Printhead Assembly of Functional Blocks on Substrates
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Solution Overview
Problem
Existing methods for assembling functional blocks on substrates, such as pick-and-place and fluidic self-assembly, are inefficient and difficult for small devices due to serial processing and challenges in handling small sizes.
Innovation Solution
A printhead system that delivers individual functional blocks to precise locations on substrates using a heat source and light source to release them from a releasable adhesive, allowing for parallel processing and precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pick-and-place process is used to assemble functional blocks, then individual placement precision can be achieved, but the serial processing makes it slow for numerous devices
Solution Approach 1:
The system segments the functional blocks into discrete units that can be independently manipulated by the printhead, allowing parallel processing of multiple blocks simultaneously while maintaining individual placement precision through digital addressing of each segment
Solution Approach 2:
The patent replaces the mechanical pick-and-place system with a digital printing system where a printhead deposits functional blocks onto the substrate. This substitution enables parallel deposition of multiple blocks in a single pass, dramatically increasing assembly speed while maintaining precision through digital control of the printhead positioning and deposition timing
2Ease of operation
If pick-and-place process is used, then individual block placement is possible, but it is difficult for very small devices because the pick and place unit is hard to make in a small size
Solution Approach 1:
The patent replaces complex mechanical grippers and positioning mechanisms with a digital printing printhead that can deposit extremely small functional blocks. This substitution eliminates the need for large mechanical structures, enabling the system to handle very small devices that would be impossible to manipulate with traditional pick-and-place machinery
Solution Approach 2:
The printhead system serves multiple functions: it positions, deposits, and secures functional blocks in a single operation. This multi-functionality eliminates the need for separate handling mechanisms, reducing overall system complexity and size while maintaining the ability to place individual blocks of varying sizes
3Productivity
If fluidic self assembly process is used, then parallel assembly can be achieved, but the functional blocks randomly align onto receptor regions reducing precision
Solution Approach 1:
The patent replaces the fluidic self-assembly mechanism with a digitally controlled printhead deposition system. This substitution maintains the parallel assembly capability of fluidic methods while introducing precise digital control over block placement, eliminating random alignment and achieving both high throughput and high precision simultaneously
Solution Approach 2:
The system incorporates feedback mechanisms where the printhead positioning is controlled by digital coordinates that specify exact deposition locations. This feedback control ensures that functional blocks are placed with high precision on receptor regions while maintaining the ability to process multiple blocks in parallel, resolving the contradiction between speed and 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
Enables efficient and precise assembly of functional blocks, particularly for small devices, by allowing for high-speed delivery and positioning of functional blocks with improved accuracy and reduced processing time.
Implementation Method 1
The releasing mechanism comprises a heat source to provide thermal energy
Implementation Method 2
a light source to provide photon energy, wherein the heat source and the light source enable releasing individual functional blocks from the reservoir
Data Source
AI summary
The present invention relates to methods and apparatuses for assembling substrates with functional blocks, using a printhead to deliver individual functional blocks to the appropriate locations on the substrates. In an embodiment, the functional block releasing mechanism comprises a heat source to provide thermal energy and a light source to provide photon energy, wherein the heat source and the light source enable releasing individual functional blocks from the reservoir for positioning on the substrate. The heat source can comprise an array of heating elements, such as thin film heating elements, which can provide localized heating to individual elements, thus enabling releasing individual functional blocks. The light source can comprise a laser beam and a moving mechanism to move the laser beam to the individual functional blocks.