System for producing patterned deposition from compressed fluids

Abstract

A system ( 10 ) produces patterned deposition on a substrate ( 14 ) from compressed fluids. A delivery system ( 12 ) cooperates with a controlled environment ( 30, 100, 200 ) retaining a substrate ( 14 ) for receiving precipitated functional material ( 44 ) along a fluid delivery path ( 13 ) from the delivery system ( 12 ). A mask ( 22 ) is arranged in close proximity to the substrate ( 14 ) for forming the patterned deposition on the substrate ( 14 ).

What is claimed is:  
     
         1 . System for producing a patterned deposition on a substrate from a compressed fluid, comprising: 
 means for controllably delivering a functional material in a compressed state and then converting said functional material into a precipitate functional material; and,    a controlled environment for receiving said precipitated functional material, said controlled environment exposing said substrate bearing at least one shadow mask to said patterned deposition of charged precipitated functional material.    
     
     
         2 . The system recited in  claim 1  wherein said controlled environment comprises a pressure modulator for maintaining pressure inside said controlled environment at a predetermined pressure level.  
     
     
         3 . The system recited in  claim 2  wherein said controlled environment comprises a temperature modulator for maintaining temperature inside said controlled environment at a predetermined temperature level.  
     
     
         4 . The system recited in  claim 3  wherein said temperature modulator comprises an electric heater.  
     
     
         5 . The system recited in  claim 3  wherein said temperature modulator comprises a water jacket in contact with a portion of said controlled environment.  
     
     
         6 . The system recited in  claim 3  wherein said temperature modulator comprises a refrigeration coil in fluid contact with a portion of said controlled environment.  
     
     
         7 . The system recited in  claim 1  wherein said controlled environment comprises means for monitoring temperature and pressure levels inside said controlled environment.  
     
     
         8 . The system recited in  claim 1  wherein said substrate is provided with an electrical charge thereby forming an electrically charged substrate to attract charged precipitated functional material in said controlled environment.  
     
     
         9 . The system recited in  claim 8  wherein said substrate comprises a material selected from the group consisting of: an organic solid material, an inorganic solid material, a metallo-organic material, a ceramic material, an alloy material, a synthetic material, a natural polymeric material, a gel material, a vitreous material, a porous material, a non-porous material, and a composite material.  
     
     
         10 . The system recited in  claim 8  wherein said electrically charged substrate has a polarity opposite that of said charged precipitated functional material.  
     
     
         11 . The system recited in  claim 1  wherein said at least one shadow mask is provided with an electrical charge forming an electrically charged shadow mask, said electrically charged shadow mask and said charged precipitated functional material having the same polarity.  
     
     
         12 . The system recited in  claim 1  further comprising means for orienting the substrate relative to a stream of charged precipitated functional material.  
     
     
         13 . The system recited in  claim 12  wherein said substrate has an orientation relative to said stream of precipitate functional material that indirectly exposes said substrate to said stream of precipitated functional material.  
     
     
         14 . The system recited in  claim 12  wherein said substrate has an orientation relative to said stream of precipitated functional material that exposes said substrate directly to said stream of precipitated functional material.  
     
     
         15 . The system recited in  claim 1  wherein said controlled environment is provided with an access port for inserting and removing said substrate.  
     
     
         17 . The system recited in  claim 1  wherein said means for controllably delivering a functional material exposes said precipitated functional material to a pressure higher than the pressure inside said controlled environment.  
     
     
         18 . The system recited in  claim 2  wherein said pressure modulator is a piston-like element.  
     
     
         18 . The system recited in  claim 2  wherein said pressure modulator is a pump.  
     
     
         19 . The system recited in  claim 2  wherein said pressure modulator is a vent arranged in said controlled environment and a pressure control means cooperatively associated with said vent.  
     
     
         20 . The system recited in  claim 1  wherein said controlled environment is further provided with a first electrostatic charging element for imparting a charge on said precipitated functional material.  
     
     
         21 . The system recited in  claim 20  wherein said controlled environment is further provided with a second electrostatic charging element for imparting an electrostatic charge on said substrate.  
     
     
         22 . The system recited in  claim 20  wherein said controlled environment is further provided with a third electrostatic charging element for imparting an electrostatic charge on said shadow mask.  
     
     
         23 . The system recited in  claim 21  wherein said electrostatic charge on said substrate is determinate of the amount of precipitated functional material deposited on said substrate.  
     
     
         24 . The system recited in  claim 23  wherein the charge applied to said substrate is applied for a predetermined duration, said predetermined duration being determinate of the amount of precipitated functional material deposited on said substrate.  
     
     
         25 . The system recited in  claim 1  wherein said functional material comprises a material selected from the group consisting of: electroluminescent molecules, imaging dyes, ceramic nano-particles, and polymeric materials.  
     
     
         26 . The system recited in clam  1  wherein said compressed fluid comprises materials selected from the group consisting of: carbon dioxide, nitrous oxide, ammonia, xenon, ethane, ethylene, propane, propylene, butane, isobutane, chlorotrifluoromethane, monofluromethane, sulfur hexafluoride, and mixtures thereof.  
     
     
         27 . The system recited in  claim 1  wherein said controlled environment is electrostatically charged to prevent deleterious particles from adhering thereto.  
     
     
         28 . The system recited in  claim 1  wherein an optical emitter cooperates with an optical detector determining the concentration of functional material inside said controlled environment.  
     
     
         29 . The system recited in  claim 28  wherein said controlled environment has at least one viewing port for observing the process inside said controlled environment.  
     
     
         30 . The system recited in  claim 28  wherein a reflective surface is arranged in said controlled environment opposite said optical emitter for reflecting energy from said optical emitter which is detected by said optical detector.  
     
     
         31 . The system recited in  claim 30  wherein said optical detector transmits an electrical signal to a microprocessor thereby generating data for future processing.  
     
     
         32 . The system recited in  claim 1  wherein said means for controllably delivering comprises a discharge assembly having a nozzle for ejecting a stream of precipitated formulation material into said controlled environment.  
     
     
         33 . The system recited in  claim 32  wherein said nozzle is a divergent nozzle.  
     
     
         34 . The system recited in  claim 32  wherein said precipitated formulation material is further propelled from said nozzle in the presence of an electromagnetic field in said controlled environment.  
     
     
         35 . The system recited in  claim 32  wherein said precipitated formulation material is further propelled from said nozzle in the presence of at least one mechanical shield arranged in said controlled environment.  
     
     
         36 . The system recited in  claim 32  wherein said precipitated formulation material is further propelled from said nozzle in the presence of at least one magnetic lens arranged in said controlled environment.  
     
     
         37 . The system recited in  claim 32  wherein said precipitated formulation material is further propelled from said nozzle in the presence of at least one electrostatic lens arranged in said controlled environment.  
     
     
         38 . The system recited in  claim 32  wherein said nozzle is provided with a heating means to promote a predetermined fluid flow rate.  
     
     
         39 . The system recited in  claim 1  wherein said substrate and a discharge assembly in said means for controllably delivering are spaced apart by a predetermined distance that enables said compressed fluid to evaporate from a liquid or a compressed phase to a gas phase prior to depositing on said substrate.  
     
     
         40 . The system recited in  claim 1  wherein said functional material is dissolved in said compressed state.  
     
     
         41 . The system recited in  claim 1  wherein said functional material is dispersed in said compressed state.