Systems and methods for high fidelity aerosol jet printing via acoustic forces

Patent metadata

Field	Value
Publication number	US-12083548-B2
Application number	US-202117195300-A
Country	US
Kind code	B2
Filing date	Mar 8, 2021
Priority date	Mar 6, 2020
Publication date	Sep 10, 2024
Grant date	Sep 10, 2024

Abstract

An aspect of the present disclosure provides a system for aerosol jet printing an aerosolized particle source configured to selectively provide aerosolized particles, a nozzle configured to deposit aerosolized particles on a substrate, an actuator configured to generate acoustic energy for migrating the particles, and a generator configured to selectively energize the actuator. The nozzle includes a proximal inlet configured for passage of aerosolized particles, a column configured to focus the aerosolized particles when vibrated by an actuator, and a distal opening configured for deposition of the particles on a substrate.

First claim

What is claimed is:

1. A system for aerosol jet printing, the system comprising:
an aerosolized particle source including aerosolized particles;
a nozzle configured to deposit the aerosolized particles on a substrate, the nozzle including:
a proximal inlet configured to receive the aerosolized particles, wherein the proximal inlet is configured for passage of the aerosolized particles;
a column configured to focus the aerosolized particles when vibrated by an actuator, wherein an inner surface of the column defines a channel, the channel is configured for the passage of the aerosolized particles, and wherein the channel includes a tapered portion; and
a distal opening configured for deposition of the aerosolized particles on a substrate;

an actuator configured to generate acoustic energy for migrating the aerosolized particles; and
a generator configured to selectively energize the actuator,
wherein the actuator vibrates the channel at a resonant frequency of the channel.

2. The system of claim 1 , wherein the distal opening includes a square, a rounded square, a rectangular, a rounded rectangle an oval, or a circular shaped cross-section.

3. The system of claim 1 , wherein the column is in registration with the proximal inlet and the distal opening.

4. The system of claim 1 , wherein the column includes an outer surface configured for mounting of the actuator.

5. The system of claim 1 , wherein the column tapers to the distal opening.

6. The system of claim 1 , wherein the column is made from a material that transfers acoustic energy.

7. The system of claim 1 , wherein the column is configured to transfer the acoustic energy of the actuator to the channel.

8. The system of claim 1 , wherein the channel is at least one of a half-wave, a quarter-wave, or an eighth-wave resonator.

9. The system of claim 1 , wherein the channel includes a square, a rectangular, an oval, or a circular shaped cross-section.

10. A nozzle for aerosol jet printing, comprising:
a proximal inlet configured for passage of aerosolized particles;
a column configured to focus the aerosolized particles when vibrated by an actuator, wherein an inner surface of the column defines a channel, the channel is configured for the passage of the aerosolized particles, and wherein the channel includes a tapered portion; and
a distal opening configured for deposition of the aerosolized particles on a substrate,
wherein the channel is configured to be vibrated by the actuator at a resonant frequency of the channel.

11. The nozzle of claim 10 , wherein the distal opening includes a rectangular, an oval, or a circular shaped cross-section.

12. The nozzle of claim 10 , wherein the column is in registration with the proximal inlet and the distal opening.

13. The nozzle of claim 10 , wherein the column includes an outer surface configured for mounting of the actuator.

14. The nozzle of claim 10 , wherein the column tapers to the distal opening.

15. The nozzle of claim 10 , wherein the column is made from a material that transfers acoustic energy.

16. The nozzle of claim 10 , wherein an inner surface of the column defines a channel, the channel is configured for the passage of the aerosolized particles.

17. The nozzle of claim 16 , wherein the column is configured to transfer the acoustic energy of the actuator to the channel.

18. A method for aerosol jet printing, the method comprising:
aerosolizing particles with a fluid media;
receiving the aerosolized particles in a proximal inlet of a nozzle, the proximal inlet configured for passage of the aerosolized particles; and
vibrating a column of the nozzle by an actuator at a resonant frequency of a channel of the column, wherein the column is configured to focus the aerosolized particles when vibrated at the resonant frequency of the channel by the actuator to focus a print line, wherein the column includes a tapered portion, wherein the aerosolized particles are vibrated in the channel.

19. The method of claim 18 , further comprising focusing the aerosolized particles in the column based on the frequency of the acoustic energy.

20. The method of claim 19 , further comprising depositing the particles on a substrate via a distal opening of the column.

21. The method of claim 19 , wherein the actuator includes a piezo transducer.

Assignees

• Univ Maryland
• The Government Of The United States As Represented By The Director Nat Security Agency

Inventors

• Ray Tyler
• Hines Daniel R

Classifications

• B05B17/0676

  Feeding means · CPC title

• B05B17/0638

  spray being produced by discharging the liquid or other fluent material through a plate comprising a plurality of orifices · CPC title

• B05B17/06

  using ultrasonic {or other kinds of} vibrations · CPC title

• B05B12/1418

  for supplying several liquids or other fluent materials in selected proportions to a single spray outlet (controlling ratio of two or more flows of fluid G05D11/02) · CPC title

• B05B17/063

  having an internal channel for supplying the liquid or other fluent material · CPC title