Actuator Wire Connection Structure Preventing Shorts
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Solution Overview
Problem
The existing connection structures between flexible wire members and piezoelectric actuators in liquid ejectors often result in shorts due to wide portions of wires formed at the edge of the substrate during cutting, which reduces the distance between wires and increases the likelihood of electrical shorts.
Innovation Solution
The actuator device incorporates a design where the wide portions of the wires are positioned to minimize the distance between adjacent wires, with a conductive adhesive applied to ensure electrical connectivity while maintaining a sufficient distance to prevent shorts, and dummy wires are used to further prevent conduction between adjacent wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the substrate is cut to separate each wire after wires are formed on the substrate, then the wires are separated individually, but the wires are crushed at the cutting area forming wide portions that increase the likelihood of shorts
Solution Approach 1:
The patent applies preliminary action by forming a protective coating on the wires before the cutting process. This coating prevents the wires from being crushed during substrate cutting, thereby avoiding the formation of wide portions that could cause shorts. The protective measure is implemented in advance to prevent the harmful effect rather than correcting it afterward.
Solution Approach 2:
The patent introduces an intermediary substance (protective coating) between the wire and the cutting process. This coating acts as a mediator that allows the cutting operation to proceed while protecting the wire from damage, thus preventing wire deformation and subsequent short circuits without interfering with the manufacturing efficiency.
2Ease of operation
If the wide portions of wires are formed at the edge portion of the substrate, then the wires are easily separated, but the distance between adjacent wires is reduced increasing the possibility of shorts
Solution Approach 1:
The patent applies preliminary action by forming a protective coating on the wires before the cutting process. This coating prevents the wires from being crushed during substrate cutting, thereby avoiding the formation of wide portions that could cause shorts. The protective measure is implemented in advance to prevent the harmful effect rather than correcting it afterward.
Solution Approach 2:
The patent introduces an intermediary substance (protective coating) between the wire and the cutting process. This coating acts as a mediator that allows the cutting operation to proceed while protecting the wire from damage, thus preventing wire deformation and subsequent short circuits without interfering with the manufacturing efficiency.
3Reliability
If conductive adhesive is applied to ensure electrical connectivity, then electrical connection is improved, but the risk of shorts between adjacent wires increases
Solution Approach 1:
The patent applies local quality by precisely controlling the application of conductive adhesive only to specific contact areas where electrical connectivity is required. By limiting the adhesive to localized regions rather than applying it broadly, the patent ensures good electrical connection at intended contact points while preventing adhesive from bridging adjacent wires and causing shorts.
Solution Approach 2:
The patent applies segmentation by dividing the adhesive application into discrete, isolated areas corresponding to specific contact points. This segmented approach ensures that conductive adhesive creates electrical connections only where needed, while maintaining electrical insulation between adjacent wire contacts, thus preventing shorts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration effectively prevents shorts between wires and enhances the reliability of the electrical connections, ensuring stable operation of the liquid ejector by maintaining a controlled distance and using conductive adhesives strategically to manage conductivity.
Implementation Method 1
a first contact and a second contact each drawn from a wire member... the first element contact and the second element contact are disposed nearer to the edge portion than a corresponding one of the first contact and the second contact
Data Source
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AI summary
The object is to prevent occurrences of shorts between wires next to each other in the case where wide portions of the wires are formed at an edge portion of a wire member. An actuator device includes COFs 50 and a piezoelectric actuator 22 including driving contacts 46. Each of the COFs 50 includes: individual contacts 54 connected to the respective driving contacts 46; and individual wires 52 that conduct with the respective individual contacts 54. A wide portion 61 having a larger wire width is formed at a distal end portion of each of the individual wires 52. The distal end portion is located at an edge portion of the COF 50. The wide portion 61 is located beyond the driving contact 46 in the longitudinal direction of the individual wire 52 in a state in which the piezoelectric actuator 22 and the COF 50 are joined to each other. The individual contact 54 is provided on a basal-end-side portion of the individual wire 52 which is located further from an edge E of the COF 50 than the wide portion 61 of the individual wire 52. The individual contact 54 is connected to the driving contact 46.