Inkjet Printhead Nozzle Plate SiC Coating Durability
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Solution Overview
Problem
Inkjet printheads face issues with durability and printing quality due to nozzle plate materials, particularly non-metal polymer materials, which are prone to abrasion and deformation, and require frequent cleaning, affecting the printing process.
Innovation Solution
A method involving a metal nozzle plate with a wetting-resistant silicon carbide (SiC) coating on the ejection surface and an adhesion-promoting SiC coating on the opposing surface, deposited using plasma-enhanced chemical vapor deposition (PECVD), ensuring stable non-wettability and adhesion properties, respectively, to enhance printing quality and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-metal polymer material is used for the nozzle plate, then ease of manufacture is improved, but durability and resistance to abrasion and deformation deteriorate
Solution Approach 1:
The patent applies composite materials by combining a metal nozzle plate (providing durability and abrasion resistance) with a deposited silicon carbide coating layer (providing wetting-resistant properties). This composite structure resolves the contradiction by integrating the mechanical strength of metal with the surface properties needed for print quality, eliminating the need to choose between ease of manufacture and durability.
2Reliability
If a metal nozzle plate is used, then durability and resistance to abrasion are improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the surface parameters of the metal nozzle plate by depositing a silicon carbide coating layer. This parameter change (adding a coating) provides the necessary wetting-resistant properties without fundamentally altering the metal substrate's durable characteristics. The solution maintains durability while managing manufacturing complexity through a standardized deposition process.
3Ease of operation
If the nozzle plate surface has high wettability, then ease of cleaning is improved, but ink spreading increases affecting printing quality
Solution Approach 1:
The patent applies local quality by creating a silicon carbide coating layer with specific wetting-resistant properties on the nozzle plate surface. This localized surface treatment provides non-wetting characteristics that prevent ink spreading and maintain printing quality, while the overall structure remains cleanable. The coating is applied specifically to the ejection surface where ink contact occurs, providing targeted functionality.
4Manufacturing precision
If frequent cleaning is performed to maintain printing quality, then printing quality is preserved, but productivity deteriorates due to process interruptions
Solution Approach 1:
The patent applies preliminary action by depositing a silicon carbide coating layer on the nozzle plate before use. This pre-applied coating provides inherent wetting-resistant properties that prevent ink buildup and spreading, eliminating the need for frequent cleaning interruptions. The preliminary coating action maintains printing quality throughout the printhead's service life, thereby preserving productivity.
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 SiC coatings reduce the need for frequent cleaning, extend the printhead's service life, and maintain printing quality by minimizing ink spreading and promoting reliable adhesion between the nozzle plate and the underlying structure, resulting in improved durability and performance.
Implementation Method 1
a wetting-resistant silicon carbide (SiC) coating on the ejection surface
Implementation Method 2
an adhesion-promoting SiC coating on the opposing surface
Implementation Method 3
deposited using plasma-enhanced chemical vapor deposition (PECVD)
Data Source
AI summary
A method of manufacturing an ink jet printhead, including: arranging a nozzle plate in which there is formed a plurality of nozzles, the nozzle plate having an upper surface and a lower surface, the upper surface being on the side of the ejection of ink drops and the lower surface being opposite to the upper surface; depositing on the upper surface a first coating including a first layer including silicon carbide, while maintaining the nozzle plate at a first deposition temperature not larger than 250° C.; depositing on the lower surface a second coating including a second layer including silicon carbide, while maintaining the nozzle plate at a second deposition temperature not larger than 250° C.; positioning the nozzle plate onto the ink barrier layer by bringing into contact the second coating layer with the ink barrier layer. The first layer is deposited before the second layer.