TWI546004B - Method and apparatus for printing using a facetted drum - Google Patents

Description

Method and apparatus for printing by using a faceted drum background

Deposit application No. 61/473,646, filed on April 18, 2011, and patent application No. 61/283,011 (filed on November 27, 2009). Application No. 954, 910 (applied on November 29, 2010) and claim No. 60/944,000 (application dated June 14, 2007) of the Provisional Application No. 12/139, 404 (application dated June 13, 2008) Priority. The disclosures of each of the identified applications are incorporated herein by reference in their entirety.

The present invention generally relates to a method and apparatus for depositing a substantially solid film on a substrate. More particularly, the present invention relates to novel methods of printing organic light emitting diode ("OLED") films using faceted rotating sources or drums.

When printing an electronic film, it is important to deposit a dry film on the surface such that the deposited material forms a substantially solid film upon contact with the substrate. This is in contrast to ink printing, in which a wet ink is deposited on the surface and then the ink is dried to form a solid film. Because the ink printing process deposits a wet film, it is commonly referred to as a wet printing process.

Wet printing has two significant drawbacks. First, as the ink dries, the solid content of the ink may not deposit evenly over the deposition area. also That is, as the solvent evaporates, the film uniformity and thickness substantially change. Such uniformity and thickness variations are unacceptable for applications requiring precise uniformity and film thickness. Second, the wetting ink may interact with the underlying substrate. This interaction is particularly problematic when the underlying substrate is pre-coated with a fine film. The deposition of organic light-emitting diode ("OLED") films is a serious problem for these problems.

The problems in wet printing can be partially solved by using dry transfer printing techniques. In transfer printing techniques, the material to be deposited is typically first applied to a transfer sheet and then the transfer sheet is brought into contact with the surface on which the material is to be transferred. This is the principle of dye sublimation printing in which the dye sublimes from the strip that is in contact with the surface on which the material is transferred. This is also the principle of carbon paper. However, dry printing introduces new problems. Because contact between the transfer sheet and the target surface is required, if the target surface is fine, it may be damaged by contact. In addition, the transfer may be adversely affected by the presence of small amounts of particles on the transfer sheet or target surface. These particles will create areas of poor contact that hinder transfer.

The particle problem is particularly significant where the transfer area consists of a large area, which is typically used in the processing of large area electronic devices such as flat panel televisions. In addition, conventional dry transfer techniques utilize only a portion of the material on the transfer medium, resulting in low material utilization and significant waste. When the film material is extremely expensive, the utilization of the film material is important. OLED film deposition is also a particularly significant application for this problem.

Accordingly, what is needed is a method and apparatus that provides, inter alia, a non-contact dry technique for depositing an OLED film and overcoming these and other disadvantages and deficiencies.

In one embodiment, the invention is directed to a facet drum that simultaneously prints a plurality of pixels. The facet drum includes a support structure and a plurality of print heads attached to the support structure, each print head having at least one microhole for receiving a first quantity of film material dissolved or suspended in a carrier fluid The liquid ink and the dispensing are substantially free of a second amount of the ink material of the carrier fluid. The plurality of print heads are disposed at a proximal end of a substrate to simultaneously print a plurality of spatially discrete and resolved image pixels on the substrate. Spatially discrete means that the pixels do not substantially overlap and the resolved image definition pixels are substantially free of bubbles or other shortcomings and physical defects. A printhead according to one embodiment of the invention comprises a microwell array and wherein each microwell is spaced from an adjacent microhole by about 1-4 [mu]m and wherein at least one of the microwells has a diameter of about 3 [mu]m. The spatially discrete and resolved pixels of the image can be printed on the substrate about 25-500 pixels per turn.

In another embodiment, the present invention is directed to a facet drum system for large scale simultaneous printing of pixels. The facet drum includes a chuck for receiving a rotary print head assembly; a plurality of facets, each facet attached to a respective surface of the rotary print head assembly in a tangential direction; and disposed on each facet a plurality of print heads, at least one of the print heads having a microwell array for receiving a first amount of liquid ink having a film material dissolved or suspended in a carrier fluid and dispensing substantially one of the carrier fluids The second amount of ink material. The micropores may include one or more grooves, channels, vias, vias, and blind vias.

In another embodiment, the invention relates to a system for printing a film on a substrate, the system comprising: a microprocessor circuit; a memory circuit in communication with the microprocessor circuit, the memory circuit storing The processor circuit has the following instructions: (1) supplying a certain amount of liquid ink to one facet of a drum having a print head and the liquid ink is loaded by a suspended and/or dissolved ink particle. a liquid definition, (2) removing the carrier liquid from the supply of ink to form a quantity of substantially liquid-free ink on the print head, and (4) evaporating the amount of substantially no liquid remaining on the print head Ink; and (5) directing the quantity of vaporized ink onto the substrate. In one embodiment of the invention, directing the quantity of vaporized ink further includes the step of aligning the print head with the substrate.

In another embodiment, the present invention is directed to a method of printing a film from a drum having a plurality of facets, the method comprising: supplying a quantity of liquid ink to one of the plurality of facets, Supporting a microstructure on the facet and the liquid ink defines a carrier liquid having suspended and/or dissolved ink particles; removing the carrier liquid from the supply amount of ink to form a quantity on the print head substantially The liquid-free ink evaporates the amount of substantially liquid-free ink remaining on the printhead; and the quantity of vaporized ink is dispensed from the printhead onto the substrate. The drum is rotatable such that the facet receives liquid ink in a first direction and the vaporized ink is dispensed in a second direction. In one embodiment of the invention, the ink is supplied to only one facet at a time. In another embodiment of the invention, ink is supplied to a plurality of facets simultaneously.

These and other specific examples of the invention are discussed with reference to the following exemplary and non-limiting description, in which like elements are numbered.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic illustration of a facet deposition system of one embodiment of the present invention. In FIG. 1, a deposition system 114 is used to deposit a quantity of film material on substrate 110 using a hexagonal drum type (used interchangeably with a faceted drum). The deposition system 114 of Figure 1 has six separate and independent facets, at least a portion of which face the surface containing one or more printheads. Each printhead can receive the film material 124 from the material transfer mechanism 122 in one direction and the received film material to the substrate 110 in the other direction.

The film material can be delivered to the printhead as a solid film, liquid ink or gas vapor ink consisting of a pure film material or a film material and a non-film (interchangeable with carrier) material. The use of an ink can be advantageous because it can provide a film material with one or more non-thin materials to the printhead to facilitate deposition of the pre-processed film material on the substrate. The film material can be composed of an OLED material. The film material can comprise a mixture of materials. The carrier material can also include a mixture of materials.

One example of a liquid ink is a film material that is dissolved or suspended in a carrier fluid. Another example of a liquid ink is a pure film material in liquid phase form, such as a film material that is liquid at ambient system temperatures or a film material that is maintained at elevated temperatures such that the film material forms a liquid melt. An example of a solid ink is a solid particle of a film material. Another example of a solid ink is a film material dispersed in a carrier solid. An example of a gas vapor ink is vaporization Film material. Another example of a gas vapor ink is a vaporized film material dispersed in a carrier gas. The ink can be deposited on the printhead in liquid or solid form and the phase can be the same or different than the phase of the ink during transfer. In one embodiment, the film material can be delivered as a gaseous vapor ink and deposited as a solid phase onto the printhead. In another embodiment, the film material can be delivered as a liquid ink and deposited in a liquid phase onto the printhead. The ink can be deposited onto the printhead in such a manner that only the film material is deposited and the carrier material is not deposited. The ink can also be deposited in a manner that deposits the film material and one or more carrier materials.

In one embodiment, the film material may be delivered in the form of a vapor-vapor ink comprising a vaporized film material and a carrier gas, and only the film material is deposited on the printhead. In another embodiment, the film material can be delivered in the form of a liquid ink comprising a film material and a carrier fluid, and both the film material and the carrier fluid are deposited on the printhead. In another embodiment, the film material is delivered in liquid form and the carrier fluid evaporates or evaporates quickly upon contact with the printhead such that only the ink material remains on the printhead. The film material transfer mechanism can further transfer the film material to the printhead in a specified pattern. Transfer of the film material to the substrate can occur with or without material contact between the printhead and the substrate. The film material can be fed to the print head by gravity or can be injected using conventional ink delivery systems.

Referring again to FIG. 1, the metered film material 124 is directed to a rotating facet drum 114. The film material can be directed to the drum 114 by gravity feed. Alternatively, the oriented film material delivery system can deliver the metered film material 124 to a designated portion of the drum 114. In one embodiment, the film material is transferred Mechanism 122 is an inkjet printhead that delivers droplets of liquid ink 124 to drum 114.

In the embodiment of Figure 1, the drum 114 has a flat surface that receives a drive plate (not shown) having a solid support (not shown) and one or more print heads (not shown) thereon. The solid support can define a solid surface with integrated components. Each facet of the drum can accept at least one or more drive plate assemblies. The printhead can be used to accept the metered film material 124 in a first direction and then transfer it to the substrate 110 in a second direction. The metered film material 124 received on the surface of the drum 114 in a first direction moves toward the substrate 110 and enters the second configuration by rotating the drum as indicated by arrow 126. The drum 114 can have a single transfer surface that defines a continuous belt surface around the drum 114 or it can define a plurality of discrete, independent or discontinuous surfaces.

The film material 124 can be delivered to the printhead in a first specified pattern. Film material 124 can be organized in a first direction, a second direction, or other intermediate direction (or plane) on the microholes (not shown) of each printhead. In the second direction (or second plane), the film material 124 is transferred onto the substrate 110 and the film material can be deposited on the substrate and the direction is assumed to coincide with the microvias (not shown). Thus, in one embodiment, the ink material is received on a first plane of the facet drum and deposited on the substrate in a second plane. In an alternative embodiment, the ink material can be received on the substrate in a first plane and deposited on the substrate in a second plane.

As described, each printhead can further comprise micropatterned features, such as microvias, microchannels, micropillars or other micropatterned structures or nanopatterned structures, and can further comprise an array of such structures (possibly Array interchange use). The micropatterned structure can organize the film material by maintaining a pattern that is transmitted as a transfer mechanism. It can also organize the film material by rearranging the film material into a new pattern. Thus, micropatterning can be used to organize the film material by maintaining a pattern of material and/or changing the pattern of the material to achieve the desired pattern. Micropatterning may assist in organizing the metered film material 124 after receiving the metered film material 124 on the transfer surface and/or print head. The tissue can be performed by means of capillary forces or other forces acting between the micropatterned structure and the material deposited on the transfer surface or printhead. When the heat dispensing nozzle is a rotating drum and wherein the transfer surface itself has a micropatterned structure, such as a micropatterned structure formed on the drum itself, the micropatterned structure can assist in organizing the film material 124 on the transfer surface, and After the tissue, the film material 124 can be substantially located on the region having the micropatterned structure, substantially on or substantially in the region of the micropatterned structure. For example, a plurality of channels or grooves can be formed on the surface of the drum such that the channels receive the ink material and deposit the ink material onto the substrate to form a printed embossing having substantially the same pattern as the channels or grooves.

The adjustment unit 116, which is optionally used, is disposed near the outer surface of the drum 114. The adjustment unit 116 can also be disposed within the drum. The conditioning unit 116 can transmit radiation, convection or conduction heating or introduce a directional gas flow to condition the metered film material before the film material is transferred from the printhead to the substrate 110. In one embodiment, the metered film material 124 comprises a quantity of liquid ink comprising a film material and a carrier fluid, and the conditioning unit 116 acts as a drying unit to substantially evaporate the carrier fluid to form a substantial mass on the print head of the drum 114 A layer of dried film material.

Light source 118 and light path 119 are optionally added and configured to excite region 120 on the transfer surface. Region 120 can be a printhead or a support surface having a plurality of printheads thereon. The region 120 contains a film material 124, each facet surface having a film material 124 previously accepted in the first configuration and now transferred to the second configuration. The film material is transferred from the faceted surface to the substrate and the film 112 is formed by exciting the print head.

In one embodiment of the invention, light source 118 is a laser source in communication with a string of optical elements (lenses, filters, etc.) that allows energy to be concentrated in one or more discrete regions of drum 114. Light source 118 can thermally excite regions 120 of the faceted surface (or print head only) either thermally or by radiant heating. In an exemplary embodiment, an infrared radiation ("IR") source can be used for this purpose. The use of light source 118 as appropriate and for exciting the faceted surface to effect transfer of the film material onto the deposition surface is well within the scope of the present invention. In one embodiment, the transfer surface and/or printhead contains an integrated heater (not shown), such as a resistive heater, and the heater can be activated to transfer the film material to the substrate, e.g., by thermally evaporating the film material. In another embodiment, the printhead includes an integrated piezoelectric material (not shown) that can be activated to transfer the film material onto the deposition surface by activation, such as by agitation, to remove the film material from the printhead. In another embodiment, an external mechanism is provided to direct vibration or pressure waves onto the printhead to assist in transferring the film material to the deposition surface, such as by agitation, to remove film material from the printhead.

2 is another schematic illustration of a rotary facet deposition system in accordance with an embodiment of the present invention. In Figure 2, the facet drum 214 has six discrete surfaces. It is numbered from surface 1 to 6. Each surface (or facet) can accept a structure having one or more print heads. In an illustrative embodiment, each facet may include a drive plate (not shown) having a support structure (not shown) for receiving a plurality of print heads (not shown). As will be discussed, the support structure can accept one or more print heads that provide members for: (1) removably mounting one or more discrete print heads, and (2) on the facets A combination of one or more printheads is mounted in a single unit and (3) provides electrical communication between the control circuitry and the printhead. As will be discussed, each printhead can contain one or more micropatterned regions that are arranged to organize the film material in a specified pattern on the printhead to form a deposited film material on the deposition surface. Specific pattern. The printhead receives a metered film material 224, which may comprise a liquid ink containing a film material dissolved or suspended in a carrier fluid.

The direction of rotation of the facet drum 214 is shown by arrow 226. The film material transfer mechanism 222 meters the film material 224 into one or more transfer print heads on the facet 1 of the facet drum 214. In one embodiment, the film material delivery mechanism 222 includes an inkjet printhead for metering film material in the form of a liquid ink. As the facet drum 214 rotates in the direction of arrow 226, one or more of the print heads on facet 1 are optionally conditioned by unit 216. The conditioning unit 216, optionally selected, can include a heater, and in the particular example where the metered film material comprises a liquid ink, the heater 216 can assist in evaporating the carrier fluid from one or more of the printheads on the facet 1 such that The pre-deposition film material forms a dry deposit on each printhead. In general, one or more printheads can have a micropatterned structure for organizing the film material.

When the facet 1 reaches the substrate 210, the film material on one or more of the printheads is substantially free of carrier liquid. The substantially liquid-free film material is then transferred from the one or more printheads on the facet 1 to the substrate 210 without material contact between the one or more printheads and the substrate 210.

The transfer of the film material from the facet to the substrate can be carried out by diffusion with external energy supplements. For example, one or more of the printheads on facet 1 can be equipped with an actuator that can remove film material from the printhead and transfer the film material onto the deposition surface. Alternatively, the printhead on facet 1 can be equipped with a thermal actuator that transfers thermal energy to the film material to transfer the film material to the deposition surface, for example by thermal evaporation or vaporization of the film material. The system of Figure 2 can also be equipped with optics (such as the optics described with respect to Figure 1) to assist in transferring film material from the printhead to the substrate 210. In one embodiment, the printhead is heated to exceed the evaporation temperature of the ink material as it is on the printhead. After the ink material is in vapor phase, it diffuses (or evaporates quickly) into the substrate. The closer the print head is to the substrate, the more the pattern printed on the substrate is within the limits.

The film material is deposited on the substrate 210 in a substantially solid phase form to form the film 212. The shape (and morphology) of the film 212 is determined by the location and alignment of the film material on the printhead prior to transfer to the substrate, and the location and alignment of the film material is determined by the spatial pattern used by the film transfer mechanism when metering the film material onto the printhead. The arrangement of the film material on the transfer surface is additionally determined by the presence of a micropatterned structure (not shown) on the transfer surface. In Figure 2, a thin film material is arranged on one or more printheads on facet 1 to provide three discrete and discontinuous regions of deposited film material on the substrate. therefore, Film 212 reflects the three discrete and discontinuous regions.

The system of Figure 2 can also include a controller (not shown) for monitoring and controlling the deposition process. The controller can include a processor circuit (not shown) in communication with a memory circuit (not shown), a membrane transfer mechanism (not shown), and one or more actuators (not shown). The processor circuit can include one or more microprocessors. The memory circuit includes instructions for transmitting to the controller circuit and the actuator, for example: (i) placing one or more print heads on the first facet near or near the film material transfer mechanism; (ii) Measuring a quantity of film material on one or more print heads on a facet; (iii) heating the transfer surface on the first facet to adjust the film material, such as substantially evaporating the carrier when the metered film material is a liquid ink a fluid; (iv) positioning the printhead at a proximal end of the substrate to transfer the film material from the printhead to the substrate; (v) heating the printhead on the first facet to heat the film, for example by thermal evaporation or vaporization of the film material Transferring the material to the substrate; and (vi) repeating the process with one or more print heads on the second facet.

Figure 3A shows an exemplary hexagonal drum deposition system in accordance with one embodiment of the present invention. In particular, Figure 3A shows a rotating facet assembly of a deposition system 310 of one embodiment of the present invention having, on each facet, a plurality of discrete, substantially coplanar surfaces for collectively mounting in the form of transfer surface elements The facet 315 of the print head. Alternatively, a substrate may be inserted between each facet of the drum (with a print head thereon) and each plane. The facet can be regarded as a transfer surface unit. Each surface of the hexagonal drum 310 has a facet 315 for mounting one or more transfer surface units. Each support structure can be coupled to a respective facet of the drum 310.

Figure 3B is an illustrative illustration of a support structure having a plurality of print heads. In particular, Figure 3B shows six shifts with a common mounting in a coplanar surface. An exemplary facet 315 of the surface unit. Facet 315 is shown to accept a plurality of printheads 330, wherein each printhead has a microporous structure that is shown schematically as region 310. Print head 330 can have the same microporous structure or a different microporous structure.

Dimensions W ₁ and H ₁ define the width and height of the transfer surface on each of the substantially identical transfer surface elements, respectively. Dimension W ₂ and H ₂ are defined width and height since the pitch is mounted on a facet transfer between the transfer surface 315 of generating units. In one specific example, W ₁ is equal to W ₂ and H ₁ is equal to H ₂ . In another embodiment, W ₂ is equal to an integer multiple of W ₁ (except for 1 time). In another embodiment, H ₂ is equal to an integer multiple of H ₁ (except for 1 time).

Figure 3C illustrates an exemplary support structure having a firing unit and a micropatterned region in accordance with one embodiment of the present invention. The support structure of FIG. 3C includes a transfer surface 310, an activation element 320 (which can be integrated with the unit), a support structure 330, and a micropatterned surface structure 340. The activation element 320 can include a heating element, such as a resistive heating element, that can be used to heat the transfer surface to condition the film material to transfer the film material to the substrate. The activation element 320 can also include a piezoelectric element that can be used to transfer the film material onto the substrate. In an exemplary embodiment, at least 6,000 microwells are included on the printhead. In another embodiment, the printhead comprises between 2,000 and 12,000 microwells.

Figure 3D illustrates another exemplary support structure for a faceted drum. In Figure 3D, the transfer surface 310 has a line 312 thereon. Line 312 schematically illustrates the pattern of microstructures formed on surface 310. Figure 3E is an exploded view of region 325 of the surface of the drum of Figure 3D. In FIG. 3E, micropatterned region 325 includes microwell arrays 342 arranged in columns and rows. This exemplary embodiment shows micropores organized into 3 rows, each row having a repeating vertical pattern of microwell pairs. Microwell array 342 defines a pixel. The illustrative embodiments can have from 2,000 to 12,000 pixels. The microwell array 342 can be micromachined in the surface of the drum to provide a transfer surface for the drum. In another embodiment, the micropatterned regions form individual transfer surface units and are then attached or adhered to the underlying rotating or transport mechanism either directly or via an intermediate substrate and/or package.

Figure 4 shows a faceted support structure of one embodiment of the present invention. The support structure 400 includes a circuit board driver 405 at its end. Circuit board 405 typically includes processor circuitry configured to communicate electromechanical instructions to printhead 440. Circuit board 405 can also include pins and I/O connectors such that it can communicate with a global controller that directs printing from other facets of the drum or facets of multiple drums.

The support structure 430 is coupled to the circuit board 405 via a plurality of fasteners 409. Although the specific example of FIG. 4 shows that the fasteners 409 are coupled, the circuit board and support structure can also be connected in any known manner. In an exemplary embodiment, support structure 430 can be a solid structure formed from tantalum or similar composites. Although not shown in FIG. 4, the support structure 430 can also have one or more flanges and channels formed therein for transmitting fluid from an external source (not shown) to the transfer surface 410. As will be discussed below, the fluid being delivered can include air or compressed gas to be used in an auxiliary printing process.

A plurality of print heads 440 are aligned on the surface of the support structure 430 and coupled to the support structure 430 via screws 412. The screw 412 enables quick removal and replacement of the printhead 430. Each print head 430 is also shown with an integrated heater 442. Heater 442 encloses the printhead area containing the microporous structure. Heater 442 is in communication with circuit board 405. The circuit controls when power is supplied to the heater Interval and amplitude. Circuit board 405 controls the frequency and amplitude of the heat generated by heater 442.

In one embodiment of the invention, when the liquid ink is deposited on the proximal surface of the support structure 430, the deposited ink has an exposed surface that includes the printhead (and the microvias formed thereon) and the transfer surface 440. The path. To transfer ink away from the transfer surface to the printing surface, an air knife can be used to drive the received ink into the micropores. In addition, the transfer surface and the surface of the printhead can be machined or formed of different materials such that the non-printing surface will repel the liquid ink material and the printing surface (i.e., the microporous structure on the surface of the printhead 440) will attract the liquid ink.

Fig. 5 schematically shows the operation of the facet drum of one embodiment of the present invention. The process begins with stage 501 in which the ink material is supplied to the facet having the print head thereon. The ink material can define a liquid carrier containing dissolved or suspended ink particles. The ink can be delivered by an ink delivery mechanism. The drum 510 is rotated counterclockwise as indicated by the arrow, and at stage 520, the ink supply face is brought close to the solvent evacuation port 520 (solvent purge port). The solvent evacuation device can be a heating station or vacuum type device for removing solvent from the faceted surface. At stage 503, substantially all of the carrier fluid has been removed from the amount of ink delivered to the facet. After stage 503, the ink material remaining on the faceted printhead is substantially free of carrier liquid and may be in solid phase form.

At stage 505, the ink supply facets are placed adjacent to a substrate (not shown). Here, the printing step is performed by evaporating substantially solid ink particles to form a vapor. The vapor is then condensed on the substrate to form a coating film. Although not shown in FIG. 5, a compressed gas may be injected on the substrate to assist in the substrate. A printed material is partially formed on the upper portion.

At stage 507, the facets (and print heads) can be cleaned by the cleaning station. The cleaning station can include one or more cleaning solutions directed to the facets of the drum to remove residual ink material from the facets. In an alternative embodiment, the cleaning station includes one or more heaters to heat the faceted surface to vaporize any residual ink material from the face of the drum or the printhead thereon. At stage 509, each facet and its respective printhead are cooled and ready for another deposition cycle. It should be noted that when the drum has a plurality of coated facets, the printing step can be performed continuously with different facets. For example, when printing a facet, adjacent facets can be cleaned or inked.

The stage shown in Figure 5 can be controlled by the controller. The controller can include one or more microprocessor circuits coupled to one or more of the memory circuits. The memory circuit can pass instructions to the processor circuit to: (1) arrange for supplying ink to the facet of the drum (including, but not limited to, supplying a predetermined amount of ink to each facet or each print head), (2) from A predetermined amount of ink removes the carrier liquid to provide a quantity of substantially liquid-free ink, (3) disperses a quantity of liquid-free ink from the print head onto the substrate, (4) cleans the facet after the deposition step, and (5) Cooling the facets and/or preparing the facets, and then repeating the steps. The controller can control a plurality of print heads globally. Alternatively, each drum or facet may have its own controller.

Figure 6 is a schematic illustration of the control system of the printing apparatus discussed herein. Controller 600 includes a microprocessor circuit 610 coupled to a database 620. The database 620 can communicate with an operator via an I/O system (not shown), wherein the operator It can transmit settings such as proper printing, heating, and cleaning. Controller 600 communicates with drum printer 640 via media 630. The drum 640 can be a facet drum that supports a plurality of print heads (not shown) as described above. Each facet may include a driver circuit board (not shown) to control the printing operation at the respective print head.

Although the principles of the present invention have been described with respect to the exemplary embodiments illustrated herein, the principles of the invention are not limited to the principles of the invention.

110‧‧‧Substrate

112‧‧‧film

114‧‧‧hexagonal drum deposition system

116‧‧‧Adjustment unit selected as appropriate

118‧‧‧Light source

119‧‧‧Light path

120‧‧‧Area

122‧‧‧Material transfer mechanism

124‧‧‧ Film material

126‧‧‧ arrow

210‧‧‧Substrate

212‧‧‧film

214‧‧‧faced drum

216‧‧‧Adjustment unit selected as appropriate

222‧‧‧Film material transfer mechanism

224‧‧‧ Film material

226‧‧‧ arrow

310‧‧‧Deposition system

312‧‧‧ line

315‧‧・facet

320‧‧‧Starting components

325‧‧‧Area

330‧‧‧Support structure

340‧‧‧Micropatterned surface structure

342‧‧‧Microwell array

400‧‧‧Support structure

405‧‧‧Circuit board driver

409‧‧‧fasteners

410‧‧‧Transfer surface

412‧‧‧ screws

430‧‧‧Support structure

440‧‧‧Print head

442‧‧‧heater

501‧‧‧ stage

503‧‧‧ stage

505‧‧‧ stage

507‧‧‧

509‧‧‧ stage

520‧‧‧ stage

600‧‧‧ controller

610‧‧‧Microprocessor circuit

620‧‧‧Database

630‧‧‧Media

640‧‧‧drum printer

W ₁ ‧‧‧Transfer surface width

W ₂ ‧‧‧Width of the spacing between the transfer surfaces

H ₁ ‧‧‧Transfer surface height

H ₂ ‧‧‧ Height of the spacing between the transfer surfaces

1 schematically illustrates a facet deposition system of one embodiment of the present invention; FIG. 2 is a schematic view of a rotary facet deposition system according to an embodiment of the present invention; and FIG. 3A shows an exemplary hexagon of one embodiment of the present invention. Drum deposition system; FIG. 3B is an illustrative illustration of a support structure having a plurality of print heads; FIG. 3C illustrates an exemplary support structure having a firing unit and a micropatterned region in accordance with one embodiment of the present invention; FIG. 3D illustrates Another exemplary support structure of the facet drum; FIG. 3E is an exploded view of a portion of the support structure of FIG. 3D; FIG. 4 schematically shows a faceted support structure of one embodiment of the present invention; FIG. 5 schematically shows the present invention The operation of a faceted drum of a specific example; and Figure 6 is a schematic view of a system of one embodiment of the present invention.

110‧‧‧Substrate

112‧‧‧film

114‧‧‧hexagonal drum deposition system

116‧‧‧Adjustment unit selected as appropriate

118‧‧‧Light source

119‧‧‧Light path

120‧‧‧Area

122‧‧‧Material transfer mechanism

124‧‧‧ Film material

126‧‧‧ arrow

Claims (34)

A facet structure for printing a plurality of pixels, comprising: a support structure; a plurality of print heads attached to the support structure, each print head having at least one microhole for receiving a film having dissolved or suspended in a carrier fluid a first quantity of liquid ink of the material and a second quantity of ink material substantially free of the carrier fluid; wherein the plurality of print heads are disposed at a proximal end of the substrate to simultaneously print a plurality of spaces on the substrate Discrete and image resolved pixels. The facet structure of claim 1, wherein the support structure further comprises a flange for receiving a fluid. The facet structure of claim 1 further comprising a drive plate coupled to the support structure, the drive plate having a processor for initiating dispensing of ink from the at least one printhead. The facet structure of claim 1, wherein at least one of the micropores is a closed micropore. The facet structure of claim 1, wherein at least one of the micropores is an open microhole extending through the printhead. The facet structure of claim 1, wherein at least one of the printheads comprises a microwell array and wherein each of the microwells is spaced apart from adjacent microwells by about 1-4 [mu]m. The facet structure of claim 1, wherein at least one of the micropores is about 3 μm. Such as the facet structure of claim 1 of the patent scope, wherein the space Discrete and image resolved pixels are printed on the substrate at approximately 25-500 pixels per turn. A facet drum system for pixel printing, comprising: a chuck for receiving a rotary print head assembly; a plurality of facets, each facet attached to a respective surface of the rotary print head assembly in a tangential direction; a plurality of print heads disposed on each facet, the at least one print head having a microwell array for receiving a first amount of liquid ink having a film material dissolved or suspended in a carrier fluid and dispensing substantially free of the carrier The second amount of ink material of the fluid. The face drum system of claim 9, wherein each facet comprises a faceted drive plate, a support structure and the plurality of print heads. The facet drum system of claim 9, wherein the support structure further comprises at least one channel to deliver fluid to the substrate. The face drum system of claim 11, wherein the fluid defines a gas. The facet drum system of claim 9, wherein the plurality of print heads are disposed at a proximal end of the substrate to simultaneously print a plurality of spatially resolved pixels. The facet drum system of claim 9, further comprising an ink delivery structure for delivering liquid ink to each facet. The face drum system of claim 9 of the patent application, further comprising a cleaning station for cleaning each facet after printing. For example, the face drum system of claim 9 of the patent scope, in which each printing The head further includes an actuator for dispensing the second amount of ink material. The facet drum system of claim 9, wherein each print head further comprises a heater for dispensing the second quantity of ink material. The facet drum system of claim 9, further comprising a controller for directing rotation of the rotary printhead assembly to receive a first quantity of liquid ink and to dispense the second quantity of ink material. The face drum system of claim 9, wherein at least one of the micropores is a closed micropore. The facet drum system of claim 9, wherein at least one of the micropores is an open microhole extending through the printhead. The facet drum system of claim 9, wherein the print heads are arranged to dispense ink to print spatially discrete and image resolved pixels on the substrate. A system for printing a film on a substrate, the system comprising: a microprocessor circuit; a memory circuit in communication with the microprocessor circuit, the memory circuit storing the following instructions of the processor circuit: (1) turning The facet of the drum is supplied with a quantity of liquid ink having a print head on the face and the liquid ink is defined by a carrier liquid having suspended and/or dissolved ink particles, (2) removing the supplied amount of ink The carrier liquid forms a quantity of substantially liquid-free ink on the print head, and (3) evaporates the amount of substantially liquid-free ink remaining on the print head; (4) The amount of vaporized ink is directed onto the substrate. A system of claim 22, further comprising heating the print head to remove the carrier liquid. The system of claim 22, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink to the facet. The system of claim 22, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink onto the print head. The system of claim 22, wherein the step of supplying a quantity of liquid ink further comprises using an air knife to force the supply of liquid ink into the print head. The system of claim 22, wherein the step of removing the carrier liquid from the supply amount of ink further comprises heating the facet or at least one of the print heads to evaporate the temperature of the carrier fluid. A method for printing a film from a plurality of facets of a drum, the method comprising: supplying a quantity of liquid ink to one of the plurality of facets, the facet supporting the microstructure and the liquid ink definition having a suspension And/or a carrier liquid of dissolved ink particles; removing the carrier liquid from the supply of ink to form a quantity of substantially liquid-free ink on the print head, evaporating the amount remaining on the print head substantially No liquid ink; and The quantity of vaporized ink is dispensed from the printhead onto the substrate; wherein rotating the drum causes the facet to receive liquid ink in a first direction and dispense the vaporized ink in a second direction. The method of claim 28, further comprising heating the microstructure to remove the carrier liquid. The method of claim 28, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink to the facet. The method of claim 28, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink onto the microstructure. The method of claim 28, wherein the step of supplying a quantity of liquid ink further comprises using a gas knife to force the supply of liquid ink into the microstructure. The method of claim 28, wherein the step of removing the carrier liquid from the supply of ink further comprises heating the facet or at least one of the microstructures to evaporate the temperature of the carrier fluid. The method of claim 28, wherein the step of directing the quantity of vaporized ink onto the substrate further comprises directing the vaporized ink onto the substrate using an auxiliary stream.