Ink Jet Nozzle Voltage Correction for Droplet Volume Uniformity
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Solution Overview
Problem
Existing ink jet application devices face challenges in uniformly controlling the volume of ink droplets across a large number of nozzles, leading to inefficiencies and quality issues in flat display manufacturing due to variations in actuator characteristics and nozzle shapes, which are exacerbated by manual adjustment methods.
Innovation Solution
An ink jet application device with a voltage control unit that automatically adjusts the voltage applied to actuators based on stored characteristic information, using a voltage calculation and correction system to ensure consistent ink droplet volume, incorporating a CCD camera for precise measurement and a three-terminal regulator for analog signal conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of variable resistance is used to control ink droplet volume, then the volume can be controlled for small number of nozzles, but it takes a lot of time and trouble when the number of nozzles is larger
Solution Approach 1:
The system automatically measures the ink droplet volume using a CCD camera and calculates the required voltage correction without manual intervention. The microcomputer controls the entire process, making the system self-adjusting rather than requiring operator intervention for each nozzle calibration.
Solution Approach 2:
The manual mechanical adjustment of variable resistance is replaced by an automated electronic control system. The microcomputer calculates correction voltages based on measured droplet volumes and automatically applies them through a voltage correction circuit, eliminating the need for manual resistance adjustment.
2Manufacturing precision
If manual adjustment of variable resistance is used to control ink droplet volume, then the volume can be controlled, but a variation of ink droplet volume is easily generated making it difficult to stably remain quality
Solution Approach 1:
The system uses a CCD camera to measure the actual ink droplet volume and feeds this information back to the microcomputer. The microcomputer then calculates the appropriate voltage correction to achieve the target droplet volume, creating a closed-loop control system that maintains consistent quality.
Solution Approach 2:
Manual adjustment is replaced by automated measurement and control. The CCD camera provides precise optical measurement of droplet volume, and the electronic voltage correction system applies precise adjustments, eliminating the variability introduced by manual resistance adjustment.
3Ease of operation
If equal voltages are applied to actuators, then the control is simple, but variations in actuator characteristic and nozzle shape cause non-uniform ink droplet volume
Solution Approach 1:
Instead of applying a uniform voltage to all nozzles, the system calculates and applies individualized correction voltages to each nozzle based on its specific characteristics. The microcomputer stores correction values for each nozzle and applies the appropriate correction voltage to compensate for manufacturing variations in actuators and nozzles.
Solution Approach 2:
The system changes the voltage parameter for each actuator based on measured droplet volumes. By adjusting the voltage applied to each individual actuator, the system compensates for variations in actuator characteristics and nozzle shapes, achieving uniform droplet volumes across all nozzles.
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 solution improves operating efficiency and productivity by automatically controlling ink droplet volume, reducing manual intervention and variations, thereby enhancing the quality and consistency of flat displays.
Implementation Method 1
When voltages are applied to the actuators 111a, 111b, 111c, the actuators 111a, 111b, 111c are deformed to vary volumes of the ink chambers 105a, 105b, 105c via the diaphragm 109
Implementation Method 2
a CCD camera 38 for measuring a shape of the ink droplet
Data Source
AI summary
An ink jet application method employed in an ink jet application device so as to apply a certain voltage to an actuator mounted to a nozzle and spray an ink-droplet from the nozzle by a uniform volume, including reading characteristic information for relating a volume of the ink-droplet to a voltage value to be applied to the actuator; calculating a voltage value related to the volume of the ink-droplet sprayed from the nozzle which is a voltage correcting object with reference to the characteristic information; calculating a voltage difference value between the calculated voltage value and a voltage value related to a specific voltage to the voltage difference value to the actuator mounted to the nozzle which is the voltage correcting object.