High-definition printing using independently developed aerosol and sheath gas flows

Abstract

An apparatus for stable aerosol-based printing features on a surface includes an aerosolization source adapted to produce an aerosol from an ink. A cooler cools at least one of the ink or the substrate to between 0 and 30 20 C. An ink cartridge retains the ink and has an inclined channel. A compressed gas source is adapted to transport the aerosol. At least one aerodynamic lens has a lens gas sheath around the aerosol transiting therethrough. A dispense nozzle or a capillary has a dispense gas sheath around the aerosol and focusing the aerosol to a minimum deposited size of 1 micron or less. A process for printing 1-micron traces with 2-micron spacing for 24 hours includes producing an aerosol distribution with droplet diameters ranging from approximately 0.3 to 5 microns. An ultrasonic aerosolization excitation frequency operates in the range of 0.1 to 1.0 MHz and acts on the ink.

Dependencies are inferred from the claim text.