Abstract:
In a first aspect, a method of curing ink on a substrate is provided. The method includes the steps of (1) placing a substrate on a support stage of an ink curing chamber; and (2) scanning an electron beam over a surface of the substrate within the ink curing chamber so as to cure ink present on the substrate. Numerous other aspects are provided.

Description:
[0001]     The present application is a continuation-in-part of and claims priority to U.S. patent application Ser. No. 10/845,629, filed May 13, 2004, titled “A METHOD FOR FORMING COLOR FILTERs IN FLAT PANEL DISPLAYS BY INKJETTING” (Attorney Docket No. 9099). The present application also claims priority to U.S. Provisional Patent Application Ser. No. 60/625,550, filed Nov. 4, 2004 and entitled “APPARATUS AND METHODS FOR FORMING COLOR FILTERS IN A FLAT PANEL DISPLAY BY USING INKJETTING” (Attorney Docket No. 9521/L). Each of these applications is hereby incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention relates to electronic device manufacturing and, more particularly, to apparatus and methods for curing ink on a substrate using an electron beam.  
       BACKGROUND OF THE INVENTION  
       [0003]     Each pixel of a flat panel display typically includes sub-pixels filled with red, green or blue ink (although other colors may be used). These sub-pixels may be manufactured using a series of photolithography steps. For example, a photoresist layer may be deposited on a substrate and patterned so as to open all sub-pixel areas in which red ink is to be deposited. Thereafter, red ink may be deposited over the entire substrate, so that the open sub-pixel areas are filled with red ink. The ink may be cured, typically using ultra-violet light, and the photoresist layer may be removed so that only red ink filled sub-pixel areas remain on the substrate. The above process then may be repeated (twice) to complete color filter formation by similarly defining and filing green and blue sub-pixel areas.  
         [0004]     While effective, such a process is time consuming and expensive and three separate photolithography steps are required to form the red, green and blue sub-pixels. Likewise, each color generally is deposited in a separate processing chamber, requiring significant fabrication facility resources. Improved methods and apparatuses are necessary to make color filters in production.  
       SUMMARY OF THE INVENTION  
       [0005]     In a first aspect, the present invention provides a method of curing ink on a substrate that includes the steps of placing a substrate on a support stage of an ink curing chamber; and scanning an electron beam over a surface of the substrate within the ink curing chamber so as to cure ink present on the substrate.  
         [0006]     In a second aspect, the present invention provides an apparatus for curing ink. The apparatus includes an electron beam emitter adapted to emit an electron beam, and an electron beam emitter positioning device. The electron beam emitter positioning device is adapted to support the electron beam emitter at a distance above a surface of a substrate containing ink and to move the electron beam emitter so as to scan an electron beam over the surface of the substrate and cure ink present on the substrate. Numerous other aspects are provided.  
         [0007]     Each computer program product described herein may be carried by a medium readable by a computer (e.g., a carrier wave signal, a floppy disc, a compact disc, a DVD, a hard drive, a random access memory, etc.).  
         [0008]     Other features and aspects of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is a functional block diagram of an exemplary ink curing apparatus of the present invention;  
         [0010]      FIG. 2  is a perspective view of an exemplary embodiment of an ink curing processing facility of the apparatus of  FIG. 1 ;  
         [0011]      FIG. 3  is a top view of the processing facility of  FIG. 2 ;  
         [0012]      FIG. 4  is a top view of a processing facility of another exemplary embodiment of the apparatus of the present invention;  
         [0013]      FIG. 5  is side view of an exemplary electron beam emitter device which can be used in connection with the apparatus of the present invention;  
         [0014]      FIG. 6  is perspective view of the electron beam emitter device of  FIG. 5 ;  
         [0015]      FIG. 7  is a flowchart illustrating an exemplary embodiment of the operation of the apparatus and methods of the present invention; and  
         [0016]      FIGS. 8A, 8B , and  8 C are a flowchart illustrating another exemplary embodiment operation of the apparatus and methods of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0017]     An alternative approach to forming flat panel displays is to use inkjet printing. During inkjet printing, one or more inkjet print heads (or heads) mounted within a carriage may be moved back and forth across a substrate. As the substrate travels relative to the heads, a control system may activate individual nozzles within the heads to deposit or eject ink (or other fluid) droplets onto predefined wells formed on the substrate. The ink is then cured.  
         [0018]     In some instances, the predefined wells formed on the substrate may be damaged if UV curing is employed. Accordingly, it is desirable to develop other curing techniques for flat panel display manufacturing.  
         [0019]     The present invention relates to electronic device manufacturing and, more particularly, to apparatus and methods for curing ink on substrates using an electron beam that does not damage predefined wells formed on the substrate. The apparatus and methods of the present invention can be used in curing ink used to form color filters in display objects, display devices, or display panels (hereinafter “display objects”) which are used in manufacturing flat panel displays, such as thin film transistor (TFT) liquid crystal displays (LCD), in a more efficient and cost effective manner.  
         [0020]     In one or more embodiments of the invention, an electron beam curing module is provided for curing ink deposited on a substrate. Inks may include, for example, polymers, pigments, dyes, encapsulated pigment, pure pigment plus dye mix, crystal UFH, UFK, and UTT (UV) inks, SOVH and SOVK (solvent) inks, OPK and OPT (oil based) inks, etc. Substrates may be of any size such as, for example, 2,000 cm 2  to 52,800 cm 2 . The electron beam curing module can include a processing chamber that houses an electron beam emitter. The electron beam emitter is adapted to emit an electron beam that can be scanned and/or moved over a surface of a substrate so as to cure ink previously deposited on the substrate. In one particular embodiment, the electron beam curing module can include an x-ray detector for detecting x-ray leakage from the processing chamber of the electron beam module. Further, the electron beam curing module can include an oxygen detector and/or an ozone detector for detecting undesired levels of these gases within the processing chamber. In response to detection of x-ray leakage from the processing chamber, and/or an undesired level of oxygen and/or ozone within the processing chamber, operation of the electron beam curing module can be halted. A chamber door interlock system or device can also be utilized to ensure that the electron beam curing module is only operated when a door of the processing chamber is properly closed and/or locked.  
       System Overview  
       [0021]      FIG. 1  is a functional block diagram of an exemplary apparatus of the present invention which is designated generally by the reference numeral  100 . With reference to  FIG. 1 , the apparatus  100  includes a system controller  150  coupled to an electron beam emitter system  200  which includes an electron beam emitter device  210  positioned within a processing chamber  220 . The electron beam emitter device  210  is adapted to emit an electron beam for curing ink on a substrate positioned with the processing chamber  220 . The apparatus  100  also includes an electron beam emitter positioning system  250  coupled to the system controller  150  for moving and/or scanning the electron beam emitter device  210  over a surface of a substrate positioned within the processing chamber  220 . A substrate handling system  300  and a substrate support system  350  (having a substrate support stage  360  located within the processing chamber  220 ) are each coupled to the system controller  150  and may be used for positioning a substrate on the substrate support stage  360  of the processing chamber  220 . A substrate database  400  can be employed by the system controller  150  for storing substrate information therein, and a purge system  450  can be provided for purging and/or reducing oxygen and/or ozone levels within the processing chamber  220 .  
         [0022]     The apparatus  100  can further include one or more of (1) an oxygen detection system  500  having an oxygen sensor or detection device  510 ; (2) an ozone detection system  550  having an ozone sensor or detection device  560 ; and/or (3) an x-ray leakage detection system  600  having an x-ray sensor or detection device  610 , each coupled to the system controller  150 . A chamber door interlock system  650  can also be provided having a door interlock detector  660  for determining whether a door  27  of the processing chamber  220  is properly closed and/or locked (and for providing such information to the system controller  150 ). Additional details of these and other components of the apparatus  100  are now described.  
         [0023]     The system controller  150  can control the operation of the apparatus  100  and one or more of the various electrical and mechanical components and systems of the apparatus  100  which are described herein. In an exemplary embodiment, the system controller  150  can be any suitable computer or computer system, or can include any number of computers or computer systems.  
         [0024]     Further, the system controller  150  can be or can include any components or devices which are typically used by, or used in connection with, a computer or computer system. In this regard, the system controller  150  can include a central processing unit(s), a read only memory (ROM) device, a random access memory (RAM) device and/or an input device or user interface device, such as a keyboard and/or a mouse or other pointing device to allow a user to operate or provide control over the apparatus  100 . The system controller  150  also can include an output device such as a printer or other device via which data and/or information can be obtained, a display device such as a monitor for displaying information to a user or operator and/or a transmitter and/or a receiver for facilitating communication with other system components and/or in a network environment. The system controller  150  further can include a database for storing any appropriate data and/or information, and/or any other computer components or systems, including any peripheral devices and/or the substrate database  400 .  
         [0025]     The electron beam emitter system  200  can be, or can include, any suitable electron beam emitter device  210  which can provide an electron beam sufficient for curing ink deposited on any of the herein-described display devices or substrates. In an exemplary embodiment, the electron beam emitter device  210  used in the apparatus  100  can be an Advanced Electron Beams, Inc. 100 Kvolt electron beam source which can provide an electron beam at 100 KVolts having a beam spot of about 10.5″×2″ and a beam uniformity variation of less than ±10%. In some embodiments, other electron beam sources having beam spots of 20 square inches or more may be employed. Beam spots may be formed in any desired shape including rectangular, circular, oval, triangular, etc. Any other suitable electron beam emitter can be used. Any number of electron beam emitter devices  210  can be utilized in the apparatus of the present invention. The system controller  150  can control and/or monitor the operation of the electron beam emitter system  200  and/or any components of the electron beam emitter system  200 .  
         [0026]     The electron beam emitter positioning system  250 , as will be described in more detail herein, can include one or more motors, control device(s) and associated hardware, including mounting hardware, support devices or support arms, etc., for mounting the electron beam emitter device  210  thereon and for moving the electron beam emitter device  210  in an X-axis direction, in a Y-axis direction, and/or in both an X-axis direction and a Y-axis direction, within the ink curing chamber  220  during an operation of the apparatus  100 .  
         [0027]     The electron beam emitter positioning system  250  can be designed to have any desired stroke capability in both the X-axis direction and the Y-axis direction. In an exemplary embodiment, the electron beam emitter positioning system  250  can have an X-axis direction stroke distance range of motion of greater than 750 mm and a Y-axis direction stroke distance range of motion of greater than 1180 mm.  
         [0028]     The electron beam emitter positioning system  250  can also be designed to move the electron beam emitter device  210  with any appropriate speed in the X-axis direction and the Y-axis direction. In an exemplary embodiment, the electron beam emitter positioning system  250  can be designed to provide an X-axis direction speed of greater than 750 mm per 2 seconds and a Y-axis direction speed of greater than 1180 mm per 2 seconds.  
         [0029]     The electron beam emitter positioning system  250  can also include any suitable movement detection device (not shown) for detecting and/or monitoring any movement of the electron beam emitter device  210  such as, for example, a linear encoder and/or other equivalent devices. The system controller  150  can control and/or monitor the operation of the electron beam emitter positioning system  250  and/or any components of the electron beam emitter positioning system  250 .  
         [0030]     The substrate handling system  300  which can be used to physically handle a substrate having one or more display devices prior to, during, and/or subsequent to, any ink curing operation which can be performed by the apparatus  100 . The substrate handling system  300  can be, or can include, any equipment, device(s), or system(s), which can be utilized to handle a substrate or substrates once inside the ink curing chamber  220  of the apparatus  100  and during any processing operation(s).  
         [0031]     In an exemplary embodiment, the substrate handling system  300  can include any number of substrate lift pins and/or conveyance devices, and/or any associated hardware which can be used to lower a substrate onto a stage, to lift a substrate from a stage, and/or to move a substrate to or from a stage. The substrate handling system  300  can also include a positioning device (not shown) which can be adapted to detect a physical position of a substrate in order to detect and determine a proper positioning or orientation of the substrate prior to and/or during a respective processing operation. The system controller  150  can control and/or monitor the operation of the substrate handling system  300  and/or any components of the substrate handling system  300 .  
         [0032]     The substrate support system  350  which can support and effectuate a movement of the substrate support stage  360  used for supporting and moving a substrate(s). In an exemplary embodiment, a substrate having one or more display objects (e.g., one or more display panels) can be placed on the stage  360  when being processed in the inking curing chamber  220  of the present invention.  
         [0033]     The stage  360  can be of any suitable size to accommodate the substrate or substrates to be processed by the apparatus  100 . In an exemplary embodiment, the stage  360  can be capable of holding substrates having dimensions of 750 mm×950 mm and 1100 mm×1300 mm (or any other size).  
         [0034]     The substrate support stage  360  can be, for example, a stationary supporting surface for a substrate. In another embodiment, the stage  360  can be an X-Y table which can be adapted to move in the X-direction, in the Y-direction, and/or in both the X-direction and the Y-direction. In one or more embodiments, the stage  360  can also be adapted to rotate (e.g., manually or via a motor or other suitable rotating mechanism) in either or both of a clockwise direction or a counter-clockwise direction, so as to facilitate any orientation or re-orientation of the stage  360  and/or a substrate and the display object(s) located thereon.  
         [0035]     The stage  360  can also include a vacuum device  362  or a suction device which can be used for securing a substrate on the top surface of the stage. A vacuum device  362  may include a vacuum pump (not shown), grooves and/or holes in the top surface of the stage  360 , piping, etc. to allow vacuum pressure to be applied to the substrate. Other securing devices may be used. Alternatively, a substrate can be held in place on the stage  360  by gravity, with no suction, vacuum, or hardware being utilized to hold the substrate in place. In some embodiments, the stage  360  may include one or more substrate movement detection devices  364  that indicate whether the substrate has shifted out of position on the stage  360 . Such substrate movement detection devices  364  may be coupled to the system controller  150  and/or the substrate handling system  300 .  
         [0036]     The substrate support system  350  can also include one or more motors, control device(s) and associated hardware, including mounting hardware, support devices or support arms, etc., for mounting the stage  360  thereon and for moving the stage  360  in an X-axis direction, in a Y-axis direction, and/or in both an X-axis direction and a Y-axis direction. The substrate support system  350  can also include any suitable movement detection device (not shown) for detecting and/or monitoring any movement of the stage  360 . In an exemplary embodiment, the movement detection device can be, or can include, any number of linear encoders or other equivalent devices. The system controller  150  can control and/or monitor the operation of the substrate support system  350  and/or any components of the substrate support system  350 .  
         [0037]     The substrate database  400  can store data and/or information regarding the type or types of substrate(s), display device(s), etc. which can be processed by the apparatus  100 , the type or types of ink or inks which can be utilized in connection with the substrate(s) or display device(s), ink curing rates, power levels, curing times, ink curing scanning patterns, and/or any other information which may be pertinent to and/or relevant to any ink curing process and/or use or operation of the apparatus  100 . The system controller  150  can control and/or monitor the substrate database  400 .  
         [0038]     The purge system  450  can include a gas supply or container and a dispensing device or dispensing devices for dispensing N 2  or another suitable gas (e.g., argon) into the ink curing chamber  220  so as to reduce the level of Oxygen in the same (as oxygen may produce Ozone when struck by an e-beam). The purge system  450  also can include an exhaust and/or vacuum system for removing nitrogen from the chamber  220 . In an exemplary embodiment, the ink curing chamber  220  of the apparatus  100  can be purged with N 2  to reduce Oxygen (O 2 ) and so as to reduce and/or prevent the formation of Ozone (O 3 ) during an electron beam curing operation. For example, the purge system  450  can operate throughout the ink curing process as described herein. Likewise, the purging rate of the ink curing chamber  220  can be increased to purge any excessive levels of Oxygen (O 2 ) and/or Ozone (O 3 ) which may be detected. The purge system  450  can be connected to, controlled by, and/or monitored by, the system controller  150 .  
         [0039]     The Oxygen (O 2 ) detection system  500  can include any number of Oxygen (O 2 ) sensors or detection devices  510  which can sense or detect the presence of Oxygen (O 2 ) in the ink curing chamber  220 . Each Oxygen (O 2 ) sensor or detection device  510  can be located at any appropriate location inside the ink curing chamber.  
         [0040]     Upon detection of Oxygen (O 2 ), a respective sensor or detection device  510  can generate an appropriate Oxygen (O 2 ) detection signal and provide the same to the controller  150 . The controller  150 , upon receiving, detecting, and/or processing the Oxygen (O 2 ) detection signal, can (1) activate the purge system  450  so as to purge, reduce or eliminate the presence or level of Oxygen (O 2 ) in the ink curing chamber; (2) prevent the electron beam emitter  210  and/or the apparatus  100  from activating or turning on if an undesired level of Oxygen (O 2 ) is detected; and/or (3) deactivate or turn off the electron beam emitter  210  and/or the apparatus  100  and/or sound an alarm (not shown) if an undesired level of Oxygen (O 2 ) is detected during operation of the electron beam emitter  210 . In an exemplary embodiment, Oxygen (O 2 ) of less than about 0.3% may be required to prevent the generation or formation of Ozone (O 3 ) during an e-beam curing operation.  
         [0041]     The Ozone (O 3 ) detection system  550  can include any number of Ozone (O 3 ) sensors or detection devices  560  which can sense or detect the presence of Ozone (O 3 ) in the ink curing chamber  220 . Each Ozone (O 3 ) sensor or detection device  560  can be located at any appropriate location inside the ink curing chamber.  
         [0042]     In an exemplary embodiment, the Ozone (O 3 ) detection system  500  can prevent the electron beam emitter  210  and/or the apparatus  100  from activating or turning on if an undesired level of Ozone (O 3 ) is detected. In another exemplary embodiment, the Ozone (O 3 ) detection system  500  can deactivate or turn off the electron beam emitter  210  and/or the apparatus  100  and/or sound an alarm (not shown) if an undesired level of Ozone (O 3 ) is detected during operation.  
         [0043]     For example, upon detection of Ozone (O 3 ), a respective sensor or detection device  560  can generate an appropriate Ozone (O 3 ) detection signal and provide the same to the controller  150 . The controller  150 , upon receiving, detecting, and/or processing the Ozone (O 3 ) detection signal can (1) activate the purge system  450  so as to purge, reduce or eliminate the presence or level of Ozone (O 3 ) in the ink curing chamber; (2) prevent activation of the electron beam emitter  210 ; and/or (3) turn off or deactivate the electron beam emitter  210 .  
         [0044]     The X-ray leakage detection system  600  can include any number of X-Ray sensors or detection devices  610  located outside or on the exterior of the ink curing chamber  220  and/or in the vicinity of the ink curing chamber  220 . An X-Ray sensor or detection device  610  can be located anywhere on the exterior or the ink curing chamber  220  and/or at any location in a room or premises wherein the ink curing chamber  220  is located. Since X-rays can be dangerous to an operator or individuals in close proximity to the ink curing chamber  220 , any detected leakage of X-rays may require a shutting down of an operation of the apparatus  100  until the problem resulting in the leakage is repaired or rectified.  
         [0045]     In an exemplary embodiment, the X-ray leakage detection system  600  can prevent the electron beam emitter  210  and/or the apparatus  100  from activating or turning on if X-ray leakage about a predetermined level is detected. In another exemplary embodiment, the X-ray leakage detection system  600  can deactivate or turn off the electron beam emitter  210  and/or the apparatus  100  and/or sound an alarm (not shown) if a predetermined level of X-ray leakage is detected during operation.  
         [0046]     For example, upon detection of X-ray leakage, a respective X-ray sensor or detection device  610  can generate an appropriate X-ray leakage detection signal and provide the same to the controller  150 . The controller  150 , upon receiving, detecting, and/or processing the X-ray leakage detection signal can de-activate the electron beam emitter  210  and/or the apparatus  100 .  
         [0047]     The chamber door interlock system  650  can include the door interlock detector  660  which can detect when the chamber door  27  of the ink curing chamber  220  is not locked, not locked properly, and/or not completely closed. Since X-rays can be generated and emitted from the electron beam emitter  210 , it is important that the ink curing chamber door  27  be properly closed and/or locked. The door interlock detector  660  of the chamber door interlock system  650  can detect a door  27  not properly closed and/or in an improperly locked condition, and generate an appropriate “door not closed” or “door not locked” signal and provide the same to the controller  150 .  
         [0048]     In an exemplary embodiment, the chamber door interlock system  650  can prevent the electron beam emitter  210  and/or the apparatus  100  from activating or turning on if a “door not closed” or “door not locked” condition is detected. In another exemplary embodiment, the chamber door interlock system  650  can deactivate or turn off the electron beam emitter  210  and/or the apparatus  100  and/or sound an alarm (not shown) if a “door not closed” or “door not locked” condition is detected during operation.  
         [0049]     For example, the controller  150 , upon receiving, detecting, and/or processing the “not closed” or “not locked” signal can de-activate or prevent activation of the electron beam emitter  210  and/or the apparatus  100 .  
         [0050]      FIG. 2  is a perspective view of an exemplary embodiment of the ink curing processing chamber  220  of the apparatus  100  of  FIG. 1 . With reference to  FIG. 2 , the ink curing processing chamber  220  includes a base frame  12  and a housing  14  as shown. In an exemplary embodiment, the housing  14  can be formed of aluminum or any other suitable material and can have a lead plate lining (not separately shown) throughout the same so as to provide sufficient protection from or against radiation leakage, such as, for example, X-ray leakage, from the respective electron beam emitter  210  or other electron beam device which is utilized in the apparatus  100 . For example, a lead plate lining having a thickness of 3.2 mm can be used to provide sufficient protection against X-ray leakage. Other lining thicknesses may be used.  
         [0051]     With reference once again to  FIG. 2 , the ink curing processing chamber  220  also includes a purge valve  20  and an exhaust port  22  for supplying purge gas (e.g., nitrogen, air, etc.) to the chamber  220  and/or for exhausting gas from the chamber  220 . The ink curing chamber  220  also includes a door opening  26  through which substrates can be transferred into, and/or removed from, the ink curing processing chamber  220 . A chamber door  27  (removed for clarity from  FIG. 2  but see  FIGS. 1 &amp; 3 ) which is used to close and seal the door opening  26  can, in an exemplary embodiment, be made from Aluminum or any other suitable metal and can be lined with lead so as to provide sufficient protection from or against radiation leakage, such as, for example, X-ray leakage. The chamber door  27  ( FIGS. 1 &amp; 3 ) can be automatically operated and/or manually operated.  
         [0052]     Lead shielding or plating may be used in any wall or structure of the ink curing processing chamber  220  in order to protection from the radiation or radiation leakage which typically may be associated with use of electron beam devices such as the electron beam emitter device  210 .  
         [0053]     With reference once again to  FIG. 2 , the electron beam emitter device  210  of the electron beam emitter system  200  is also shown. Other components of the electron beam emitter system  200  shown in  FIG. 2  include an electron beam device support  215  on which the electron beam curing device  210  can be mounted and moved about inside the ink curing chamber  220 . The ink curing chamber  220  also includes the electron beam device positioning system  250  which can control and effectuate movement of the electron beam emitter device  210 . Operation of the electron beam device positioning system  250  can be controlled and/or monitored, for example, by the system controller  150  which is also shown in  FIG. 2 . In  FIG. 2 , cable  152  is used to connect the system controller  150  to the components of the processing chamber  220 . Other communication types/mediums may be used such as wireless communication.  
         [0054]     In an exemplary embodiment, the electron beam device positioning system  250  includes an X-axis actuator  254 , which is adapted to move the electron beam emitter device  210  in the X-axis direction, and a Y-axis actuator  256  which is adapted to move the electron beam emitter device  210  in the Y-axis direction (e.g., along rails  258 ). In this regard, the electron beam emitter device  210  can be moveable in both the X-axis direction and in the Y-axis direction and may be scanned over a substrate (not shown) for curing inks deposited thereon.  
         [0055]     With reference once again to  FIG. 2 , the stage  360  which can support a substrate  330  having one or more display devices is also shown. As illustrated, the electron beam emitter device  210  is supported above the stage  360  and substrate  330  and can be moveable relative to and above the stage  360  and substrate  330 . In  FIG. 2 , the substrate  330  is held in place on the top surface of the stage  360  by gravity. In another embodiment, the substrate  330  can be held in place by a vacuum device or a suction device (not shown) or by a clamp or other hardware device (also not shown).  
         [0056]     An X-ray sensor  610  is also shown adjacent the door opening  26  in  FIG. 2 . Any number of X-ray sensors or detection devices  610  can be utilized and can be placed at any location on the exterior structure of the ink curing chamber  220  as well as at any location in the vicinity of the ink curing chamber  220 .  
         [0057]     With reference once again to  FIG. 2 , in an exemplary embodiment, an Oxygen (O 2 ) sensor or detection device  510  and/or an Ozone (O 3 ) sensor or detection device  560  can be mounted to an inner wall of the housing  14 . Alternatively or additionally, an Oxygen (O 2 ) sensor or detection device  510  and/or an Ozone (O 3 ) sensor or detection device  560  can be mounted to the moveable electron bean emitter device  210 , as shown. Any number of Oxygen (O 2 ) sensors or detection devices  510  and/or Ozone (O 3 ) sensors or detection devices  560  can be utilized inside the processing chamber  220  and can be mounted to any stationary and/or moveable components of the processing chamber  220 .  
         [0058]     A door interlock detector  660  is also shown in  FIG. 2  as being mounted adjacent to the opening  26 .  
         [0059]      FIG. 3  is a top view of the processing chamber  220  of  FIG. 2  shown with the top wall of the housing  14  removed. With reference to  FIG. 3 , the above-described elements of the processing chamber  220  and/or the apparatus  100  are shown from a top view perspective. In this regard,  FIG. 3  shows the purge valve  20 , the exhaust port  22 , the door opening  26  and the X-ray sensor  610  and the door interlock detector  660  shown mounted adjacent to the door opening  26 . A chamber door  27  and the system controller  150  are also shown in  FIG. 3 .  
         [0060]     With reference once again to  FIG. 3 , shown as being located within the ink curing processing chamber  220  are the stage  360 , the substrate  360 , the electron beam emitter device  210 , and the electron beam device support  215  on which the electron beam curing device  210  can be mounted and moved about inside the ink curing processing chamber  220 . In the exemplary embodiment of  FIG. 3 , an Oxygen (O 2 ) sensor or detection device  510  and an Ozone (O 3 ) sensor or detection device  560  can be mounted to an inner wall of the housing  14  and/or on the electron beam emitter device  210  as shown.  
         [0061]     With reference once again to  FIG. 3 , also shown are the electron beam device positioning system  250 , the X-axis actuator  254 , the Y-axis actuator  256 , and the rails  258 .  FIG. 3  also illustrates an electrical connection  152  between the system controller  150  and each of the purge valve  20 , the exhaust port  22 , the X-ray sensor  610 , the door interlock detector  660 , the electron beam emitter device  210 , the Oxygen (O 2 ) sensor or detection device  510 , the Ozone (O 3 ) sensor or detection device  560 , and the electron beam device positioning system  250 .  
         [0062]     In another exemplary embodiment, the apparatus  100  can be equipped with a plurality of electron beam emitter devices  210  which can be arranged in an array in order to facilitate performing ink curing for a larger area of substrate.  FIG. 4  is a top view of a processing chamber of another exemplary embodiment of the apparatus of the present invention wherein the apparatus  100  is provided with a plurality of electron beam emitter devices which are arranged in an array.  
         [0063]     In the exemplary embodiment of  FIG. 4 , three electron beam emitter devices  210  are shown as being mounted on the electron beam device support  215 . It is important to note although  FIG. 4  shows three electron beam emitter devices  210  being utilized and being arranged in a side-by-side array manner, any number of electron beam emitter devices  210  can be utilized in the apparatus  100  and can be arranged in any suitable manner or fashion.  
         [0064]      FIG. 4  further shows the other components of the apparatus  100  and/or the processing chamber  220  described above in connection with the exemplary embodiments of  FIG. 2  and  FIG. 3 .  
         [0065]      FIG. 5  is side view of an exemplary electron beam emitter device  210  which can be used in connection with the apparatus of the present invention. As noted above, in an exemplary embodiment, the electron beam emitter device  210  can be an Advanced Electron Beams, Inc. 100 Kvolt electron beam source which can provide an electron beam at 100 KVolts and having a beam spot of about 10.5″×2″. The beam spot is a measure of the aperture through which the electron beam is emitted. Other electron beam emitters may be used.  
         [0066]     A large beam spot allows for a more efficient ink curing process and may dispense with a need to operate the electron beam emitter  210  with precise alignment. In this regard, pre-alignments, rotations, etc., of the substrate  330  relative to the electron beam emitter  210  can be dispensed with.  
         [0067]     With reference once again to  FIG. 5 , the electron beam emitter device  210  includes a vacuum chamber  210 A, a high voltage plate (HVP) element  210 B, a filament  210 C, an acceleration zone  210 D and a foil  210 E which, in an exemplary embodiment, can be a titanium foil or a silicon foil. For example, the foil  210 E can be a Titanium foil having a thickness of about 6 microns or a Silicon foil having a thickness of about 2-3 microns. Other foil types and/or sizes may be used. In an exemplary embodiment, the foil  210 E has a number of slots, slits, holes, and/or apertures formed therein.  
         [0068]     In one particular embodiment, the electron beam emitter device  210  is held above the substrate  330  so that the foil  210 E is situated at a distance of approximately 2 to 3 millimeters from the substrate  330 . Other distances may be used. A small gap between the foil  210 E and the substrate  330  is preferred during curing so as to reduce the incidence of collisions between electrons emitted from the electron beam emitter device  210  and air molecules and so as to maximize the amount of electron beams which strike the ink on the display object(s) of the substrate  330 . In such embodiments, the stage  360  may be operable to move down during load and unload operations to provide sufficient clearance between the stage  360  and foil  210 E for loading and unloading. This allows the emitter device  210  to remain stationary. More specifically, in some embodiments, the stage  360  may be operable to move downward a certain amount away from the foil  210 E to provide clearance above the substrate  330 . The stage  360  then may continue to move downward to allow stationary lift pins (not shown) to protrude through openings in the stage  360  and to contact and support the substrate  330  as the stage  360  continues to lower to provide sufficient clearance below the substrate  330 , e.g., for an atmospheric robot to remove the substrate  330  from the lift pins and to then insert a new substrate  330  on the lift pins. The stage  360  may then be raised to contact the new substrate and position the substrate below the emitter device  210 .  
         [0069]     In operation, a high voltage of, for example, about 80-100 kVolts is applied to the HVP element  210 B and current of, for example, about 10-20 mAmps is passed through the filament  210 C. The high voltage applied to the HVP element  210 B strips electrons from the filament  210 C. The electrons accelerate toward the foil  210 E and pass through the slots, slits, holes, and/or apertures formed therein. The electrons pass toward and through the foil  210 E and hit or strike ink on the display object(s) of the substrate  330  and thereby cure the ink.  
         [0070]      FIG. 6  is perspective view of the electron beam emitter device of  FIG. 5 . With reference to  FIG. 6 , the electron beam emitter device  210  also includes a face plate  210 F. The faceplate  210 F has a series of channels  210 G therein and therethrough for providing cooling water through the face plate  210 F. The cooling water is provided from a reservoir (not shown) and supply system (not shown). The cooling water serves to cool the face plate  210 F during operation of the electron beam emitter device  210 .  
         [0071]      FIG. 6  also illustrates the foil  210 E and an electron beam window  210 H. An electron beam is directed through the electron beam window  210 H and toward the substrate  330 .  
         [0072]     The apparatus and methods of the present invention allow ink on a substrate or on substrates to be cured by using an electron beam. In an exemplary embodiment, the electron beam is provided by the electron beam emitter device  210  which is supported a distance above the substrate and is moveable relative to the substrate. The electron beam emitter device  210  can be moved across the substrate such as by being scanned across the substrate while the electron beam is emitted therefrom. The electron beam emitter device  210  can moved across the substrate in a continuous scanning motion, or by being moved or scanned across the substrate in a step-wise manner, such as by being moved in discrete steps. The electron beam can be emitted during the entire scanning process.  
         [0073]      FIG. 7  is a flowchart illustrating an exemplary embodiment of the operation of the apparatus and methods of the present invention.  
         [0074]     With reference to  FIG. 7 , the operation of the apparatus  100  commences at step  700 . At step  701 , the substrate  330  having ink previously deposited thereon is delivered to the processing chamber  220  and placed on the stage  360 . At step  702 , the purge system  450  is activated and the processing chamber is purged of undesirable gases such as Oxygen. In some embodiments, the purge system  450  may continue to purge undesirable gases during the entire ink curing process described herein. In alternative and/or additional embodiments, the purge system  450  may purge gases in response to the electron beam emitter device  210  being active.  
         [0075]     At step  703 , the electron beam emitter device  210  is activated. Once activated, the electron beam emitter device  210  emits an electron beam which is used to cure the ink previously deposited on the substrate  330 .  
         [0076]     At step  704 , the substrate  330  is scanned with the electron beam emitter device  210  and the ink previously deposited on the substrate  330  is cured. Once the scanning process is completed at step  704 , the electron beam emitter device  210  is turned off at step  705 .  
         [0077]     At step  706 , the substrate  330  can be removed from the processing chamber  220 . The operation of the apparatus  100  will thereafter cease at step  707 .  
         [0078]     In another exemplary embodiment, the electron beam scanning operation illustrated in  FIG. 7  can be performed with a plurality of electron beam emitter devices  210 .  
         [0079]     In yet another exemplary embodiment, the apparatus and methods of the present invention can be utilized in connection with one or more of the Oxygen (O 2 ) detection system  500 , the Ozone (O 3 ) detection system  550 , the X-ray leakage detection system  600 , and/or the chamber door interlock system  650  as described below.  
         [0080]      FIGS. 8A, 8B , and  8 C illustrate a flowchart of another exemplary ink curing operation of the apparatus  100  of the present invention. With reference to  FIGS. 8A, 8B , and  8 C, the operation of the apparatus commences at step  800 . At step  801 , the substrate  330  is delivered to the processing chamber  220  and at step  802  the substrate is placed on the stage  360 .  
         [0081]     At step  803 , the chamber door  27  is closed and/or sealed so as to prevent the leakage of gases and X-rays from the processing chamber  220 .  
         [0082]     At step  804 , the system controller  150  can be activated. At step  805 , the system controller  150  can obtain and process data regarding the substrate to be processed. For example, the system controller  150  can obtain substrate data from the substrate database  400 . As described above the substrate data can include data and/or information regarding one or more of the type of substrate, a display device on the substrate, the type of ink to be cured, the ink curing rate, power level, curing time, ink curing scanning pattern, and/or any other data and/or information which may be pertinent to the operation of the apparatus  100 .  
         [0083]     At step  805 , the system controller can also activate the purge system  450  and purge the ink curing chamber  220  of gases such as Oxygen (O 2 ). In an exemplary embodiment, Nitrogen gas (N 2 ) can be used to purge the ink curing chamber  220 . The purge system  450  may continue to operate during the operation of the apparatus  100  if desired. In at least one embodiment, as described herein, the purge system  450  can be controlled to provide purging at an enhanced purging level or rate if Oxygen (O 2 ) or Ozone (O 3 ) is detected during the ink curing process.  
         [0084]     At step  806 , the system controller  150  can process information regarding one or more of the Oxygen (O 2 ) detection system  500 , the Ozone (O 3 ) detection system  550 , the X-ray leakage detection system  600 , and/or the chamber door interlock system  650 , in order to respectively ensure that no unsafe levels of Oxygen (O 2 ) or Ozone (O 3 ) are present in the chamber  220 , that no X-ray leakage is detected, and/or that the chamber door  27  is properly closed and/or sealed.  
         [0085]     At step  807 , the system controller  150  can perform a test on one or more of the Oxygen (O 2 ) detection system  500 , the Ozone (O 3 ) detection system  550 , the X-ray leakage detection system  600 , and/or the chamber door interlock system  650 , in order to respectively ensure that no unsafe levels of Oxygen (O 2 ) or Ozone (O 3 ) are present in the chamber  220 , that no X-ray leakage is detected, and/or that the that the chamber door  27  is properly closed and/or sealed. If, at step  807 , it is determined that one or more unsafe levels of Oxygen (O 2 ) or Ozone (O 3 ) are present in the processing chamber, that X-ray leakage is detected, and/or that the chamber door  27  is not properly sealed or locked, the processing of the system controller  150  may proceed to step  808 , and the system controller  150  can (1) elevate the purging level of the purge system  450  to reduce the level of Oxygen (O 2 ) or Ozone (O 3 ); (2) sound an alarm to provide an alert; and/or (3) disable activation of the electron beam emitter device  210 .  
         [0086]     Upon completion of step  808 , the system controller  150  may proceed to step  806  and repeat the above processing and testing until it is determined that the ink curing process can safely proceed.  
         [0087]     If, at step  807 , it is determined that the Oxygen (O 2 ) or Ozone (O 3 ) levels are within safe limits, that no X-ray leakage is present, and that the chamber door  27  is properly closed and locked, then operation will proceed to step  809 .  
         [0088]     At step  809 , the system controller  150  activates the electron beam emitter positioning system  250  and moves the electron beam emitter device  210  to the start or “home” position relative to the substrate. The start or “home” position can be determined from data and/or information obtained from the substrate database  400 . At step  810 , the system controller  150  activates the electron beam emitter device  210 . For example, the power level at which the electron beam emitter device  210  is operated can also be controlled by the system controller  150  and can be determined based upon data and/or information obtained for the particular substrate from the substrate database  400 .  
         [0089]     At step  811 , the system controller  150  activates the electron beam emitter positioning system  250  and commence scanning the electron beam emitter device  210  and, hence, the electron beam emitted therefrom, over and across the substrate surface. The electron beam cures the ink on the substrate as it is scanned over the ink.  
         [0090]     In an exemplary embodiment, the scanning pattern used to move the electron beam emitter  210  can be obtained from the substrate database  400  and the system controller  150  can control the electron beam emitter positioning system  250  so that the electron beam emitter device  210  is scanned over the substrate so as to effectuate a complete ink curing operation. The system controller  150  can also control the scanning speed of the electron beam emitter device  210 .  
         [0091]     During step  811 , the system controller  150  can automatically effectuate the scanning of the electron beam emitter device  210  over the substrate until the scanning pattern and for example, all requisite X-axis direction and/or Y-axis direction movements of the electron beam emitter device  210  are performed for the substrate. Any suitable scanning patterns can be employed. For example, any suitable longitudinal, raster, and/or any other scanning convention can be utilized until the scanning operation is completed.  
         [0092]     In an exemplary embodiment, the scanning operation performed during step  811  can be accomplished by performing a continuous scanning motion, with the ink being cured as the electron beam from the electron beam emitter device  210  is passed over the substrate. Alternatively, the scanning operation performed during step  811  can be accomplished by performing a discrete step scanning motion, whereby the electron beam emitter device  210  is moved in discrete steps through the scanning pattern.  
         [0093]     In an exemplary embodiment wherein an array of electron beam emitter devices  210  is utilized, such as described in connection with  FIG. 4 , the scanning pattern can be adjusted to account for the additional electron beam emitter devices  210  which are utilized.  
         [0094]     During the electron beam scanning and ink curing operation which takes place during step  811 , the system controller  150  can simultaneously monitor, receive data and/or information from, and/or process data and/or information from or regarding, one or more of the Oxygen (O 2 ) detection system  500 , the Ozone (O 3 ) detection system  550 , the X-ray leakage detection system  600 , and/or the chamber door interlock system  650 . If, at any time, any undesired condition arises, the system controller  150  can control a suitable response.  
         [0095]     For example, if Oxygen (O 2 ) or Ozone (O 3 ) is detected in the processing chamber  220 , the system controller  150  can employ, during step  811 , the purge system  450  to reduce the level of Oxygen (O 2 ) or Ozone (O 3 ). If X-ray leakage is detected, the system controller  150  can shut down the electron beam emitter device  210  and sound an appropriate safety alarm. If the chamber door  27  is determined to have become unlocked or opened, the system controller  150  can shut down the electron beam emitter device  210  and sound an appropriate safety alarm. Other responses may be performed or initiated.  
         [0096]     Once the scanning and ink curing operation is completed at step  811 , the system controller  150  can, at step  812 , shut down the electron beam emitter device  210 , and/or return the electron beam emitter device  210  to the start or “home” position. At step  813 , the system controller  150  can employ the purge system  450  to reduce any level(s) of Oxygen (O 2 ) and/or Ozone (O 3 ). At step  814 , the chamber door  27  can be opened and the substrate  330  can be removed from the processing chamber  220 . Thereafter, the operation of the apparatus  100  will cease at step  815 .  
         [0097]     The foregoing description discloses only exemplary embodiments of the invention. Modifications of the above disclosed apparatus and methods which fall within the scope of the invention will be readily apparent to those of ordinary skill in the art. For instance, another suitable electron beam source may include, but is not limited to, an electron gun as disclosed in commonly assigned U.S. patent application Ser. No. 10/055,869, which was filed on Jan. 22, 2002 under the title “Electron Beam Lithography System Having Improved Electron Gun,” which is incorporated by reference herein in its entirety. Examples of chemical substituents which may serve as effective electron beam crosslinking substituents suitable for inclusion in the monomers and/or oligomers contained in the color ink may include, but are not limited to, (a) carbon-carbon double bonds (for example, an alkene functionality built into or attached onto a pendent group, such as an adamantyl cage) or attached either to the pendant group or a polymer; (b) “strained” ring systems such as, for example, and without limitation, three (3) or four (4) member cycloalkanes prone to ring opening and cross-linking upon exposure to electron beam irradiation; (c) halogenated compounds such as for example, a halomethyl substituent prone to cross-linking under electron beam irradiation through processes correlated with the extrusion of a hydrogen halide (such as, for example, HCl); and/or (d) one or more organo-silicon moieties, which are more particularly described in commonly assigned U.S. patent application Ser. No. 10/447,729, which was filed on May 28, 2003 under the title “E-Beam Curable Resist And Process For E-Beam Curing The Resist,” which is incorporated by reference herein in its entirety.  
         [0098]     As used herein, the term electron beam, or e-beam, treatment refers to exposure of a film to a beam of electrons, for example, and without limitation, a relatively uniform beam of electrons. As used herein, the term electron beam source, or electron beam emitter, or e-beam emitter refers to a device capable of producing an electron beam. It is preferred that the e-beam treatment step be conducted using a wide, large beam of electron radiation from a uniform, large-area electron beam source. In one embodiment, such an electron beam source may simultaneously cover an entire substrate area or display object. In a production environment where the substrate size is larger than the broad e-beam source, the color filters may be scanned by the electron beam emitter in a manner to achieve a uniform exposure by the electron beam. The e-beam treatment may be conducted, for example, at atmospheric pressure. Another suitable electron beam chamber includes the ElectronCure™ chamber that is available from Applied Materials, Inc. of Santa Clara, Calif. The principles of operation and performance characteristics of such an apparatus are described in commonly assigned U.S. Pat. No. 5,003,178, which is incorporated by reference herein in its entirety. The electron beam energy may be in a range from about 1 to about 200 KeV, depending on processing pressure and conditions, although other energy ranges may be employed. The total dose of electrons for the polymerization of the color filters may be adjusted according to the type and thickness of color filters, chamber or enclosure conditions, speed of substrate movement, and/or e-beam energy.  
         [0099]     The gas ambient in the electron beam chamber can include, but is not limited to, nitrogen, oxygen, hydrogen, argon, xenon, helium, carbon dioxide, or any combination of two or more of these gases. The e-beam treatment is preferably conducted at atmospheric pressure. In one embodiment, when a vacuum chamber is employed, the vacuum conditions may be maintained at a pressure range from just below atmospheric pressure to about 10 −7  Torr. Other pressures may be employed. In at least one embodiment, the temperature of the substrate may vary in a range from about 20° C. to about 200° C. In a particular embodiment, the temperature may be controlled in the range from 20° C. to 80° C. Other temperature ranges may be used (e.g., room temperature). In addition, for thick films, the electron beam dose may be divided into steps of decreasing voltage which provides a uniform dose process in which the material is cured from the bottom up. Thus, the depth of electron beam penetration may be varied during the treatment process. As those of ordinary skill in the art can readily appreciate, the length of e-beam treatment may depend on one or more of the above-identified parameters.  
         [0100]     Accordingly, while the present invention has been disclosed in connection with exemplary embodiments thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention, as defined by the following claims.