Droplet Processing Device for Thin Film Thickness Control
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Solution Overview
Problem
Current inkjet methods for forming thin films on substrates are limited by random print patterns, which restrict the thickness of the film to 50% of the total ink discharge, leading to unfilled areas due to surface tension and agglomeration issues, particularly in edge areas where ink is attracted to the active area.
Innovation Solution
A droplet processing device and method that generate a synthesized image with distinct area settings for general and target areas, allowing for differential brightness and resolution adjustments, enabling the inkjet system to discharge up to 100% of the ink, preventing random print patterns on the outer areas and thus increasing the thickness of the thin film beyond the conventional 50% limit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a random print pattern is used to prevent agglomeration, then dot distribution is improved, but the film thickness is limited to 50% of total ink discharge
Solution Approach 1:
The substrate area is divided into a first area (active area) and a second area (edge area). Different printing patterns are applied to each area: random print pattern for the first area and non-random print pattern for the second area. This segmentation allows optimization of dot distribution in the active area while achieving sufficient film thickness in the edge area.
Solution Approach 2:
Different printing patterns are applied to different regions of the substrate based on their specific requirements. The first area uses a random print pattern for uniform dot distribution, while the second area uses a non-random print pattern for increased ink discharge and film thickness. This local quality approach tailors the printing strategy to the functional needs of each region.
2Manufacturing precision
If the film thickness in the edge area is increased to prevent unfilled areas, then coverage is improved, but agglomeration occurs due to surface tension
Solution Approach 1:
The substrate is segmented into regions with different printing patterns. The second area (edge area) uses a non-random print pattern that allows higher ink discharge and greater film thickness without causing agglomeration, while the first area maintains random printing for uniform distribution.
Solution Approach 2:
The printing pattern is locally optimized for each area. In the second area, a non-random pattern enables increased ink discharge to achieve complete coverage and prevent unfilled areas, while the first area uses random printing to maintain dot separation and prevent agglomeration.
3Quantity of substance
If all nozzles discharge ink in every printing pass, then film thickness increases, but dot distribution uniformity deteriorates
Solution Approach 1:
The printing system is segmented into different operational modes for different areas. In the first area, selective nozzle discharge maintains uniform dot distribution, while in the second area, all nozzles discharge ink to achieve sufficient film thickness without causing agglomeration.
Solution Approach 2:
The ink discharge strategy is locally adapted to each area's requirements. The first area uses selective discharge for uniform distribution, while the second area uses full nozzle discharge for adequate thickness, with the non-random pattern preventing harmful agglomeration in the edge region.
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
This approach effectively increases the thickness of targeted areas while preventing unfilled areas by optimizing ink distribution, allowing for thicker films to be formed without agglomeration, thereby enhancing the manufacturing capabilities of substrates like display and semiconductor substrates.
Implementation Method 1
the dots are attracted to each other by surface tension. In this case, the surface tension is highest toward the center of the active area and decreases toward the outer side of the edge area.
Data Source
AI summary
Provided are a droplet processing device and a droplet processing method which may increase a thickness of a targeted area to be greater than a thickness of an untargeted area in a process of forming a thin film by using a dot pattern of ink. The droplet processing device includes: a droplet profile generating terminal for generating a general area halftoning image to which a random print pattern is applied, generating a target area halftoning image to which the random print pattern is not applied, and synthesizing the general area halftoning image and the target area halftoning image to generate a synthesized image; and an inkjet system for receiving an input of the synthesized image and spraying droplets onto a substrate based on dot locations present in the synthesized image.