Gradient Metal Member for Liquid Discharge Heads
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Solution Overview
Problem
Existing metal members used in liquid discharge heads, such as those made from electroformed alloys containing palladium and nickel, face challenges in achieving optimal corrosion resistance and adhesion of surface treatment films due to uniform distribution of platinum-group metals, leading to compromised performance in liquid resistance and film adhesion.
Innovation Solution
A novel metal member with a gradient composition where the amount of platinum-group metals, specifically palladium, is higher on the outermost surface than in the interior, enhancing corrosion resistance and adhesion by varying the palladium and nickel concentrations across the surface and depth, achieved through a manufacturing process involving etching and diffusion of palladium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform distribution of platinum-group metals is used in the metal member, then the manufacturing process is simpler, but the adhesion of surface treatment films and corrosion resistance are compromised
Solution Approach 1:
The patent applies local quality by creating a metal member with non-uniform distribution of platinum-group metals. The outermost surface layer contains a higher concentration of platinum-group metals compared to the interior, providing enhanced adhesion for surface treatment films and improved corrosion resistance where these properties are most needed, while the interior maintains a different composition optimized for other properties.
2Reliability
If the concentration of platinum-group metals is increased throughout the entire metal member, then corrosion resistance improves, but the cost and complexity of the alloy composition increases
Solution Approach 1:
The patent concentrates platinum-group metals specifically in the outermost surface layer rather than distributing them uniformly throughout the entire metal member. This localized concentration provides the necessary corrosion resistance at the surface where it is most critical, while reducing the overall quantity of expensive platinum-group metals required in the alloy.
3Reliability
If a gradient composition of palladium and nickel is implemented, then both corrosion resistance and film adhesion are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent employs preliminary action by first forming a pure palladium layer on the metal member surface, then using this layer as a source for controlled diffusion of palladium atoms into the underlying alloy. This preliminary formation of the pure palladium layer simplifies the overall process of creating the desired gradient composition, as it provides a ready-made reservoir of palladium that can diffuse under controlled conditions to establish the optimal concentration gradient.
Solution Approach 2:
The patent replaces complex mechanical or manual methods of creating gradient compositions with a chemical diffusion process. By utilizing thermal or concentration-driven diffusion of palladium atoms from the pure palladium layer into the alloy, the desired gradient structure is formed through atomic-level mass transport rather than mechanical mixing or layering, simplifying the manufacturing approach.
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 gradient composition improves both corrosion resistance and adhesion of surface treatment films, ensuring reliable performance in liquid discharge applications by optimizing the distribution of platinum-group metals.
Implementation Method 1
forming a film of pure palladium layer on a surface of an alloy member containing nickel and palladium using etching gas having an etching rate of palladium higher than an etching rate of nickel
Implementation Method 2
diffusing palladium from the pure palladium layer into the alloy member
Data Source
AI summary
A metal member includes an alloy containing platinum-group metal. An amount of the platinum-group metal in an outermost surface of the metal member is higher than the amount of the platinum-group metal in an interior of the metal member.