Method and apparatus for thermal jet printing

Abstract

The disclosure relates to a method for depositing films on a substrate which may form part of an LED or other types of display. In one embodiment, the disclosure relates to an apparatus for depositing ink on a substrate. The apparatus includes a chamber for receiving ink; a discharge nozzle having an inlet port and an outlet port, the discharge nozzle receiving a quantity of ink from the chamber at the inlet port and dispensing the quantity of ink from the outlet port; and a dispenser for metering the quantity of ink from the chamber to the inlet port of the discharge nozzle; wherein the chamber receives ink in liquid form having a plurality of suspended particles and the quantity of ink is pulsatingly metered from the chamber to the discharge nozzle; and the discharge nozzle evaporates the carrier liquid and deposits the solid particles on the substrate.

1 . A system for controlling a printing device, the system comprising:
 a first controller having a first processor circuit in communication with a first memory circuit, the first memory circuit containing instructions for directing the first processor to:
 identify a plurality of chambers, each chamber receiving liquid ink having a plurality of dissolved or suspended particles in a carrier liquid, engage each of the plurality of chambers to meter a quantity of liquid ink for dispensing 
   a second controller having a second processor circuit in communication with a second memory circuit, the second memory circuit containing instructions for directing the second processor to:
 identify a plurality of discharge nozzles, each of the plurality of discharge nozzles receiving the quantity of liquid from a corresponding one of the plurality of chambers, 
 activate each of the plurality of the discharge nozzles to evaporate at least a part of the carrier liquid, 
 direct each of the plurality of discharge nozzles to deposit substantially solid ink particles onto a substrate. 
   
     
     
         2 . The system of  claim 1 , wherein the first processor identifies the plurality of chambers from a group of available chambers. 
     
     
         3 . The system of  claim 1 , wherein the first processor engages each chamber to meter substantially the same quantity of liquid ink for dispensing. 
     
     
         4 . The system of  claim 1 , wherein the first processor engages a first chamber of the plurality of chambers to meter relatively more liquid ink than a second chamber of the plurality of chambers. 
     
     
         5 . The system of  claim 1 , wherein the first processor engages each of the plurality of chambers to meter the quantity of ink by activating one or more of a heater, a piezoelectric element or a valve associated with each chamber. 
     
     
         6 . The system of  claim 1 , wherein the second processor directs each of the plurality of discharge nozzles to deposit solid ink particles by rotating a surface of the discharge nozzle relative to the substrate. 
     
     
         7 . The system of  claim 1 , wherein the processor directs each of the plurality of discharge nozzles to deposit solid ink particles by engaging a plurality of piezoelectric elements corresponding to each of the discharge nozzles. 
     
     
         8 . The system of  claim 1 , wherein the second processor directs each of the plurality of discharge nozzles to deposit solid particles of ink onto a substrate by plurality of heaters corresponding to each of the discharge nozzles. 
     
     
         9 . A method for printing an OLED composition on a substrate, the method comprising:
 (a) receiving a first quantity of OLED material having a plurality of dissolved or suspended particles in a carrier liquid at a discharge nozzle;   (b) heating the discharge nozzle to substantially remove the carrier liquid;   (c) rotating the discharge nozzle;   (d) heating the discharge nozzle to vaporize the suspended particles; and   (e) condensing the vaporized OLED particles on the substrate to form the OLED composition on the substrate.   
     
     
         10 . The method of  claim 9 , further comprising heating the discharge nozzle to a first temperature to substantially remove the carrier liquid and heating the discharge nozzle to a second temperature to vaporize the suspended particles. 
     
     
         11 . The method of  claim 10 , wherein the first temperature and the second temperature are substantially the same. 
     
     
         12 . The method of  claim 9 , wherein the step of heating the discharge nozzle to substantially remove the carrier liquid further comprises leaving substantially solid particles at the discharge nozzle. 
     
     
         13 . The method of  claim 9 , wherein step (c) is performed simultaneously with or prior to step (b). 
     
     
         14 . The method of  claim 9 , wherein the step of rotating the discharge nozzle further comprise rotating the discharge nozzle to face the substrate. 
     
     
         15 . The method of  claim 10 , wherein step (d) further comprises discharging the vaporized particles from the discharge nozzle onto the substrate. 
     
     
         16 . The method of  claim 10 , wherein the discharge nozzle further comprises a plurality of micropores. 
     
     
         17 . A method for printing an OLED composition on a substrate, the method comprising:
 positioning a discharge nozzle to receive a quantity of OLED material having a plurality of dissolved or suspended particles in a carrier liquid;   receiving the quantity of OLED material at a micropore associated with the discharge nozzle;   evaporating the carrier liquid and the dissolved or suspended particles at the micropore;   aligning the discharge nozzle with a deposition location on the substrate; and   dispensing the vaporized OLED material from the discharge nozzle onto the substrate.   
     
     
         18 . The method of  claim 17 , wherein the step of positioning the discharge nozzle further comprises aligning the discharge nozzle with a chamber for receiving the OLED material. 
     
     
         19 . The method of  claim 17 , wherein the step of receiving the quantity of OLED material at a micropore further comprises receiving the quantity of the OLED material at a plurality of micropores. 
     
     
         20 . The method of  claim 19 , wherein the plurality of micropores extend to, but not through, the discharge nozzle. 
     
     
         21 . The method of  claim 17 , further comprising maintaining the substrate at a temperature below the vaporized OLED material. 
     
     
         22 . The method of  claim 17 , further comprising heating the discharge nozzle to a first temperature to substantially remove the carrier liquid and heating the discharge nozzle to a second temperature to vaporize the suspended particles. 
     
     
         23 . The method of  claim 22 , wherein the first and the second temperatures are substantially the same. 
     
     
         24 . The method of  claim 17 , wherein the evaporating step and the aligning steps are performed simultaneously. 
     
     
         25 . The method of  claim 17 , wherein the aligning step precedes the evaporating step. 
     
     
         26 . The method of  claim 17 , wherein the at least two of the steps of evaporating, aligning and dispensing is performed substantially simultaneously or sequentially.