Rapid ink-charging of a dry ink discharge nozzle

Abstract

The present teachings relate to methods and apparatus for depositing one or more materials (e.g., one or more films, such as one or more solids) on one or more substrates, which may form part of an OLED or other type(s) of display. In some embodiments, the disclosure relates to apparatus and methods for depositing ink on one or more substrates. The apparatus can include, for example, one or more chambers for receiving ink, and plural orifices configured for ejecting droplets of the ink. The ejected droplets of ink can be received at unique, spaced-apart locations. In some embodiments, a single liquid ink-holding chamber, which includes plural orifices (e.g., three), receives ink in liquid form having a plurality of dissolved or suspended particles, and droplets of the ink are ejected substantially simultaneously to respective, spaced-apart locations on one or more substrates.

1 . An apparatus for a depositing one or more materials on one or more substrates, the apparatus comprising:
 a chamber for receiving ink;   a discharge nozzle disposed in spaced relation to said chamber and including a plurality of micro-pores, with each micro-pore including a first end region defining an inlet port, confronting said chamber, and a second end region defining an outlet port;   a plurality of orifices in fluid communication with said chamber, said orifices adapted to meter droplets of ink from the chamber along separate respective delivery paths to respective spaced-apart locations on the inlet ports of the discharge nozzle; and   an activator proximate each orifice for providing pulsating energy for ejecting respective droplets of the ink through each orifice from within the chamber;   wherein the chamber receives ink in liquid form, said ink being defined by a plurality of substantially solid particles dissolved or suspended in a carrier liquid, and the droplets of ink are pulsatingly metered from the chamber through the orifices to the discharge nozzle; and   the discharge nozzle evaporates the carrier liquid and deposits the substantially solid particles on the substrate.   
     
     
         2 . An inkjet apparatus, comprising:
 a chamber for receiving a liquid ink, said ink being defined by an organic material dissolved or suspended in a carrier liquid;   a plurality of orifices in fluid communication with said chamber, said orifices adapted to meter droplets of ink from the chamber along separate respective delivery paths to respective spaced-apart target locations; and,   an activator proximate each orifice for providing energy for ejecting respective droplets of the ink through each orifice from within the chamber;   wherein said orifices include a first orifice configured to eject droplets of a first size, and a second orifice configured to eject droplets of a second size, with the second size being smaller than the first size.   
     
     
         3 . The apparatus of  claim 2 , further comprising a housing, wherein said chamber is disposed within said housing; and further comprising an inert gas environment within said housing. 
     
     
         4 . The apparatus of  claim 3 , wherein said inert gas environment comprises nitrogen. 
     
     
         5 . An OLED manufacturing system, comprising:
 (a) a housing,   (b) a printing system disposed within said housing, wherein said printing system includes a print device that comprises (i) a chamber configured to hold a liquid ink, said ink being defined by an organic material dissolved or suspended in a carrier liquid; (ii) a plurality of orifices in fluid communication with said chamber; and, (iii) an activator proximate each orifice for providing energy for ejecting respective droplets of the ink through each orifice from within the chamber; and   (c) an inert gas environment within said housing.   
     
     
         6 . The apparatus of  claim 5 , wherein said apparatus comprises a plurality of said print devices. 
     
     
         7 . The apparatus of  claim 6 , wherein said plurality of said print devices are disposed in an array. 
     
     
         8 . The apparatus of  claim 5 , wherein said inert gas environment comprises nitrogen. 
     
     
         9 . The apparatus of  claim 8 , wherein said activator comprises a piezoelectric element. 
     
     
         10 . A method for ejecting organic material from an inkjet, comprising:
 providing a housing, including an inert gas environment therein;   providing an inkjet within said housing, said inkjet comprising a chamber for receiving a liquid ink;   placing a liquid ink in said chamber, said ink being defined by an organic material dissolved or suspended in a carrier liquid;   ejecting a plurality of droplets of said ink from a plurality of orifices, leading from said chamber towards a substrate, along separate respective delivery paths to respective spaced-apart target locations; and,   forming a thin film of the organic material on the substrate.   
     
     
         11 . The method of  claim 10 , wherein said inert gas environment comprises nitrogen. 
     
     
         12 . The method of  claim 11 , wherein at least some of said droplets are ejected substantially simultaneously. 
     
     
         13 . The method of  claim 11 , wherein at least some of said droplets are ejected serially. 
     
     
         14 . The method of  claim 10 , further comprising heating said ink. 
     
     
         15 . The method of  claim 10 , wherein at least two of said orifices are of uniform size. 
     
     
         16 . The method of  claim 10 , wherein at least two of said orifices are of different sizes.