TWI890925B - Method and apparatus for manufacturing substrates with wrap around electrodes - Google Patents

Abstract

A method and apparatus of manufacturing a display tile includes depositing a first portion of an electrode on a first major surface and an edge surface of a substrate and depositing a second portion of the electrode on an opposing second major surface and the edge surface of the substrate. The electrode extends along a portion of a first major surface, an edge surface, and a portion of a second major surface of the substrate.

Description

Method and apparatus for manufacturing a substrate having a wrap-around electrode

This application claims the benefit of priority under patent law to U.S. Provisional Application No. 63/147,854, filed on February 10, 2021, and U.S. Provisional Application No. 63/196,360, filed on June 3, 2021, and this application relies upon and is incorporated herein by reference in its entirety.

The present disclosure relates generally to methods and apparatus for fabricating substrates having wrapped surrounding electrodes, and more particularly, to methods and apparatus for fabricating substrates having wrapped surrounding electrodes using aerosol jetting.

Displays such as micro-LED displays include frameless, bezel-less and/or tiled displays. Top-emitting micro-LED displays require a method for electrically interconnecting the LEDs on the top surface of the substrate with the driver controller board located behind the substrate. This can be accomplished by using flex connectors attached at the edge of the substrate. However, in the case of frameless, bezel-less or tiled displays, it is undesirable to use flex connectors attached to the top surface of the substrate. In such cases, the flex connectors are either visible to the viewer and need to be hidden by the bezel, or the flex connectors take up too much space between the tiles and prevent seamless tiling. One solution for electrically connecting the top surface of a display substrate to a driver controller board is to utilize wraparound electrodes.

Wrap-around electrodes can be fabricated around the edge of a substrate. This allows them to occupy less physical space and be less visually obtrusive. Wrap-around electrodes have been demonstrated in frameless, bezel-less, and tiled displays. These electrodes can be made from a variety of materials and fabricated using methods including printing, vacuum deposition, flexure bonding, and electroplating. Improvements in materials and processes are being used to improve the electrical performance and reliability of wrap-around electrodes.

Embodiments disclosed herein include a method for manufacturing a display tile. The method includes depositing a first portion of an electrode onto a first major surface and an edge surface of a substrate. The method includes depositing a second portion of the electrode onto an opposing second major surface and an edge surface of the substrate. The first major surface extends in a direction generally parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface. Furthermore, the electrode extends along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate.

Embodiments disclosed herein also include an apparatus for manufacturing display tiles. The apparatus includes a first orifice for directing a first aerosol jet toward a first major surface and an edge surface of a substrate. The apparatus also includes a second orifice for directing a second aerosol jet toward an opposing second major surface and an edge surface of the substrate. The first major surface extends in a direction generally parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface. In addition, the first aerosol jet is used to deposit a first portion of an electrode onto the first major surface and the edge surface of the substrate, and the second aerosol jet is used to deposit a second portion of the electrode onto the second major surface and the edge surface of the substrate.

Additional features and advantages of the embodiments disclosed herein will be set forth in the detailed description that follows, and those skilled in the art will in part be obvious from that description or will recognize additional features and advantages by practicing the disclosed embodiments as described herein (including the following detailed description, claims, and accompanying drawings).

It should be understood that the foregoing general description and the following detailed description of the present embodiments are intended to provide an overview or framework for understanding the nature and character of the claimed embodiments. The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the present disclosure and, together with the description, serve to explain the principles and operation thereof.

Reference will now be made in detail to the presently preferred embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

Ranges may be expressed herein as from "about" one particular value and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximate, for example, by use of the antecedent "about," it should be understood that the particular value forms another embodiment. It should be further understood that the endpoints of each range are meaningful both in relation to the other endpoint and independently of the other endpoint.

Directional terms as used herein (eg, up, down, right, left, front, back, top, bottom) refer only to the drawings as they are drawn and are not intended to imply an absolute orientation.

Unless otherwise expressly stated, it is not intended that any method described herein be understood as requiring that steps be performed in a specific order, nor is it intended to require any particular orientation of the apparatus. Thus, if a method claim does not actually list an order in which its steps must be performed, or if any apparatus claim does not actually list an order or orientation of individual components, or if the claim or description does not otherwise specifically state that steps are subject to a specific order, or does not list a specific order or orientation of apparatus components, no order or orientation is intended to be inferred in any way. This applies to any possible non-expression of the interpretation, including: logical matters with respect to arrangement of steps, operational flow, order of components, or orientation of components; ordinary meaning derived from grammatical structure or punctuation; and the number or type of embodiments described in the specification.

As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" element includes aspects of having two or more such elements unless the context clearly dictates otherwise.

FIG1 illustrates an exemplary glassmaking apparatus 10. In some examples, the glassmaking apparatus 10 may include a glass melting furnace 12, which may include a melting tank 14. In addition to the melting tank 14, the glass melting furnace 12 may optionally include one or more additional components, such as heating elements (e.g., a furnace or electrodes) that heat the raw material and convert it into molten glass. In further examples, the glass melting furnace 12 may include a thermal management device (e.g., an insulating component) to reduce heat loss near the melting tank. In yet further examples, the glass melting furnace 12 may include electronic devices and/or electromagnetic devices that assist in melting the raw material into molten glass. Furthermore, the glass melting furnace 12 may include a support structure (e.g., a support base, support members, etc.) or other components.

The glass melting tank 14 generally comprises a refractory material, such as a refractory ceramic material, for example, a refractory ceramic material comprising aluminum oxide or zirconium oxide. In some embodiments, the glass melting tank 14 can be constructed of refractory ceramic bricks. Specific embodiments of the glass melting tank 14 will be described in more detail below.

In some examples, a glass melting furnace can be incorporated as a component of a glassmaking apparatus for producing glass sheets, e.g., continuous lengths of glass ribbon. In some examples, the glass melting furnaces of the present disclosure can be incorporated as a component of a glassmaking apparatus, including a slotting apparatus, a floating bath apparatus, a downdraw apparatus (e.g., a fusion process), an updraw apparatus, a roll apparatus, a tube drawing apparatus, or any other glassmaking apparatus that can benefit from the aspects disclosed herein. For example, FIG. 1 schematically illustrates a glass melting furnace 12 as a component of a fusion downdraw glassmaking apparatus 10 for fusing drawn glass ribbons for subsequent processing into individual glass sheets.

The glassmaking apparatus 10 (e.g., fusion downdraw apparatus 10) may optionally include an upstream glassmaking apparatus 16 positioned upstream relative to the glass melting tank 14. In some examples, part or all of the upstream glassmaking apparatus 16 may be incorporated as part of the glass melting furnace 12.

As shown in the illustrated example, the upstream glassmaking equipment 16 may include a storage tank 18, a raw material delivery device 20, and a motor 22 connected to the raw material delivery device. The storage tank 18 may be used to store a quantity of raw material 24, which may be fed to the melting tank 14 of the glass melting furnace 12 as indicated by arrow 26. The raw material 24 typically includes one or more glass-forming metal oxides and one or more modifiers. In some examples, the raw material delivery device 20 may be powered by the motor 22 so that the raw material delivery device 20 delivers a predetermined quantity of raw material 24 from the storage tank 18 to the melting tank 14. In a further example, the motor 22 can power the raw material delivery device 20 to introduce the raw material 24 at a controlled rate based on the level of molten glass sensed downstream of the melting tank 14. Thereafter, the raw material 24 in the melting tank 14 can be heated to form molten glass 28.

The glassmaking apparatus 10 may also optionally include a downstream glassmaking apparatus 30 positioned downstream relative to the glass melting furnace 12. In some examples, portions of the downstream glassmaking apparatus 30 may be incorporated as part of the glass melting furnace 12. In some instances, the first connecting conduit 32 discussed below, or other portions of the downstream glassmaking apparatus 30, may be incorporated as part of the glass melting furnace 12. Components of the downstream glassmaking apparatus, including the first connecting conduit 32, may be made of a precious metal. Suitable precious metals include a platinum group metal selected from the group consisting of platinum, iridium, rhodium, zirconium, ruthenium, and palladium, or alloys thereof. For example, downstream components of glassmaking equipment can be made of a platinum-rhodium alloy comprising from about 70 wt.% to about 90 wt.% platinum and from about 10 wt.% to about 30 wt.% rhodium. However, other suitable metals may include molybdenum, palladium, arsenic, tungsten, titanium, and alloys thereof.

The downstream glassmaking equipment 30 can include a first conditioning (i.e., processing) tank, such as a finishing tank 34, located downstream from the melting tank 14 and coupled to the melting tank 14 via the first connecting conduit 32 referenced above. In some examples, the molten glass 28 can be gravity-fed from the melting tank 14 to the finishing tank 34 via the first connecting conduit 32. For example, gravity can cause the molten glass 28 to pass from the melting tank 14 to the finishing tank 34 via an internal path of the first connecting conduit 32. However, it should be understood that other conditioning tanks can be positioned downstream from the melting tank 14, for example, between the melting tank 14 and the finishing tank 34. In some embodiments, a conditioning tank may be employed between the melting tank and the finishing tank, wherein the molten glass from the main melting tank is further heated to continue the melting process, or is cooled to a temperature lower than the temperature of the molten glass in the melting tank before entering the finishing tank.

Bubbles from the molten glass 28 in the refining tank 34 can be removed by various techniques. For example, the starting material 24 may include a polyvalent compound (i.e., a refining agent), such as tin oxide, which undergoes a chemical reduction reaction when heated and releases oxygen. Other suitable refining agents include, but are not limited to, arsenic, antimony, iron, and barium. The refining tank 34 is heated to a temperature higher than the melting tank temperature, thereby heating the molten glass and the refining agent. Oxygen bubbles generated by the chemical reduction induced by the temperature of the refining agent rise in the molten glass in the refining tank, where gases formed in the molten glass in the melting furnace can diffuse or coalesce into the oxygen bubbles formed by the refining agent. The enlarged gas bubbles can then rise to the free surface of the molten glass in the refining tank and thereafter exit the refining tank. The oxygen bubbles can further induce mechanical mixing of the molten glass in the refining tank.

The downstream glassmaking equipment 30 may further include another conditioning tank, such as a mixing tank 36 for mixing the molten glass. The mixing tank 36 may be located downstream of the refining tank 34. The mixing tank 36 may be used to provide a homogenous glass melt composition, thereby reducing streaks of chemical or thermal inhomogeneities that may otherwise exist in the refined molten glass leaving the refining tank. As shown, the refining tank 34 may be coupled to the mixing tank 36 via a second connecting conduit 38. In some examples, the molten glass 28 may be gravity fed from the refining tank 34 to the mixing tank 36 via the second connecting conduit 38. For example, gravity may cause the molten glass 28 to be transferred from the refining tank 34 to the mixing tank 36 via an internal path of the second connecting conduit 38. It should be noted that although the mixing tank 36 is shown as being located downstream of the refining tank 34, the mixing tank 36 may be positioned upstream of the refining tank 34. In some embodiments, the downstream glassmaking apparatus 30 may include multiple mixing tanks, for example, a mixing tank located upstream of the refining tank 34 and a mixing tank located downstream of the refining tank 34. These multiple mixing tanks may have the same design or may have different designs.

The downstream glassmaking apparatus 30 may further include another conditioning tank, such as a delivery tank 40, which may be located downstream of the mixing tank 36. The delivery tank 40 may condition the molten glass 28 to be fed to the downstream forming device. For example, the delivery tank 40 may act as a collector and/or flow controller to regulate a consistent flow of molten glass 28 and/or provide it to the forming body 42 via the outlet conduit 44. As shown, the mixing tank 36 may be coupled to the delivery tank 40 via a third connecting conduit 46. In some examples, the molten glass 28 may be gravity-fed from the mixing tank 36 to the delivery tank 40 via the third connecting conduit 46. For example, gravity may drive the molten glass 28 from the mixing tank 36 through the internal path of the third connecting conduit 46 to the delivery tank 40.

The downstream glassmaking apparatus 30 may further include a forming apparatus 48 including the forming body 42 and an inlet conduit 50 referenced above. An outlet conduit 44 may be positioned to deliver the molten glass 28 from the delivery trough 40 to the inlet conduit 50 of the forming apparatus 48. For example, the outlet conduit 44 may be nested within and spaced apart from the inner surface of the inlet conduit 50, thereby providing a free surface of molten glass positioned between the outer surface of the outlet conduit 44 and the inner surface of the inlet conduit 50. The forming body 42 in the fusion down-draw glassmaking apparatus may include grooves 52 positioned on an upper surface of the forming body and converging forming surfaces 54 that converge in the draw direction along a bottom edge 56 of the forming body. Molten glass delivered to the main channel via the delivery trough 40, outlet conduit 44, and inlet conduit 50 overflows the sides of the channel and descends along the converging forming surface 54 as separate streams of molten glass. The separate streams of molten glass converge below along the bottom edge 56 to form a single glass ribbon 58. The single glass ribbon 58 is drawn from the bottom edge 56 in a draw or flow direction 60 by applying tension (e.g., by gravity, edge rollers 72, and draw rollers 82) to the glass ribbon to control the dimensions of the glass ribbon as the glass cools and its viscosity increases. As a result, the glass ribbon 58 undergoes a viscoelastic transition and acquires mechanical properties that impart stable dimensional characteristics to the glass ribbon 58. In some embodiments, the glass ribbon 58 can be separated into individual glass sheets 62 by a glass separation device 90 in the elastic region of the glass ribbon. A robot 64 can then use a gripping tool 65 to transfer the individual glass sheets 62 to a conveyor system, where they can be further processed. For example, the glass sheets 62 can be further processed onto one or more substrates 100 as described herein.

FIG2 shows a perspective view of a substrate 100 having a first major surface 102, an opposite second major surface 104 (on a side of the substrate 100 opposite the first major surface) extending in a direction substantially parallel to the first major surface 102, and an edge surface 106 extending between the first major surface 102 and the second major surface 104 and extending in a direction substantially perpendicular to the first major surface 102 and the second major surface 104.

In certain exemplary embodiments, the substrate 100 may include glass, such as the substrate 100 formed from a glass sheet 62.

FIG3 shows a perspective view of electrode deposition on a substrate 100 positioned at an oblique angle relative to a deposition orifice 300. As shown in FIG3, a plurality of contact pads 202 are disposed on a major surface of the substrate 100, and at least a portion of a plurality of electrodes 204 are deposited onto the contact pads 202, the major surface, and an edge surface of the substrate 100. Subsequently, the substrate 100 can be rotated or flipped to deposit at least a portion of the plurality of electrodes 204 onto the opposing major surface and edge surface of the substrate 100. For example, WO2019079253 discloses electrode deposition in which the substrate can be oriented at various angles relative to the deposition orifice, and the entire disclosure of that application is incorporated herein by reference. Such electrodes can be deposited by various techniques including, but not limited to, seed layer plating, direct printing, laser induced metallization, pen dispensing, and aerosol jetting.

Embodiments disclosed herein include those in which electrodes are deposited onto a substrate via one or more aerosol jets. Aerosol jet deposition is described, for example, in US20090061077, the entire disclosure of which is incorporated herein by reference. Such deposition involves using an aerosol jet to form an annular propagating jet comprising an outer sheath flow and an inner aerosol-containing carrier flow. In an aerosol jet process, an aerosol stream enters a print head, preferably directly after an aerosolization process or after passing through a heater assembly, and is directed along the axis of the device toward a print head orifice. Mass throughput can be controlled by an aerosol carrier gas mass flow controller. Inside the printhead, the aerosol stream can be collimated by passing it through a 0.1 mm orifice. The exiting particle stream can then be combined with an annular sheath gas to reduce nozzle clogging and focus the aerosol stream. The carrier gas and sheath gas can, for example, comprise dry nitrogen, compressed air, or an inert gas, one or all of which can be modified to contain solvent vapor. For example, when the aerosol is formed from an aqueous solution, water vapor can be added to the carrier gas or sheath gas to prevent droplet evaporation.

The sheath gas can then enter through a sheath air inlet below the aerosol inlet and form an annular flow with the aerosol stream. As with the aerosol carrier gas, the sheath gas flow rate can be controlled by a mass flow controller. The combined air stream leaves the nozzle at a high speed (e.g., 50 meters per second) through an orifice directed toward the target and then impacts the target. This annular flow focuses the aerosol stream onto the target and allows the printing of features having a size of less than, for example, about 1 micron. The print pattern can be created by moving the print head relative to the target. Examples of commercially available aerosol jet print heads, devices, and systems include aerosol jet print heads, devices, and systems available from Optomec.

FIG4 shows a side cross-sectional view of a portion of the substrate 100 on which a wrap-around electrode 204 is deposited. Specifically, the electrode 204 extends along a portion of the first major surface 102, the edge surface 106, and the second major surface 104 of the substrate 100 while contacting the contact pad 202. Furthermore, while the edge region of the substrate 100 is shown as having a rectangular cross-section, embodiments disclosed herein encompass edge regions of the substrate 100 having other cross-sections, including but not limited to curved or beveled (e.g., chamfered) regions (not shown).

The electrode 204 may include a conductive material, such as a conductive metallic material, including at least one material selected from silver or copper.

FIG5 shows a side perspective view of electrode deposition on substrate 100 according to embodiments disclosed herein. FIG10 shows an exploded side perspective view of electrode deposition on substrate 100 in circled area "A" of FIG5 . As shown in FIG5 and FIG10 , mask 206 is positioned over first major surface 102 and second major surface 104 of substrate 100. As further shown in FIG5 and FIG10 , first portion 204a1 of electrode 204a is deposited over first major surface 102 and edge surface 106 of substrate 100, and second portion 204a2 of electrode 204a is deposited over second major surface 104 and edge surface 106 of substrate 100. Specifically, a first portion 204a1 of the electrode 204a is deposited by a first aerosol jet emitted from a first orifice (e.g., nozzle) 300a directed toward the first major surface 102 and edge surface 106 of the substrate 100, and a second portion 204a2 of the electrode 204a is deposited by a second aerosol jet emitted from a second orifice (e.g., nozzle) 300b directed toward the second major surface 104 and edge surface 106 of the substrate 100. The first orifice 300a is removably mounted on a first support 302a, and the second orifice 300b is removably mounted on a second support 302b.

FIG6 shows a top perspective view of electrode deposition on a substrate 100 according to embodiments disclosed herein. As can be seen in FIG5, FIG6, and FIG10, a first plurality of electrodes 204a extend along portions of the first major surface 102, the edge surface 106, and a portion of the second major surface 104 of the substrate 100. Additionally, a second plurality of electrodes 204b extend along portions of the first major surface 102, the opposing edge surface 106, and a portion of the second major surface 104 of the substrate 100. Specifically, the second plurality of electrodes 204b are deposited by a third aerosol jet emitted from a third orifice (e.g., nozzle) 300c and a fourth aerosol jet emitted from a fourth orifice (e.g., nozzle) 300d. In certain exemplary embodiments, the second plurality of electrodes 204b are deposited concurrently with the deposition of the first plurality of electrodes 204a. The third port 300c is removably mounted on the third support 302c, and the fourth port is removably mounted on the fourth support 302d.

FIG7 shows an end perspective view of electrode deposition on substrate 100 according to embodiments disclosed herein. As can be seen in FIG6 and FIG7 , a third plurality of electrodes 204 c extends along portions of first major surface 102, edge surface 106, and portions of second major surface 104 of substrate 100. Specifically, third plurality of electrodes 204 c are deposited by a fifth aerosol jet emitted from a fifth orifice (e.g., nozzle) 300 e and a sixth aerosol jet emitted from a sixth orifice (e.g., nozzle) 300 f. In certain exemplary embodiments, third plurality of electrodes 204 c are deposited concurrently with deposition of first plurality of electrodes 204 a. The fifth port 300e is removably mounted on the fifth bracket 302e, and the sixth port 300f is removably mounted on the sixth bracket 302f.

As further shown in FIG. 7 , the fourth plurality of electrodes 204 d extends along portions of the first major surface 102, the opposing edge surface 106, and portions of the second major surface (not shown) of the substrate 100. Specifically, the fourth plurality of electrodes 204 d is deposited by a seventh aerosol jet emitted from a seventh orifice (e.g., nozzle) 300 g and an eighth aerosol jet emitted from an eighth orifice (e.g., nozzle) (not shown). In certain exemplary embodiments, the fourth plurality of electrodes 204 d is deposited simultaneously with the deposition of the second plurality of electrodes 204 b. The seventh orifice 300 g is removably mounted on a seventh support 302 g, and the eighth orifice (not shown) is removably mounted on an eighth support (not shown).

11A and 11B each show an end perspective view of electrode deposition on a substrate 100 according to embodiments disclosed herein. Specifically, FIG11A and FIG11B show a first portion 204a1 of a first plurality of electrodes 204a deposited onto the first major surface 102 and edge surface 106 of the substrate 100, and a second portion 204a2 of the first plurality of electrodes 204a deposited onto the second major surface 104 and edge surface 106 of the substrate 100. More specifically, a first portion 204a1 of the first plurality of electrodes 204a is deposited onto the first major surface 102 and the edge surface 106 of the substrate 100 by a first aerosol jet emitted from a first orifice (e.g., nozzle) 300a, and a second portion 204a2 of the first plurality of electrodes 204a is deposited onto the second major surface 104 and the edge surface 106 of the substrate 100 by a second aerosol jet emitted from a second orifice (e.g., nozzle) 300b.

In certain exemplary embodiments, as shown in FIG. 11A and FIG. 11B , a first portion 204a1 of one of the first plurality of electrodes 204a is deposited onto the first major surface 102 and the edge surface 106 of the substrate 100, and a second portion 204a2 of one of the first plurality of electrodes 204a is simultaneously deposited onto the second major surface 104 and the edge surface 106 of the substrate 100. As shown in FIG. 11A , the first portion 204a1 and the second portion 204a2 are portions of the same electrode. As shown in FIG. 11B (an exploded view of the circled area "B" in FIG. 7 ), the first portion 204a1 and the second portion 204a2 are portions of different electrodes (i.e., the first opening 300a and the second opening 300b are in a staggered configuration).

FIG8 and FIG9 respectively show side and top perspective views of an electrode deposition apparatus 340 according to embodiments disclosed herein. The electrode deposition apparatus 340 includes a plurality of stages 350, each of which includes a Y-axis motion mechanism 352, an X-axis motion mechanism 354, and a plurality of movably mounted orifices (e.g., nozzles) 300 for emitting aerosol jets onto substrates 100 to deposit a plurality of electrodes thereon. Each substrate 100 can be fixedly mounted on a substrate positioning mechanism 356, which is capable of moving each substrate 100 between pairs of stages 350. Furthermore, although FIG. 9 shows four pairs of stages 350, embodiments disclosed herein may include any number of stages 350 or any number of pairs of stages 350. Additionally, although FIG. 9 shows two removably mounted apertures 300 for each stage 350, embodiments disclosed herein include each stage 350 including any number of removably mounted apertures 300.

The plurality of stages 350 enables, for example, a first plurality of electrodes to be deposited onto a substrate 100 at an upstream stage 350 (or a first and second plurality of electrodes to be deposited onto a substrate 100 by a pair of upstream stages 350), and subsequently an additional plurality of electrodes to be deposited onto the same substrate 100 by one or more downstream stages 350 (or one or more pairs of downstream stages 350). Thus, embodiments disclosed herein include embodiments in which, after depositing the first plurality of electrodes, a third plurality of electrodes extending along a portion of the first major surface 102, the edge surface 106, and a portion of the second major surface 104 of the substrate 100 is deposited (e.g., wherein the third plurality of electrodes is deposited onto the substrate 100 by a stage 350 downstream from the stage 350 that deposited the first plurality of electrodes). Subsequently, a plurality of electrodes can additionally be deposited onto the substrate 100 via one or more further downstream stages 350. This can, for example, enable electrodes having varying dimensions in the X direction to be deposited on the substrate 100.

The Y-axis movement mechanism 352 and the X-axis movement mechanism 354 are each capable of moving the orifice 300 relative to the substrate 100 in the Y and X directions, respectively. FIG12 illustrates the X and Y movement of the orifice 300 relative to the substrate. As shown in FIG12 , the orifice 300 begins in a first position P1 away from the edge surface 106 of the substrate 100 and is then moved in the Y direction to a second position P2, as indicated by the solid arrow M1, by the Y-axis movement mechanism 352. During this movement, the orifice 300 emits an aerosol jet onto the substrate 100 to deposit an electrode thereon. Next, the orifice 300 is moved in the X-direction to a third position P3, as indicated by the dashed arrow M2, by the X-axis movement mechanism 354. During this movement, the orifice 300 does not emit an aerosol jet onto the substrate 100. Instead, the length of this movement provides the pitch distance between adjacent electrodes (the pitch distance is the shortest distance between the mid-widths of adjacent electrodes in the X-direction). Next, the orifice is moved in the Y-direction to a fourth position P4, as indicated by the solid arrow M3, by the Y-axis movement mechanism 352. During this movement, the orifice 300 emits an aerosol jet onto the substrate 100 to deposit electrodes thereon. Next, the orifice 300 is again moved in the Y direction by the Y-axis movement mechanism 354 to a fifth position P5, as indicated by the dashed arrow M4. During this movement, the orifice 300 does not emit an aerosol spray onto the substrate 100. Finally, the orifice 300 is moved in the X direction by the X-axis movement mechanism 354 to a sixth position P6, as indicated by the dashed arrow M5. During this movement, the orifice 300 does not emit an aerosol spray onto the substrate 100. The length of this movement provides the pitch distance between adjacent electrodes.

In certain exemplary embodiments, during periods of movement in which the orifice 300 is not emitting an aerosol spray onto the substrate 100, one or more shield members (not shown) may effectively prevent flow between the orifice 300 and the substrate 100. This may, for example, enable more efficient continuous operation of the aerosol spray emission from the orifice 300.

Although FIG. 12 and other figures of this disclosure indicate an approximately constant pitch distance between adjacent electrodes, embodiments disclosed herein include cases where the X-axis motion mechanism can produce a varying pitch distance between adjacent electrodes. In addition, although FIG. 12 shows unilateral movement in the Y direction by the Y-axis movement mechanism to deposit the electrode (e.g., as indicated by solid arrows M1 and M3), the embodiments disclosed herein include cases where the electrode is deposited by bilateral movement of the Y-axis mechanism (i.e., the Y-axis mechanism moves the nozzle in the Y direction to partially deposit the electrode, and then reverses in the Y direction to continue depositing the same or another (e.g., adjacent) electrode).

In certain exemplary embodiments, the electrodes 204 may range from about 10 microns to about 100 microns in the X direction, e.g., from about 20 microns to about 80 microns, including about 50 microns. In certain exemplary embodiments, the pitch distance between adjacent electrodes may range from about 20 microns to about 200 microns, e.g., from about 50 microns to about 150 microns, including about 100 microns.

In certain exemplary embodiments, the substrate 100 may have a thickness between the first major surface 102 and the second major surface 104 ranging from about 0.1 mm to about 1 mm, such as from about 0.2 mm to about 0.8 mm, and further such as from about 0.3 mm to about 0.7 mm, including about 0.5 mm.

Repeated incremental movement of a motion mechanism (e.g., Y-axis motion mechanism 352 and/or X-axis motion mechanism 354), as illustrated in FIG. 12 and with the dimensions described above, can be achieved, for example, by a parallel motion flexure mechanism actuated by a voice coil motor. Such a mechanism can be used to provide repeated accurate orifice positioning over relatively small distances, enabling millions, hundreds of millions, or even billions of repetitions. Such a mechanism can also provide minimal cumulative part movement relative to other configurations while still providing rapid electrode deposition on a variety of desired display tile configurations including substrate 100 and electrode 204 as described herein.

Relative movement between the substrate 100 and the electrode deposition apparatus 340 can be facilitated by various exemplary configurations, as further described herein.

For example, FIG. 13 shows a side perspective view of an electrode deposition configuration on a substrate 100 according to embodiments disclosed herein. As shown in FIG. 13 , the first end 110 of the substrate 100 is constrained by a fixture 400 , while the second end 112 of the substrate 100 can be flexed by an actuator 500 (as shown in the dashed area). The actuator 500 can be moved relative to the substrate 100 , and the flexure of the second end 112 of the substrate 100 can achieve movement relative to the deposition orifice 300 , thereby partially printing an electrode (not shown) near the second end 112 of the substrate 100 . This configuration, as well as other configurations shown in FIG. 14 through FIG. 16 , can achieve high-precision positioning without requiring a precise bearing system to guide the print stroke of the deposition orifice 300 .

FIG14 shows a side perspective view of another electrode deposition configuration on a substrate 100 according to embodiments disclosed herein. As shown in FIG14 , the first major surface 102 of the substrate 100 is in fluid communication with an air bearing 600, which can be vacuum preloaded to rotationally constrain and stabilize the substrate 100. An actuator 500 can further displace the substrate 100 along the air bearing 600 in two dimensions to provide movement relative to the deposition orifice 300, thereby partially printing a plurality of electrodes (not shown). The actuator 500 can, for example, comprise a vacuum blade or an edge gripper.

FIG15A and FIG15B show side perspective views of another electrode deposition configuration on a substrate 100 according to embodiments disclosed herein. Similar to the configuration shown in FIG14 , an air bearing 600 is employed. The air bearing 600 can be vacuum preloaded and, in this state, rotationally constrains a support 700 (e.g., a vacuum chuck). The support 700 rotationally constrains and secures the substrate 100, with the first major surface 102 of the substrate in fluid communication with the support 700. The carriage 700 may include reference features (not shown) to secure and position the substrate 100, and the actuator 500 may displace the carriage 700 in two dimensions along the air bearing 600 to provide movement relative to the deposition orifice 300 to partially print a plurality of electrodes (not shown). Additionally, as shown in FIG. 15B , the carriage 700 and substrate 100 may be reoriented relative to the air bearing 600 and deposition orifice 300 to print opposite sides of the plurality of electrodes (not shown).

FIG16 shows a side perspective view of an electrode deposition configuration on a substrate 100 according to an embodiment disclosed herein. As shown in FIG16 , the substrate 100 is rotated about a rotation axis (A) by an actuator 500, thereby enabling relative movement between the substrate 100 and the deposition orifice 300, so that a complete electrode (not shown) can be deposited onto the substrate 100 in a single movement.

FIG17 shows a side perspective view of an electrode deposition configuration on a substrate 100 according to an embodiment disclosed herein. As shown in FIG17 , the substrate 100 is positioned at an angle relative to the deposition aperture 300, thereby simultaneously depositing electrodes (not shown) on opposite ends of the substrate 100, wherein the deposition aperture 300 is oriented in opposite vertical directions.

Because the embodiments herein (including the embodiments shown in Figures 13-16) can include an oblique bevel relationship between the major surface of the substrate 100 and the major axis of the aerosol jet emitted from the deposition orifice 300, including a varying bevel relationship between the deposition orifice 300 and the substrate 100, this can naturally result in a varying distance between the deposition orifice 300 and the substrate 100. Because the aerosol jet emitted from the deposition orifice 300 tends to be tapered in nature, the varying distance between the deposition orifice 300 and the substrate 100 can result in a varying electrode width. Such an oblique angle relationship can also result in variable deposition of electrode material per unit length along the substrate 100, resulting in inconsistent electrode thickness. These issues can be addressed (i.e., compensated for) by controlling the relative motion between the deposition orifice 300 and the substrate 100, for example by controlling or varying the distance and/or speed at which the substrate 100 moves relative to the deposition orifice 300, so as to deposit an electrode of relatively constant or uniform width and thickness (e.g., by controlling the motion of the actuator 500). This can be accomplished, for example, according to three-dimensional (3D) printing techniques known to those skilled in the art, which can be applied to any of the embodiments disclosed herein.

Embodiments disclosed herein also include electronic devices comprising any of the display tiles disclosed herein.

Although the above embodiments have been described with reference to a fusion down-draw process, it should be understood that such embodiments are also applicable to other glass forming processes, such as float processes, slit processes, up-draw processes, tube drawing processes, and roll processes.

Those skilled in the art will appreciate that modifications and variations can be made in the embodiments of the present disclosure without departing from the spirit and scope of the present disclosure. Therefore, it is intended that the present disclosure covers such modifications and variations as come within the scope of the appended claims and their equivalents.

10: Glassmaking equipment 12: Glass melting furnace 14: Melting tank 16: Upstream glassmaking equipment 18: Storage tank 20: Raw material delivery device 22: Motor 24: Raw material 26: Arrow 28: Molten glass 30: Downstream glassmaking equipment 32: First connecting conduit 34: Refining tank 36: Mixing tank 38: Second connecting conduit 40: Delivery trough 42: Forming body 44: Outlet conduit 46: Third connecting conduit 48: Forming equipment 50: Inlet conduit 52: Groove 54: Converging forming surface 56: Bottom edge 58: The single glass ribbon 60: Draw or flow direction 62: Individual glass sheets 64: Robot 65: Gripping tool 72: Edge roller 82: Pull roller 90: Glass separation apparatus 100: Substrate 102: First major surface 104: Opposing second major surface 106: Edge surface 110: First end 112: Second end 202: Contact pad 204: Electrode 204a: Electrode 204a1: First portion of electrode 204a2: Second portion of electrode 204b: Electrode 204c: Third plurality of electrodes 204d: Fourth plurality of electrodes 206: Mask 300: Deposition orifice 300a: First opening 300b: Second opening 300c: Third opening 300d: Fourth opening 300e: Fifth opening 300f: Sixth opening 300g: Seventh opening 302a: First bracket 302b: Second bracket 302c: Third bracket 302d: Fourth bracket 302e: Fifth bracket 302f: Sixth bracket 302g: Seventh bracket 340: Electrode deposition equipment 350: Stage 352: Y-axis motion mechanism 354: X-axis motion mechanism 356: Substrate positioning mechanism 400: Fixing element 500: Actuator 600: Air bearing 700: Bracket X-axis Y: Axis A: Circular area B: Circular area P1: First position P2: Second position P3: Third position P4: Fourth position P5: Fifth position P6: Sixth position M1: Arrow M2: Arrow M3: Arrow M4: Arrow M5: Arrow

Figure 1 is a schematic diagram of an example fusion down-draw glass manufacturing apparatus and process;

FIG2 is a perspective view of the substrate;

FIG3 is a perspective view of an electrode deposition positioned at an oblique angle relative to the deposition orifice;

FIG4 is a side cross-sectional view of a portion of a substrate on which a coating surrounding an electrode is deposited;

FIG5 is a side perspective view of electrode deposition on a substrate according to embodiments disclosed herein;

FIG6 is a top perspective view of electrode deposition on a substrate according to embodiments disclosed herein;

FIG7 is an end perspective view of electrode deposition on a substrate according to embodiments disclosed herein;

FIG8 is a side perspective view of an electrode deposition apparatus according to an embodiment disclosed herein;

FIG. 9 is a top perspective view of an electrode deposition apparatus according to embodiments disclosed herein;

FIG. 10 is a side perspective view of electrode deposition on a substrate according to embodiments disclosed herein;

11A and 11B are end perspective views of electrode deposition on a substrate according to embodiments disclosed herein;

FIG12 is a top view of the X and Y orifice movement relative to the substrate;

FIG13 is a side perspective view of an electrode deposition configuration on a substrate according to embodiments disclosed herein;

FIG14 is a side perspective view of an electrode deposition configuration on a substrate according to embodiments disclosed herein;

15A and 15B are side perspective views of electrode deposition configurations on a substrate according to embodiments disclosed herein;

FIG. 16 is a side perspective view of an electrode deposition configuration on a substrate according to embodiments disclosed herein; and

FIG. 17 is a side perspective view of an electrode deposition configuration on a substrate according to embodiments disclosed herein.

Domestic Storage Information (Please enter in order by institution, date, and number) None International Storage Information (Please enter in order by country, institution, date, and number) None

100:Substrate

204a: Electrode

204b: Electrode

300a: First orifice

300b: Second orifice

300c: Third orifice

300d: Fourth orifice

302a: First bracket

302b: Second bracket

302c: Third bracket

302d: Fourth bracket

206: Mask

A: Circular area

Claims (28)

A method for manufacturing a display tile comprises the following steps: Depositing a first plurality of electrodes, the first plurality of electrodes extending along a portion of a first major surface, an edge surface, and a portion of an opposing second major surface of a substrate, the step of depositing each of the first plurality of electrodes comprising the following steps: Depositing a first portion of the electrode onto the first major surface and the edge surface of the substrate; and Depositing a second portion of the electrode onto the opposing second major surface and the edge surface of the substrate; Wherein: The depositing step includes simultaneously depositing a first portion of one of the first plurality of electrodes onto the first major surface and the edge surface of the substrate; and depositing a second portion of one of the first plurality of electrodes onto the second major surface and the edge surface of the substrate, wherein the first portion and the second portion are portions of different electrodes; The first major surface extends in a direction substantially parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface; and The electrode extends along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. The method of claim 1, wherein the first portion of the electrode is deposited by a first aerosol jet emitted from a first orifice and directed toward the first major surface and the edge surface of the substrate, and the second portion of the electrode is deposited by a second aerosol jet emitted from a second orifice and directed toward the second major surface and the edge surface of the substrate. The method of claim 1, wherein the method comprises the steps of depositing a second plurality of electrodes simultaneously with depositing the first plurality of electrodes, the second plurality of electrodes extending along a portion of the first major surface, an opposite edge surface, and a portion of the second major surface of the substrate. The method of claim 1, wherein the method comprises the steps of depositing a third plurality of electrodes simultaneously with depositing the first plurality of electrodes, the third plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. The method of claim 1, wherein the method comprises the steps of depositing a third plurality of electrodes after depositing the first plurality of electrodes, the third plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. A method as described in claim 3, wherein the method includes the following steps: depositing a third plurality of electrodes simultaneously with depositing the first plurality of electrodes, wherein the third plurality of electrodes extend along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate, and depositing a fourth plurality of electrodes simultaneously with depositing the second plurality of electrodes, wherein the fourth plurality of electrodes extend along a portion of the first major surface, the opposite edge surface, and a portion of the second major surface of the substrate. The method of claim 1, wherein the method comprises the steps of moving the substrate relative to an orifice that deposits an aerosol jet onto the substrate. The method of claim 7, wherein the movement of the substrate is affected by an actuator. The method of claim 8, wherein the substrate is in fluid communication with an air bearing. The method of claim 1, wherein during the deposition, the substrate is positioned on a support that is in fluid communication with an air bearing. The method of claim 1, wherein during the depositing, the first major surface of the substrate is beveled relative to a major axis of the aerosol jet. The method of claim 7, wherein the speed of movement of the substrate relative to the orifice and a distance between the substrate and the orifice are controlled to deposit the electrode with approximately uniform width and thickness. The method of claim 1, wherein the substrate comprises glass. A method for manufacturing a display tile comprises the following steps: Depositing a first plurality of electrodes, the first plurality of electrodes extending along a portion of a first major surface, an edge surface, and a portion of an opposing second major surface of a substrate, the step of depositing each of the first plurality of electrodes comprising the following steps: Depositing a first portion of the electrode onto the first major surface and the edge surface of the substrate; Depositing a second portion of the electrode onto the opposing second major surface and the edge surface of the substrate; and Depositing a second plurality of electrodes, the second plurality of electrodes extending along a portion of the first major surface, an opposing edge surface, and a portion of the second major surface of the substrate Wherein: Depositing the first plurality of electrodes occurs simultaneously with depositing the second plurality of electrodes. The first major surface extends in a direction substantially parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface. The electrodes extend along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. The method of claim 14, wherein the first portion of the electrode is deposited by a first aerosol jet emitted from a first orifice and directed toward the first major surface and the edge surface of the substrate, and the second portion of the electrode is deposited by a second aerosol jet emitted from a second orifice and directed toward the second major surface and the edge surface of the substrate. The method of claim 14, wherein during the deposition, the substrate is positioned on a support that is in fluid communication with an air bearing. The method of claim 14, wherein the substrate comprises glass. An apparatus for manufacturing a display tile comprises: a first orifice for directing a first aerosol jet toward a first major surface and an edge surface of a substrate; and a second orifice for directing a second aerosol jet toward an opposing second major surface and an edge surface of the substrate; wherein: the first major surface extends in a direction generally parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface; the first aerosol jet is used to deposit a first portion of an electrode onto the first major surface and the edge surface of a substrate; the second aerosol jet is used to deposit a second portion of the electrode onto the second major surface and the edge surface of the substrate; The apparatus is configured to deposit a first plurality of electrodes, the first plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate; and simultaneously with depositing the first plurality of electrodes, the apparatus is configured to deposit a second plurality of electrodes, the second plurality of electrodes extending along a portion of the first major surface, an opposing edge surface, and a portion of the second major surface of the substrate. The apparatus of claim 18, wherein the apparatus is configured to deposit a third plurality of electrodes simultaneously with depositing the first plurality of electrodes, the third plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. The apparatus of claim 18, wherein the apparatus is configured to deposit a third plurality of electrodes after depositing the first plurality of electrodes, the third plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate. The apparatus of claim 18, wherein the apparatus is configured to deposit a third plurality of electrodes simultaneously with depositing the first plurality of electrodes, the third plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate, and to deposit a fourth plurality of electrodes simultaneously with depositing the second plurality of electrodes, the fourth plurality of electrodes extending along a portion of the first major surface, the opposite edge surface, and a portion of the second major surface of the substrate. The apparatus of claim 18, wherein the apparatus comprises an actuator for affecting movement of the substrate relative to the first orifice. The apparatus of claim 22, wherein the apparatus comprises an air bearing in fluid communication with the substrate. The apparatus of claim 22, wherein the apparatus comprises a support for positioning the substrate thereon and for fluidly communicating with an air bearing. The apparatus of claim 22, wherein the apparatus is configured to position the substrate such that the first major surface of the substrate is angled obliquely relative to a major axis of the first aerosol jet. A display tile manufactured by the method of claim 1. An electronic device comprising the display tile of claim 26. An apparatus for manufacturing a display tile comprises: a first orifice for directing a first aerosol jet toward a first major surface and an edge surface of a substrate; and a second orifice for directing a second aerosol jet toward an opposing second major surface and an edge surface of the substrate; wherein: the first major surface extends in a direction generally parallel to the second major surface, and the edge surface extends between the first major surface and the second major surface; the first aerosol jet is used to deposit a first portion of an electrode onto the first major surface and the edge surface of a substrate; the second aerosol jet is used to deposit a second portion of the electrode onto the second major surface and the edge surface of the substrate; The apparatus is configured to deposit a first plurality of electrodes, the first plurality of electrodes extending along a portion of the first major surface, the edge surface, and a portion of the second major surface of the substrate; and the apparatus is configured to simultaneously deposit the first portion and the second portion of different electrodes of the first plurality of electrodes, wherein the first portion and the second portion are portions of different electrodes.