Modular print head assembly for plasma jet printing

Abstract

Described herein are apparatus and methods of printing in the presence of plasma. The apparatus includes a modular print head comprising an inlet module, a plasma module with movable electrode configurations, and a nozzle module. The modular design of the print head allows for printing on and treatment of surfaces in many different applications.

1 .- 24 . (canceled) 
     
     
         25 . A method for multi-material plasma jet printing, comprising:
 (a) providing a plasma module, a cartridge, and a dielectric spacer disposed between the plasma module and the cartridge, wherein the plasma module comprises a dielectric tube, a first electrode, and a second electrode, wherein the dielectric spacer has a length that is greater than a distance between respective centers of the first electrode and the second electrode, and wherein the cartridge comprises an atomizer;   (b) aerosolizing an ink, using the atomizer, to generate an aerosolized ink;   (c) flowing the aerosolized ink, through the dielectric spacer, from the cartridge to the plasma module;   (d) exposing the aerosolized ink to plasma generated by the first and second electrode of the plasma module to generate a plasma-treated aerosolized ink; and   (e) printing the plasma-treated aerosolized ink on a substrate.   
     
     
         26 . The method of  claim 25 , further comprising, sequentially after (b)-(e),
 (f) aerosolizing a second ink, using a second atomizer of a second cartridge, to generate a second aerosolized ink;   (g) flowing the second aerosolized ink, through the dielectric spacer, from the second cartridge to the plasma module;   (h) exposing the second aerosolized ink to plasma generated by the first and second electrode of the plasma module to generate a second plasma-treated aerosolized ink; and   (i) printing the second plasma-treated aerosolized ink.   
     
     
         27 . The method of  claim 25 , further comprising, simultaneously with (b)-(e),
 (f) aerosolizing a second ink, using a second atomizer of a second cartridge, to generate a second aerosolized ink;   (g) flowing the second aerosolized ink, through the dielectric spacer, from the second cartridge to the plasma module;   (h) exposing the second aerosolized ink to plasma generated by the first and second electrode of the plasma module to generate a second plasma-treated aerosolized ink; and   (i) printing the second plasma-treated aerosolized ink.   
     
     
         28 . The method of  claim 25 , wherein the first electrode and the second electrode are encapsulated with one or more dielectric materials to prevent arcing between the first electrode and the second electrode. 
     
     
         29 . The method of  claim 28 , wherein the first electrode is encapsulated with a first dielectric material and the second electrode is encapsulated with a second dielectric material to prevent arcing between the first electrode and the second electrode. 
     
     
         30 . The method of  claim 28 , wherein the one or more dielectric materials has a thickness that is greater than a thickness of the dielectric tube. 
     
     
         31 . The method of  claim 30 , wherein the one or more dielectric materials has a thickness that is at least three times greater than a thickness of the dielectric tube. 
     
     
         32 . The method of  claim 25 , wherein the first electrode and the second electrode are located on the outside of the dielectric tube. 
     
     
         33 . The method of  claim 25 , wherein the first electrode is located on the outside of the dielectric tube, and the second electrode is located on the inside of the dielectric tube. 
     
     
         34 . The method of  claim 25 , wherein the first electrode has a first surface area different from a second surface area of the second electrode. 
     
     
         35 . The method of  claim 25 , wherein a distance between the first electrode and the second electrode is adjustable. 
     
     
         36 . The method of  claim 25 , wherein both of the first electrode and the second electrode are configured to move in the direction along the length of the dielectric tube. 
     
     
         37 . The method of  claim 25 , further comprising introducing a gas into the cartridge, and wherein the first electrode and the second electrode are configured to generate the plasma within the dielectric tube in presence of the gas. 
     
     
         38 . The method of  claim 25 , wherein the atomizer comprises a piezo electric atomizer. 
     
     
         39 . The method of  claim 38 , wherein the piezo electric atomizer operates at a frequency of from about 50 kHz to about 10 MHz. 
     
     
         40 . The method of  claim 25 , further comprising attaching or detaching a detachable nozzle module to a proximal end of the plasma module, wherein the plasma-treated aerosolized ink is printed on the substrate via a nozzle of the detachable nozzle module. 
     
     
         41 . The method of  claim 25 , wherein (a) comprises providing two or more cartridges in fluid communication with the plasma module. 
     
     
         42 . The method of  claim 25 , wherein the cartridge comprises an ink inlet that allows entry of the ink into the cartridge. 
     
     
         43 . The method of  claim 25 , wherein the exposing in (h) of the aerosolized ink alters a property of the aerosolized ink.