Inkjet Printed Structured Organic Film Micro-Features

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Solution Overview

Problem

Current methods for forming structured organic films (SOFs) lack precision in placing micro-features, resulting in inconsistent physical and chemical properties, and fail to provide tunable functionalities through specific spatial configurations of surface micro-features.

Innovation Solution

The method involves using an inkjet technique to deposit droplets of a reaction mixture comprising molecular building blocks on a substrate, promoting a change to form SOF micro-features with specific segment and linker arrangements, enabling precise control over the spatial configuration and functionality of the SOF micro-features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional coating methods are used to prepare SOF films, then large area coverage is achieved, but precision in placing micro-features is lost

Engineering Contradiction:

Improveprecision in placing micro-featuresVSAvoidcomplexity of deposition process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent segments the SOF film preparation into distinct functional zones: a bulk SOF layer providing general coverage and pinhole-free properties, and surface micro-features deposited by inkjet printing for precise spatial configuration. This segmentation allows each method to optimize its strength - conventional coating for大面积 coverage and inkjet for precision micro-feature placement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by using inkjet printing to deposit specific molecular building blocks only at predetermined locations where micro-features are needed, rather than uniformly across the entire substrate. This enables precise spatial control of micro-features while the bulk film is formed by conventional methods, achieving both precision and ease of manufacture.

Inventive Principle:

Principle #3Local quality

2Reliability

If conventional coating methods are used, then large area coverage is achieved, but consistent physical and chemical properties are not maintained

Engineering Contradiction:

Improveconsistency of physical and chemical propertiesVSAvoidcontrol over spatial configuration

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses preliminary action by first forming a uniform bulk SOF film through conventional coating methods to ensure consistent pinhole-free coverage and reliable physical/chemical properties across the entire substrate. Then, micro-features are added in a subsequent step, preserving the consistency already achieved by the bulk layer.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If inkjet printing is used to deposit micro-features, then precise spatial configuration is achieved, but surface morphology and friction are not optimized

Engineering Contradiction:

Improvespatial configuration of micro-featuresVSAvoidsurface friction and wear

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent merges two deposition approaches: conventional coating to form a smooth bulk SOF layer that minimizes friction and wear, and inkjet printing to add precisely positioned micro-features on top. This combination allows the bulk layer to provide low-friction surface morphology while the micro-features provide enhanced functionality without compromising the beneficial surface properties.

Inventive Principle:

Principle #5Merging (Combining)

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 creation of SOFs with desirable physical and chemical properties, including pinhole-free films with improved surface morphology, reduced friction, and enhanced print quality, while extending the life of photoreceptor units by minimizing wear and ghosting.

Implementation Method 1

discharging at least one droplet toward the substrate by an inkjet method and depositing the at least one droplet on a surface of the substrate

Methodology Applied

Scientific EffectInkjet deposition:

Implementation Method 2

promoting a change in one or more of the at least one deposited droplets to form at least one SOF micro-feature, the SOF micro-feature comprising a plurality of segments including at least a first segment type and a plurality of linkers including at least a first linker type arranged as a covalent organic framework

Methodology Applied

Scientific EffectCovalent bonding: Chemical Bonding

Data Source

PatentUS8529997B2Methods for preparing structured organic film micro-features by inkjet printing

Publication Date: 2013.09.10 XEROX CORP

AI summary

Methods for making a substrate comprising structured organic film nano- to micro-features are disclosed. The methods for forming SOF micro-features may include: providing a substrate; discharging at least one droplet toward the substrate by an ink jet method, the at least one droplet including a plurality of molecular building blocks each comprising a segment and a number of functional groups; depositing the at least one droplet on the substrate; promoting a change in the deposited at least one droplet and forming at least one dry structured organic film (SOF) on the substrate.