External Polymer Filter for Inkjet Ejector Clogging
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Solution Overview
Problem
Inkjet print heads face clogging issues due to solid debris in the ink flow, which is exacerbated by the increasing density of inkjet ejectors per unit distance, necessitating effective filtering to ensure unimpeded ink passage through smaller fluid passageways.
Innovation Solution
A manifold assembly with a polymer filter layer positioned external to the inkjet ejectors, comprising an adhesive layer and a polymer layer with aligned filter areas, filters the ink before it enters the inkjet ejectors, preventing debris from entering the pressure chambers and ensuring continuous ink flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of inkjet ejectors per unit distance is increased, then the productivity of the print head is improved, but the fluid passageways become smaller and more susceptible to clogging by solid debris
Solution Approach 1:
The filter is positioned upstream in the ink flow path, before the ink enters the inkjet ejectors. This preliminary filtering action removes solid debris before it can reach and clog the smaller fluid passageways of the high-density ejector array, enabling increased ejector density without proportionally increasing clogging risk
Solution Approach 2:
The filter acts as an intermediary component between the ink supply and the inkjet ejectors. It mediates the ink flow by selectively removing harmful solid particles while allowing the ink to pass through, protecting the vulnerable high-density ejector configuration from clogging
2Reliability
If filters are placed within each inkjet ejector, then the reliability against clogging is improved, but the device complexity and number of filters required increases
Solution Approach 1:
The filter is extracted from the individual inkjet ejector structure and repositioned to a shared upstream location in the ink manifold. This single external filter serves multiple ejectors simultaneously, reducing the total number of filters needed while maintaining protection against clogging for all ejectors
Solution Approach 2:
The single external filter positioned in the ink manifold serves a universal function for multiple inkjet ejectors. It filters ink for the entire array of ejectors rather than being dedicated to a single ejector, achieving multi-functionality and reducing overall device complexity
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 external filter configuration effectively prevents debris from entering the inkjet ejectors, reducing clogging and enabling higher frequency operation of the inkjet stack while reducing the number of filters required, thus enhancing print head design and operational efficiency.
Implementation Method 1
a polymer layer having a plurality of filter areas, the filter areas being aligned with the openings in the ink manifold layer and the openings in the adhesive layer
Implementation Method 2
an adhesive layer having openings, an ink manifold layer having a plurality of openings, the openings in the adhesive layer being aligned with the openings in the ink manifold layer
Data Source
AI summary
A manifold assembly has been constructed that filters ink before the ink enters an inkjet ejector in an inkjet print head. The manifold assembly includes an adhesive layer having openings, an ink manifold layer having a plurality of openings, the openings in the adhesive layer being aligned with the openings in the ink manifold layer, and a polymer layer having a plurality of filter areas, the filter areas being aligned with the openings in the ink manifold layer and the openings in the adhesive layer, the adhesive layer being interposed between the polymer layer and the ink manifold layer.