Liquid Jet Head Gap Control for Pattern Accuracy
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Solution Overview
Problem
Existing ink jet printing technologies face challenges in maintaining high position accuracy for pattern formation due to variations in ink jet head characteristics and the risk of ink jet head collision with the medium, limiting the improvement of drawing accuracy.
Innovation Solution
A method involving multiple relative movements between a board and a liquid jet head, where a slower relative movement speed is applied during the initial movement to ensure constant position accuracy, and the same conditions are applied to subsequent movements to maintain accuracy and prevent satellite formation, while adjusting the distance between the jet head and the board to avoid collision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the ink jet head and the medium is shortened to improve drawing accuracy, then position accuracy is improved, but the risk of collision between the ink jet head and the medium increases
Solution Approach 1:
The patent applies dynamics by making the gap distance between the ink jet head and the medium variable rather than fixed. The control unit dynamically adjusts the gap distance based on the relative movement speed - using a first gap distance during first relative movement and a second gap distance during second relative movement. This allows the system to optimize the balance between drawing accuracy and collision prevention at different stages of the printing process.
Solution Approach 2:
The patent changes the parameter of gap distance between the ink jet head and the medium based on printing conditions. By setting different gap distances for different relative movement phases, the system adapts the physical parameter to achieve both high positioning accuracy during slow movement and collision avoidance during normal operation.
2Productivity
If the relative movement speed is increased to improve productivity, then printing speed is improved, but position accuracy deteriorates
Solution Approach 1:
The patent segments the relative movement process into multiple phases with different speed characteristics. The printing process is divided into first relative movement (slower speed for high accuracy) and second relative movement (faster speed for productivity). This segmentation allows the system to optimize for accuracy during critical phases and for speed during less critical phases, achieving overall productivity improvement while maintaining required precision.
Solution Approach 2:
The system dynamically adjusts relative movement speed based on the printing phase and pattern characteristics. The control unit sets a first relative movement speed during initial positioning and a second relative movement speed during subsequent printing operations. This dynamic speed adjustment enables the system to balance between positioning accuracy and printing throughput.
3Productivity
If multiple scanning operations are performed to improve pattern coverage, then printing completeness is improved, but position accuracy deteriorates due to accumulation of errors
Solution Approach 1:
The patent implements feedback mechanisms where the control unit acquires position information about the board and pattern data, then uses this information to calculate appropriate relative movement speeds. The system feeds back the actual printing results and adjusts subsequent scanning operations accordingly, compensating for accumulated errors and maintaining position accuracy across multiple operations.
Solution Approach 2:
The patent applies preliminary action by performing a first relative movement with slower speed to establish accurate initial pattern elements before performing second relative movement with faster speed for additional pattern coverage. This preliminary accurate positioning establishes a reference framework that guides subsequent faster printing operations, preventing error accumulation.
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 ensures consistent position accuracy and prevents satellite formation, enhancing the printing quality and productivity by maintaining the same jetting frequency and using smaller droplet sizes, thereby improving the overall accuracy and reducing the risk of collision.
Implementation Method 1
jetting liquid to the board from the liquid jet head during each relative movement to form a pattern on the board
Data Source
AI summary
In a case where a plurality of times of relative movement between a board and a liquid jet head are performed and liquid is jetted to the board from the liquid jet head during each relative movement to form a pattern on the board, a first relative movement is performed and the liquid is jetted from the liquid jet head to form a first pattern element on the board, a second relative movement is performed and the liquid is jetted from the liquid jet head to form a second pattern element at a position in contact with the first pattern element and to form the pattern including the first pattern element and the second pattern element, and a relative movement speed lower than a relative movement speed of the second relative movement is applied to the first relative movement.