Electromechanical Transducer Layer Coating via Electrostatic Droplet Collection
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Solution Overview
Problem
Inkjet recording apparatuses face challenges in forming electromechanical transducer layers with high accuracy due to small split droplets from the nozzle, which can attach to unintended surfaces and cause patterning failures and uniformity issues, especially with low viscosity solutions used for PZT layers.
Innovation Solution
A method involving the use of a Self-Assembled Monolayer (SAM) layer to selectively reform the surface of the substrate, where the electromechanical transducer layer is not intended, to be hydrophobic, while maintaining the intended area as hydrophilic, combined with applying voltage to attract and collect split droplets, and subsequent heat treatment to crystallize the layer, ensuring precise coating and pattern formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a solution with low viscosity is used to form the electromechanical transducer layer, then the solution can be easily discharged from the nozzle, but small split droplets are easily split from the main droplet and attach to unintended surfaces
Solution Approach 1:
A Self-Assembled Monolayer (SAM) is formed on the substrate surface before discharging the solution. The SAM creates a hydrophobic barrier on areas where the electromechanical transducer layer should not be formed, preventing split droplets from attaching to unintended surfaces. This preliminary protective action resolves the contradiction by maintaining patterning accuracy while allowing easy solution discharge.
2Manufacturing precision
If voltage is applied to attract and collect split droplets, then patterning accuracy is improved, but device complexity increases
Solution Approach 1:
A deflection electrode is introduced as an intermediary component between the nozzle and substrate. This electrode generates an electric field that attracts and collects split droplets, improving patterning accuracy. The intermediary electrode simplifies the overall system architecture compared to more complex droplet control mechanisms while achieving the desired precision.
3Manufacturing precision
If the substrate surface is made hydrophobic in areas not intended for coating, then split droplet attachment is prevented, but surface treatment complexity increases
Solution Approach 1:
The substrate surface undergoes preliminary treatment to form a Self-Assembled Monolayer (SAM) before the inkjet coating process. This advance surface modification creates hydrophobic regions that repel split droplets, preventing unwanted attachment. By performing this action beforehand, the actual coating process is simplified and does not require complex real-time surface control mechanisms.
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 allows for the accurate formation of electromechanical transducer layers with desired patterns without unnecessary droplet attachment, preventing patterning failures and ensuring stable liquid discharging characteristics and improved image quality.
Implementation Method 1
A method involving the use of a Self-Assembled Monolayer (SAM) layer to selectively reform the surface of the substrate
Implementation Method 2
where the electromechanical transducer layer is not intended, to be hydrophobic
Implementation Method 3
applying voltage between the nozzle plate and the substrate such that the split droplet which is charged with a second polarity is attracted and collected by the nozzle plate
Implementation Method 4
the voltage being applied between the nozzle plate and the substrate such that the split droplet becomes charged at the second polarity and is attracted and collected by the nozzle plate
Implementation Method 5
applying a heat treatment to the substrate on which the solution is coated to crystallize the solution to form the electromechanical transducer layer
Data Source
AI summary
Disclosed is a method of manufacturing an electromechanical transducer layer on a surface of a substrate, including discharging a solution including a source material to form the electromechanical transducer layer from a nozzle of a nozzle plate to coat the solution on the surface of the substrate while applying voltage between the nozzle plate and the substrate to charge the nozzle plate at a first polarity and the substrate at a second polarity opposite to the first polarity such that a split droplet split from a main droplet which is coated on the surface of the substrate becomes charged at the second polarity and is attracted and collected by the nozzle plate; and applying a heat treatment to the substrate on which the solution is coated to crystallize the solution to form the electromechanical transducer layer.