Electrode Assembly Shaping Liquid Layers for Uniform Inkjet Coatings
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Solution Overview
Problem
Existing methods for manufacturing display devices face challenges in controlling the surface shape of liquid layers due to nonuniformities in droplet formation, wetting, and drying during processes like inkjet printing, leading to quality issues in printed materials.
Innovation Solution
A method and apparatus using an electrode assembly to control the surface shape of liquid layers through dielectrophoresis (DEP) forces, where an electric field is applied to move and shape the liquid layer, allowing for a flat or non-uniform surface formation as needed, using an electrode assembly with first and second electrodes to form an electric field and manipulate the liquid layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing or jetting process is used to dispose liquid layer on base, then productivity is improved, but manufacturing precision deteriorates due to nonuniformities in droplet formation, wetting, and drying
Solution Approach 1:
The patent applies a preliminary action by using an electrode assembly to reshape the liquid layer surface before the drying and curing processes occur. The electrode assembly corrects nonuniformities in droplet formation, wetting, and drying by applying electric fields to redistribute the liquid material, ensuring a uniform surface shape is established before final drying completes. This preliminary resurfacing action prevents quality issues that would otherwise result from the inherent nonuniformities of inkjet printing processes.
2Manufacturing precision
If electrode assembly is used to control surface shape of liquid layer, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The electrode assembly serves multiple functions within the manufacturing process. It not only controls the surface shape of the liquid layer by applying electric fields for dielectrophoresis, but it also facilitates material redistribution, prevents defects during drying, and ensures uniform thickness. This multi-functionality reduces the need for separate dedicated devices for each function, thereby limiting the increase in overall device complexity while achieving precise surface shape control.
3Loss of substance
If liquid layer is deposited using inkjet process, then loss of substance is reduced, but manufacturing precision deteriorates due to nonuniform droplet formation
Solution Approach 1:
The patent extracts and corrects the nonuniformities in droplet formation after deposition but before final drying. The electrode assembly selectively applies electric fields to specific regions of the liquid layer to redistribute material and eliminate nonuniformities. This extraction of the defect-correction function from the deposition process itself allows the inkjet process to maintain its material efficiency while the subsequent electrode-based resurfacing ensures uniformity without requiring additional material to compensate for defects.
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 enables precise control over the surface shape of liquid layers, reducing the risk of spreading and improving process efficiency by ensuring consistent thickness and reducing the need for extended curing times, thereby enhancing the quality of manufactured layers.
Implementation Method 1
The controlling may include forming, by the electrode assembly, an electric field, and moving the liquid layer by a dielectrophoresis (DEP) force imparted to the liquid layer by the electric field.
Data Source
AI summary
A method of controlling a surface shape of a liquid layer includes: disposing the liquid layer on a base; providing an electrode assembly at the periphery of the liquid layer; and controlling the surface shape of the liquid layer disposed on the base, using the electrode assembly.