Laser Diode Array Curing Nanoparticle Ink
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Solution Overview
Problem
Conventional methods for sintering nanoparticle-based inks, such as those using Xenon lamps, suffer from incomplete or uneven curing due to broad spectral distributions, which can lead to premature sealing of top layers, reduced conductivity, and damage to certain substrates, limiting their applicability and efficiency.
Innovation Solution
A system employing an array of laser diodes coupled through optical fibers, allowing for precise, wavelength-selective illumination that corresponds to the pattern of the ink, enabling efficient curing and sintering of nanoparticle-based materials with improved energy delivery and reduced substrate damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If Xenon lamps are used for nanoparticle curing, then large surface areas can be illuminated, but the broad spectral distribution causes incomplete or uneven curing and substrate damage
Solution Approach 1:
The patent segments the broadband Xenon lamp spectrum into multiple discrete wavelength bands using dichroic mirrors and beam splitters. Each wavelength band is directed to a separate detector or processing channel, allowing independent optimization of curing parameters for each band while maintaining uniform coverage across the substrate surface.
Solution Approach 2:
The patent changes the spectral parameters by using tunable filters or adjustable monochromators to select specific wavelength ranges from the Xenon lamp output. This allows optimization of the light spectrum to match the absorption characteristics of the nanoparticle ink, achieving uniform curing without the harmful effects of broad spectral distribution.
2Productivity
If high energy levels are applied for nanoparticle sintering, then curing speed increases, but substrate damage and overheating occur
Solution Approach 1:
The patent applies local quality by using spatially selective optical elements such as masks, spatial light modulators, or focused beam delivery systems. These elements allow the high energy density required for rapid sintering to be delivered only to the nanoparticle ink regions, while surrounding substrate areas receive reduced or no illumination, preventing thermal damage.
Solution Approach 2:
The patent employs periodic or pulsed illumination rather than continuous high-power exposure. By delivering energy in controlled pulses with appropriate duty cycles, the system achieves rapid heating and sintering of nanoparticles during the pulse duration, followed by cooling periods that prevent cumulative thermal damage to the substrate.
3Stability of the object's composition
If conventional heat-based curing is used, then uniform heating is achieved, but high temperatures damage temperature-sensitive substrates
Solution Approach 1:
The patent replaces the mechanical/thermal convection-based heating system with a photonic illumination system. Light energy from the Xenon lamp (filtered and directed as described in previous principles) directly excites and heats the nanoparticle ink through photothermal conversion, eliminating the need for bulk thermal convection that causes uniform substrate heating and damage to temperature-sensitive materials.
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 high-resolution, single-pass curing of large volumes with controlled energy distribution, avoiding unwanted sealing and substrate damage, and facilitating the use of a broader range of substrates, including those with high thermal conductivity.
Implementation Method 1
an array of laser diodes coupled through optical fibers to direct patterned illumination for curing nanoparticle-based inks
Implementation Method 2
laser diodes coupled through optical fibers to direct patterned illumination
Implementation Method 3
High light energy levels are required for nanoparticle curing... provided that the illumination system delivers adequate energy to volatilize coatings used in the ink formulations and to sinter and cure the inks
Implementation Method 4
delivers adequate energy to volatilize coatings used in the ink formulations
Data Source
AI summary
An apparatus for forming a pattern of a nanoparticle-based ink on a substrate has a printing apparatus that is energizable to deposit the nanoparticle-based ink in a pattern on a surface of the substrate. An illumination apparatus is energizable to direct a patterned illumination to cure the deposited ink pattern on the substrate, the illumination apparatus having an array having at least a first and a second laser diode, each laser diode coupled to a channel in a laser light coupling element through an optical fiber and having an illumination lens disposed to direct illumination from the coupling element onto the surface of the substrate. A transport apparatus is energizable to provide relative motion between the substrate and the illumination apparatus.