Electrostatic Pattern Substrate for Maskless Micro-Component Placement
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Solution Overview
Problem
Conventional methods for manufacturing pattern substrates for micro-component location using surface tension of liquids require masks or plates, leading to inefficiencies in pattern change, accuracy limitations, and potential damage to components due to residual stress and heat.
Innovation Solution
A method of forming patterns on substrates using electrostatic latent images and charged particles, where liquid-repellent or lyophilic materials are used to create regions that guide liquid droplets for precise component placement without the need for masks, utilizing a particle carrying member with a photoconductive layer and electrostatic transfer to achieve high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If photolithography and etching are used to perform patterning, then the pattern can be formed on the substrate, but masks or plates are required which leads to time and money consumption when pattern needs to be changed
Solution Approach 1:
The patent replaces the mechanical mask/plate system with an electrostatic field-based patterning system. Charged particles are used to transfer patterns to the substrate through electrostatic attraction, eliminating the need for physical masks. This allows digital control of patterns through electrostatic fields, enabling rapid pattern changes without physical mask replacement.
Solution Approach 2:
The patent changes the patterning mechanism from chemical (photolithography) to electrostatic. By controlling the charge distribution on particles and the electrostatic field strength, patterns can be dynamically adjusted and transferred to substrates. This parameter-based control enables flexible pattern modification without time-consuming physical mask changes.
2Ease of operation
If magnetic force is used for autonomous locating, then components can be positioned, but noise is produced by residual magnetic force
Solution Approach 1:
The patent replaces magnetic field-based locating with electrostatic field-based locating. Charged particles interact with components through electrostatic forces, providing autonomous positioning capability. This substitution eliminates residual magnetic noise while maintaining the autonomous locating function, as electrostatic forces can be precisely controlled and turned off without leaving residual fields.
3Ease of operation
If electrostatic force is used for autonomous locating, then components can be positioned, but components may be broken
Solution Approach 1:
The patent optimizes electrostatic force parameters by using charged particles with controlled charge distribution. The electrostatic forces are applied gradually and locally through particle interaction, enabling autonomous locating while avoiding sudden high-force impacts that could break components. The particle-mediated approach distributes forces more evenly compared to direct electrostatic plate application.
4Ease of operation
If surface tension of molten solder is used for autonomous locating, then components can be positioned, but components vulnerable to heat cannot be used and residual stress is produced
Solution Approach 1:
The patent replaces thermal-based locating (molten solder surface tension) with electrostatic field-based locating using charged particles. This substitution eliminates the need for high temperatures, allowing vulnerable components to be positioned without heat damage. The electrostatic interaction occurs at room temperature, avoiding thermal stress while maintaining autonomous locating capability.
5Manufacturing precision
If masks or plates are used for patterning, then patterns can be formed, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates the mask and plate components from the patterning system. By using charged particles that can be directly controlled by electrostatic fields, the pattern formation process no longer requires these intermediate physical elements. This reduction in components simplifies the device while maintaining the ability to form precise patterns through electrostatic particle distribution.
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 precise and efficient location of micro-components on substrates without masks, reducing residual stress and heat-related issues, while allowing for flexible pattern changes and high accuracy in component placement.
Implementation Method 1
a step of forming the predetermined pattern by the particle on the surface of the particle carrying member is such that an electrostatic latent image of the predetermined pattern is formed on the particle carrying member
Implementation Method 2
the charged particle is electrically moved to the electrostatic latent image and that the predetermined pattern by the particle is formed on the surface of the particle carrying member
Implementation Method 3
when a component 9 is arranged so as to make contact with the droplet 81, the droplet 81 is spread even over the surface of the component 9 in contact with the droplet 81 (FIG. 11H), and thus the component 9 is autonomously located in a predetermined position by the surface tension of the droplet 81
Implementation Method 4
the liquid member has water as a main ingredient... an angle of contact of the liquid member with a liquid-repellent region is greater than an angle of contact with the lyophilic region
Data Source
AI summary
There is provided a method of manufacturing a pattern substrate in which a pattern is formed on the surface of the substrate. The manufacturing method includes a step of preparing the substrate and a step of arranging a liquid-repellent or lyophilic material on the surface of the substrate so as to form the pattern on the surface of the substrate in which the surface of the substrate has a liquid-repellent region and a lyophilic region, the pattern is formed by one of the liquid-repellent region and the lyophilic region and the pattern is used to locate a component by the surface tension of a liquid member.