Nozzle Density Adjustment for Pattern Film Coating
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Solution Overview
Problem
Inkjet droplet discharge devices face inefficiencies when forming pattern films with varying size regions, such as in organic EL devices, where the discharge amount is limited by the relative speed and nozzle density, leading to uneven coating and increased work time.
Innovation Solution
The method involves using a greater number of nozzles for narrower pattern film formation regions compared to wider regions, ensuring balanced droplet discharge and reducing the time required for the process by adjusting nozzle density according to the size of the regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed number of nozzles is used for all pattern film formation regions, then the device structure is simple, but the discharge amount becomes unbalanced between narrow and wide regions leading to increased work time
Solution Approach 1:
The patent applies local quality by varying the number of nozzles assigned to different pattern film formation regions based on their width characteristics. Narrow regions are assigned fewer nozzles while wide regions receive more nozzles, creating a localized adaptation that balances discharge amounts across all regions and eliminates the need for repeated discharge processes.
Solution Approach 2:
The patent implements dynamics by making the nozzle assignment flexible and adaptive to region characteristics. Instead of a static one-to-one mapping, the system dynamically adjusts the number of nozzles per region based on real-time width measurements, allowing the discharge configuration to optimize itself for different region sizes and maintain balanced coating efficiency.
2Productivity
If the relative speed between substrate and discharge heads is increased, then productivity improves, but the discharge amount per unit surface area becomes insufficient requiring repeated processes
Solution Approach 1:
The patent applies parameter changes by adjusting the discharge amount parameter in response to region width variations. For narrow regions, the system reduces the discharge amount per nozzle to prevent over-coating, while for wide regions it increases the discharge amount to ensure sufficient coverage, thereby maintaining balanced coating quality at high discharge speeds without requiring repeated processes.
3Manufacturing precision
If more nozzles are used for narrow regions, then discharge amount balance is achieved, but the device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the pattern film formation regions into distinct categories (narrow and wide) and assigning different nozzle configurations to each segment. This segmentation allows the system to manage complexity by creating discrete, manageable groups rather than attempting to individually configure every region, simplifying the control logic while achieving balanced discharge amounts.
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 allows for efficient droplet discharge in both narrow and wide regions, achieving a specified coating amount while minimizing the time needed for the process, thereby improving the efficiency and balance of droplet distribution.
Implementation Method 1
a piezoelectric element (35) used as pressure application means for applying pressure to the functional liquid (33) in the cavity (32)
Data Source
AI summary
A pattern film formation method includes: discharging liquid from at least one first nozzle toward a first pattern film formation region on a substrate; and discharging liquid from a plurality of second nozzles toward a second pattern film formation region that is narrower than the first pattern film formation region. A number of the second nozzles is greater than a number of the at least one first nozzle.