Inkjet-Printed Shrinkable Films for Localized Substrate Planarization
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Solution Overview
Problem
Conventional methods for correcting bowing and warping in optical devices and substrates are expensive and lack the ability for localized corrections, which are necessary for optimal optical performance.
Innovation Solution
A method using inkjet printing to apply films that polymerize and contract, allowing for precise control of substrate deformation by printing materials with different shrinkage properties in specific areas to induce a bend and correct substrate curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional planarization or polishing methods are used to correct bowing, then substrate deformation can be corrected, but the process becomes expensive and complex
Solution Approach 1:
The patent applies parameter changes by utilizing materials with different shrinkage characteristics (first and second shrinkage values) to correct substrate deformation. By selecting materials with specific shrinkage properties and controlling their deposition thickness, the method achieves substrate planarization through controlled contraction during curing, avoiding complex mechanical polishing processes
Solution Approach 2:
The patent implements local quality by applying different materials or different thicknesses of the same material to different regions of the substrate based on their specific deformation characteristics. This allows localized correction of bowing and warping in specific areas rather than treating the entire substrate uniformly, reducing overall process complexity
2Manufacturing precision
If conventional CVD or PVD deposition is used to correct bowing, then substrate deformation can be corrected, but the method becomes expensive and does not allow localized corrections
Solution Approach 1:
The patent utilizes parameter changes by employing materials with specifically controlled shrinkage values (first shrinkage value for convex areas, second shrinkage value for concave areas) to achieve deformation correction. This material parameter selection enables cost-effective deposition through inkjet printing rather than expensive CVD/PVD processes
Solution Approach 2:
The patent applies local quality by selectively depositing materials with different shrinkage properties in specific regions of the substrate. Convex areas receive materials with first shrinkage values while concave areas receive materials with second shrinkage values, enabling localized correction without requiring expensive conventional deposition methods across the entire substrate
3Ease of manufacture
If uniform material deposition is applied across the substrate, then the process is simple, but it cannot provide localized corrections for optimal optical performance
Solution Approach 1:
The patent implements local quality by varying material properties or deposition thickness in different regions of the substrate. The system identifies convex and concave areas and applies different shrinkage characteristics to each region, enabling localized deformation correction while maintaining a relatively simple inkjet printing process compared to conventional methods
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 cost-effective, localized correction of substrate deformation, improving optical device performance by allowing for precise shaping and planarity without affecting areas that do not require correction.
Implementation Method 1
printing a first film on a first area of a surface of the substrate via inkjet printing, the first film being a material that polymerizes and contracts when cured
Implementation Method 2
the first film being a material that polymerizes and contracts when cured
Data Source
AI summary
Methods of curing a deformation in a substrate are provided. In some embodiments, the method includes identifying one or more areas on the substrate with deformation. The method further includes printing a first film on a first area of a surface of the substrate via inkjet printing, the first film being a material that polymerizes and contracts when cured. The method includes printing a second film on a second area of the surface of the substrate via inkjet printing, the second film being a material that polymerizes and contracts when cured. The method further includes curing the first film and the second film to induce a bend in the substrate. In some embodiments, the method includes inkjet printing a third film and a fourth film on the surface of the substrate.