Rolling Applicator Deposition on Polymer Template
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Solution Overview
Problem
Conventional material deposition methods, such as CVD and spin-coating, are expensive and inefficient for high-volume applications like solar cells and data storage, while existing non-vacuum techniques like inkjet printing lack the resolution required for emerging technologies.
Innovation Solution
The method involves using a polymer template with self-assembled monolayers (SAMs) and an applicator shaped like a cylinder or cone to selectively deposit functional materials onto substrates through rolling contact, leveraging capillary forces and surface energy differences to achieve precise material placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional vacuum-based deposition methods (CVD, ALD, PVD) are used, then material deposition quality is maintained, but processing cost increases and throughput decreases
Solution Approach 1:
The patent replaces vacuum-based mechanical deposition systems with a liquid-phase rolling deposition system. The applicator rolls coated with functional material are pressed against the substrate, transferring material through capillary action and surface energy differences, eliminating the need for expensive vacuum equipment while achieving comparable deposition quality at higher throughput
Solution Approach 2:
The invention changes the deposition parameters from vacuum conditions to ambient conditions, and from vapor/liquid phase to rolled liquid transfer. By controlling surface energy parameters of the template and applicator, the system achieves selective material transfer with high precision without requiring vacuum environments
2Ease of manufacture
If inkjet printing technique is used, then processing cost decreases, but resolution deteriorates to >10 um
Solution Approach 1:
The patent introduces a polymer template with self-assembled monolayers as an intermediary between the inkjet printing process and the final substrate. The template captures and concentrates the deposited material into precise patterns at sub-10 micrometer scale, transforming the low-resolution inkjet output into high-resolution functional patterns
Solution Approach 2:
The system segments the deposition process into two distinct stages: first, low-cost inkjet deposition of material onto a template; second, high-precision transfer of material from template to substrate through rolling. This segmentation allows each stage to be optimized independently for cost and precision
3Ease of manufacture
If spin-coating or immersion-coating methods are used, then material deposition is achieved, but applicability to large substrates deteriorates
Solution Approach 1:
The patent uses a roller applicator as a movable copy or template that can be repeatedly pressed against different areas of large substrates. The applicator carries the functional material and transfers it selectively to substrate regions, enabling coverage of large areas through sequential rolling operations rather than requiring the entire substrate to be processed simultaneously
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 enables cost-effective, high-throughput deposition of materials with improved resolution and selectivity, suitable for large-area substrates like solar glass panels and flat panel displays, while maintaining the ability to remove the template post-deposition.
Implementation Method 1
leveraging capillary forces and surface energy differences to achieve precise material placement
Implementation Method 2
polymer template is made of Self-assembled monolayer (SAM) and terminal group is chosen to have high affinity to the functional material, thus the material creates strong bond only at the areas of template mask
Implementation Method 3
template polymer has low surface energy, thus repels functional materials, and as a result, functional material is deposited only in the exposed areas of the substrate
Data Source
AI summary
Embodiments of the invention relate to a method of functional materials deposition using a polymer template fabricated on a substrate. Such template forms an exposed and masked areas of the substrate material, and can be fabricated using polymer resists or Self-assembled monolayers. Deposition is performed using an applicator, which is fabricated in the shape of cylinder or cone made of soft elastomeric materials or laminated with soft elastomeric film. Functional materials, for example, metals, semiconductors, sol-gels, colloids of particles are deposited on the surface of applicator using liquid immersion, soaking, contact with wetted surfaces, vapor deposition or other techniques. Then wetted applicator is contacted the surface of the polymer template and rolled over it's surface. During this dynamic contact functional material is transferred selectively to the areas of the template. Patterning of functional material is achieved by lift-off of polymeric template after deposition. According to another embodiment, where self-assembled monolayers are used as template, selective deposition of functional materials is achieved either due to low surface energy of SAM or reactivity of terminal groups.