Inkjet Print Head Movement for Optical Structure Uniformity
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Solution Overview
Problem
Inkjet printing of three-dimensional optical structures, such as lenses, faces issues with inequalities and non-uniformities due to deviations in ejection characteristics between nozzles, leading to optical defects like diffractive phenomena, as the locations of inaccurately working nozzles are unknown and change over time.
Innovation Solution
The method involves moving the print head relative to deposited droplets between consecutive steps to ensure droplets at each position are ejected from multiple nozzles, distributing potential deviations uniformly across the structure, thereby compensating for inaccuracies and averaging out defects, even if some nozzles malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If droplets are deposited using a fixed print head position, then the printing process is simple and fast, but inequalities and non-uniformities occur due to nozzle deviations
Solution Approach 1:
The patent applies the dynamics principle by making the print head movable between consecutive depositing steps. Instead of a fixed print head position, the print head is moved in a moving step performed between at least two consecutive depositing steps. This dynamic adjustment ensures that droplets deposited in the same position are ejected from different ejection nozzles, distributing nozzle deviations uniformly and compensating for inaccuracies, thereby resolving the contradiction between manufacturing precision and device complexity.
2Manufacturing precision
If multiple nozzles are used to deposit droplets at each position, then nozzle inaccuracies are averaged out, but the printing time increases
Solution Approach 1:
The patent applies partial action by moving the print head only between consecutive depositing steps rather than continuously during deposition. The moving step is performed selectively between steps, not during every droplet ejection. This partial movement approach distributes nozzle deviations uniformly across the three-dimensional structure while minimizing the impact on printing speed, thus resolving the contradiction between manufacturing precision and productivity.
3Manufacturing precision
If the print head is moved between depositing steps, then droplet deposition uniformity improves, but the process duration increases
Solution Approach 1:
The patent applies periodic action by alternating between depositing steps and moving steps in a regular cycle. The print head performs a depositing step, then executes a moving step, then performs another depositing step, and so on. This periodic alternation between deposition and movement ensures uniform droplet distribution while structuring the process in manageable cycles, thereby resolving the contradiction between manufacturing precision and time loss.
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 significantly enhances printing accuracy, minimizing optical defects and ensuring high-quality three-dimensional structures suitable for optical components by spreading inaccuracies uniformly, thus avoiding visible aberrations.
Implementation Method 1
Manufacturing three-dimensional optical structures by inkjet printing, in particular droplet-on-demand (DOD) printing is well known from several prior documents
Implementation Method 2
After deposition of the droplets, adjacent deposited droplets merge which each other
Implementation Method 3
adjacent deposited droplets merge which each other and are subsequently cured by UV-light
Data Source
AI summary
A method and printing system for printing a three-dimensional structure, in particular an optical component, by depositing droplets of printing ink side by side and one above the other in several consecutive depositing steps by means of a print head. In each depositing step a plurality of droplets is ejected simultaneously by a plurality of ejection nozzles of the print head. The print head is moved relative to the deposited droplets in a moving step performed between at least two consecutive depositing steps in such a manner that the droplets deposited in the same position in the at least two consecutive depositing steps are ejected at least partly from two different ejection nozzles.