Flex Circuit Board Topographical Structures for Printhead Fluid Integrity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Ink leakage through passageways in flex circuit boards of laminated printheads due to height differences between electrical conductor patterns and foundational materials, which compromises the integrity of ink flow and can lead to adverse interactions with electrical currents.

Innovation Solution

A flex circuit board design featuring electrically insulating and conductive materials with isolated islands and aligned passageways to maintain the height of electrical conductor layers adjacent to passageways, preventing ink leakage and electrical contact, thus preserving fluid integrity and preventing ink from seeping into other areas of the printhead.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a flex circuit board with electrical conductor patterns is used in a laminated printhead, then electrical signals can be delivered to actuators, but height differences between the electrical conductor pattern and the foundational material cause ink to seep out of passageways

Engineering Contradiction:

Improveelectrical signal deliveryVSAvoidink passageway integrity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

An electrically insulating material is introduced as an intermediary layer between the foundational material and the electrical conductor pattern. This insulating layer fills the spaces around the conductor pattern, creating a flush surface that prevents ink from seeping out while allowing electrical signals to pass through to the actuators. The insulating material acts as a mediator that resolves the conflict between electrical functionality and fluid integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The surface of the flex circuit board is modified locally around the passageway areas by adding the electrically insulating material. This creates a localized height adjustment that specifically addresses the problem areas where ink leakage occurs, while maintaining the overall electrical conductor pattern integrity. The local quality change ensures that only the critical regions are modified to prevent ink seepage.

Inventive Principle:

Principle #3Local quality

2Reliability

If the electrical conductor pattern is made taller to prevent ink leakage, then passageway integrity improves, but the complexity of the flex circuit board manufacturing increases

Engineering Contradiction:

Improvepassageway integrityVSAvoidflex circuit board structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of changing the height parameter of the electrical conductor pattern itself, the invention changes the parameter of the surrounding material by adding an electrically insulating layer. This parameter change approach maintains the simplicity of the conductor pattern manufacturing while achieving the desired height uniformity through a separate, easily applied insulating material layer.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flex circuit board becomes a composite structure combining the foundational material, electrical conductor pattern, and electrically insulating material. This composite approach allows each layer to perform its specific function independently - the conductor layer for electrical signals and the insulating layer for fluid sealing - without requiring complex modifications to any single layer.

Inventive Principle:

Principle #40Composite materials

3Productivity

If ink is allowed to flow freely through passageways, then ink ejection functionality is maintained, but ink may escape and interact with electrical currents causing adverse effects

Engineering Contradiction:

Improveink ejection functionalityVSAvoidink-electrical current interaction

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The space around the passageways is segmented off from the electrical conductor areas by the electrically insulating material. This segmentation creates distinct zones: a fluid flow zone for ink passage and an electrical zone for signal transmission. The insulating material acts as a barrier that prevents ink from migrating into electrical areas while maintaining open passageways for proper ink ejection functionality.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20160039205A1Flex circuit board with topographical structures to facilitate fluid flow through the layer

Publication Date: 2016.02.11 GENESEE VALLEY INNOVATIONS LLC

AI summary

A flex circuit board provides islands of electrically isolated material surrounding openings in the flex circuit board to preserve fluid integrity of passageways passing through an electrically insulating layer of the flex circuit board. The electrically isolated islands surround exits of the passageways through the electrically insulating material and extend the passageways through an electrically conductive layer of the flex circuit board. Consequently, fluid passing through the passageways and electrically isolated islands in the flex circuit board is not subjected to electrical current.