Fluidic Die Segmented Recirculation for Nozzle Clogging
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Solution Overview
Problem
Pigment settling in printable fluids leads to clogging of nozzles in fluid ejection dies, resulting in suboptimal printing performance and increased waste heat from micro-recirculation pumps, which limits the effectiveness of micro-recirculation in preventing nozzle capping and maintaining low operating temperatures.
Innovation Solution
A fluidic die design with a carrier substrate, interposer layer, and microfluidic pumps that includes a system for recirculating fluid through a fluid reservoir, with a fluid channel layer and interposer layer optimized for uniform fluid flow, and overmolded with a moldable material to manage temperature and fluid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If micro-recirculation pumps are used to prevent pigment settling and nozzle clogging, then nozzle health is improved, but waste heat increases and operating temperature rises
Solution Approach 1:
The fluid delivery system is segmented into multiple independent fluid channels, each serving specific nozzle groups. This segmentation allows selective recirculation of fluid through specific channels using dedicated micro-recirculation pumps, enabling localized pigment resuspension without requiring system-wide recirculation that would generate excessive waste heat throughout the entire die structure.
Solution Approach 2:
Different regions of the fluid delivery system are treated differently: fluid channels near the nozzle array receive enhanced recirculation flow to prevent pigment settling, while other channels maintain standard flow patterns. This local quality approach concentrates the heat-generating recirculation activity only where needed for nozzle health, minimizing overall temperature rise.
2Reliability
If micro-recirculation is enhanced to prevent nozzle capping, then printing performance is improved, but thermal defects increase
Solution Approach 1:
A dedicated recirculation fluid channel acts as an intermediary pathway between the fluid reservoir and the nozzle array. This intermediate channel allows fluid to be recirculated through a controlled path with dedicated pumping, separating the recirculation function from the primary ejection channels and enabling better thermal management by isolating the heat-generating recirculation flow in a dedicated pathway.
3Reliability
If fluid is recirculated through the die to prevent pigment settling, then nozzle clogging is reduced, but energy consumption increases
Solution Approach 1:
Instead of recirculating fluid through the entire die structure continuously, the system applies partial recirculation action by using multiple small-diameter micro-recirculation channels that only serve specific nozzle groups. This partial action approach recirculates fluid only where pigment settling is detected or anticipated, reducing total energy consumption compared to system-wide recirculation while still effectively preventing nozzle clogging.
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
The solution reduces the likelihood of nozzle capping, enhances micro-recirculation efficiency, improves nozzle health, and convectively cools the fluid ejection die, maintaining print quality and reducing thermal defects.
Implementation Method 1
The fluid ejection die may include resistive or piezoelectric elements used to cause fluid to be ejected from the fluid ejection die
Implementation Method 2
The fluid ejection die may include resistive or piezoelectric elements used to cause fluid to be ejected from the fluid ejection die
Implementation Method 3
convectively cools the fluid ejection die
Data Source
Figure 1A~1C
Figure 2
Figure 3
AI summary
A fluidic die includes a fluid channel layer including at least one fluid channel defined along a length of the fluid ejection device. The fluidic die also includes an interposer layer coupled to the fluid channel layer. The interposer layer includes a number of inlet ports defined in the interposer layer to fluidically couple the at least one channel layer to a fluid source, and a number of outlet ports defined in the interposer layer to fluidically couple the at least one channel layer to the fluid source.