Donor Substrate Recoating for Residual Material Reuse

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Solution Overview

Problem

In laser-assisted deposition systems, residual material left on donor substrates after printing is typically wasted, rather than being reused, which limits the efficiency and cost-effectiveness of the process, especially for viscous materials like solder pastes and polymers.

Innovation Solution

A system that collects residual material from donor substrates using a squeegee or blade after printing, allowing it to be reused by recoating the donor substrate, enabling immediate reuse and reducing material waste through controlled gap management and imaging for monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If residual material is collected and reused on the donor substrate, then material waste is reduced and cost-effectiveness improves, but the risk of contamination and process complexity increase

Engineering Contradiction:

Improvematerial wasteVSAvoidcontamination risk

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The system divides the donor substrate into different zones: a printing area where material is deposited and jetted, and a collection area where residual material is aggregated. The squeegee blade selectively collects material from specific regions while leaving other areas clean for subsequent printing operations, thus enabling reuse without cross-contamination.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The squeegee blade acts as an intermediary tool between the residual material and the collection system. It gently aggregates the residual material without causing contamination, and the bidirectional translation mechanism serves as an intermediary to precisely control the positioning of the substrate during collection and recoating processes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If residual material is collected and immediately reused, then productivity and efficiency improve, but the complexity of the system increases

Engineering Contradiction:

Improveprinting efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The coating system is designed to perform multiple functions: initial material coating, residual material collection, and recoating operations. The bidirectional translation mechanism also serves dual purposes by positioning the substrate for both collection and subsequent printing operations, reducing the need for separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system enables self-service by automatically collecting and recoating residual material without requiring manual intervention. The bidirectional translation and gap control mechanisms work autonomously to position the substrate and adjust coating parameters, allowing the system to maintain high productivity with minimal external control.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If bidirectional translation is used for substrate positioning, then collection precision improves, but the mechanical complexity and control difficulty increase

Engineering Contradiction:

Improvecollection precisionVSAvoidmechanical complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system employs dynamic gap control between coating rollers, allowing the gap width to be adjusted during operation. This dynamic adjustment enables precise control over material deposition thickness and facilitates the collection process by creating optimal conditions for material aggregation without requiring complex fixed mechanical structures.

Inventive Principle:

Principle #15Dynamics

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 reuse of residual material, reducing waste and extending the life of viscous materials by allowing for continuous printing operations with minimal material consumption and contamination prevention.

Implementation Method 1

a laser-based system that contains a laser (e.g., a high frequency laser) to enable jetting of the material from the donor substrate to the receiving substrate

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

The donor substrate is then moved towards and through a well-defined gap (e.g., between rollers or knives) to create a uniform layer of the printed material with a thickness that is defined by the gap

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentUS11779955B1Methods for residual material collection in laser-assisted deposition

Publication Date: 2023.10.10 REOPHOTONICS LTD

AI summary

In a laser-assisted deposition system, a uniform layer of material is coated onto a donor substrate at a coating system, and portions of the material are jetted from the donor substrate to a receiving substrate at a printing unit, leaving residual portions of the material on the donor substrate. In order to not waste the residual portions of the material, the donor substrate with the residual portions of the material is returned to the coating system where the residual portions of the material are aggregated into a blob and subsequently recoated onto the donor substrate. The blob may be formed by translating the residual portions of the material towards an interface formed by two coating rollers, a squeegee and the donor substrate, or a film and the donor substrate.