Ink-Jet Head Lamination Pressure Control
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Solution Overview
Problem
The existing manufacturing methods for ink-jet heads face challenges in preventing adhesive from bulging into communication holes and flowing into nozzle holes, which can block ink ejection and require tight control over adhesive conditions, increasing manufacturing costs.
Innovation Solution
A method involving lamination of a first plate with nozzle holes and a second plate with communication holes, where the nozzle hole opening is within the communication hole opening, and applying pressure only outside the communication hole opening, reducing stress on the nozzle plate overhang and preventing adhesive bulging and flow into the nozzle holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniform pressure is applied during lamination, then bonding strength is improved, but adhesive bulges into communication holes and flows into nozzle holes
Solution Approach 1:
The pressure application is localized to specific regions rather than uniformly distributed. The patent applies pressure only to regions outside the communication holes, creating different pressure conditions in different areas: high pressure for bonding strength in most regions, and zero pressure over the communication holes to prevent adhesive bulging. This local differentiation resolves the contradiction between achieving strong bonding and preventing adhesive contamination.
Solution Approach 2:
The pressure application area is segmented into multiple zones: regions where pressure is applied for bonding, and regions (over communication holes) where pressure is excluded. This segmentation allows simultaneous achievement of strong bonding in pressured areas and clean adhesive containment in unpressured areas, resolving the contradiction between bonding strength and adhesive control.
2Manufacturing precision
If tight control over adhesive conditions is implemented, then adhesive bulging is prevented, but manufacturing cost increases
Solution Approach 1:
The pressure distribution pattern is predetermined and prepared in advance through the design of the pressure application mechanism. By pre-configuring which areas receive pressure and which don't, the system eliminates the need for complex real-time control of adhesive properties, temperature, and pressure. This preliminary arrangement of pressure zones simplifies the manufacturing process and reduces costs while maintaining precise adhesive control.
3Productivity
If communication hole diameter is made larger than nozzle hole diameter, then ink ejection is facilitated, but stress concentrates on nozzle plate overhang and causes adhesive bulging
Solution Approach 1:
The patent applies preliminary anti-action by excluding pressure from the regions over the communication holes during lamination. This counteracts the stress concentration that would otherwise occur on the nozzle plate overhang areas, preventing adhesive bulging while maintaining the larger communication hole diameter needed for efficient ink ejection. The pressure exclusion zone acts as a preventive measure against stress-related defects.
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 approach effectively prevents adhesive from blocking nozzle holes and causing ink ejection issues without the need for precise control over adhesive conditions, reducing manufacturing costs and improving yield.
Implementation Method 1
laminating with an adhesive a first plate having a nozzle hole that ejects an ink droplet and a second plate having a communication hole
Data Source
AI summary
A manufacturing method of an ink-jet head comprises the steps of: laminating with an adhesive a first plate having a nozzle hole that ejects an ink droplet and a second plate having a communication hole; and applying pressure to the first and second plates in their laminated direction. In the step of laminating, an opening of the nozzle hole is included within an opening of the communication hole on an interface between the first plate and the second plate. In the step of applying pressure, pressure is applied to only a region outside of the opening of the communication hole with respect to a plane parallel to planes of the first and second plate.