JP2017018951A - Device and method for control of print gap - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide: a thin film printer with a gas support system for closely controlling a gap between a transfer surface of a print head and a base material to which a material is printed; and a printing method.SOLUTION: A gas support system 20 accommodates one or more printing module packages 32, is provided with inkjet and/or thermal printing such as manufacturing of an organic light emitting device (OLED), etc., uses one or more of pressurized gas and vacuum, uses inactive gas such as nitrogen gas as the pressurized gas for oxygen sensitive use, in which first, second fluid channels 48, 50 and first, second openings 44, 46 of a gas support system 32 can be changed from viewpoints of size and a relative position to each other, the first, second fluid channels 48, 50 and the first, second openings 44, 46 are constituted of a group or a pair of one or more manifolds, and the pressurized gas and/or a vacuum source.SELECTED DRAWING: Figure 1

Description

(Cross-reference to related applications)
This application claims the benefit of US Provisional Patent Application No. 13 / 570,154, which claims the benefit of US Provisional Patent Application No. 61 / 521,604, filed Aug. 9, 2011. All cross-reference applications listed herein are incorporated by reference in their entirety.

(Field of Invention)
The present teachings relate to thin film printing apparatus and methods.

(Background of the Invention)
In various situations, it may be beneficial for the print head to maintain a tightly controlled gap between its transfer surface or discharge nozzle and the substrate surface on which the print head prints material. Such control is particularly important in printing using a thermal printing printhead designed to deposit dry ink without contacting the surface on which the dry ink is deposited. If the print head is too far away from the substrate surface, the print can spread excessively. If the print head is too close to the substrate surface, the print can become excessively grainy. When too close, the print head can even contact the substrate and cause damage to both the substrate and the print head. Gap control between the inkjet print head and the substrate is also important in inkjet printing. Therefore, it is desirable to optimize printing results and printing processes by controlling the printing gap between the substrate and the print head in both thermal and inkjet printing systems.

US Patent Application Publication No. 2008/0308307 US Patent Application Publication No. 2008/0311307 US Patent Application Publication No. 2008/0311289 US Patent Application Publication No. 2006/0115585 US Pat. No. 7,908,885 US Pat. No. 7,857,121 US Pat. No. 7,604,439 US Pat. No. 7,603,028 US Pat. No. 7,530,778 US Patent Application Publication No. 2010/0188457 US Patent Application Publication No. 2011/0008541 US Patent Application Publication No. 2010/0171780 US Patent Application Publication No. 2010/0201749

(Overview)
According to various embodiments, the present teachings hold the printhead and print module package and maintain a tightly controlled gap between the printhead transfer surface and the substrate on which the material is printed. It relates to a gas support system that can be used. The system includes a housing having a sidewall having an outer surface and an inner surface. The sidewall defines an internal cavity configured to receive the printing module package. The inner surface can terminate at an opening to the inner cavity. The sidewall can also have an end surface between its outer surface and its inner surface, and the end surface can comprise a first plurality of openings and a second plurality of openings. The first plurality of fluid channels can be included in the sidewalls, can extend into the sidewalls from the first plurality of openings, and can be in fluid communication with the first manifold. The first manifold can be inside the sidewall, outside, or both. The second plurality of fluid channels can be included in the sidewall, can extend into the sidewall from the second plurality of openings, and can be in fluid communication with the second manifold. The second manifold can be inside the sidewall, outside, or both. The first manifold can be in fluid communication with the environment outside the housing, for example, via a first port. The second manifold can be in fluid communication with the environment outside the housing, for example, via a second port.

  According to various embodiments, a print gap control system is provided comprising a gas support system as described herein and a substrate comprising a first planar surface. The system has a gas-supported end surface in a first plane and at least one transfer surface of at least one ink jet print head or thermal printing print head in a second plane, the first surface of the substrate. The planar surface can be configured to be in the third plane. The first, second, and third planes can be substantially parallel to each other. The gas support gap can be defined by the distance between the first plane and the third plane. The print gap can be defined by the distance between the second plane and the third plane. At least one of the end surface, the transfer surface, and the first planar substrate surface of the substrate may be adjustable to control the size of the print gap, the size of the gas support gap, or both. It should be understood that in some embodiments, the print gap can be controlled by controlling the gas support gap.

According to various embodiments of the present teachings, the method includes positioning the print module package relative to the substrate and printing the material on the substrate by using the print module package. Provided. Positioning can be accomplished using a gas support system as described herein, for example, the system comprises a housing and the housing comprises a sidewall defining an internal cavity. The sidewall can have an outer surface and an inner surface, and the printing module package can be received within the internal cavity. The inner surface can terminate at an opening to the inner cavity. The method can include mounting a printing module package within the internal cavity. The sidewall can further have an end surface between the outer surface and the inner surface, and the end surface can comprise a first plurality of openings and a second plurality of openings. The sidewall can further comprise a first plurality of fluid channels extending from the first plurality of openings into the sidewall and in communication with the first manifold, the method comprising: Supplying a source of pressurized gas from one manifold to the first plurality of fluid channels can be included. In addition, the sidewall can comprise a second plurality of fluid channels extending from the second plurality of openings into the sidewall and in communication with the second manifold, the method comprising a second to a vacuum source. Generating a vacuum from a plurality of fluid channels to a second manifold and to a second manifold. The first manifold can be in fluid communication with the environment outside the housing, for example, via a first port, and the second manifold can be external to the housing, for example, via a second port. In fluid communication with the environment. The method can include controlling the print gap using a combination of pressurized gas and vacuum to and from the first and second plurality of openings. .
For example, the present invention provides the following.
(Item 1)
A gas support system, the gas support system comprising:
A housing having a sidewall having an exterior surface and an interior surface, the sidewall defining an interior cavity configured to receive a print module package, the interior surface being an opening to the interior cavity. The sidewall further includes an end surface between the outer surface and the inner surface, the end surface including a first plurality of openings and a second plurality of openings, and the sidewall further includes the first A first plurality of fluid channels extending from the plurality of openings into the sidewall and communicating with the first manifold; and a second manifold extending from the second plurality of openings into the sidewall. A second plurality of fluid channels in communication with the first manifold, wherein the first manifold is in fluid communication with an environment outside the housing via a first port, and the second manifold is a second manifold. Environment outside the enclosure through the port In fluid communication, said first plurality of apertures and the second plurality of openings surrounds the opening to the internal cavity, a gas support system.
(Item 2)
The gas support system of claim 1, wherein the end surface further comprises a third plurality of fluid channels extending into the sidewall and communicating with a third manifold that is different from the first manifold and the second manifold. .
(Item 3)
The gas support system of claim 2, wherein the third manifold is in fluid communication with an environment outside the housing through a third port.
(Item 4)
The gas support system of claim 1, wherein individual apertures of the first plurality of openings and the second plurality of openings are spaced apart from each other by an average distance of about 1.0 mm to about 10 mm.
(Item 5)
The gas support system of claim 1, wherein the apertures of the first plurality of openings and the second plurality of openings have an average diameter of about 0.001 inches to about 0.1 inches.
(Item 6)
The first plurality of openings has an average diameter of about 0.005 inches to about 0.025 inches, and the second plurality of openings has an average diameter of about 0.030 inches to about 0.090 inches. The gas support system according to item 1, comprising:
(Item 7)
The gas support system of claim 1, wherein the first plurality of fluid channels are in fluid communication with a pressurized gas source and the second plurality of fluid channels are in fluid communication with a vacuum source.
(Item 8)
Item 8. The gas support system of item 7, wherein the pressure gas source comprises a pressurized inert gas source.
(Item 9)
9. The gas support system of item 8, wherein the pressurized inert gas source comprises a nitrogen gas source, a noble gas source, or a combination thereof.
(Item 10)
The gas support system according to item 1, wherein the housing includes a base plate, a manifold compartment attached to the base plate, and a face plate attached to the manifold, and the face plate includes the end face.
(Item 11)
Item 11. The gas support system of item 10, wherein the base plate comprises the first port and the second port, and the manifold compartment comprises the first manifold and a second manifold.
(Item 12)
4. The gas support system according to item 3, wherein the housing includes a base plate, a manifold compartment attached to the base plate, and a face plate attached to the manifold, and the face plate includes the end face.
(Item 13)
In item 12, wherein the base plate comprises the first port, the second port, and a third port, and the manifold compartment comprises the first manifold, the second manifold, and a third manifold. The gas support system as described.
(Item 14)
The gas support system of claim 10, further comprising a connector flange connected to the base plate and configured for connection to at least one of a support and an actuator.
(Item 15)
The apparatus further comprises a second opening to the internal cavity, the second opening being located opposite to the first opening such that the internal cavity has a through hole through the housing. The gas support system according to Item 1.
(Item 16)
The gas support system of claim 1, further comprising at least one printing module package mounted within the internal cavity.
(Item 17)
The gas of claim 16, wherein the at least one printing module package comprises at least one thermal printing printhead having at least one transfer surface and at least one heater in thermal communication with the at least one transfer surface. Support system.
(Item 18)
The gas support system of claim 16, wherein the at least one print module package comprises at least one inkjet printhead.
(Item 19)
A printing gap control system, the printing gap control system comprising:
A gas support system according to item 18, and
And the end surface is in a first plane, the at least one inkjet printhead is in a second plane, and the first plane surface of the substrate is in a third plane , The first plane, the second plane, and the third plane are substantially parallel to each other, and the gas support gap is a distance between the first plane and the third plane. And the print gap is defined by the distance between the second plane and the third plane, and is defined by the end face, the inkjet print head, and the first plane surface of the substrate. A print gap control system, wherein at least one is adjustable to control the size of the print gap.
(Item 20)
Item 19 further comprising a second gas support system facing the first gas support system, wherein the substrate is positioned between the first gas support system and the second gas support system. Printing gap control system as described in.
(Item 21)
Item 21. The print gap control system of item 20, wherein the second gas support comprises a plurality of pressurized gas channels and, optionally, a plurality of vacuum channels.
(Item 22)
Item 20. The print gap control system of item 19, wherein the gas support system is positioned above the substrate.
(Item 23)
Item 20. The print gap control system of item 19, wherein the gas support system is positioned below the substrate.
(Item 24)
Using a gas support system to position a printing module package relative to a first planar substrate surface, the gas support system comprising a housing, the housing having an outer surface and an inner surface Comprising a side wall, the side wall defining an interior cavity configured to receive a printing module package, the inner surface terminating in an opening to the inner cavity, the side wall further comprising the outer surface and the inner surface. An end surface between the plurality of openings, the end surface including a first plurality of openings and a second plurality of openings, and the side wall further extends into the side wall from the first plurality of openings. A first plurality of fluid channels in communication with one manifold and a second plurality of fluid channels in the side walls extending from the second plurality of openings and in communication with a second manifold; First Maniho And the second manifold is in fluid communication with the environment outside the housing through a first port, and the second manifold is in fluid communication with the environment outside the housing through a second port; ,
Using the printing module package to print material onto the first planar substrate surface.
(Item 25)
25. The method of item 24, wherein the first plurality of openings and the second plurality of openings surround the opening to the internal cavity.
(Item 26)
25. A method according to item 24, wherein the printing comprises solid transfer printing.
(Item 27)
25. A method according to item 24, wherein the printing comprises inkjet printing.
(Item 28)
The positioning includes maintaining a positive flow of fluid from the first manifold through the first plurality of fluid channels and into the second plurality of fluid channels. 25. The method of item 24, comprising maintaining a negative flow of fluid through.
(Item 29)
The print module package comprises a printhead transfer surface or inkjet nozzle orifice, the printhead transfer surface or inkjet nozzle orifice faces the first planar substrate surface and is spaced apart from each other by a print gap, 25. The method of item 24, wherein positioning includes controlling a size of the print gap by controlling fluid flow through at least one of the first manifold and second manifold. .
(Item 30)
30. The method of item 29, wherein the printing gap has a distance of about 5 μm to about 100 μm.
(Item 31)
30. The method of item 29, wherein the printing gap has a distance of about 20 [mu] m to about 30 [mu] m.
(Item 32)
30. A method according to item 29, wherein the printing gap has a distance of about 25 [mu] m.
(Item 33)
25. The method of item 24, further comprising flowing an inert gas through the first plurality of fluid channels at a pressure of about 30 psig to about 90 psig.
(Item 34)
25. The method of item 24, further comprising pulling a vacuum through the second plurality of fluid channels at a negative pressure of about −5.0 psig to about −13 psig.
(Item 35)
Positioning a second gas support system adjacent to the second planar substrate surface and opposite the first gas support system, the second gas support system including the first gas support system; 25. The method of item 24, further comprising: positioning the planar substrate surface of the substrate to maintain a desired print gap.
(Item 36)
25. A method according to item 24, wherein the gas support system is positioned above the substrate.
(Item 37)
25. A method according to item 24, wherein the gas support system is positioned below the substrate.

  A further understanding of the features and advantages of the present disclosure may be obtained by reference to the accompanying drawings, which are intended to illustrate but not limit the present teachings.

FIG. 1 is a cross-sectional side view of a gas support system, a print module package positioned therein, a substrate printed thereon, and a substrate support, according to various embodiments of the present teachings.

FIG. 2 is a cross-sectional side view of a gas support system, a print module package positioned therein, a substrate, and a substrate positioning system, according to various embodiments of the present teachings.

FIG. 3 is a bottom perspective exploded view of a gas support system in accordance with various embodiments of the present teachings.

4 is a left bottom perspective view of the gas support system shown in FIG. 3 in an assembled state and the print module package adjustably mounted therein.

FIG. 5 is a perspective view of the gas support system shown in FIG. 3 upside down in an assembled state and the print module package adjustably mounted or secured therein.

6 is a right bottom perspective view of the gas support system and printing module package shown in FIG.

FIG. 7 is a perspective view of the gas support system and printing module package shown in FIGS. 5 and 6 secured to a rotary actuator and positioned to perform a thermal printing operation.

(Detailed explanation)
According to various embodiments of the present teachings, a gas support system includes a housing having side walls, the side walls including an outer surface and an inner surface. The sidewall defines an internal cavity configured to receive the printing module package. The inner surface can terminate at the top, the bottom, or both, and define an opening to the internal cavity. The internal cavity can form a through hole through the housing or can have only a single opening at one end. The sidewall can also have an end surface between its outer surface and its inner surface, and the end surface can comprise a first plurality of openings and a second plurality of openings. The first plurality of fluid channels can be included in the sidewalls, can extend into the sidewalls from the first plurality of openings, and can be in fluid communication with the first manifold. The second plurality of fluid channels can be included in the sidewall, can extend into the sidewall from the second plurality of openings, and can be in fluid communication with the second manifold. Each of the first manifold and the second manifold can independently be inside the sidewall, outside the sidewall, or both. The first manifold can be in fluid communication with the environment outside the housing, for example, via a first port. The second manifold can be in fluid communication with the environment outside the housing, for example, via a second port. A conduit, such as tubing, can be in fluid communication with each of the manifolds and can be further connected to a source of pressurized gas, a vacuum source, or both. The first plurality of openings and the second plurality of openings can be arranged to surround the opening to the internal cavity. The internal cavity can have a cross-sectional shape that is square, rectangular, round, or any other shape. The opening can surround the opening to the internal cavity on two sides, three sides, four sides, or at least five sides.

  In some embodiments, the end surface of the sidewall can further comprise a third plurality of fluid channels, the third plurality of fluid channels extending into the sidewall, and the first and second manifolds and Communicate with a different third manifold. The third manifold can be in fluid communication with the environment outside the housing, for example, via a third port. The third manifold can be in fluid communication with a pressurized gas source, a vacuum source, or both. The third manifold can be in fluid communication with the same pressurized gas source in fluid communication with the first manifold, or in fluid communication with a different pressurized gas source. The individual openings of the first and second plurality of openings may have an average distance of about 0.5 mm to about 20 mm, for example, an average distance of about 1.0 mm to about 10 mm, about 2.0 mm to about An average distance of 8.0 mm, or an average distance of about 3.0 mm to about 6.0 mm can be spaced from adjacent apertures. The apertures of the first and second plurality of apertures have an average diameter of about 0.001 inches to about 0.1 inches, for example, an average diameter of about 0.003 inches to about 0.075 inches, about 0 It can have an average diameter of .005 inches to about 0.05 inches, or an average diameter of about 0.01 inches to about 0.04 inches. In some embodiments, the first plurality of openings can have an average diameter of about 0.005 inches to about 0.025 inches, and the second plurality of openings is about 0.030 inches to about 0.025 inches. It can have an average diameter of 0.090 inches.

  According to various embodiments, the first plurality of fluid channels can be in fluid communication with a pressurized gas source and the second plurality of fluid channels can be in fluid communication with a vacuum source. The pressurized gas source can comprise a pressurized inert gas source, such as a nitrogen gas source, a noble gas source, or a combination thereof.

  In some embodiments, the housing may comprise a plurality of components, such as a base plate, a manifold compartment mounted on the base plate, and a face plate mounted on the manifold. In an exemplary configuration, the face plate comprises an end face. The base plate can comprise first and second ports, and the manifold compartment can comprise first and second manifolds. In some embodiments, the base plate comprises a third port and the manifold compartment comprises a third manifold. In some embodiments, the base plate can include first, second, and third ports, and the manifold compartment can include first, second, and third manifolds. In some embodiments, one or more of the manifold compartments or manifolds can comprise one or more of the ports. A connector flange can be connected to the base plate and can be configured to connect to at least one of the support and the actuator. One or more of the components may define sidewalls or may partially define sidewalls, for example, a stack of components including a faceplate together define sidewalls, internal cavities, or both can do.

  In some embodiments, the housing can provide a second opening to the internal cavity. The second opening can be located opposite the first opening such that the internal cavity can include a through hole extending through the entire housing. At least one printing module package can be mounted within the internal cavity. In some cases, the at least one printing module package includes at least one inkjet printhead or at least one thermal printing printhead having at least one transfer surface, and at least one in thermal communication with the at least one transfer surface. And two heaters. In some embodiments, the second opening allows exhaust to be emitted from the internal cavity. The second opening may allow printing module package loading from the top of the system, from the bottom of the system, or both. It should be understood that the orientation of the gas support system can be varied and that the indications such as top and bottom are intended to be relative terms rather than absolute terms. In some embodiments, the features are inverted so that the second opening can allow the print module package to be loaded from the bottom of the system.

  According to various embodiments, a print gap control system is provided comprising a gas support system as described herein and a substrate comprising a first planar surface. The system can be configured such that the end surface is in a first plane, the at least one transfer surface is in a second plane, and the first planar substrate surface is in a third plane. The first, second, and third planes are substantially parallel to each other, i.e., parallel to each other or tilted by an angle of less than 10 ° or less than 5 ° with respect to each other. be able to. The gas support gap can be defined by the distance between the first plane and the third plane. The print gap can be defined by the distance between the second plane and the third plane. At least one of the end face, the inkjet printhead or transfer surface, and the first planar substrate surface can be adjustable to control the size of the print gap, the size of the gas support gap, or both. . The print gap can be controlled independently and / or by controlling the size of the gas support gap. The gas support system can be positioned above, below, or above and below the substrate. The gas support system comprises one or more actuators or is operatively associated with one or more actuators, for the substrate and / or for the one or more inkjet printheads. Allows you to adjust the position.

  A second gas support system can be provided facing the first gas support system such that the substrate is positioned between the first gas support system and the second gas support system. . The second gas support system can also comprise a plurality of pressurized gas channels and optionally a plurality of vacuum channels. The pressurized gas channel and the vacuum channel can be arranged in any desired configuration. In some embodiments, every other or alternate fluid channel comprises a pressurized channel and a vacuum channel. A second gas support that can be mounted in the chuck can provide temperature control for the substrate. That is, in addition to providing force to the substrate, the second gas support can transfer heat to and / or from the substrate to achieve heating and / or cooling of the substrate. Such thermal control can be advantageous compared to direct contact with a heating element, eg, a heated chuck. The heating and cooling channels can be arranged in any desired configuration. In some embodiments, every other fluid channel can comprise a heating channel or a cooling channel. In some embodiments, alternating fluid channels comprise heating channels, cooling channels, heating channels, cooling channels, and the like. Thermal control can also be used to control the size of the substrate because heat can tend to expand the substrate and cooling can tend to shrink the substrate. Maintaining a constant size is advantageous. Thermal size changes can be significant, especially for larger substrates, for example, thermal size changes are significant for Generation 8 size glass (2.2 m × 2.5 m). Uncontrolled thermal changes of the substrate can adversely affect product quality by shifting the ink deposition on the substrate horizontally and / or vertically. In some embodiments, the print gap can have a tolerance of about +/− 10 μm, +/− 7 μm, or +/− 5 μm.

  According to various embodiments of the present teachings, a method is provided that includes positioning a print module package relative to a substrate and printing the material onto the substrate by using the print module package. The Positioning can be accomplished using a gas support system as described herein, for example, the gas support system comprises a housing, and the housing defines an internal cavity. The sidewall can have an outer surface and an inner surface, and the printing module package can be received within the internal cavity. The inner surface can be terminated with an opening to the inner cavity, and the method can include mounting a print module package in the inner cavity. The sidewall can further have an end surface between the outer surface and the inner surface, and the end surface can comprise a first plurality of openings and a second plurality of openings. The method can include supplying pressurized gas to and through the first plurality of openings and pulling a vacuum through the second plurality of openings. The sidewall may further comprise a first plurality of fluid channels extending from the first plurality of openings into the sidewall and in communication with the first manifold. In addition, the sidewall can comprise a second plurality of fluid channels extending from the second plurality of openings into the sidewall and in communication with the second manifold. The method can include supplying pressurized gas to the first manifold and applying a vacuum to the second manifold. The first manifold can be in fluid communication with the environment outside the housing, for example, via a first port, and the second manifold can be external to the housing, for example, via a second port. In fluid communication with the environment. Tubing, piping, or other conduits can connect the first manifold and the source of pressurized gas, and can connect the second manifold and vacuum. In some embodiments, the first plurality of openings and the second plurality of openings surround the opening to the internal cavity.

  In some embodiments, the printing comprises thermal printing (eg, thermal printing including inkjet printing using a printing module package, followed by inkjet transfer followed by solid transfer printing by solid sublimation or evaporation). be able to. Examples of thermal printing and printing module packages that can be used in accordance with the present teachings are described, for example, in US Patent Application Publication Nos. US2008 / 0308307A1, US2008 / 0311307A1, US2008 / 0311289A1, and US2006 / 0115585A1. Which are incorporated herein by reference in their entirety. The print module package can comprise a printhead transfer surface and / or an inkjet nozzle orifice, the substrate can comprise a first surface, and the printhead transfer surface and / or the inkjet nozzle orifice can be provided on the substrate. Facing the first surface can be spaced apart from each other by a printing gap. The printhead transfer surface can receive deposited ink by inkjet printing, for example, from an inkjet printing subsystem. In some embodiments, one or more printhead transfer surfaces are rotated to receive ink and / or rotated to face the substrate to be printed. In some embodiments, one or more ink jet print heads are rotated to transfer ink to one or more print head transfer surfaces. The gas support system and / or printhead transfer surface can be positioned above, below, or above and below the substrate during printing. In some embodiments, printing can include ink jet printing directly on the substrate. In such embodiments, the print module package can comprise an inkjet printhead. For example, the print module package can comprise a SAMBA printhead module (FUJIFILM Dimatix, Inc., Santa Clara, California). The gas support system and / or ink jet print head can be positioned above, below, or above and below the substrate during printing.

  Positioning the gas support system relative to the substrate can include controlling the size of the print gap by controlling fluid flow through at least one of the first and second manifolds. In some embodiments, positioning includes maintaining a positive flow of fluid from the first manifold through the first plurality of fluid channels and into the second plurality of fluid channels. Maintaining a negative flow of fluid through the manifold. Positioning can include controlling the size of the print gap, the gas support gap, or both by adjusting the flow of pressurized gas, vacuum, or both. The control unit can be used to provide control of a pressurized gas source, a vacuum source, or both.

  In some embodiments, the print gap can be defined as a distance of about 5 μm to about 100 μm, such as a distance of about 20 μm to about 30 μm, or a distance of about 25 μm. The method includes, for example, flowing an inert gas through the first plurality of fluid channels at a pressure of about 10 psig to about 200 psig, a pressure of about 30 psig to about 90 psig, a pressure of about 50 psig to about 70 psig, or a pressure of about 60 psig. By doing so, a printing gap can be maintained or provided. The positioning further includes a negative pressure of about −3.0 psig to about −13 psig, a negative pressure of about −5.0 psig to about −10 psig, or about −7.5 psig through the second plurality of fluid channels. It may include drawing a vacuum with a negative pressure. In some cases, printing can include printing on a first surface of the substrate, the substrate having a second surface opposite the first surface, the method comprising: The method further includes positioning a second gas support system adjacent to the second surface of the substrate and opposite the first gas support system. The second gas support system can be configured to position the first surface of the substrate and maintain a desired print gap. The second gas support system can be used instead of or in addition to the first gas support system.

  Various embodiments of the present teachings relate to an apparatus and method for using air support to maintain and control printing gaps and to control the environment surrounding the ink deposition printing process. For example, ink deposition can be performed in a non-oxidizing environment. In some embodiments, the print head is mounted in a gas support housing such that the set gap is fixed at a specific distance that can be as close to 0 mm as possible. The set gap corresponds to the distance between the transfer surface of the print head and the end surface of the gas support housing. The gas support gap is the distance between the end face and the substrate. Regardless of whether the substrate moves below the print head and / or the print head moves above the substrate, there is a relative motion between the print head and the substrate in any case. . By pressurizing the fluid passage of the gas support casing, gas flows out of the opening into the casing, and a gas support gap is maintained between the end surface of the gas support casing and the base material. In this way, the printing gap is the sum of the gas support gap and the set gap, so that the printing gap is controlled by these other two gaps. For example, subtle changes of about a few microns can be introduced into the print gap by changing the gas pressure in the gas support housing. The flow of gas from the gas support housing to the exhaust holes creates an environment filled with support gas. If the ink is sensitive to oxygen gas, non-oxygen gas and / or an inert gas such as nitrogen gas can be used to provide a non-oxidizing environment. The process of evaporating the liquid ink in or on the print head can generate solvent vapor. The exhaust opening allows both removal of nitrogen gas injected by the gas support system and removal of solvent evaporation emitted during evaporation of the liquid ink.

  In some embodiments, both pressure and vacuum sources are employed in defining the desired print gap. In some embodiments, a vacuum source and a nitrogen gas pressure source are provided. These sources are arranged, for example, in fluid communication with respective channels in a gas support housing arranged around the print head, so that a gas support gap can be established. The printing gap can be variable with respect to the support housing. The gas support housing and the print head can be placed adjacent to a substrate, eg, glass. The print head can deposit a film material (eg, an ink comprising a film-forming material dissolved or suspended in a carrier fluid) on a substrate. In some embodiments, the substrate is supported via a chuck with a gas lift or gas support system. In some embodiments, the substrate is supported via a vacuum chuck that contacts the substrate.

  As mentioned above, the gas support system of the present teachings can be used alone or in combination with one or more additional gas support systems. The additional gas support system can utilize any gas or mixture of gases. The additional gas support system may use the same or different gas or gaseous mixture as included in a gas encapsulation system (eg, a system that encapsulates a thermal printing operation). In some embodiments, the air support uses an inert gas, such as nitrogen gas, one or more noble gases, or combinations thereof. Gas support systems and related methods and systems that can be used are described in New Way Machine Components, Inc. (Aston, Pennsylvania). They can be used alone or in combination with the gas support system described in the present teachings. Devices, systems, methods, and applications relating to gas support systems that can be used in connection with the present teachings include, for example, those described in US Pat. No. 7,908,885B2, which is incorporated by reference in its entirety. Is incorporated herein by reference. Coreflow Scientific Solutions LTD. The gas support system and related methods and systems available from (Yoqneam, Israel) can also be used alone or in combination with the gas support system described in the present teachings. Devices, systems, methods, and applications relating to gas support systems that can be further used in connection with the present teachings are, for example, US Pat. Nos. 7,857,121B2, US7,604,439B2, US7,603,028B2. No., and those described in US Pat. No. 7,530,778 B2, which are incorporated herein by reference in their entirety.

  Aspects of the present teachings include, for example, U.S. Patent Application Publication Nos. No. 61 / 521,631 (named “Face-Down Thermal-Jet Printing Apparatus and Methods”), which may be implemented herein by reference in its entirety. Incorporated into.

  FIG. 1 is a cross-sectional view of a gas support system 20 in accordance with various embodiments of the present teachings. The gas support system 20 includes a housing 22 that includes a side wall 24. The side wall 24 includes an outer surface 26 and an inner surface 28. The inner surface 28 defines an internal cavity 30 that is configured to receive the printing module package 32. The inner surface 28 terminates in a cavity opening 34 in the inner cavity 30. The end surface 36 is disposed between the inner surface 28 and the outer surface 26. Opposite the end face 36 is an annular end portion 38 with a second cavity opening 40. The second cavity opening 40 can include a through hole 42. The first opening 44 and the second opening 46 can be located on the end face 36. A first fluid channel 48 that extends into the sidewall 24 of the housing 22 may extend from the first opening 44. The second fluid channel 50 can extend from the second opening 46 into the sidewall 24 of the housing 22.

  As seen in FIG. 1, the printing module package 32 can include a transfer surface 52 from which material is transferred onto a substrate 56, and more specifically onto a substrate surface 57. The deposited material 54 can be formed. The print gap 58 is defined as the distance between the transfer surface 52 and the substrate surface 57. The gas support gap 60 is defined as the distance between the end face 36 and the substrate surface 57. Set gap 62 is defined as the difference between gas support system gap 60 and print gap 58 that is the same as the distance between transfer surface 52 and end surface 36.

  FIG. 2 is a schematic cross-sectional view of a gas support system 120 in accordance with various embodiments of the present teachings. The gas support system 120 includes a housing 122 and the housing 122 includes a side wall 124. The side wall 124 includes an outer surface 126 and an inner surface 128 and defines an internal cavity 130. The internal cavity 130 is configured to receive the printing module package 132 through the cavity opening 134. Between the outer surface 126 and the inner surface 128 is an end surface 136. The second cavity opening 138 can be located opposite the cavity opening 134. The end surface 136 can include a first opening 140 and a second opening 142. The first fluid channel 144 can extend from the first opening 140 into the sidewall 124 of the housing 122. The second fluid channel 146 can extend from the second opening 142 into the sidewall 124 of the housing 122.

  As seen in FIG. 2, the first fluid channel 144 and the second fluid channel 146 can be in fluid communication with the first manifold 148. The end surface 136 can further include a third opening 150, a fourth opening 152, a fifth opening 154, and a sixth opening 156. The third fluid channel 158 can extend from the third opening 150 into the sidewall 124 of the housing 122, and the fourth fluid channel 160 extends from the fourth opening 152 into the sidewall 124 of the housing 122. The fifth fluid channel 162 can extend from the fifth opening 154 into the sidewall 124 of the housing 122, and the sixth fluid channel 164 extends to the sixth opening 156. Can extend into the side wall 124 of the housing 122. Third fluid channel 158, fourth fluid channel 160, fifth fluid channel 162, and sixth fluid channel 164 can be in fluid communication with second manifold 166. In some embodiments, the pressurized gas source 168 is in fluid communication with the first manifold 148. In some embodiments, the vacuum source 170 is in fluid communication with the second manifold 166. The transfer surface 172 of the printing module package 132 can be configured to deposit a material, eg, a film-forming material, on the substrate. The deposited material 174 can be located on the substrate 176, more specifically on the substrate surface 178. The print gap 180 can be defined as the distance between the transfer surface 172 and the substrate surface 178. The gas support system gap can be defined as the distance between the end face 136 and the substrate surface 178. The set gap can be defined as the distance between the end surface 136 and the transfer surface 172. In some embodiments, a second gas support system 186 is provided. The second gas support system 186 can include a plurality of openings 188 in fluid communication with a plurality of fluid channels (not shown). The opening 188 can face the second substrate surface 190 of the substrate 176.

  FIG. 3 is an exploded view of a gas support system 220 according to various embodiments of the present teachings. The gas support system 220 can include a plurality of fasteners 222 for securing the face plate 224, the manifold assembly cover 226, the manifold assembly base 228, and the base plate 230 together. The fastener 222 can include a first fastener 232, a second fastener 234, a third fastener 236, and a fourth fastener 238. The face plate 224 can include an end surface 240. The end surface 240 can receive the fastener 222. A first fastener hole portion 242, a second fastener hole portion 244, a third fastener hole portion 246, and a fourth fastener hole portion 248 extending from the end surface 240 into the face plate 224 are provided. be able to. The face plate 224 can include an outer surface 250 and an inner surface 252. The inner surface 252 can define an inner cavity portion 254 as well as a first inner cavity opening 255. A plurality of fluid channel portions 256 can be disposed in the faceplate 224 between the inner surface 252 and the outer surface 250. Each fluid channel portion 256 may terminate at a respective opening (not shown) on the end face of faceplate 224.

  The manifold assembly cover 226 can include a first fastener hole portion 258, a second fastener hole portion 260, a third fastener hole portion 262, and a fourth fastener hole portion 264. The fastener hole portion can be disposed between the outer surface 266 and the inner surface 268 of the manifold assembly cover 226. The inner surface 268 can define an inner cavity portion 270. A plurality of fluid channel portions included within the complementary manifold portion 274 can be disposed between the inner surface 268 and the outer surface 266.

  The manifold assembly base 228 can include a first fastener hole portion 276, a second fastener hole portion 278, a third fastener hole portion 280, and a fourth fastener hole portion 282. The fastener hole portion of the manifold assembly base 228 can be positioned between the outer surface 284 and the inner surface 286 of the manifold assembly base 228. The inner surface 286 can define an internal cavity portion 288. Outer surface 284 and inner surface 286 may also define a plurality of fluid channel portions within complementary manifold portion 292 therebetween. The port receiving opening 294 can extend from the outer surface 284.

  The base plate 230 can include a first port 296, a second port 298, and a third port 300. The first fluid line 302 can be connected to the first port 296. The second fluid line 304 can be connected to the second port 298. The third fluid line 306 can be connected to the third port 300. The faceplate 230 can include a main baseplate portion 308. The main baseplate portion 308 can comprise an internal cavity portion 310 and a second internal cavity opening 312. The inner base surface 314 can face the manifold assembly base 228. The outer base surface 316 of the base plate 230 is similar to the end surface 240 of the face plate 224 but can face outward in the opposite manner. A plurality of printing module package adjustment screw receiving holes may be disposed in the outer base surface 316. These may include a first print module package adjustment screw receiving hole 318 and a second print module package adjustment screw receiving hole 320. Other adjustment screw receiving holes can also be provided, for example, one for each adjustment screw on the printing module package. The base plate 230 can further include a flange 326. The flange 326 can be configured for attachment to, for example, an actuator, robot arm, rotary actuator, support component, or the like. The flange 326 can include a first flange fastener receiving hole 328, a second flange fastener receiving hole 330, a third flange fastener receiving hole 332, and a fourth flange fastener receiving hole 334.

  FIG. 4 is a left bottom perspective view of the gas support system 220 assembled and shown adjacent to the print module package 336. A first fastener 232, a second fastener 234, a third fastener 236, and a fourth fastener 238 are shown disposed through the end surface 240 and include a face plate 224, a manifold assembly cover 226, a manifold assembly base 228, and The base plate 230 is fixed together. The print module package 336 includes a print head 338 as its top end. The print head 338 can include one or more transfer surfaces 340. The print module package 336 can include one or more print module package adjustment devices, such as linear adjustment screws. FIG. 4 shows a first print module package adjustment screw 342, a second print module package adjustment screw 344, and a third print module package adjustment screw 346. Any number, eg, 3 or 4 adjustment screws can be used. The linear adjustment screw aligns the θx and y rotations of the print head 338 and / or causes the transfer surface 340 of the print head 338 to be flush with and indented relative to the end surface 240 of the gas support system 220. And / or can be used to extend slightly therefrom. The first print module package adjustment screw 342 and the second print module package adjustment screw 344 may be secured to, attached to, and / or adjustably disposed on the first print module package base flange 350. it can. Third print module package adjustment screw 346 and one or more other print module package adjustment screws are secured to, attached to, and / or adjustably disposed on second print module base flange 352. Can do.

  The print module package 336 can be secured to the gas support system 220 using any of a variety of fasteners. In FIG. 3, two magnets 322 and 324 are shown mounted on the underside of the base plate 230. Magnets 322 and 324 are magnetically aligned with corresponding magnets (not shown) on print module package 336 or are part of print module package 336, such as base flanges 350 and 352 shown in FIG. Can be matched with sensitive metal materials. Any number of magnets can be used.

  Inner cavity 354 may result from the assembly of gas support system 220 including inner cavity portion 254, inner cavity opening 255, inner cavity portion 288 (FIG. 3), and inner cavity portion 310 (FIG. 3). . A plurality of openings 360 are shown disposed on the end surface 240 between the outer surface 250 and the inner surface 252. A plurality of manifolds 362 are included in the manifold assembly cover 226 and the manifold assembly base 228.

  FIG. 5 is a perspective view of the upside down gas support system 220 assembled with the print module package 336. The print module package 336 is installed in the internal cavity 354, and the first print module package adjustment screw 342, the second print module package adjustment screw 344, and the third print module package adjustment screw 346 are included in the print module. Used to adjust the relative positioning between the package 336 and the gas support system 220. This configuration presses the first printing module package base flange 350 and the second printing module package base flange 352 against the outer base surface 316 of the base plate 230.

  FIG. 6 is a right bottom perspective view of the gas support system 220 and the print module package 336 in the assembled configuration. The print head 338 and the transfer surface 340 are visible through the first internal cavity opening 255 and are surrounded by a plurality of openings 360 disposed on the end surface 240.

  FIG. 7 is a perspective view of gas support system 220 connected to actuator 364 through flange 326. The actuator 364 can include an actuator motor 366 and a rotatable actuator face plate 368. The flange 326 can be secured to the actuator faceplate 368.

  Load lock features and methods of using them that may be utilized in accordance with various embodiments of the present teachings are described, for example, in US Patent Application Publication No. US 2010 / 02749A1, which is hereby incorporated by reference in its entirety. including.

  All publications, patents, and patent applications mentioned herein are as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. , Incorporated herein by reference.

  While embodiments of the present disclosure have been shown and described herein, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will occur to those skilled in the art without departing from the disclosure. It should be understood that various alternatives to the embodiments of the teachings described herein may be employed in practicing the present disclosure. The following claims define the scope of the disclosure, and methods and structures within the scope of these claims and their equivalents are intended to be encompassed thereby.

Claims (1)

Invention described in this specification.

Images