Ink-jet Head Substrate Segmentation for Cost Reduction
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Solution Overview
Problem
The existing ink-jet head designs are costly due to the large size of the channel forming substrate, which includes both pressure chambers and manifolds, and the nozzle plate, leading to increased production costs and limited miniaturization of the nozzle plate.
Innovation Solution
The design separates the pressure chambers and manifolds onto different substrates, allowing for miniaturization of the upper substrate and reducing the size of the nozzle plate by decreasing the distance between nozzle arrays, thereby decreasing the overall size and production cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the channel forming substrate includes both pressure chambers and manifolds, then the ink supply function is complete, but the substrate size increases leading to higher production cost
Solution Approach 1:
The patent divides the channel forming substrate into two separate substrates: one dedicated to pressure chambers and another to manifolds. This segmentation allows each substrate to be minimized in size for its specific function, reducing the total area required and enabling more substrates to be produced from a single wafer, thereby lowering production costs.
Solution Approach 2:
The patent transitions from a two-dimensional integration of pressure chambers and manifolds on a single substrate to a three-dimensional stacked configuration using multiple substrates. This dimensional change enables independent optimization of each substrate's size and shape, reducing overall material usage and production cost.
2Productivity
If the channel forming substrate size is increased to include manifolds, then the ink supply capability is improved, but the number of substrates producible from one wafer decreases
Solution Approach 1:
By segmenting the substrate into separate pressure chamber and manifold components, each can be produced as a smaller, standardized unit. This increases the number of such units that can be manufactured from a single wafer, improving productivity while maintaining complete ink supply functionality through their combination.
Solution Approach 2:
The separated manifold substrate can be designed as a universal component that interfaces with multiple pressure chamber substrates. This modular approach allows for mass production of standardized substrates from wafers, increasing productivity while ensuring complete ink supply through the universal interface design.
3Area of stationary object
If the distance between nozzle arrays is reduced for miniaturization, then the nozzle plate size decreases, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the nozzle plate into multiple smaller nozzle arrays on separate substrates that can be positioned closely together. This segmentation allows for miniaturization of the overall nozzle plate while maintaining manageable manufacturing complexity through standardized, modular components that can be produced using conventional techniques.
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 reduces the size and production cost of the ink-jet head components, enabling more substrates to be produced from a single wafer and improving the efficiency of ink discharge by minimizing the distance between nozzle arrays.
Implementation Method 1
a plurality of piezoelectric elements arranged on an upper surface of the pressure chamber forming substrate while corresponding to the plurality of pressure chambers respectively
Data Source
AI summary
A liquid discharge apparatus is provided, including a liquid discharge head including: an upper substrate, a plurality of piezoelectric elements, an intermediate substrate, a lower substrate and a plurality of individual traces arranged on the upper substrate and extending toward the contacts arranged on the one end side in the second direction from the plurality of piezoelectric elements respectively.