Optical Guide Path Correction for Precision Material Deposition
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Solution Overview
Problem
Industrial printers face challenges in achieving precision due to mechanical errors in conveyance systems, leading to positional and rotational inaccuracies that affect the uniformity and quality of thin layers in electronic devices, such as OLED pixels and solar panels, particularly as devices become smaller and more complex.
Innovation Solution
The implementation of a system that uses sensors and transducers to detect deviations from an optical guide, allowing for real-time correction of mechanical errors in the transport path, ensuring the substrate or printhead follows an ideal path, thereby reducing the need for extensive computing resources and improving print accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional conveyance systems are used for substrate transport, then device complexity is reduced, but manufacturing precision deteriorates due to mechanical errors in transport path
Solution Approach 1:
The patent replaces complex mechanical error correction mechanisms with computational methods. Instead of using additional mechanical components to physically correct transport path deviations, the system uses software algorithms to calculate and compensate for positional and rotational inaccuracies in droplet placement, thereby achieving high manufacturing precision without increasing mechanical device complexity
Solution Approach 2:
The patent changes operational parameters (droplet ejection timing, position, and trajectory) based on detected transport path deviations. By dynamically adjusting these parameters in response to measured errors, the system compensates for mechanical inaccuracies and maintains precise droplet placement without requiring a more complex conveyance system
2Manufacturing precision
If computational methods are used to correct transport errors, then manufacturing precision improves, but use of energy increases due to extensive computing resources required
Solution Approach 1:
The patent applies partial correction by focusing computational resources on correcting only the most significant error components (positional and rotational deviations) rather than attempting to correct all possible transport errors. This selective approach achieves sufficient layer thickness uniformity while reducing the computational energy required compared to comprehensive error correction methods
3Manufacturing precision
If real-time error correction is implemented, then manufacturing precision improves, but device complexity increases due to additional sensors and transducers
Solution Approach 1:
The patent makes existing components multi-functional by enabling them to perform both their primary functions and error detection/correction functions. For example, existing position sensors used for basic substrate tracking are also utilized for detecting transport path deviations, eliminating the need for separate dedicated error detection sensors and reducing overall device complexity while maintaining high manufacturing precision
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 enhances the precision and uniformity of layer deposition, reducing errors and improving the quality of electronic devices by compensating for mechanical imperfections in the conveyance system, allowing for the production of thinner, more reliable layers with reduced computational burden.
Implementation Method 1
an optical guide (e.g., using a laser) is used to define a desired path
Implementation Method 2
sensors mounted to the component dynamically detect deviation from this path
Data Source
AI summary
A printer deposits material onto a substrate as part of a manufacturing process for an electronic product; at least one transported component experiences error, which affects the deposition. This error is mitigated using transducers that equalize position of the component, e.g., to provide an “ideal” conveyance path, thereby permitting precise droplet placement notwithstanding the error. In one embodiment, an optical guide (e.g., using a laser) is used to define a desired path; sensors mounted to the component dynamically detect deviation from this path, with this deviation then being used to drive the transducers to immediately counteract the deviation. This error correction scheme can be applied to correct for more than type of transport error, for example, to correct for error in a substrate transport path, a printhead transport path and/or split-axis transport non-orthogonality.