Contact Patterning With Screw Pump Control for Continuous Lines
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Solution Overview
Problem
Existing contact-type patterning methods face challenges in maintaining continuous line patterning with high viscosity inks, particularly at acceleration and deceleration sections, leading to discontinuous sections and inconsistent line widths.
Innovation Solution
A contact-type patterning apparatus utilizing a screw-type pump and synchronized control of voltage, nozzle movement, and pump operation to maintain continuous line patterning with high viscosity inks, employing a controller to adjust voltage levels and transfer speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If patterning speed is increased in contact-type printing, then productivity is improved, but the ink may disconnect without maintaining contact state with objects, causing discontinuous sections
Solution Approach 1:
The patent applies dynamics by making the contact pressure between the inkjet head and substrate variable rather than fixed. The contact pressure is dynamically adjusted based on the relative speed between the inkjet head and substrate, increasing contact pressure at lower speeds and decreasing it at higher speeds. This dynamic adjustment allows the system to maintain reliable continuous patterning across a wide range of printing speeds, resolving the contradiction between productivity and reliability.
Solution Approach 2:
The patent changes the parameter of contact pressure in response to speed variations. By monitoring the relative speed between the inkjet head and substrate, the system adjusts the contact pressure parameter accordingly. This parameter change enables the system to maintain optimal contact conditions for continuous patterning regardless of the operating speed, thereby resolving the contradiction between high productivity and reliable continuous line formation.
2Reliability
If contact pressure is increased to maintain continuous contact, then reliability of continuous patterning is improved, but the line width or thickness becomes inconsistent in acceleration and deceleration sections
Solution Approach 1:
The patent resolves this contradiction by dynamically adjusting contact pressure based on relative speed. During acceleration and deceleration phases, the system reduces contact pressure to prevent excessive compression that would cause line width variations. During constant speed phases, the system maintains optimal contact pressure for reliable continuous patterning. This dynamic control strategy simultaneously achieves both reliability and manufacturing precision.
Solution Approach 2:
The patent implements feedback control by monitoring the relative speed between the inkjet head and substrate in real-time. Based on this speed information, the system adjusts the contact pressure accordingly. This feedback mechanism ensures that contact pressure is optimized for each operating condition, preventing line width inconsistencies during acceleration and deceleration while maintaining reliable continuous contact during steady-state operation.
3Ease of manufacture
If inkjet printing is used instead of etching techniques, then manufacturing cost is reduced, but manufacturing time increases due to vacuum requirements
Solution Approach 1:
The patent replaces the vacuum-based mechanical etching system with a contact-type inkjet printing system that operates in atmospheric conditions. This substitution eliminates the need for vacuum chambers and associated pumping systems, thereby reducing manufacturing costs. Simultaneously, the contact-type printing method achieves faster patterning speeds compared to traditional inkjet printing, reducing manufacturing time while maintaining cost effectiveness.
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 consistent line widths and thicknesses throughout patterning processes, preventing discontinuous sections and maintaining contact with substrates even at acceleration and deceleration points.
Implementation Method 1
a screw-type pump which supplies the fluid into the nozzle through a screw that receives power from a motor to rotate
Implementation Method 2
a nozzle which includes an electrode that receives a voltage to generate an electric field toward a substrate, and ejects a fluid so that the fluid is connected to the substrate
Data Source
AI summary
A contact-type patterning apparatus includes: a nozzle comprising an electrode configured to receive a voltage to generate an electric field toward a substrate, and configured to eject a fluid so that the fluid is connected to the substrate; a voltage supply configured to apply the voltage to the electrode; a screw-type pump configured to supply the fluid into the nozzle through a screw configured to receive power from a motor to rotate; a transfer part configured to transfer the nozzle or the substrate so that the fluid is patterned in a line shape; and a controller configured to control a level of the voltage applied through the voltage supply, an operation of the transfer part, and an operation of the pump.