Multicolor Electronic Device Printing via Alternating Nozzle Patterns
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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, particularly when producing three colors like red, green, and blue, which increases production time and complexity.
Innovation Solution
A process involving a printing head with nozzles arranged in a specific pattern and spacing, where q colors are printed using a regular alternating pattern, and r colors are applied using a non-printing method, allowing for efficient formation of a regular array of subpixels with reduced recalibration and realignment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple colors are printed sequentially with recalibration and realignment, then color accuracy is improved, but production time increases
Solution Approach 1:
The printing head is pre-configured with nozzles arranged in a specific pattern (p=2s spacing) that corresponds to the subpixel array geometry. The nozzle arrangement and spacing are predetermined to match the required color pattern, eliminating the need for recalibration between color deposits. This preliminary configuration enables continuous printing of multiple colors without interruption for realignment.
Solution Approach 2:
The printing head is divided into multiple nozzles (z=3n1), with each nozzle assigned to deposit a specific color in a regular alternating pattern. This segmentation allows simultaneous deposition of multiple colors in their correct positions within the subpixel array, eliminating sequential printing and the associated recalibration steps between different color layers.
2Productivity
If a printing head with specific nozzle arrangement is used, then printing efficiency is improved, but device complexity increases
Solution Approach 1:
Different nozzles in the printing head are assigned different functions (depositing different colors) based on their position in the array. The nozzle spacing p=2s and the pattern of ink supply create local variations in the printing head that correspond to the required color distribution in the subpixel array. This localized differentiation enables efficient multi-color printing while maintaining a regular, manufacturable overall structure.
3Manufacturing precision
If three colors are printed with recalibration between each, then color precision is improved, but manufacturing complexity increases
Solution Approach 1:
The deposition of multiple colors is merged into a single continuous printing operation. The printing head combines multiple nozzles arranged in a specific pattern, and the ink supply system combines multiple ink streams in a regular alternating pattern. This merging eliminates the need for separate printing operations and recalibration steps for each color, reducing manufacturing complexity while maintaining color precision through the predetermined nozzle geometry.
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 process enhances the efficiency of electronic device manufacturing by minimizing recalibration and realignment time, enabling faster production of devices with multiple colors while maintaining precise color alignment.
Implementation Method 1
One process of making electronic devices is to deposit organic layers over a substrate by printing (e.g., ink-jet printing, continuous printing, etc.). In a printing process, the liquid composition being printed includes an organic material in a solution, dispersion, emulsion, or suspension with an organic solvent, with an aqueous solvent, or with a combination of solvents.
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.
Data Source
AI summary
There is provided a process of forming a regular array of rows of subpixels on a workpiece. The subpixels having 3 different colors, and a subpixel pitch s. Of the three colors, q colors are formed by printing and r colors are formed by a non-printing method. The process includes the steps: (1) providing a printing head having z nozzles arranged in a row with a spacing between the nozzles of p, where z=3n1 and p=2s, the printhead being at a first position relative to the workpiece; (2) providing q different printing inks, one for each of the q printed colors; (3) supplying each of the printing inks to the nozzles in a regular alternating pattern; (4) printing a first set of z rows of subpixels with the printing head; (5) moving and printing in a first pattern with the steps: (a) moving the workpiece laterally relative to the printing head by a distance d1, where d1=3n2; and (b) printing a set of z rows of subpixels with the printing head; (6) moving and printing in a second pattern with the steps: (c) moving the workpiece laterally relative to the printing head by a distance d2, where d2=3n3, such that d1+d2=pz; and (d) printing a set of z rows of subpixels with the printing head; (7) repeating steps (5) and (6) multiple times in the same order; and (8) applying r colors by a non-printing method.Variables include:n1, an integer greater than 0;n2 and n3, odd integers, such that n2+n3=2n1;q, an integer from 1-3; andr, an integer, such that q+r=3.