Multicolor Printing Head for Electronic Subpixel Arrays

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Solution Overview

Problem

The existing processes for manufacturing electronic devices with multiple colors, such as LCDs and OLEDs, are inefficient due to the need for recalibration and realignment between printing colors, which increases production time and complexity.

Innovation Solution

A method involving a printing head with nozzles arranged in a row, where different colors are supplied in a regular alternating pattern, and the workpiece is moved laterally to allow for continuous printing of subpixels in a regular array, optimizing the printing process by reducing the need for recalibration between colors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple colors are printed using separate printing operations, then each color can be printed with proper calibration, but the production time increases and the process complexity increases

Engineering Contradiction:

Improvecolor alignment precisionVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines multiple color printing capabilities into a single printing head assembly, where multiple nozzles for different colors (cyan, magenta, yellow, black) are integrated and can print simultaneously or in rapid sequence without requiring the substrate to be moved between different printers or recalibrated between colors

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The printing process maintains continuous operation by having all color nozzles ready and positioned simultaneously, eliminating idle time for recalibration and realignment between color printing operations, thus keeping the printing action continuous and productive

Inventive Principle:

Principle #20Continuity of useful action

2Manufacturing precision

If the substrate is moved between different printers for different colors, then each printer can be optimized for its color, but the alignment time and setup complexity increase

Engineering Contradiction:

Improvecolor registration accuracyVSAvoidprinting system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple color printing systems are merged into a single integrated printing head, eliminating the need for multiple separate printers and the complex coordination required to move and align substrates between them

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The printing head is designed as a universal multi-functional device that can print all colors (cyan, magenta, yellow, black) from a single position, making the system more versatile and eliminating the need for multiple specialized single-color printers

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If recalibration is performed between each color printing, then color accuracy is maintained, but the production time increases

Engineering Contradiction:

Improvecolor accuracyVSAvoidrecalibration time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

All color nozzles are pre-calibrated and positioned together during initial setup, and this calibration is maintained throughout the printing process, eliminating the need for repeated recalibration actions between color printing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #20Continuity of useful action

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 method enhances the efficiency of printing multiple colors by allowing continuous operation with minimal interruption, reducing production time and improving the overall printing process for electronic devices.

Implementation Method 1

deposit organic layers over a substrate by printing (e.g., ink-jet printing, continuous printing, etc.)

Methodology Applied

Scientific EffectPrinting/Ink-jet deposition: Deposition (physical)

Implementation Method 2

After printing, the solvent(s) is(are) evaporated and the organic material remains to form an organic layer for the electronic device

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS8616666B2Multicolor electronic devices and processes of forming the same by printing

Publication Date: 2013.12.31 LG CHEM LTD

AI summary

There is provided a method of printing a regular array of rows of subpixels on a workpiece. The subpixels have c different colors and have a subpixel pitch s. A printing head has z nozzles arranged in a row with a spacing p, where z=n1(c) and p=n2(s), the printhead being at a first position relative to the workpiece. There are c different printing inks, one for each of the c colors, and each of the printing inks is supplied to the nozzles in a regular alternating pattern. The method includes steps of printing a first set of z rows of subpixels with the printing head; moving the workpiece laterally relative to the printing head by a distance d1, where d1=n3(s); printing a second set of z rows of subpixels with the printing head; repeating the printing steps for a total of n2 sets of z rows of subpixels. Variables include:c, an integer greater than 1;n1, n2, and n3 which are the same or different and are independently selected from integers greater than 0, with the proviso that n2 is not a multiple of c.