Transport Path Correction for Precise Droplet Placement
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Solution Overview
Problem
Existing industrial printers face challenges in achieving precise deposition of ultra-thin layers due to mechanical transport system errors, such as translational and rotational inaccuracies, which result in non-uniformity and quality issues in electronic devices like OLED displays and solar panels.
Innovation Solution
The use of fine-positioning transducers with a floating pivot point to correct for mechanical imperfections in the transport path, allowing for precise alignment and deposition of droplets by counteracting errors in multiple dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mechanical transport systems are used for substrate and printhead conveyance, then device complexity is reduced, but manufacturing precision deteriorates due to translational and rotational errors in the 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 errors, the system uses software algorithms to calculate and compensate for translational 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 measured transport path errors. By dynamically adjusting these parameters in response to detected transport inaccuracies, the system compensates for mechanical errors and maintains precise droplet placement without requiring a more complex transport mechanism
2Manufacturing precision
If computational methods are used to correct transport path errors, then manufacturing precision improves, but use of energy and computing resources increases
Solution Approach 1:
The patent applies partial correction by focusing computational resources on correcting only the most significant error components (translational and rotational errors) rather than attempting to correct all possible transport path deviations. This selective approach achieves sufficient layer thickness uniformity while reducing the computational energy required compared to comprehensive error correction methods
3Manufacturing precision
If complex error correction algorithms are implemented, then manufacturing precision improves, but productivity decreases due to increased computing time
Solution Approach 1:
The patent performs error characterization and correction algorithm development in advance, before actual printing operations. By pre-calculating correction parameters and storing them for reuse, the system achieves high positional accuracy during printing without requiring extensive real-time computing, thereby maintaining high productivity
Solution Approach 2:
The patent creates a computational model (copy) of the transport path errors based on initial measurements, and then uses this model to predict and correct errors during printing. This approach allows the system to achieve accurate error compensation without performing complex real-time calculations during the printing process, thus preserving high print speeds
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 reduces the need for substantial computing resources and time, enabling a simpler, faster, and more accurate print process with improved layer uniformity and device quality.
Implementation Method 1
the transducers can be predicated on voice coils, which cooperate with a floatation table and floating, mechanical pivot assembly to provide frictionless, but mechanically-supported error correction
Implementation Method 2
the transducers can be predicated on voice coils, which cooperate with a floatation table and floating, mechanical pivot assembly to provide frictionless, but mechanically-supported error correction
Data Source
Figure 1~2A
Figure 2B~2C
Figure 2D~2E
AI summary
A printer deposits material onto a substrate as part of a manufacturing process for an electronic product. At least one mechanical component experiences mechanical error, which is mitigated using transducers that equalize position of a transported thing, e.g., to provide an "ideal" conveyance path; a substrate conveyance system and/or a printhead conveyance system can each use transducers in this manner to improve precise droplet placement. In one embodiment, errors are measured in advance, with corrections being "played back" during production runs to mitigate repeatable transport path error. In a still more detailed embodiment, the transducers can be predicated on voice coils, which cooperate with a floatation table and floating, mechanical pivot assembly to provide frictionless, but mechanically-supported error correction.