Four-Layer Nozzle Coating for Wear-Resistant Inkjet Heads
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Solution Overview
Problem
Existing inkjet heads used in display device manufacturing suffer from wear resistance issues, leading to potential deterioration in ink discharge characteristics.
Innovation Solution
The inkjet head is manufactured with a multi-layer coating system, including a preliminary nozzle plate made of organic material, a piezoelectric plate, and multiple coating films with different materials to enhance wear resistance and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single coating film is applied to the nozzle plate, then the manufacturing process is simple, but the wear resistance and protection of the nozzle plate is insufficient
Solution Approach 1:
The patent applies a multi-layer coating structure where each layer has different material properties optimized for specific functions. The first coating film (organic-inorganic composite) provides adhesion and basic protection, the second coating film (metal oxide) provides hardness and wear resistance, the third coating film (inorganic material) provides chemical stability, and the fourth coating film (fluorine-containing polymer) provides hydrophobicity and chemical inertness. This composite material approach resolves the contradiction by combining multiple materials to achieve superior overall performance that no single material could provide alone.
Solution Approach 2:
The coating system is segmented into four distinct functional layers, each addressing specific protection needs. This segmentation allows each layer to be optimized independently for its specific function while working together as an integrated protection system, resolving the contradiction between simple structure and effective protection.
2Manufacturing precision
If multiple coating films are applied to improve wear resistance, then the wear resistance and ink discharge precision are improved, but the manufacturing process becomes more complex
Solution Approach 1:
Each coating film is applied with specific local quality characteristics - the first film covers the entire inner surface for comprehensive protection, the second film is applied to provide localized hardness where wear occurs, the third film provides chemical stability in specific regions, and the fourth film provides hydrophobic properties where needed. This localized quality approach ensures each layer contributes its specific function to maintaining ink discharge precision while managing manufacturing complexity through targeted application.
3Ease of manufacture
If the nozzle plate is made of organic material, then the manufacturing process is easier, but the wear resistance and durability are reduced
Solution Approach 1:
The organic material nozzle plate is prepared in advance with a preliminary coating film that provides immediate protection during subsequent processing steps. This preliminary action protects the organic material from damage during manufacturing while maintaining the ease of manufacture advantage, and the complete multi-layer coating system is then applied to extend the lifespan, resolving the contradiction between easy manufacturing and durability.
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 multi-layer coating system improves the wear resistance of the inkjet head, reducing the occurrence of scratches and tears, and thereby maintaining the ink discharge precision and extending the lifespan of the inkjet head.
Implementation Method 1
forming a nozzle plate including a plurality of nozzles formed by processing the preliminary nozzle plate using a laser
Data Source
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AI summary
A method of manufacturing an inkjet head, the method includes forming a preliminary nozzle plate including an organic material, forming a nozzle plate including a plurality of nozzles formed by processing the preliminary nozzle plate using a laser, forming a piezoelectric plate on the nozzle plate, forming a first coating film on a lower surface of the nozzle plate, forming a second coating film covering the first coating film and including a material different from the first coating film, forming a third coating film under the second coating film and including a material different from the first and second coating films, and forming a fourth coating film under the third coating film and including a material different from the first, second, and third coating films.