Carrier Liquid Drop Patterning for High Viscosity Inkjet Printing
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Solution Overview
Problem
Current printing technologies face challenges in patterned deposition of complex liquids with high viscosities and the need for digital control in manufacturing applications, as existing inkjet systems struggle to eject such liquids effectively, and contact printing methods lack digital control and flexibility.
Innovation Solution
A liquid dispenser array that uses a carrier liquid to transport discrete drops of a functional liquid to a receiver, with a drop formation device actuated to form and control the size of the functional liquid drops, allowing for precise and patterned deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal ink jet technology is used to eject liquid, then digital control and non-impact printing are achieved, but high viscosity complex liquids cannot be effectively ejected
Solution Approach 1:
The patent introduces a carrier liquid as an intermediary substance that mixes with the complex functional liquid to form a jettable mixture. The carrier liquid has properties optimized for inkjet ejection (lower viscosity, suitable surface tension), while the functional liquid provides the desired functionality. This intermediary approach allows digital inkjet printing to handle high viscosity liquids that would otherwise be impossible to eject.
Solution Approach 2:
The patent changes the physical parameters of the liquid by mixing the functional liquid with a carrier liquid in specific ratios. This modification alters the viscosity, surface tension, and other flow properties to make the mixture compatible with thermal ink jet ejection parameters, enabling reliable drop formation and ejection of materials that in their pure form would be too viscous.
2Productivity
If contact printing methods are used to deposit complex liquids, then high throughput and reliability are achieved, but digital control and pattern flexibility are lost
Solution Approach 1:
The patent segments the continuous liquid stream into discrete digital drops using thermal ink jet technology. Each drop can be independently controlled in terms of formation, ejection timing, and placement location. This segmentation enables digital pattern control and on-the-fly design changes while maintaining the high throughput capability of contact-like deposition speeds.
Solution Approach 2:
The patent performs preliminary mixing of the functional liquid with the carrier liquid before ejection, creating a pre-formulated jettable mixture. This preliminary preparation allows the system to maintain high ejection speeds and throughput while the digital control system can still dynamically adjust patterns without changing physical masks or screens.
3Reliability
If continuous ink jet is used to encapsulate high viscosity liquid, then ejection of difficult liquids is enabled, but selective injection at needed locations is not achieved
Solution Approach 1:
The patent transitions from a static continuous ink jet system to a dynamic drop-on-demand system where drops are formed and ejected only when and where needed. The thermal actuator dynamically controls the formation and ejection of each drop based on digital input, enabling selective deposition at specific locations while maintaining the ability to handle high viscosity liquids through the carrier liquid mixture.
Solution Approach 2:
The patent replaces the mechanical continuous jet system with a thermal field-based drop-on-demand system. Instead of using mechanical pressure to create a continuous stream that is then selectively deflected, the system uses thermal energy to locally generate vapor bubbles that eject drops only at activated nozzle locations, enabling precise digital control while handling viscous materials.
4Ease of operation
If thermal actuation is used to eject ink drops, then digital control is achieved, but excessive heat and clogging occur with complex liquids
Solution Approach 1:
The patent modifies the liquid parameters by adding a carrier liquid that has thermal and flow properties better suited for inkjet ejection. This mixture reduces the overall viscosity and adjusts the surface tension to match optimal ranges for thermal ink jet operation, preventing clogging and reducing the heat energy required for drop formation and ejection.
Solution Approach 2:
The carrier liquid acts as a protective intermediary between the thermal actuator and the complex functional liquid. It absorbs and distributes the thermal energy more effectively, preventing localized overheating that would cause clogging of the nozzle. The carrier liquid also prevents the functional liquid from directly contacting and potentially clogging the nozzle interior.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient and precise deposition of complex liquids with high viscosities, combining the digital control of inkjet printing with the high throughput and reliability of contact printing methods, while preventing excessive heat and clogging.
Implementation Method 1
A drop formation device causes a meniscus of the functional liquid breaks into drops of the functional liquid in a controlled manner
Implementation Method 2
The carrier liquid transports the discrete drops of the functional liquid to a transfer location
Data Source
AI summary
A liquid dispenser array structure includes a liquid dispensing channel. A first liquid supply provides a carrier liquid that flows continuously through an outlet of the liquid dispensing channel during a drop dispensing operation. A plurality of liquid dispensers, located on a common substrate, includes a liquid supply channel and a second liquid supply that provides a functional liquid, immiscible in the carrier liquid, to the liquid dispensing channel through the liquid supply channel. A drop formation device, associated with an interface of the liquid supply channel and the liquid dispensing channel, is selectively actuated to form a discrete drop of the functional liquid in the carrier liquid flowing through the liquid dispensing channel.