WO2010109457A1 - Procédé et appareil pour inspection et étalonnage d'une unité d'impression - Google Patents

Procédé et appareil pour inspection et étalonnage d'une unité d'impression Download PDF

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Publication number
WO2010109457A1
WO2010109457A1 PCT/IL2010/000240 IL2010000240W WO2010109457A1 WO 2010109457 A1 WO2010109457 A1 WO 2010109457A1 IL 2010000240 W IL2010000240 W IL 2010000240W WO 2010109457 A1 WO2010109457 A1 WO 2010109457A1
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WO
WIPO (PCT)
Prior art keywords
pattern
print
substrate
nozzles
image
Prior art date
Application number
PCT/IL2010/000240
Other languages
English (en)
Inventor
Ran Asher Peleg
Hanan Gothait
Ofir Baharav
Original Assignee
Xjet Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Xjet Ltd filed Critical Xjet Ltd
Publication of WO2010109457A1 publication Critical patent/WO2010109457A1/fr

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41JTYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J29/00Details of, or accessories for, typewriters or selective printing mechanisms not otherwise provided for
    • B41J29/38Drives, motors, controls or automatic cut-off devices for the entire printing mechanism
    • B41J29/393Devices for controlling or analysing the entire machine ; Controlling or analysing mechanical parameters involving printing of test patterns

Definitions

  • Materials deposition systems such as inkjet or aerosol jet are considered one of the promising methods for selective fabrication of thin layers in the printable electronics industry and have a potential of becoming the technology of choice for fabricating front contacts in solar photovoltaic cells.
  • This technology has several advantages over the traditional methods, for example, it does not require contact with the fragile surface of solar cells, has better resolution, and offers higher productivity.
  • a "drop on demand” inkjet technology works by selectively ejecting fine droplets of ink onto the printed media by a plurality of nozzles which can be turned on or off.
  • the printed pattern is formed by scanning a printhead (a print unit containing several dispensing nozzles) relative to the substrate; a position of the dot on the substrate is controlled by controlling which nozzle is forced to eject droplets, and the timing of drop ejection.
  • a desired pattern may be formed on the substrate.
  • the preferred type of scan for inkjet systems for mass manufacturing of solar cells comprises conveyor processing, that is, a linear scan along a single axis, referred to as the "scan axis".
  • the solar cell is scanned under the print unit (that may comprise one or more printheads) in a linear motion while the printheads remain stationary during the scan.
  • a difficulty that may be common to all deposition printers may be associated with faulty nozzles which, at the extreme cases, can be manifested by total occlusion of the orifice, thus completely blocking the ejection of droplets. More often however, faulty nozzles will be characterized by adverse printed features, e.g., wrong droplet size and/or location. Another problem may relate to a misalignment or generally a position of a printhead which may cause a pattern to be misplaced, distorted or otherwise incorrect. [0004] Although methods and systems known in the art may enable off line inspection and service of print units, such off line methods may only be performed when the system is not printing or is otherwise idle but may not be performed without impeding production.
  • Fig. 1 shows an exemplary pattern comprising narrow finger lines and wider bus bars according to embodiments of the invention
  • FIG. 2 shows an exemplary printing system according to embodiments of the invention
  • FIG. 3 shows exemplary pattern comprising test patterns according to embodiments of the invention shows exemplary pattern comprising test patterns according to embodiments of the invention
  • FIG. 4 is a flowchart diagram illustrating a method for inspecting and servicing print units according to embodiments of the present invention.
  • FIG. 5 shows an exemplary printing system according to embodiments of the invention.
  • Embodiments of the invention are directed to a printing system having an inspection system where the inspection system may operate simultaneously with a printing process. Embodiments of the invention are further directed to a system and method for online or on-the-fly inspection of print units. According to embodiments, jetting nozzles or other dispensing units that participate in a current, ongoing print job may be inspected online, on-the-fly or otherwise at the same time a print job is in process. It will be understood that any applicable dispensing units, e.g., inkjets, aerosol jets or any other dispensing systems may be inspected and serviced as described herein. Likewise, embodiments of the invention are not limited by the type of the material dispensed, printed or deposited.
  • printheads that comprise a plurality of jetting or other type of nozzles
  • any applicable arrangement or assembly may be used for positioning a plurality of print units and/or material deposition devices with respect to a substrate.
  • the discussion herein will mainly refer to a deposition of metallization lines on photovoltaic solar cells, it will be understood that online or on-the-fly inspection of print units used for deposition of any applicable pattern and/or any suitable material on any applicable substrate may be performed as described herein.
  • one or more test patterns may be printed in reserved areas on the surface of the substrate in a first scan.
  • reserved areas where a test pattern is printed may be areas where material is deposited in a subsequent or second scan.
  • An image of the test patterns may be acquired, e.g., using a digital camera or any suitable imaging system. An analysis of the acquired image may be performed and used to determine faults, e.g., faulty nozzles or misaligned printheads.
  • depositing the test pattern and the first and second parts of the pattern, acquiring and analyzing the image may be performed during a continuous translation of the substrate in a single scan direction.
  • Fig. 1 shows an exemplary metallization pattern that may be deposited on a substrate 100.
  • the substrate may be a solar cell.
  • the pattern may comprise a plurality of finger lines 101 and a plurality of bus bars 102.
  • the finger lines 101 may be deposited first, e.g., by one or more nozzles in a first set of printheads positioned or arranged across a scan axis.
  • a nozzle array comprising a finger printhead is typically arranged along the scan axis.
  • substrate 100 may be rotated by ninety degrees (90°) and, maintaining the scan direction, scanned by a second set of printheads that deposit bus bars 102.
  • a nozzle array comprising a bus printhead is typically arranged at a small angle along the scan axis.
  • a linear scan, non-contact " material deposition system implementing embodiments of the invention may deposit the pattern shown in Fig. 1.
  • rotation of substrate 100 is not included.
  • the bus heads with their nozzle arrays are positioned in a cross-scan orientation.
  • the substrate may be translated in a first direction when the finger lines are deposited, and in a second, orthogonal direction, when the bus bars are deposited.
  • the pattern 100 shown in Fig. 1 is an exemplary pattern that, for the sake of clarity and simplicity, will be referred to herein. However, it will be understood that embodiments of the invention may be applied to various other patterns, in particular, any pattern having intersecting lines or other shapes may be applicable.
  • system 200 may be an inkjet printing system used for fabrication of front contact metallization of photovoltaic (PV) solar cells.
  • system 200 may comprise a processing unit 260, a control unit 270, printheads 210 and 250, a substrate mounting and translation unit 220, a rotational unit 223 and an image acquisition unit 240.
  • system 200 may deposit patterns 222, 224 and 251 on a substrate 221.
  • Control unit 270 may be operatively connected to printheads 210 and 250, processing unit 260, image acquisition system 240, rotational unit 223 and/or any other component of system 200.
  • Control unit 270 may be operatively connected to a conveyor (not shown) or other translation unit that translates substrate 221 (e.g., by translating unit 220) from printheads 210 through image acquisition unit 240 to printheads 250. Accordingly, any relevant data, information or parameters related to a printing on substrate 221 may be available to control unit 270. For example, a velocity, location, position or orientation of substrate 221 may be known to control unit 270.
  • Control unit 270 may control operation of nozzles in printheads 210 and 250. For example, control unit 270 may control the period during which a specific nozzle in a specific printhead will deposit material on substrate 221. Accordingly, control unit 270 may cause any pattern including a test pattern to be printed on substrate 221 by selected nozzles or units. Any selection of print units, printheads or specific nozzles may be made by control unit 270. for example, a first set of units or nozzles may be selected to print a first part of a pattern, a second and third sets may be selected and/or caused to print a second and third parts of a pattern and a fourth set (that may be the set to be inspected) may be selected and caused to print a test pattern.
  • idle nozzles may be inspected.
  • Idle, redundant or backup nozzles may be any nozzles in a print unit that do not actively or currently participate in printing.
  • Such idle, backup or redundant nozzles may be reserved as backup, and, according to embodiments of the invention, may be made or designated active on-the-fly or in realtime, while a print job is in progress.
  • a print unit such as a printhead may be Idle, redundant or backup, similarly, based on an inspection as described herein, an idle printhead may be made or designated active on-the-fly or in realtime, while a print job is in progress.
  • control unit 270 may cause service actions to be performed. For example, control unit 270 may instruct actions such as priming a jet, setting parameters such as temperature, pressure level or setting particle size of a jet to be performed. In other cases, an action may comprise designating active nozzles as inactive and/or designating or making idle nozzles, printheads or print units active. Accordingly, embodiments of the invention may enable on-the-fly or realtime replacement of faulty nozzles by backup, redundant or idle nozzles.
  • a pattern comprising finger lines 222 and test patterns 224 may be deposited on a substrate 221.
  • the pattern deposited on substrate 221 may further comprise bus bars 251 that may be printed by printheads 250.
  • System 200 may be an inkjet system utilizing a linear scan technique. In this type of scan, the substrate is scanned under the printheads in a linear motion while ink is discharged from inkjet nozzles.
  • the printheads (210 and 250) may remain stationary during the scan but may be provided with translation means for alignment or positioning.
  • Translation unit 220 may be a moving table (e.g., connected to a conveyor) for transporting substrate 221 in a direction referred to as the scan axis, or the x axis as shown by 280.
  • Translation unit 220 may be provided with a sensor, such as for example an optical encoder, which may track the motion of translation unit 220 with a high degree of precision and may provide feedback to control unit 270.
  • the orientation of the substrate may be similarly tracked or determined by control of, and feedback from, rotational unit 223.
  • Printheads 210 and 250 may each include a plurality of inkjet nozzles that may be arranged along these printheads. As shown, printheads 210 may be arranged or aligned along the scan direction such that each of thin finger lines 222 may be printed by one or more nozzles. To produce wider bus lines 251, printheads 250 may be position at a predefined angle with respect to the scan axis such that a number of nozzles may deposit a bus bar having a corresponding predefined width.
  • a final pattern may be produced by combining a first and a second pattern.
  • a first pattern may comprise thin finger lines and a second pattern may comprise wider bus lines or bars which may be orthogonal to the finger lines.
  • the pattern shown in Fig. 1 may be thus produced.
  • a test pattern may be printed with the first pattern at areas or regions where the first and second patterns intersect.
  • finger lines 222 and test patterns 224 may be printed such that test patterns 224 are printed at locations where bus bars 251 are to be subsequently printed. Accordingly, test patterns 224 may become invisible or may be covered or hidden by bus bars 251.
  • An advantage of the methods and systems described herein relates to printing test patterns on reserved areas, e.g., areas to be subsequently printed on. For example, printing the test pattern on areas reserved for bus bars is such that no shadow losses are added by covering the surface of a solar cell with non transparent test pattern lines. Yet another advantage is that many nozzles can be simultaneously tested and possibly serviced without impeding a current or on going printing process. For example, printing test patterns, analyzing such patterns and possibly correcting faults may be done simultaneously with a progress of a print job. Yet another advantage relates to inspecting print units during, while, or simultaneously with, conducting an actual printing job.
  • control unit 270 may control printheads 210 to print test patterns 224.
  • control unit 270 may determine that a specific nozzle in one of printheads 210 is positioned such that it may dispense material at a location where bus bars 251 are to be deposited. Accordingly, control unit 270 may cause such specific nozzle to dispense a test pattern in such location.
  • control unit 270 may control a nozzle to deposit a continuous line (or finger) in a first region or during a first period of time, and a series of dots or other test patterns in a second region, or during a second period of time.
  • Control unit may cause any nozzle in any one of printheads 210 to print a test pattern.
  • an active nozzle e.g., a nozzle participating in printing finger lines 222
  • idle, backup or redundant nozzles e.g., nozzles not participating in printing fingers 222
  • a combination of active and inactive nozzles may be caused to print test patterns.
  • pattern 300 may comprise finger lines deposited on a substrate (e.g., a photovoltaic solar cell). As shown, pattern 300 may comprise finger lines 310 and 311 and test patterns 350, 360, 370 and 380.
  • control unit 270 may cause nozzles in printheads 210 to deposit finger lines 310 and 31 1 during a first period of a scan. When determining that a region where bus bars (e.g., 102 in Fig. 1) are to be printed is located under nozzles to be inspected, control unit 270 may cause such nozzles to deposit test patterns 350, 360, 370 and 380. Accordingly, a pattern such as 300 may be produced in a first scan.
  • any nozzle in a print unit may be caused to print a test pattern as described herein.
  • printheads 210 may be fitted with hundreds of nozzles where only some of the nozzles (also referred to as active nozzles herein) may actively participate in a print job.
  • a printhead may comprise a large number of redundant nozzles that may be used for backup. Both active and redundant nozzles, e.g., on printheads 210, may be caused to print a test pattern. Accordingly, both active and redundant or inactive nozzles may be inspected and serviced online as described herein.
  • substrate 221 may be rotated by ninety degrees (90°).
  • rotational unit 223 may rotate substrate 221 as shown.
  • substrate 221 may be translated to an area close to image acquisition unit 240 where an image of test patterns 224 may be acquired.
  • an image of test patterns may be acquired by a camera placed above or beside a conveyor (not shown) translating substrate 221 in a scan direction shown by 280.
  • rotating the substrate prior to acquiring an image may be in accordance with a best point or field of view provided to image acquisition unit 240.
  • rotating substrate 221 as shown may enable image acquisition unit 240 to acquire a large number of images along a test pattern.
  • Rotating the substrate as shown may provide more time for acquiring images since in such orientation, the test patterns are translated along a stationary point rather than across.
  • An additional advantage of the rotation is that if two bus bars are to be printed as shown by 251 then two cameras covering the width of bus bars 251 may suffice in order to acquire an image of test patterns 224. Without such rotation, a possible larger number of cameras would be required, e.g., in order to cover the entire width of substrate 221.
  • substrate 221 may be translated under printheads 250 that may deposit bus bars 251. Deposition of bus bars 251 may be over test patterns 224 thus test patterns 224 may be covered by bus bars 251. Accordingly, test patterns 224 do not use any additional space on substrate 221, namely, material that may block sun light from reaching photoelectric cells is not deposited on substrate 221 at regions other than those regions already dedicated for deposition of material.
  • processing and/or analyzing acquired images by processing unit 260 may be done while the substrate is being printed on. For example, such analysis may be performed while printheads 250 deposit bus bars 251.
  • the method may include printing a first part of a pattern on a substrate.
  • the finger lines 222 printed on substrate 221 are a first part of a final pattern where the final pattern comprises finger lines 222 and bus bars 251.
  • Any suitable pattern having intersecting sections may be divided into a first and second part and accordingly, a first part may be printed as shown by block 410.
  • the method may include printing a test pattern on the substrate.
  • test patterns 224 may be printed in regions where bus bars 251 are to be subsequently printed.
  • an area reserved for bus bars 251 may have a width of 0.2 mm while a typical drop of ink may cover a spherical area having a diameter of 50 ⁇ m. Accordingly, five to seven evenly spaced dots may be deposited by selected nozzles in a test area across a width of a bus bar.
  • the method may include rotating the substrate.
  • a substrate may be rotated by ninety degrees (90°) such that a small number of imaging devices (e.g., two) located above regions where bus bars are to be printed may acquire images of test patterns.
  • ninety degrees 90°
  • any rotation, orientation or positioning of a substrate may be performed or affected to best suit a position, point of views, capability or other relevant aspects of an imaging system used for acquiring images of test patterns printed as shown by block 415.
  • System 500 may comprise components similar to those described herein with respect to system 200 shown in Fig. 2 and may be an inkjet or aerosol printing system used in the production of photovoltaic (PV) solar cells.
  • system 500 may comprise a processing unit, a control unit and a substrate mounting unit similar to those of system 200.
  • System 500 may comprise a first set of printheads 510, a second set of printheads 550 and one or more image acquisition units 540.
  • System 500 may comprise two translation units positioned at a right angle, or ninety degrees (90°) with respect to each other.
  • a substrate may be translated in a first direction during a first time period and in a second, e.g., orthogonal direction, during a second time period where the two time periods are related to the same print job or process. Accordingly, instead of, or in addition to, rotating a substrate as described herein, the substrate may be made to travel in two or more directions during a print process.
  • a camera placed over a first conveyor that translates the substrate in that direction may be used.
  • a second or another camera may be placed over a second conveyor and may obtain an image of a test pattern during a scan in a second direction.
  • a first part of a pattern and test patterns may be printed by printheads 510.
  • Image acquisition units may acquire an image of the test patterns shown by 521 in one of two angles with respect to the patterns and translation, printheads 550 may print a second part of a pattern that may partly or completely cover the test patterns. Accordingly, a final pattern as shown by 560 may be produced.
  • the method may include acquiring an image of the test pattern.
  • Any suitable imaging system and related optic systems known in the art may be used to acquire images of test patterns as described herein.
  • the number of cameras may be equal to the number of bus bars.
  • Acquiring images as described herein may be performed while the substrate is scanned, namely, is translated or in motion as described herein.
  • the substrate may be held stationary under the imaging system while an image is acquired. Accordingly, parameters such as exposure time, amount of light and the like may be adjusted and or controlled, e.g., control unit 270, to ensure an optimal image.
  • the method may include analyzing an image of the test pattern.
  • an acquired image may be provided by image acquisition system 240 to processing unit 260.
  • Various aspects may be analyzed and various faults may be identified based on an image of a test pattern.
  • an angular deviation of the direction of a set of dots printed by a set of nozzles may indicate a deviation of the nozzle array from the scanning direction that may result from a misalignment of the related printhead.
  • Another aspect may relate to a specific nozzle, for example, absence of a dot in a specific location may indicate a clogged nozzle.
  • any applicable parameters, configurations or other aspects that may be modified or controlled may be set or adjusted as part of an action as shown by block 440.
  • Further actions may be a classification of nozzles, e.g., an active yet faulty nozzle may be classified as inactive and an inactive, redundant or backup nozzle may be set as active.
  • Various alignments may be performed, e.g., repositioning a printhead based on analysis results etc.
  • Parameters related to a rotation of a substrate may likewise be adjusted. For example, an analysis of test patterns may reveal that the rotation of a substrate is not by the desired angle, accordingly, parameters related to a unit such as rotational unit 223 may be adjusted.
  • a data base or other storage may be updated based on the analysis. For example, an entry indicating the number of faulty nozzle for a given printhead may be update, consequently, based on such entry it may be determined if the printhead needs servicing or replacement.
  • the terms “plurality” and “a plurality” as used herein may include, for example, “multiple” or “two or more”.
  • the terms “plurality” or “a plurality” may be used throughout the specification to describe two or more components, devices, elements, units, parameters, or the like.

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  • Coating Apparatus (AREA)
  • Ink Jet (AREA)

Abstract

L'invention porte sur un système et sur un procédé pour inspecter un système d'impression. Une première partie d'un motif et d'un motif de test peut être imprimée sur un substrat. Dans certains modes de réalisation, le substrat peut être mis en rotation. Une image du motif de test peut être acquise. Une image acquise du motif de test peut être analysée. Une action peut être effectuée en fonction d'une analyse d'une image du motif de test. Une seconde partie d'un motif peut être déposée et peut recouvrir une partie ou la totalité du motif de test.
PCT/IL2010/000240 2009-03-23 2010-03-23 Procédé et appareil pour inspection et étalonnage d'une unité d'impression WO2010109457A1 (fr)

Applications Claiming Priority (2)

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US16260709P 2009-03-23 2009-03-23
US61/162,607 2009-03-23

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WO2010109457A1 true WO2010109457A1 (fr) 2010-09-30

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106696462A (zh) * 2015-11-13 2017-05-24 林崇璘 自动辨识物件印刷位置的印刷系统及其印刷方法

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Publication number Priority date Publication date Assignee Title
US5448277A (en) * 1993-06-30 1995-09-05 Xerox Corporation Virtual process controls test pattern for electronic printers
US6106094A (en) * 1996-01-30 2000-08-22 Neopt Corporation Printer apparatus and printed matter inspecting apparatus
WO2002076752A1 (fr) * 2001-03-27 2002-10-03 Hewlett-Packard Company Detection de points, de couleurs et de supports par une imprimante pour controler la qualite
US20030112283A1 (en) * 1996-08-01 2003-06-19 Ward Jefferson P. Print-quality control method and system
US20050264596A1 (en) * 2004-05-26 2005-12-01 Hewlett-Packard Development Company, L.P. Image-forming device diagnosis
US20070024664A1 (en) * 2005-07-28 2007-02-01 Applied Materials, Inc. Methods and apparatus for concurrent inkjet printing and defect inspection
WO2008112316A1 (fr) * 2007-03-14 2008-09-18 E. I. Du Pont De Nemours And Company Procédé d'impression à jet d'encre

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5448277A (en) * 1993-06-30 1995-09-05 Xerox Corporation Virtual process controls test pattern for electronic printers
US6106094A (en) * 1996-01-30 2000-08-22 Neopt Corporation Printer apparatus and printed matter inspecting apparatus
US20030112283A1 (en) * 1996-08-01 2003-06-19 Ward Jefferson P. Print-quality control method and system
WO2002076752A1 (fr) * 2001-03-27 2002-10-03 Hewlett-Packard Company Detection de points, de couleurs et de supports par une imprimante pour controler la qualite
US20050264596A1 (en) * 2004-05-26 2005-12-01 Hewlett-Packard Development Company, L.P. Image-forming device diagnosis
US20070024664A1 (en) * 2005-07-28 2007-02-01 Applied Materials, Inc. Methods and apparatus for concurrent inkjet printing and defect inspection
WO2008112316A1 (fr) * 2007-03-14 2008-09-18 E. I. Du Pont De Nemours And Company Procédé d'impression à jet d'encre

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106696462A (zh) * 2015-11-13 2017-05-24 林崇璘 自动辨识物件印刷位置的印刷系统及其印刷方法

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