Systems and methods for printing electronic device assembly

Abstract

The present invention discloses systems and methods for printing functional blocks from a plurality of printheads to a target substrate. In exemplary embodiments, the printing system comprises a main printhead for the majority of printing process, and a secondary printhead for supplemental printing. The system further comprises a controller, utilizing a positioning intelligence system to distribute the printing of the functional blocks between the main printhead and the secondary printhead, to minimize the motions of the printheads while maximize the printing speed.

What is claimed is: 
     
         1 . A controller for distributing the printing of functional blocks on a substrate between one or more main printheads and one or more secondary printheads to meet a desired objective,
 wherein the one or more main printheads print a majority of the functional blocks, and the one or more secondary printheads serve to print the functional blocks on locations on the substrate that the main printheads skip.   
     
     
         2 . A controller as in  claim 1  wherein the desired objective comprises at least one of
 exceeding a predetermined speed of printing for achieving a desired printing throughput, and 
 not exceeding a predetermined amount of movements of the main printheads for achieving a desired reliability. 
 
     
     
         3 . A controller as in  claim 1  wherein the main printheads skip printing functional blocks due to at least one of
 conflicting with other commands, 
 incapability to print on the desired locations, 
 interfering with a desired speed of printing, and 
 exceeding a predetermined amount of movements of the main printheads. 
 
     
     
         4 . A system for printing functional blocks on a target substrate, comprising:
 one or more main printheads for printing a majority of functional blocks on the substrate;   one or more secondary printheads for printing functional blocks on locations on the substrate that the one or more main printheads skip; and   a controller to distribute the printing of the functional blocks between the one or more main printheads and the one or more secondary printheads to meet a desired objective.   
     
     
         5 . A system as in  claim 4  wherein the target substrate is a roll-to-roll substrate. 
     
     
         6 . A system as in  claim 4  wherein the printheads have the functional blocks adhered by a releasable adhesive. 
     
     
         7 . A system as in  claim 4  wherein the one or more secondary printheads provide printing while the one or more main printheads are being refilled. 
     
     
         8 . A system as in  claim 4  wherein the desired objective comprises at least one of
 a predetermined printing speed for achieving a predetermined throughput, and 
 not exceeding a predetermined amount of movements of the one or more main printheads for achieving a desired reliability. 
 
     
     
         9 . A system as in  claim 4  wherein the one or more main printheads skip printing functional blocks due to at least one of
 conflicting with other commands, 
 incapability to print on the desired locations, 
 interfering with a desired speed of printing, and 
 exceeding a predetermined amount of movements of the one or more main printheads. 
 
     
     
         10 . A system as in  claim 4  wherein the controller determines the movements of the one or more main printheads from the locations of the functional blocks and the printing locations on the target substrate. 
     
     
         11 . A system as in  claim 4  wherein the controller determines the errors on printing after the one or more main printheads reach the target locations for printing. 
     
     
         12 . A system as in  claim 4  wherein the controller utilizes a predictive and self-adaptive algorithm to predict variations between original target sampling and actual target locations. 
     
     
         13 . A system for printing functional blocks on a target substrate, comprising:
 one or more main printheads for printing a majority of functional blocks on the substrate;   one or more secondary printheads for printing functional blocks on locations on the substrate that the one or more main printheads skip; and   a controller to distribute the printing of the functional blocks between the one or more main printheads and the one or more secondary printheads,   wherein the controller is configured to instructing the one or more main printheads to skip printing based deviations from printing the functional blocks on the corresponding targets, and to instructing the one or more secondary printheads to print on the skipped locations.   
     
     
         14 . A system as in  claim 13  wherein the controller is further configured to determining locations of the functional blocks and locations of corresponding targets, wherein the functional blocks positioned on the main printheads, and the targets located on the target substrate. 
     
     
         15 . A system as in  claim 13  wherein the controller is further configured to calculating movements of the main printheads to position the functional blocks at the corresponding targets. 
     
     
         16 . A system as in  claim 13  wherein the controller is configured to determining deviations from printing the functional blocks on the corresponding targets, wherein determining deviations comprises determining estimated errors in printing. 
     
     
         17 . A system as in  claim 13  wherein the controller is configured to determining deviations from printing the functional blocks on the corresponding targets, wherein determining deviations comprises moving the main printheads to desired target locations and determining actual errors in printing. 
     
     
         18 . A system as in  claim 13  wherein skipping printing from the main printheads is based on at least one of
 a deviation that there are no functional blocks on the main printheads to print at corresponding target locations; 
 a deviation that there are conflicting movement commands of the main printheads at corresponding target locations; and 
 a deviation that the main printheads movement deviations affects a printing throughput of the process of printing functional blocks on the target substrate. 
 
     
     
         19 . A system as in  claim 13  wherein the controller is configured to instruct the main printheads to print at a constant speed. 
     
     
         20 . A system as in  claim 13  wherein the controller is configured to move the main printheads at a predetermined path with deviations less than a predetermined amount.