Multinozzle deposition system for direct write applications

Abstract

A multinozzle deposition system for direct write applications comprises a body including a first network of microchannels embedded therein, where the first network of microchannels extends from a parent microchannel through a series of furcations to a plurality of branching microchannels. The series consists of k generations with furcation number m where the k th generation includes m k branching microchannels. A first end of the body includes a single inlet to the parent microchannel and a second end of the body includes m k outlets from the branching microchannels, where k is an integer greater than or equal to 1 and m is an integer greater than or equal to 2. The body comprises a material having a sufficient rigidity to sustain a pressure in the microchannels of about 690 kPa or greater without distortion.

We claim: 
     
         1 . A multinozzle deposition system for direct write applications, the system comprising:
 a body including a first network of microchannels embedded therein, the first network of microchannels extending from a parent microchannel through a series of furcations to a plurality of branching microchannels, the series consisting of k generations with furcation number m where the k th  generation includes m k  branching microchannels, a first end of the body including a single inlet to the parent microchannel and a second end of the body including m k  outlets from the branching microchannels, where k is an integer greater than or equal to 1 and where m is an integer greater than or equal to 2,   wherein the body comprises a material having a sufficient rigidity to sustain a pressure in the microchannels of about 690 kPa or greater without distortion.   
     
     
         2 . The multinozzle deposition system of  claim 1 , wherein k lies in the range of 2 to 10, and m lies in the range of 2 to 6. 
     
     
         3 . The multinozzle deposition system of  claim 2 , wherein k lies in the range of 4 to 8 and m lies in the range of 2 to 4. 
     
     
         4 . The multinozzle deposition system of  claim 1 , wherein each of the microchannels comprises a square transverse cross-section. 
     
     
         5 . The multinozzle deposition system of  claim 1 , wherein a plurality of the microchannels are self-similar such that one of a first ratio and a second ratio is equivalent to a proportionality constant C,
 wherein the first ratio is equal to L/w, where L is a total length and w is a width w of each microchannel of the plurality, and   wherein the second ratio is equal to h c /w, where h c  is a center height and w is the width w of each microchannel of the plurality.   
     
     
         6 . The multinozzle deposition system of  claim 5 , wherein all of the microchannels are self-similar. 
     
     
         7 . The multinozzle deposition system of  claim 5 , wherein the first ratio is between about 10 and about 15. 
     
     
         8 . The multinozzle deposition system of  claim 5 , wherein the second ratio is between about 2 and about 4. 
     
     
         9 . The multinozzle deposition system of  claim 1 , wherein each of the outlets has a width w of about 300 microns or less. 
     
     
         10 . The multinozzle deposition system of  claim 1 , wherein the single inlet to the parent microchannel is a conical passageway. 
     
     
         11 . The multinozzle deposition system of  claim 1 , further comprising a prefilter for removing particulate debris from the deposition system during use, the prefilter comprising a plurality of micropassageways in fluid communication with the parent microchannel and positioned downstream of the single inlet. 
     
     
         12 . The multinozzle deposition system of  claim 1 , wherein the material is a polymer. 
     
     
         13 . The multinozzle deposition system of  claim 12 , wherein the polymer is poly(methyl methacrylate) (PMMA). 
     
     
         14 . The multinozzle deposition system of  claim 1 , wherein the pressure in the microchannels ranges from about 400 psi to about 800 psi. 
     
     
         15 . The multinozzle deposition system of  claim 1 , wherein the body further comprises a second network of microchannels embedded therein, the second network of microchannels extending from a second parent microchannel through a progression of furcations to a plurality of second branching microchannels, the progression consisting of k generations with furcation number m where the k th  generation includes m k  second branching microchannels, the first end of the body including a single inlet to the second parent microchannel and a second end of the body including m k  outlets from the second branching microchannels, where k is an integer greater than or equal to 1 and m is an integer greater than or equal to 2. 
     
     
         16 . The multinozzle deposition system of  claim 15 , wherein the second network of microchannels is laterally offset from the first network of microchannels by an amount equal to half a center-to-center spacing between adjacent microchannels of the k th  generation of the first network. 
     
     
         17 . The multinozzle deposition system of  claim 15 , wherein the second network of microchannels is spaced apart from the first network of microchannels in a thickness direction of the body. 
     
     
         18 . The multinozzle deposition system of  claim 1 , further comprising:
 at least one ink source in fluid communication with at least one of: (a) the single inlet of the first network and (b) the single inlet of the second network;   a substrate underlying the m k  outlets and supported by a printing stage; and   a motion controller operably connected to at least one of the body and the printing stage.   
     
     
         19 . The multinozzle deposition system of  claim 18 , wherein the substrate comprises an area of at least about 0.5 m 2 . 
     
     
         20 . The multinozzle deposition system of  claim 19 , wherein the area is at least about 1 m 2 .