mentioned liquid ejection device 50 will be exemplified. The manufacturing method may include a coating step of coating an organic light-emitting material at multiple locations on a processing object (e.g., a substrate) by the liquid ejection device 50, and a processing step of processing the processing object to obtain an organic light-emitting device. The manufacturing method may further include a drying step of drying the organic light-emitting material coated at the multiple locations on the processing object in the coating step, and a baking step of baking the organic light-emitting material that has been through the drying step. In this case, in the processing step, the processing object that has been through the baking step is processed. The organic light-emitting material may be, for example, a solution containing a solute and a solvent for forming an organic film. The organic film may be, for example, any one of a hole injection layer, a hole transport layer, a light-emitting layer, an electron transport layer, and an electron injection layer of an organic EL (OLED) element. The manufacturing method for an organic EL element may include a step of forming each organic film, such as a hole injection layer, a hole transport layer, a light-emitting layer, an electron transport layer, and an electron injection layer, on a substrate. (Item 1) a lifting mechanism that lifts and lowers a support unit that supports a carriage that holds a head that ejects liquid between a first height and a second height that is lower than the first height; a holder that holds the carriage when the support portion is located at the second height; a positioning mechanism that positions the carriage when the support portion is located at the second height, the holding portion receives the carriage from the support portion while the support portion is descending from the first height to the second height, and the support portion receives the carriage from the holding portion while the support portion is ascending from the second height to the first height. A liquid ejection device comprising: (Item 2) The holding portion is capable of holding the carriage via air. 2. The liquid ejection device according to item 1, (Item 3) the holding portion holds the carriage via air when the carriage is positioned by the positioning mechanism. 3. The liquid ejection device according to item 2, (Item 4) the holding portion holds the carriage without air after the carriage has been positioned by the positioning mechanism; 4. The liquid ejection device according to item 3, (Item 5) the holding portion has a holding surface that holds a held surface of the carriage, the holding portion supplies air to a space between the held surface and the holding surface when the carriage is positioned by the positioning mechanism; the holding portion does not supply air to the space after the carriage is positioned by the positioning mechanism. 3. The liquid ejection device according to item 2, (Item 6) the positioning mechanism includes a pressing mechanism that positions the carriage by applying a pressing force to the carriage; 4. The liquid ejection device according to item 3, (Item 7) The pressing mechanism presses the carriage with a pressing member. 7. The liquid ejection device according to item 6, (Item 8) the positioning mechanism includes a slide mechanism that enables the pressing member to move down together with the carriage while the carriage is positioned; 8. The liquid ejection device according to item 7, (Item 9) the positioning mechanism includes a plurality of pressing mechanisms that apply a pressing force to the carriage to position the carriage; 2. The liquid ejection device according to item 1, (Item 10) The plurality of pressing mechanisms is at least four pressing mechanisms. 10. The liquid ejection device according to item 9, (Item 11) The at least four pressing mechanisms press the carriage with a pressing member. 11. The liquid ejection device according to item 10. (Item 12) The positioning mechanism includes a kinematic coupling. 2. The liquid ejection device according to item 1, (Item 13) the positioning mechanism positions the carriage in a horizontal direction; 13. The liquid ejection device according to any one of items 1 to 12. (Item 14) the positioning mechanism positions the head with respect to rotation about a horizontal and vertical direction; 13. The liquid ejection device according to any one of items 1 to 12. (Item 15) Further comprising a stage mechanism for moving the processing object, the head ejects liquid onto the processing object while the carriage is held by the holding portion; 2. The liquid ejection device according to item 1, (Item 16) a maintenance unit configured to perform maintenance on the head while the support unit is positioned at the first height and the carriage is supported by the support unit, 2. The liquid ejection device according to item 1, (Item 17) The liquid includes an organic light-emitting material. Item 16. The liquid ejection device according to item 15. (Item 18) A coating process in which an organic light-emitting material is applied to a plurality of locations on a processing object by the liquid ejection device according to item 17; a processing step of processing the processing object to obtain an organic light-emitting device; A method for manufacturing an organic light-emitting device comprising the steps of: (Item 19) a drying step of drying the organic light-emitting material applied to the plurality of locations of the processing object in the application step; and a baking step of baking the organic light-emitting material that has been subjected to the drying step, In the treatment step, the treatment object that has undergone the firing step is treated. Item 19. The method for producing the present invention according to item 18. (Item 20) A method for operating a carriage that holds a head that ejects liquid, comprising the steps of: lowering a support portion that supports the carriage from a first height to a second height that is lower than the first height; a holding portion receiving and holding the carriage from the support portion while descending from the first height to the second height; positioning the carriage when the support is at the second height; receiving the carriage from the holder by the support while the support is elevated from the second height to the first height; A method of operation comprising:

[0031] The invention is not limited to the above-described embodiment, and various modifications and variations are possible within the scope of the gist of the invention. [Explanation of symbols]

[0032] 1: head, 5: carriage, 30: lift mechanism, 40: positioning mechanism, 50: liquid ejection device, H1: first height, H2: second height

Claims

1. a lifting mechanism that lifts and lowers a support part that supports a carriage that holds a head that ejects liquid between a first height and a second height that is lower than the first height; a holding portion that holds the carriage when the support portion is located at the second height; a positioning mechanism that positions the carriage when the support portion is located at the second height, the holding portion receives the carriage from the support portion while the support portion is descending from the first height to the second height, and the support portion receives the carriage from the holding portion while the support portion is rising from the second height to the first height; A liquid ejection device comprising:

2. The holding portion is capable of holding the carriage via air. The liquid ejection device according to claim 1 .

3. the holding portion holds the carriage via air when the carriage is positioned by the positioning mechanism. The liquid ejection device according to claim 2 .

4. the holding portion holds the carriage without air after the carriage has been positioned by the positioning mechanism; 4. The liquid ejection device according to claim 3.

5. the holding portion has a holding surface that holds a held surface of the carriage, the holding portion supplies air to a space between the held surface and the holding surface when the carriage is positioned by the positioning mechanism; the holding portion does not supply air to the space after the carriage is positioned by the positioning mechanism. The liquid ejection device according to claim 2 .

6. the positioning mechanism includes a pressing mechanism that positions the carriage by applying a pressing force to the carriage; 4. The liquid ejection device according to claim 3.

7. The pressing mechanism presses the carriage with a pressing member.

7. The liquid ejection device according to claim 6.

8. the positioning mechanism includes a slide mechanism that enables the pressing member to move down together with the carriage while the carriage is positioned; 8. The liquid ejection device according to claim 7.

9. the positioning mechanism includes a plurality of pressing mechanisms that apply a pressing force to the carriage to position the carriage; The liquid ejection device according to claim 1 .

10. The plurality of pressing mechanisms is at least four pressing mechanisms. The liquid ejection device according to claim 9 .

11. The at least four pressing mechanisms press the carriage with pressing members. The liquid ejection device according to claim 10 .

12. The positioning mechanism includes a kinematic coupling. The liquid ejection device according to claim 1 .

13. the positioning mechanism positions the carriage in a horizontal direction; The liquid ejection device according to any one of claims 1 to 12.

14. the positioning mechanism positions the head with respect to rotation about a horizontal and vertical direction; The liquid ejection device according to any one of claims 1 to 12.

15. Further comprising a stage mechanism for moving the processing object, the head ejects liquid onto the processing object while the carriage is held by the holding portion; The liquid ejection device according to claim 1 .

16. a maintenance unit configured to perform maintenance on the head while the support unit is positioned at the first height and the carriage is supported by the support unit, The liquid ejection device according to claim 1 .

17. The liquid includes an organic light-emitting material. The liquid ejection device according to claim 15 .

18. a coating step of coating an organic light-emitting material at a plurality of locations on a processing object by the liquid ejection device according to claim 17; a processing step of processing the processing object to obtain an organic light-emitting device; A method for manufacturing an organic light-emitting device comprising the steps of:

19. a drying step of drying the organic light-emitting material applied to the plurality of locations of the processing object in the application step; and a baking step of baking the organic light-emitting material that has been subjected to the drying step, In the treatment step, the treatment object that has undergone the firing step is treated. The method of claim 18.

20. A method for operating a carriage that holds a head that ejects liquid, comprising the steps of: lowering a support portion that supports the carriage from a first height to a second height that is lower than the first height; a holding portion receiving and holding the carriage from the support portion while the carriage is lowered from the first height to the second height; positioning the carriage when the support is at the second elevation; receiving the carriage from the retainer by the support while the support is elevated from the second height to the first height; A method of operation comprising:

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