All-in-One Printed Electronics Printer with Modular Nozzle Heads
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Solution Overview
Problem
Current printing apparatuses for printed electronics are limited in their ability to pattern various types of inks and cannot handle inks with different viscosities using a single apparatus, requiring multiple specialized apparatuses and nozzles for different printing techniques.
Innovation Solution
A single all-in-one printing apparatus with ejection head units, jetting observation units, lighting units, alignment observation units, and fluid supply units, including single-nozzle and multi-nozzle head units, capable of performing drop-on-demand, continuous, electrohydrodynamic, and electrospray printing, with syringe pumps and air pressure control modules to manage ink flow and pressure for diverse ink properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple specialized printing apparatuses are used for different printing techniques (EHD, drop-on-demand, electrospray, NFES), then each printing technique can be performed with optimized performance, but the device complexity and cost increase significantly
Solution Approach 1:
The patent implements a universal printing apparatus that can perform multiple printing techniques (EHD, drop-on-demand, electrospray, NFES) using a single device. The system includes a replaceable nozzle unit that can be exchanged between different nozzle types, allowing one apparatus to fulfill multiple specialized functions. This resolves the contradiction by maintaining optimized performance for each technique while reducing the total number of apparatuses needed.
Solution Approach 2:
The printing apparatus is segmented into modular components, particularly the nozzle unit that can be detached and replaced. This segmentation allows the system to switch between different printing techniques by changing only the nozzle component rather than replacing the entire apparatus, thereby reducing device complexity while maintaining technique-specific performance.
2Adaptability or versatility
If a single printing apparatus is used to pattern various types of inks with different viscosities, then the adaptability increases, but the device complexity and control difficulty increase
Solution Approach 1:
The system adapts to different ink viscosities by changing operational parameters such as ejection voltage, frequency, and fluid supply pressure. The control unit adjusts these parameters based on the selected nozzle type and ink properties, enabling a single apparatus to handle various ink types without increasing physical device complexity.
Solution Approach 2:
The printing apparatus incorporates dynamic control capabilities that allow real-time adjustment of ejection conditions and fluid supply based on the specific ink viscosity and desired patterning requirements. This dynamic adaptability enables versatile ink handling while maintaining a compact single-apparatus design.
3Productivity
If multiple nozzles are used together for high-speed printing, then the productivity increases, but the alignment precision and control difficulty worsen
Solution Approach 1:
The system performs preliminary alignment of multiple nozzles during the nozzle unit installation or setup phase. The control unit includes pre-programmed alignment procedures that ensure precise positioning of multiple nozzles before printing begins, thereby maintaining high alignment precision while enabling high-speed multi-nozzle printing.
Solution Approach 2:
The patent employs observation units with imaging devices to optically detect and verify nozzle alignment rather than relying solely on mechanical positioning. This substitution of optical detection for mechanical alignment verification enhances precision while maintaining productivity.
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
Enables patterning of various inks with different viscosities using a single apparatus, reducing the need for multiple printing apparatuses and nozzles, allowing for more versatile and cost-effective printing processes.
Implementation Method 1
a line width of about 1 to 30 μm may be implemented by using an electrohydrodynamic (EHD) inkjet printing technique
Implementation Method 2
a jetting observation unit which is provided at one side of the nozzle and configured to observe the ink droplet ejected from the nozzle
Implementation Method 3
a lighting unit which is provided at the other side of the nozzle and configured to provide light to the jetting observation unit
Data Source
AI summary
A printing apparatus for printed electronics according to the present invention may include: ejection head units which each have at least one nozzle for ejecting ink droplets to perform drop-on-demand or continuous printing; a jetting observation unit which is provided at one side of the nozzle and configured to observe the ink droplet ejected from the nozzle; a lighting unit which is provided at the other side of the nozzle and configured to provide light to the jetting observation unit; an alignment observation unit which is configured to observe an aligned state between the nozzle and a substrate; and a fluid supply unit which is configured to supply the ink to the nozzle, in which the ejection head units include a single-nozzle head unit, and a multi-nozzle head unit provided separately from the single-nozzle head unit.