Electrowetting Nozzle Plate for High DPI Printing
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Solution Overview
Problem
Current printheads face challenges in achieving high image resolution due to limitations in nozzle arrangement and deflection control, which restrict the ability to print high DPI images using low CPI printheads, leading to increased size and cost.
Innovation Solution
The use of a nozzle plate with electro-wetting technology, featuring electrode segments and insulating layers along the nozzle circumference, allows for controlled deflection of fluid droplets by varying the contact angle through applied voltages, enabling higher DPI printing without increasing the printhead size or cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of nozzles per inch (CPI) is increased to improve image resolution (DPI), then manufacturing precision requirements increase and device complexity increases, but current processing technology cannot keep pace with demand for higher resolution
Solution Approach 1:
The patent applies dynamics by making the nozzle deflection controllable and adjustable through electro-wetting technology. Instead of fixing nozzles in rigid positions, the system dynamically changes the ejection direction of each nozzle by applying voltage to electrode segments, allowing the same physical nozzle to serve multiple positions dynamically
Solution Approach 2:
The patent changes the physical state and behavior parameters of the nozzle system by introducing electro-wetting control. By changing the contact angle parameter through applied voltage, the system transforms the ejection trajectory of fluid droplets, enabling high DPI printing without increasing physical nozzle density
2Manufacturing precision
If traditional printhead designs are used to print high DPI images, then the printhead size and cost must be increased
Solution Approach 1:
The system uses dynamic nozzle deflection through electro-wetting to achieve high resolution without increasing physical size. The same compact printhead can produce high DPI output by dynamically redirecting droplets from each nozzle to different locations on the print medium
Solution Approach 2:
The patent adds a dimensional degree of freedom by controlling the angular direction of droplet ejection in addition to the traditional linear nozzle arrangement. This vertical/angular dimension of control allows multiple dots to be generated from each nozzle position, effectively multiplying resolution without expanding footprint
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 enables printing of images at DPI higher than the CPI of the nozzle plate, effectively doubling or tripling the image resolution by alternately deflecting droplets, thus overcoming the limitations of traditional printhead designs.
Implementation Method 1
The use of a nozzle plate with electro-wetting technology, featuring electrode segments and insulating layers along the nozzle circumference, allows for controlled deflection of fluid droplets by altering the contact angle through applied voltages
Data Source
AI summary
A nozzle plate and printhead allowing for control of a deflection direction of ejected droplets using electro-wetting, and methods of operating and manufacturing the same. The nozzle plate has at least one nozzle for ejecting fluid and includes electrode segments disposed along a circumference of the nozzle, an insulating layer disposed on a surface of each electrode segment so as to contact fluid in the nozzle, the insulating layer divided into at least two insulating layer segments corresponding to the electrode segments, and a wire pattern electrically coupled to the electrode segments.