Multicolor Subpixel Printing via Merged Nozzle Passes
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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 different colors, which increases production time and complexity.
Innovation Solution
A method involving a printing head with nozzles arranged in a specific pattern to print four colors, where three colors are printed using the head and the fourth color is applied using a non-printing method, allowing for efficient lateral movement and alignment to form a regular array of subpixels with reduced recalibration requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple colors are printed sequentially using a printing head, then color accuracy and manufacturing precision are improved, but production time and device complexity increase due to recalibration and realignment requirements between color prints
Solution Approach 1:
The patent combines multiple color printing operations into a single continuous printing pass by arranging nozzles to print multiple colors simultaneously. The printing head deposits cyan, magenta, yellow, and black inks in one linear sequence without stopping or recalibrating between colors, eliminating the time loss associated with sequential printing and recalibration.
Solution Approach 2:
The printing process maintains continuous operation by printing all colors in one uninterrupted pass. The method eliminates idle time for recalibration and realignment between color prints, keeping the printing head continuously productive throughout the entire multi-color deposition process.
2Manufacturing precision
If multiple colors are printed sequentially using a printing head, then color accuracy and manufacturing precision are improved, but device complexity increases due to recalibration and realignment requirements
Solution Approach 1:
The patent merges multiple printing operations into a single integrated process. By arranging nozzles to print multiple colors in one pass, the system eliminates the need for separate printing steps, recalibration procedures, and realignment operations, thereby reducing overall process complexity despite maintaining color accuracy.
Solution Approach 2:
The printing head is designed with multi-functional nozzles that can deposit multiple colors sequentially in one operation. This universal design allows a single printing head to perform what would traditionally require multiple specialized printing operations, simplifying the overall device architecture.
3Manufacturing precision
If three colors are printed using separate printing operations, then color accuracy is maintained, but productivity decreases due to repeated setup and alignment time
Solution Approach 1:
The patent combines three separate color printing operations into one continuous printing pass. The printing head deposits multiple colors in a single linear sequence without interruption, eliminating the setup and alignment time that would otherwise reduce productivity while maintaining color accuracy through precise nozzle positioning.
Solution Approach 2:
The printing process achieves continuous productive action by eliminating idle time between color prints. The printing head remains continuously engaged in depositing color layers without stopping for recalibration or realignment, maximizing production efficiency while maintaining manufacturing precision.
Data Source
AI summary
Disclosed is process of forming a regular array of rows of subpixels on a workpiece. The subpixels having four different colors, and a subpixel pitch s. Of the four 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=4n1 and p=3s, the printing head 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 printing pattern by: (a) moving the workpiece laterally relative to the printing head by a distance d1, where d1=4n2s; (b) printing a set of z rows of subpixels with the printing head; (6) moving and printing in a second printing pattern by: (c) moving the workpiece laterally relative to the printing head by a distance d2, where d2=d1; (d) printing a set of z rows of subpixels with the printing head; (7) moving and printing in a third printing pattern by: (e) moving the workpiece laterally relative to the printing head by a distance d3, where d3=4n3s, such that d1+d2+d3=pz; and (f) printing a set of z rows of subpixels with the printing head; (8) repeating steps (5) through (7) multiple times in the same order; and (9) applying r colors by a non-printing method.