JP7054542B2 - Equipment and methods for controlling print gaps - Google Patents

Description

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

(Field of invention)
This teaching relates to thin film printing devices and methods.

(Background of invention)
In various situations, it may be beneficial for the printhead to maintain a tightly controlled gap between its transfer surface or ejection nozzle and the surface of the substrate on which the printhead prints the material. Such control is particularly important in printing with a thermal printing printhead devised to deposit dry ink without contacting the surface on which the dry ink is deposited. If the printhead is too far from the substrate surface, the print can be overspread. If the printhead is too close to the substrate surface, the print can be over-granular. When too close, the printhead can even come into contact with the substrate, causing damage to both the substrate and the printhead. Gap control between the inkjet print head and the substrate is also important in inkjet printing. Therefore, in both thermal and inkjet printing systems, it is desirable to optimize printing results and printing processes by controlling the printing gap between the substrate and the printhead.

U.S. Patent Application Publication No. 2008/030307 U.S. Patent Application Publication No. 2008/0311307 U.S. Patent Application Publication No. 2008/0311289 U.S. Patent Application Publication No. 2006/0115585 U.S. Pat. No. 7,908,885 U.S. Pat. No. 7,857,121 U.S. Pat. No. 7,604,439 U.S. Pat. No. 7,603,028 U.S. Pat. No. 7,530,778 U.S. Patent Application Publication No. 2010/0188457 U.S. Patent Application Publication No. 2011/0008541 U.S. Patent Application Publication No. 2010/0171780 U.S. Patent Application Publication No. 2010/0201949

(overview)
According to various embodiments, the teachings are for holding the printhead and print module package and for maintaining a tightly controlled gap between the transfer surface of the printhead and the substrate on which the material is printed. Regarding gas support systems that can be used in. The system comprises a housing having side walls with outer and inner surfaces. The sidewalls define an internal cavity configured to receive the print module package. The inner surface can be terminated with an opening to the internal cavity. The side wall can also have an end face between its outer surface and its inner surface, which can include a first plurality of openings and a second plurality of openings. The first plurality of fluid channels can be contained within the sidewalls and extend into the sidewalls from the first plurality of openings to allow fluid communication with the first manifold. The first manifold can be inside, outside, or both inside and outside the side wall. The second plurality of fluid channels can be contained within the sidewalls and extend into the sidewalls from the second plurality of openings to allow fluid communication with the second manifold. The second manifold can be inside, outside, or both inside and outside the side wall. The first manifold can communicate fluid with the environment outside the enclosure, for example, through the first port. The second manifold can communicate fluid with the environment outside the enclosure, for example, through a second port.

According to various embodiments, a print gap control system comprising a gas support system as described herein and a substrate with a first planar surface is provided. The system has a gas-supported end face in a first plane and at least one transfer surface of at least one inkjet print head or thermal printing print head in a second plane and a first surface of the substrate. The plane surface can be configured to be in a 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 face, transfer surface, and 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 appreciated that in some embodiments, the print gap can be controlled by controlling the gas support gap.

According to various embodiments of the present teaching, the method comprises positioning the print module package with respect to the substrate and printing the material onto 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, which comprises a side wall defining an internal cavity. The side wall can have an outer surface and an inner surface, and the print module package can be received in the inner cavity. The inner surface can be terminated with an opening to the internal cavity. The method can include mounting the print module package in an internal cavity. The side wall can further have an end face between the outer surface and the inner surface, and the end face can be provided with a first plurality of openings and a second plurality of openings. The sidewall can further include a first plurality of fluid channels extending into the sidewall from the first plurality of openings and communicating with the first manifold, the method being the first manifold and the first. It can include supplying a pressurized gas source from one manifold to the first plurality of fluid channels. In addition, the sidewall can include a second plurality of fluid channels extending into the sidewall from the second plurality of openings and communicating with the second manifold, the method comprising a second to a vacuum source. It can include creating a vacuum from multiple fluid channels from the manifold to the second manifold. The first manifold can communicate fluid with the environment outside the enclosure, eg, through a first port, and the second manifold can, for example, through a second port, outside the enclosure. Can communicate with the environment of the fluid. The method can include controlling the print gap using a combination of pressurized gas and vacuum to and from the first and second openings and from the first and second openings. ..
The present invention provides, for example,:
(Item 1)
It is a gas support system, and the gas support system is
The housing comprises a side wall having an outer surface and an inner surface, wherein the side wall defines an internal cavity configured to receive the print module package, and the inner surface is an opening to the internal cavity. Terminated with, the sidewall further has an end face between the outer surface and the inner surface, the end face comprising a first plurality of openings and a second plurality of openings, the sidewall further comprising said first. A first plurality of fluid channels extending from the plurality of openings of 1 into the side wall and communicating with the first manifold, and a second manifold extending from the second plurality of openings into the side wall. A second plurality of fluid channels communicating with the environment, the first manifold communicating with the environment outside the housing through the first port, and the second manifold being a second. A gas support system in which the first plurality of openings and the second plurality of openings surround the opening to the internal cavity, with fluid communication with the environment outside the enclosure through a port.
(Item 2)
The gas support system of item 1, wherein the end face further comprises a third fluid channel that extends into the sidewall and communicates with the first manifold and a third manifold that is different from the second manifold. ..
(Item 3)
The gas support system according to item 2, wherein the third manifold is in fluid communication with the environment outside the housing through the third port.
(Item 4)
The gas support system according to item 1, wherein the individual diameters of the first plurality of openings and the second plurality of openings are separated from each other by an average distance of about 1.0 mm to about 10 mm.
(Item 5)
The gas support system of item 1, wherein 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 have an average diameter of about 0.005 inches to about 0.025 inches, and the second plurality of openings have an average diameter of about 0.030 inches to about 0.090 inches. The gas support system according to item 1.
(Item 7)
The gas support system according to item 1, wherein the first plurality of fluid channels communicate with a pressurized gas source, and the second plurality of fluid channels communicate with a vacuum source.
(Item 8)
The gas support system according to item 7, wherein the pressure gas source comprises a pressurized inert gas source.
(Item 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 comprises a base plate, a manifold compartment mounted on the base plate, and a face plate mounted on the manifold, wherein the face plate comprises an end face.
(Item 11)
10. 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 the second manifold.
(Item 12)
The gas support system according to item 3, wherein the housing comprises a base plate, a manifold compartment mounted on the base plate, and a face plate mounted on the manifold, wherein the face plate comprises an end face.
(Item 13)
Item 12, wherein the base plate comprises the first port, the second port, and the third port, and the manifold compartment comprises the first manifold, the second manifold, and the third manifold. The described gas support system.
(Item 14)
10. The gas support system of item 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)
Further comprising a second opening to the internal cavity, the second opening is located opposite the first opening so that the internal cavity comprises a through hole through the housing. , The gas support system according to item 1.
(Item 16)
The gas support system of item 1, further comprising at least one printing module package mounted in the internal cavity.
(Item 17)
Item 16. The gas according to item 16, wherein the at least one printing module package comprises at least one thermal printing print head having at least one transfer surface and at least one heater that thermally communicates with the at least one transfer surface. Support system.
(Item 18)
16. The gas support system of item 16, wherein the at least one print module package comprises at least one inkjet print head.
(Item 19)
The print gap control system is a print gap control system.
The gas support system according to item 18, and
It comprises a substrate, the end face is in a first plane, the at least one inkjet printhead is in a second plane, and the first planar 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 the distance between the first plane and the third plane. The print gap is defined by the distance between the second plane and the third plane and is of the end face, the inkjet printhead, and the first plane surface of the substrate. At least one is a print gap control system that is adjustable to control the size of the print gap.
(Item 20)
Item 19 further comprises 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. The print gap control system described in.
(Item 21)
The print gap control system according to item 20, wherein the second gas support comprises a plurality of pressurized gas channels and, if necessary, a plurality of vacuum channels.
(Item 22)
19. The print gap control system according to item 19, wherein the gas support system is positioned above the substrate.
(Item 23)
19. The print gap control system according to item 19, wherein the gas support system is positioned below the substrate.
(Item 24)
A gas support system is used to position the print module package with respect to the surface of the first planar substrate, wherein the gas support system comprises a housing, which has an outer surface and an inner surface. It comprises a side wall, the side wall defining an internal cavity configured to receive the print module package, the inner surface ending with an opening to the inner cavity, the side wall further comprising the outer surface and the inner surface. The end face comprises a first plurality of openings and a second plurality of openings, the sidewall further extending from the first plurality of openings into the sidewall. A first plurality of fluid channels communicating with one manifold and a second plurality of fluid channels extending from the second plurality of openings into the sidewall and communicating with the second manifold are provided. The first manifold communicates fluidly with the environment outside the enclosure through the first port, and the second manifold communicates fluidly with the environment outside the enclosure through the second port. , That and
A method comprising printing a material onto the surface of the first planar substrate using the printing module package.
(Item 25)
24. 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)
24. The method of item 24, wherein the printing comprises solid transfer printing.
(Item 27)
24. The method of item 24, wherein the printing comprises inkjet printing.
(Item 28)
The positioning means 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. 24. 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 an inkjet nozzle orifice, wherein the printhead transfer surface or the inkjet nozzle orifice faces the surface of the first flat substrate and is separated from each other by a print gap. 24. The method of item 24, wherein positioning comprises controlling the size of the print gap by controlling the flow of fluid through at least one of the first and second manifolds. ..
(Item 30)
29. The method of item 29, wherein the print gap has a distance of about 5 μm to about 100 μm.
(Item 31)
29. The method of item 29, wherein the print gap has a distance of about 20 μm to about 30 μm.
(Item 32)
29. The method of item 29, wherein the print gap has a distance of about 25 μm.
(Item 33)
24. The method of item 24, further comprising flowing the inert gas at a pressure of about 30 psig to about 90 psig through the first plurality of fluid channels.
(Item 34)
24. The method of item 24, further comprising drawing a vacuum at a negative pressure of about −5.0 psig to about -13 psig through the second plurality of fluid channels.
(Item 35)
By positioning the second gas support system adjacent to the surface of the second flat substrate and facing the first gas support system, the second gas support system is the first gas support system. 24. The method of item 24, further comprising positioning the surface of a flat substrate and maintaining the desired printing gap.
(Item 36)
24. The method of item 24, wherein the gas support system is positioned above the substrate.
(Item 37)
24. The method of item 24, wherein the gas support system is positioned below the substrate.

Further understanding of the features and advantages of the present disclosure can be obtained by reference to the accompanying drawings, which are intended to illustrate, but not limit, this teaching.

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

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

FIG. 3 is a bottom perspective exploded view of the gas support system according to various embodiments of the present teaching.

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

FIG. 5 is a perspective view of the gas support system shown in FIG. 3 upside down in the assembled state and a printing module package that is adjustablely mounted or anchored therein.

FIG. 6 is a right bottom side perspective view of the gas support system and the 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 that are secured to a rotary actuator and positioned to perform thermal printing operations.

(Detailed explanation)
According to various embodiments of the present teaching, the gas support system comprises a housing with side walls, the side walls comprising outer and inner surfaces. The sidewalls define an internal cavity configured to receive the print module package. The inner surface can be terminated at the top, bottom, or both to 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 side wall can also have an end face between its outer surface and its inner surface, which can include a first plurality of openings and a second plurality of openings. The first plurality of fluid channels can be contained within the sidewalls and extend into the sidewalls from the first plurality of openings to allow fluid communication with the first manifold. The second plurality of fluid channels can be contained within the sidewalls and extend into the sidewalls from the second plurality of openings to allow fluid communication with the second manifold. The first manifold and the second manifold can be independently located inside the side wall, outside the side wall, or both. The first manifold can communicate fluid with the environment outside the enclosure, for example, through the first port. The second manifold can communicate fluid with the environment outside the enclosure, for example, through a second port. Conduit such as pipes can communicate fluid with each of the manifolds and can be 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 so as 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 face of the sidewall can further comprise a third fluid channel, the third fluid channel extending within the sidewall and with the first and second manifolds. Communicate with a different third manifold. The third manifold can communicate fluid with the environment outside the enclosure, for example, through a third port. The third manifold can communicate fluid with a pressurized gas source, a vacuum source, or both. The third manifold can communicate with the same pressurized gas source and fluid communication with the first manifold, or with different pressurized gas sources. The individual openings of the first and second plurality of openings 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. It can be separated from adjacent openings by an average distance of 8.0 mm, or an average distance of about 3.0 mm to about 6.0 mm. The diameters of the first and second openings are an average diameter of about 0.001 inches to about 0.1 inches, eg, 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 can have an average diameter of about 0.030 inches to about 0.030 inches. It can have an average diameter of 0.090 inches.

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

In some embodiments, the enclosure 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 faceplate comprises an end face. The base plate can include first and second ports, and the manifold compartment can include 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 comprises first, second, and third ports, and the manifold compartment can include first, second, and third manifolds. In some embodiments, the manifold compartment, or one or more of the manifolds, may comprise one or more of the ports. The 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 the side walls or partially define the side walls, for example, stacking of components including faceplates together define side walls, 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 so that the internal cavity may have a through hole extending through the entire housing. At least one print module package can be mounted within the internal cavity. In some cases, the at least one print module package has at least one inkjet print head having at least one transfer surface or at least one thermal printing print head and at least one that thermally communicates with at least one transfer surface. Can be equipped with two heaters. In some embodiments, the second opening allows the exhaust to be expelled from the internal cavity. The second opening can allow loading of the print module package 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 changed and that the instructions such as top and bottom are intended to be relative terms rather than absolute terms. In some embodiments, the feature is flipped 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 comprising a gas support system as described herein and a substrate with a first planar surface is provided. The system can be configured such that the end face is in the first plane, at least one transfer plane is in the second plane, and the surface of the first plane substrate is in the third plane. The first, second, and third planes are substantially parallel to each other, that is, they are parallel to each other or tilted at 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 surface of the first planar substrate 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 operably associated with one or more actuators, and / or for the substrate and / or for one or more inkjet printheads of the gas support system. Allows you to adjust the position.

The second gas support system can be provided facing the first gas support system so that the substrate is positioned between the first gas support system and the second gas support system. .. The second gas support system can also include a plurality of pressurized gas channels and optionally a plurality of vacuum channels. Pressurized gas channels and vacuum channels can be arranged in any desired configuration. In some embodiments, every other fluid channel or alternating fluid channel comprises a pressurized channel and a vacuum channel. A second gas support that can be mounted within 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 may be advantageous as 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, the alternating fluid channels include heating channels, cooling channels, heating channels, cooling channels, and the like. Thermal control can also be used to control the size of the substrate, as 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 particularly significant for larger substrates, for example, thermal size changes are significant for Generation 8 size glass (2.2 m x 2.5 m). Uncontrolled thermal changes in the substrate can adversely affect product quality by shifting the deposition of ink 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 teaching, methods are provided that include positioning the print module package with respect to the substrate and printing the material onto the substrate by using the print module package. Ru. Positioning can be accomplished using a gas support system as described herein, for example, a gas support system comprising a housing, the housing defining an internal cavity. The side wall can have an outer surface and an inner surface, and the print module package can be received in the inner cavity. The inner surface can be terminated with an opening into the inner cavity, and the method can include mounting the print module package inside the inner cavity. The side wall can further have an end face between the outer surface and the inner surface, and the end face can be provided with a first plurality of openings and a second plurality of openings. The method can include supplying the pressurized gas to and through the first plurality of openings and drawing a vacuum through the second plurality of openings. The side wall can further include a first plurality of fluid channels that extend into the side wall from the first plurality of openings and communicate with the first manifold. In addition, the sidewall can include a second plurality of fluid channels that extend into the sidewall from the second plurality of openings and communicate with the second manifold. The method can include supplying pressurized gas to the first manifold and evacuating the second manifold. The first manifold can communicate fluid with the environment outside the enclosure, eg, through a first port, and the second manifold can, for example, through a second port, outside the enclosure. Can communicate with the environment of the fluid. Pipes, pipes, or other conduits can connect the first manifold to the pressurized gas source and can connect the second manifold to the 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, wherein the inkjet printing is followed by solid transfer printing by sublimation or evaporation of the solid). be able to. Examples of thermal printing and printing module packages that can be used in accordance with this teaching are described, for example, in US Patent Application Publications US2008 / 0308307A1, US2008 / 031307A1, US2008 / 0311289A1, and US2006 / 0115585A1. These include, and are incorporated herein by reference in their entirety. The print module package can include 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 a substrate. It faces the first surface and can be separated from each other by a print gap. The printhead transfer surface can receive the 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 to face a substrate to be printed. In some embodiments, the one or more inkjet printheads are rotated to transfer the ink to the one or more printhead transfer surfaces. The gas support system and / or the printhead transfer surface can be positioned above, below, or above and below the substrate during printing. In some embodiments, printing can include inkjet printing directly onto the substrate. In such an embodiment, the print module package can include an inkjet print head. For example, the print module package can include a SAMBA print head module (FUJIFILM Dimatix, Inc., Santa Clara, California). The gas support system and / or the inkjet printhead can be positioned above, below, or above and below the substrate during printing.

Positioning the gas support system with respect to the substrate can include controlling the size of the print gap by controlling the flow of fluid through at least one of the first and second manifolds. In some embodiments, positioning is to maintain a positive flow of fluid from the first manifold through the first plurality of fluid channels and into the second plurality of fluid channels. It can include maintaining a negative flow of fluid through the manifold of the fluid. 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, for example, a distance of about 20 μm to about 30 μm, or a distance of about 25 μm. In this method, for example, the inert gas flows 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 allowing the print gap to be maintained or provided. Positioning is further through a second plurality of fluid channels with 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. It can include drawing a vacuum with negative pressure. In some cases, printing can include printing on a first surface of the substrate, the substrate having a second surface opposite to the first surface, the method. Further comprising positioning the second gas support system adjacent to the second surface of the substrate and facing the first gas support system. The second gas support system can be configured to position the first surface of the substrate and maintain the desired printing gap. The second gas support system can be used in place of or in addition to the first gas support system.

Various embodiments of this teaching relate to devices and methods for using air supports 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 printhead is mounted within the gas support enclosure so that the set gap is fixed at a particular 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 enclosure. The gas support gap is the distance between the end face and the substrate. In any case, there is a relative motion between the printhead and the substrate, regardless of whether the substrate moves below the printhead and / or the printhead moves above the substrate. .. By pressurizing the fluid passage of the gas support housing, the gas flows out of the opening into the housing and maintains a gas support gap between the end face of the gas support housing and the substrate. In this way, the print gap is the sum of the gas support gap and the set gap, whereby the print gap is controlled by these other two gaps. For example, subtle changes of about a few microns can be brought to the print gap by changing the gas pressure in the gas support enclosure. The flow of gas from the gas support enclosure to the exhaust holes creates an environment filled with the support gas. If the ink is sensitive to oxygen gas, a non-oxygen gas and / or an inert gas such as, for example, nitrogen gas can be used to provide a non-oxidizing environment. The process of evaporating the liquid ink in or on the printhead can generate solvent vapor. The exhaust opening allows both the removal of nitrogen gas injected by the gas support system and the removal of solvent evaporation generated during the evaporation of the liquid ink.

In some embodiments, both a pressure source and a vacuum source 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, for fluid communication with each channel in a gas-supported enclosure placed around the printhead, thus a gas-supporting gap can be established. The print gap can be variable with respect to the support enclosure. The gas support enclosure and printhead can be placed adjacent to the substrate, eg glass. The printhead can deposit a film material (eg, an ink containing a film-forming material dissolved or suspended in a carrier fluid) on a substrate. In some embodiments, the substrate is supported via a gas lift or a chuck with a 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 teaching 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 a mixture of gases. The additional gas support system can use the same or different gaseous or gaseous mixture as contained within the gas encapsulation system (eg, the system encapsulating the thermal printing operation). In some embodiments, the air support uses an inert gas, such as nitrogen gas, one or more noble gases, or a combination thereof. Gas support systems and related methods and systems that may be used are described in New Way Machine Components, Inc. Includes those available from (Aston, Pennsylvania). They can be used alone or in combination with the gas support system described in this teaching. Devices, systems, methods, and uses for gas support systems that can be used in connection with this teaching include, for example, those described in US Pat. No. 7,908,885B2, which is to be referred to in its entirety. Is incorporated herein by. Coreflow Scientific Solutions LTD. Gas support systems and related methods and systems available from (Yokne'am, Israel) can also be used alone or in combination with the gas support systems described in this teaching. Devices, systems, methods, and applications relating to gas support systems that may be further used in connection with this teaching include, for example, US Pat. Nos. US7,857,121B2, US7,604,439B2, US7,603,028B2. No., and those described in US 7,530,778B2, which are incorporated herein by reference in their entirety.

Aspects of this teaching are, for example, US Patent Application Publications US2008 / 031307A1, US2008 / 0311289A1, US2006 / 0115585A1, US2010 / 0188457A1, US2011 / 0008541A1, US2010 / 0171780A1, and US2010 / 021749A1. It can be carried out in connection with the teachings of Patent Application No. 61 / 521,631 (named "Face-Down Thermal-Jet Printing Apparatus and Methods"), which are incorporated herein by reference in their entirety. Will be incorporated into.

FIG. 1 is a cross-sectional view of the gas support system 20 according to various embodiments of the present teaching. The gas support system 20 includes a housing 22 with 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 configured to receive the print module package 32. The inner surface 28 terminates at the cavity opening 34 of the inner cavity 30. The end surface 36 is arranged between the inner surface 28 and the outer surface 26. On the opposite side of the end face 36 is an annular end portion 38 with a second cavity opening 40. The second cavity opening 40 can be provided with 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 extending within the side wall 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 side wall 24 of the housing 22.

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

FIG. 2 is a schematic cross-sectional view of the gas support system 120 according to various embodiments of the present teaching. The gas support system 120 comprises a housing 122, and the housing 122 comprises a side wall 124. The side wall 124 includes an outer surface 126 and an inner surface 128, and defines an inner cavity 130. The internal cavity 130 is configured to receive the print module package 132 through the cavity opening 134. There is an end face 136 between the outer surface 126 and the inner surface 128. The second cavity opening 138 can be located opposite the cavity opening 134. The end face 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 side wall 124 of the housing 122. The second fluid channel 146 can extend from the second opening 142 into the side wall 124 of the housing 122.

As seen in FIG. 2, the first fluid channel 144 and the second fluid channel 146 can communicate fluid with the first manifold 148. The end face 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 side wall 124 of the housing 122, and the fourth fluid channel 160 extends from the fourth opening 152 into the side wall 124 of the housing 122. The fifth fluid channel 162 can extend from the fifth opening 154 into the side wall 124 of the housing 122, and the sixth fluid channel 164 can extend into the sixth opening 156. Can extend into the side wall 124 of the housing 122. The third fluid channel 158, the fourth fluid channel 160, the fifth fluid channel 162, and the sixth fluid channel 164 can communicate with the second manifold 166. In some embodiments, the pressurized gas source 168 fluidly communicates 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 print module package 132 can be configured to deposit a material, eg, a film forming material, onto a substrate. The deposited material 174 can be located on the substrate 176, more specifically, 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 face 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 fluid channels (not shown) and a plurality of openings 188 for fluid communication. The opening 188 can face the second substrate surface 190 of the substrate 176.

FIG. 3 is an exploded view of the gas support system 220 according to various embodiments of the present teaching. The gas support system 220 may include a face plate 224, a manifold assembly cover 226, a manifold assembly base 228, and a plurality of fasteners 222 for anchoring 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 face 240. The end face 240 can receive the fastener 222. A first fastener hole portion 242 extending from the end face 240 into the face plate 224, a second fastener hole portion 244, a third fastener hole portion 246, and a fourth fastener hole portion 248 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 the inner cavity portion 254 and the first inner cavity opening 255. A plurality of fluid channel portions 256 can be arranged within the face plate 224 between the inner surface 252 and the outer surface 250. Each fluid channel portion 256 can be terminated at its respective opening (not shown) on the end face of the 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 arranged between the outer surface 266 and the inner surface 268 of the manifold assembly cover 226. The inner surface 268 can define the inner cavity portion 270. The plurality of fluid channel portions contained within the complementary manifold portion 274 can be arranged 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 the inner cavity portion 288. The outer surface 284 and the inner surface 286 can also define a plurality of fluid channel portions within the complementary manifold portion 292 between them. 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 face plate 230 can include a main base plate portion 308. The main base plate portion 308 can include an internal cavity portion 310 and a second internal cavity opening 312. The internal 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 face 240 of the face plate 224, but may face outward in the opposite manner. Multiple print module package adjustment screw receiving holes can be located within the outer base surface 316. These can include a first print module package adjusting screw receiving hole 318 and a second printing module package adjusting screw receiving hole 320. Another adjusting screw receiving hole can also be provided, for example, one for each adjusting screw on the printing module package. The base plate 230 can further include a flange 326. Flange 326 can be configured for attachment to, for example, actuators, robot arms, rotary actuators, support components, 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 side perspective view of the gas support system 220, which is assembled and shown adjacent to the print module package 336. The first fastener 232, the second fastener 234, the third fastener 236, and the fourth fastener 238 are arranged and shown through the end face 240, and the face plate 224, the manifold assembly cover 226, the manifold assembly base 228, and the fourth fastener 238 are shown. 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 may 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 adjusting screw 342, a second printing module package adjusting screw 344, and a third printing module package adjusting screw 346. Any number, eg, 3 or 4 adjusting screws, can be used. The linear adjustment screw aligns the θx and y rotations of the printhead 338 and / or aligns the transfer surface 340 of the printhead 338 with the end face 240 of the gas support system 220, with respect to it, parallel to it. And / or can be used to extend slightly from it. The first print module package adjusting screw 342 and the second printing module package adjusting screw 344 may be fastened to, mounted on, and / or be adjustable in place on the first print module package base flange 350. can. The third print module package adjuster screw 346 and one or more other print module package adjuster screws shall be fastened to, mounted on, and / or adjustable on the second print module base flange 352. Can be done.

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. The magnets 322 and 324 are aligned with the corresponding magnets (not shown) on the print module package 336, or are part of the print module package 336, eg, base flanges 350 and 352 shown in FIG. 4, magnetically. Can be matched with metal materials that are susceptible to. Any number of magnets can be used.

The internal cavity 354 can result from the assembly of the gas support system 220 including the internal cavity portion 254, the internal cavity opening 255, the internal cavity portion 288 (FIG. 3), and the internal cavity portion 310 (FIG. 3). .. The plurality of openings 360 are arranged and shown on the end face 240 between the outer surface 250 and the inner surface 252. The 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 adjusting screw 342, the second printing module package adjusting screw 344, and the third printing module package adjusting screw 346 are the printing modules. It is used to adjust the relative positioning between the package 336 and the gas support system 220. In this configuration, the first print module package base flange 350 and the second print module package base flange 352 are pressed against the outer base surface 316 of the base plate 230.

FIG. 6 is a right bottom side perspective view of the gas support system 220 and the print module package 336 in the assembled configuration. The printhead 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 face 240.

FIG. 7 is a perspective view of the gas support system 220 connected to the actuator 364 through the 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 face plate 368.

Load-locking features and methods of using them that may be utilized in accordance with various embodiments of this teaching are described, for example, in US Patent Application Publication US2010 / 0201749A1 incorporated herein by reference in their entirety. including.

All publications, patents, and patent applications described herein are, as in the case where each individual publication, patent, or patent application is specifically and individually indicated to be incorporated by reference. , Incorporated herein by reference.

Although embodiments of the present disclosure are 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, modifications, and substitutions are recalled to those of skill in the art without departing from the present disclosure. It is to be understood that various alternatives to the embodiments of the teachings described herein may be adopted in carrying out the present disclosure. The following claims define the scope of the present disclosure, by which methods and structures within the scope of these claims and their equivalents are intended to be incorporated.

Claims (16)

The gas support housing that defines the inside and
A gas source fluidly coupled to the inside of the gas support housing,
A printhead module disposed internally and having at least one printhead for depositing a film-forming material on a first surface of the substrate, wherein the substrate is on the opposite side of the first surface. With a printhead module having two surfaces,
A gas support system with multiple pressurized gas channels and multiple vacuum channels that use gas to support the substrate on the second surface, fluidizing the environment surrounding the print module package. Gas support system and
A control unit that controls the gas support system and
A printing system. The printing system according to claim 1, further comprising an exhaust system coupled to the gas support housing. The printing system of claim 2, wherein the gas support system further comprises a plurality of cooling channels. The printing system of claim 3, wherein the control unit can be used to control a second gas source that communicates fluidly with the pressurized gas channel. The control unit can be used to control a gas source that communicates with the pressurized gas channel, controls a vacuum source that communicates with the vacuum channel, or both. The printing system described in. The printing system of claim 1, wherein the gas support enclosure has a side wall defining the interior, wherein the side wall comprises a fluid channel inside the side wall. The printing system of claim 6, wherein the fluid channel communicates with the manifold. The printing system of claim 7, wherein the sidewall comprises a plurality of fluid channels that communicate with the manifold, respectively. The printing system according to claim 1, wherein the gas source communicates with a plurality of fluid channels of the gas support housing. The printing system according to claim 1, wherein the gas support housing includes a gas support system. The printing system according to claim 9, wherein the pressure channel and the vacuum channel are arranged alternately. The printing system of claim 1, wherein the gas support system comprises a heating channel and a cooling channel. 12. The printing system of claim 12, wherein the heating channels and the cooling channels are arranged alternately. The gas support system includes a heating channel and a cooling channel, the heating channel and the cooling channel are arranged alternately, and the pressurized gas channel and the vacuum channel are arranged alternately, according to claim 1. The printing system described. 14. The printing system of claim 14, wherein the gas-supported enclosure comprises a side wall defining the interior, wherein the side wall comprises a plurality of fluid channels each communicating with the manifold. The printing system according to claim 1, wherein the gas support housing includes a pressurized gas channel and a vacuum channel.

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