Extrusion/Dispensing Systems And Methods

Abstract

A device for extruding/dispensing materials on a substrate includes a housing with at least two channels formed to facilitate flow. The housing includes entrance ports for each of the channels for receiving different materials. The housing further includes an exit port for co-extruding the materials on the substrate to generate a relatively fine feature with a relatively high aspect ratio.

1 . A device for co-extruding first and second materials onto a substrate such that the first material forms a central line structure contacting a surface of the substrate, and such that the second material forms support structures contacting opposing side surfaces of the central line structure, the device comprising:
 a housing defining an exit port and first, second and third inlet ports that extend through one or more outer surfaces of the housing, and a convergent path defined inside housing, the convergent path including:
 a central channel extending between a closed end and an open end, the closed end of the central channel communicating with the first inlet port, 
 first and second side channels disposed on opposite sides of the central channel, each of the first and second side channels extending between an associated closed end and an associated open end, wherein the closed ends of the first and second side channels respectively communicate with the second and third inlet ports, and 
 a merge region communicating with the open ends of each of the central channel and the first and second side channels, the merge region also communicating with the exit port, 
   wherein the first and second side channels and the central channel converge at the merge region such that when the first material is introduced into the central channel through the first inlet port and the second material is introduced into the first and second side channels through the second and third inlet ports, the first material and second material form a single flow in the merge region in which the first material is sandwiched between portions of the second material to form said central line structure and said support structures before exiting said exit port.   
     
     
         2 . The device of  claim 1 , wherein the convergent path is formed such that said central line structure has an aspect ratio greater than 2:1. 
     
     
         3 . The device of  claim 1 , wherein the convergent path is formed such that said central line structure has a width in the range of 100 nanometers to 100 microns. 
     
     
         4 . The device of  claim 1 , further comprising means for causing the first and second materials to flow through the housing such that the first and second materials maintain a laminar flow in the convergent path. 
     
     
         5 . The device of  claim 1 , wherein the housing comprises a plurality of laminated plates. 
     
     
         6 . The device of  claim 1 , further comprising means for pumping the first and second materials through the housing. 
     
     
         7 . The device of  claim 6 , wherein said means for pumping comprises at least one positive displacement pump. 
     
     
         8 . The device of  claim 1 , further comprising means for translating at least one of the substrate and the housing during co-extrusion of the first and second materials. 
     
     
         9 . A device for co-extruding first and second materials onto a substrate such that the first and second materials form parallel elongated structures on the surfaces of the substrate, each said elongated structure including a central line structure formed by said first material that contacts the surface of the substrate, and support structures formed by the second material that contacts opposing side surfaces of the central line structure, the device comprising:
 a housing defining a plurality of exit ports and a plurality of inlet ports that extend through one or more outer surfaces of the housing, and a plurality of convergent paths defined inside housing, each of the convergent paths including:
 a central channel extending between a closed end and an open end, the closed end of the central channel communicating with a first inlet port of said plurality of inlet ports, 
 first and second side channels disposed on opposite sides of the central channel, each of the first and second side channels extending between an associated closed end and an associated open end, wherein the closed ends of the first and second side channels respectively communicate with second and third inlet ports of said plurality of inlet ports, and 
 a merge region communicating with the open ends of each of the central channel and the first and second side channels, the merge region also communicating with an associated exit port of said plurality of exit ports, 
   wherein the first and second side channels and the central channel of each said convergent path converge at the merge region such that when the first material is introduced into the central channel through the first inlet port and the second material is introduced into the first and second side channels through the second and third inlet ports, the first material and second material form a single flow in the merge region in which the first material is sandwiched between portions of the second material to form said central line structure and said support structures before exiting said associated exit port.   
     
     
         10 . The device of  claim 9 , wherein each of the plurality of convergent paths are formed such that said central line structure of each of said elongated structures has an aspect ratio greater than 2:1. 
     
     
         11 . The device of  claim 9 , wherein each of the plurality of convergent paths are formed such that said central line structure of each of said elongated structures has a width in the range of 100 nanometers to 100 microns. 
     
     
         12 . The device of  claim 9 , further comprising means for causing the first and second materials to flow through the housing such that the first and second materials maintain a laminar flow in the plurality of convergent paths. 
     
     
         13 . The device of  claim 9 , wherein the housing comprises a plurality of laminated plates. 
     
     
         14 . The device of  claim 9 , further comprising means for pumping the first and second materials through the housing. 
     
     
         15 . The device of  claim 14 , wherein said means for pumping comprises at least one positive displacement pump. 
     
     
         16 . The device of  claim 9 , further comprising means for translating at least one of the substrate and the housing during co-extrusion of the first and second materials.