Miniature Aerosol Jet Array for Maskless Micron-Size Deposition
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Solution Overview
Problem
Current printing technologies face challenges in achieving high-resolution, maskless deposition of aerosolized materials onto planar or non-planar surfaces with micron-size features without the use of masks and under atmospheric conditions, particularly in miniaturized formats that allow for efficient and parallel deposition.
Innovation Solution
A miniature deposition head assembly that combines an aerosol stream with a sheath gas to form an annular jet, featuring a compact design with a diameter of less than 1 cm, and an array of channels for simultaneous deposition, allowing for precise control and miniaturization, enabling the deposition of materials with linewidths as small as 5 microns and facilitating the use of multiple deposition heads for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional printing technologies are used for deposition, then deposition can be performed, but maskless deposition of aerosolized materials with micron-size features cannot be achieved
Solution Approach 1:
The deposition system is segmented into multiple independent channels, each capable of depositing material with micron-size precision. The array of channels allows parallel deposition while maintaining individual control over each jet's output, achieving high resolution without requiring complex masking systems.
Solution Approach 2:
The patent replaces mechanical masking systems with an aerosol jet-based deposition method. Instead of using physical masks to define patterns, the system uses controlled aerosolization and jet formation to directly deposit material with precision, eliminating the need for complex mechanical mask components.
2Productivity
If miniaturized deposition heads are used, then deposition time is reduced through parallel processing, but manufacturing precision control becomes more difficult
Solution Approach 1:
The deposition head is divided into multiple miniaturized channels arranged in an array, allowing parallel deposition operations. Each channel is independently controlled to maintain precision while the collective array increases overall productivity through simultaneous multi-point deposition.
Solution Approach 2:
The system controls deposition parameters such as aerosol concentration, jet diameter, and deposition speed independently for each channel, enabling precise feature size control even in miniaturized formats. The parameters are optimized to maintain micron-size precision while operating at higher deposition rates.
3Loss of time
If a single deposition head is used, then device complexity is low, but deposition time increases due to sequential processing
Solution Approach 1:
The deposition system uses an array of multiple channels instead of a single head, allowing parallel material deposition. This segmentation enables simultaneous deposition at multiple locations, significantly reducing total deposition time while the modular channel design keeps individual component complexity manageable.
Solution Approach 2:
Multiple deposition channels are merged into a single integrated array structure that operates as a coordinated system. The channels share common support and control mechanisms while maintaining independent deposition capability, achieving parallel processing without proportionally increasing overall device complexity.
4Manufacturing precision
If maskless deposition is implemented, then manufacturing precision is improved, but reliability of deposition process decreases
Solution Approach 1:
The deposition system incorporates feedback mechanisms that monitor and adjust aerosol flow rates, jet parameters, and deposition conditions in real-time. This feedback control ensures stable and reliable deposition while maintaining the precision benefits of maskless operation, compensating for variations in material properties and environmental conditions.
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
The solution enables high-resolution, maskless deposition of materials with micron-size features, reduces deposition time through parallel processing, and allows for the miniaturization of deposition heads, enhancing the deposition rate and nozzle density, making it suitable for compact arrays and diverse applications.
Implementation Method 1
a region proximate to an exit of the channel for combining the aerosol with the sheath gas, thereby forming an annular jet comprising an outer sheath flow surrounding an inner aerosol flow
Implementation Method 2
The present invention is a deposition head assembly for depositing a material on a target
Data Source
AI summary
A miniaturized aerosol jet, or an array of miniaturized aerosol jets for direct printing of various aerosolized materials. In the most commonly used embodiment, an aerosol stream is focused and deposited onto a planar or non-planar target, forming a pattern that is thermally or photochemically processed to achieve physical, optical, and/or electrical properties near that of the corresponding bulk material. The apparatus uses an aerosol jet deposition head to form an annularly propagating jet composed of an outer sheath flow and an inner aerosol-laden carrier flow. Miniaturization of the deposition head facilitates the fabrication and operation of arrayed deposition heads, enabling construction and operation of arrays of aerosol jets capable of independent motion and deposition. Arrayed aerosol jets provide an increased deposition rate, arrayed deposition, and multi-material deposition.