Droplet Ejection Head Orifice Plate Flexure Control
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Solution Overview
Problem
Conventional droplet ejection heads face issues with orifice plate flexure due to non-uniform pressure bonding and surface flatness, leading to misalignment and increased power consumption, which is exacerbated by thinning the orifice plate or reducing the gap between the energy-generating element and the orifice plate.
Innovation Solution
A method involving a substrate with an energy-generating element and an orifice plate laminated through a flow channel member, where the orifice plate has voids or recesses to accommodate deformation, allowing the flow channel member to be heated and compressed, thereby conforming to the surface shape and reducing flexure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the orifice plate is thinned to reduce power consumption, then energy efficiency improves, but the orifice plate becomes more prone to flexure and deformation
Solution Approach 1:
The flow channel member is designed with non-uniform thickness, having a first thickness in the region overlapping the orifice plate and a second thickness (greater than the first) in other regions. This local variation in thickness provides enhanced rigidity and support specifically where needed to prevent orifice plate flexure, while allowing the orifice plate itself to remain thin for reduced power consumption.
2Strength
If pressure bonding is applied to bond the orifice plate with the flow channel member, then bonding strength improves, but non-uniform pressure causes orifice plate flexure and misalignment
Solution Approach 1:
The flow channel member has a non-uniform thickness distribution with a first thickness in the orifice plate overlapping region and a greater second thickness in other regions. This local structural variation ensures uniform pressure distribution during bonding, preventing orifice plate flexure and misalignment while achieving adequate bonding strength.
3Productivity
If the gap between the energy-generating element and the orifice plate is reduced to improve ejection efficiency, then droplet ejection performance improves, but the orifice plate becomes more susceptible to flexure
Solution Approach 1:
The flow channel member is designed with a first thickness in the region overlapping the orifice plate and a greater second thickness in other regions. This local reinforcement provides stable support that maintains a consistent gap between the energy-generating element and orifice plate, enabling efficient droplet ejection without flexure-induced variability.
4Strength
If conventional pressure bonding is used to bond the orifice plate, then bonding is achieved, but the bonding process is complex and requires additional equipment
Solution Approach 1:
The flow channel member is formed by patterning an organic thin film using photolithography, creating a non-uniform thickness structure. This parameter change in the flow channel member's geometry enables self-aligning bonding behavior that eliminates the need for complex pressure bonding equipment and processes.
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 approach effectively prevents orifice plate flexure and stabilizes the gap between the energy-generating element and the orifice plate, improving droplet ejection accuracy and reducing power consumption without adding complexity or cost to the manufacturing process.
Implementation Method 1
heating the flow channel member to the glass transition temperature of the flow channel member or higher
Implementation Method 2
collectively pressurizing the orifice plate, the flow channel member and the substrate toward the face of the substrate, in a state of the flow channel member kept at the glass transition temperature or higher, thereby compressing the flow channel member
Data Source
AI summary
In a method for manufacturing a droplet ejection head, a structure of a substrate having an energy-generating element that imparts energy to a liquid to eject a liquid droplet from an ejection orifice and an orifice plate having the ejection orifice formed therein are laminated through a flow channel member for forming a pattern of a liquid flow channel that is a region in which the liquid flows. At least one of a plate before being laminated and the flow channel member before being laminated has a void of at least one of a through-hole other than the ejection orifice and a recess in the face to be laminated.