External Ink Manifold for Jet Stack Flow Efficiency

Solution Overview

Problem

Current inkjet printers face increased costs and reduced ink flow efficiency due to the need for multiple gold-plated stainless steel plates to accommodate larger ink manifolds for higher jet counts and firing frequencies, which also lengthens and circuitously routes ink passageways, limiting mass throughput.

Innovation Solution

An external ink manifold system that replaces internal manifolds within the jet stack, using a single contiguous material for the manifold body and adhesive layers to connect it to the jet stack, reducing the number of plates required and providing more direct ink paths for improved flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the number of jets and firing frequency are increased to improve printing speed, then productivity is improved, but the size of the ink manifold must be increased which requires more plates and increases device complexity and cost

Engineering Contradiction:

Improveprinting speedVSAvoidnumber of plates

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The ink manifold is segmented from the jet stack structure. Instead of being integrated within the stack of gold-plated stainless steel plates, the manifold is now a separate component that can be independently sized and configured. This allows the jet stack to use fewer plates (reducing complexity) while the external manifold provides the necessary large cross-section for high-volume ink delivery to support increased jet count and firing frequency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ink manifold is moved from a two-dimensional integration within the plate stack to a three-dimensional external structure. The external manifold can extend in multiple directions and utilize vertical space more efficiently, providing large ink storage and distribution capacity without increasing the footprint or requiring additional plates in the stack.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Quantity of substance

If the ink manifold size is increased to accommodate more jets and higher firing frequency, then ink supply capacity is improved, but the number of plates increases which increases manufacturing cost

Engineering Contradiction:

Improveink supply capacityVSAvoidmanufacturing cost

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The ink manifold is segmented from the jet stack structure. Instead of being integrated within the stack of gold-plated stainless steel plates, the manifold is now a separate component that can be independently sized and configured. This allows the jet stack to use fewer plates (reducing complexity) while the external manifold provides the necessary large cross-section for high-volume ink delivery to support increased jet count and firing frequency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ink manifold is extracted from the internal structure of the jet stack and placed externally. This extraction allows the manifold to be optimized independently for ink storage and delivery capacity without being constrained by the need to maintain a compact stack configuration. The external manifold can be manufactured as a single piece or with fewer joints, reducing manufacturing complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If the passageways are routed to widely distributed ink jets, then all jets can be supplied, but the passageways become long and circuitous which increases drag and limits mass throughput

Engineering Contradiction:

Improvejet coverageVSAvoidink flow drag

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The ink manifold is moved from a two-dimensional integration within the plate stack to a three-dimensional external structure. The external manifold can extend in multiple directions and utilize vertical space more efficiently, providing large ink storage and distribution capacity without increasing the footprint or requiring additional plates in the stack.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The external manifold pre-distributes ink to multiple outlet ports positioned near different groups of jets. This preliminary distribution occurs before ink enters the jet stack, creating multiple shorter flow paths instead of one long circuitous path. Ink is delivered to each jet group from a nearby manifold outlet, reducing the distance and drag for each flow path while ensuring all jets are supplied.

Inventive Principle:

Principle #10Preliminary action

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 decreases the number of plates needed, lowers production costs, and enhances ink flow efficiency by reducing drag, allowing for increased mass flow and firing frequency.

Implementation Method 1

An adhesive layer that includes a plurality of ports arranged to connect the chambers to a jet stack overlies and seals the one or more ink manifold chambers

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7600863B2Inkjet jet stack external manifold

Publication Date: 2009.10.13 XEROX CORP

AI summary

An inkjet external ink manifold is provided that allows for use of a jet stack that does not internally contain ink manifolds. The external ink manifold has a manifold body that includes one or more ink manifold chambers and includes ports arranged to connect the chambers to one or more ink reservoirs. The external ink manifold further includes an adhesive layer overlying and sealing the ink manifold chambers. The adhesive layer includes a plurality of ports arranged to connect the external ink manifold chambers to the jet stack.