Integrally Connected Actuators for Continuous Ink Jet Printheads
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Solution Overview
Problem
Prior art actuators in continuous ink jet printheads face challenges due to manufacturing and assembly variations, requiring high accuracy in physical dimensions and strict control over ink composition and temperature, leading to poor jet break-up uniformity.
Innovation Solution
The droplet generator features an elongate cavity with nozzle orifices and integrally connected actuators to the mounting plate via a thin membrane, manufactured by laser metal sintering or melting, allowing for precise vibration and improved jet formation with reduced assembly complexity and increased tolerance in operating parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If actuators are manufactured separately and assembled, then assembly flexibility is improved, but manufacturing precision and jet break-up uniformity deteriorate
Solution Approach 1:
The patent merges the actuator and mounting plate into a single integrally connected component. The actuator is directly formed as part of the mounting plate structure, eliminating separate assembly steps. This integration ensures precise positioning and consistent physical dimensions, directly resolving the contradiction by prioritizing manufacturing precision over assembly flexibility.
2Manufacturing precision
If high accuracy is required in physical dimensions, then jet break-up uniformity is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The actuator and mounting plate are combined into a single integrally connected component, reducing the number of parts and assembly steps. This integration simplifies manufacturing while ensuring the required high precision for jet break-up uniformity is achieved through the unified structure.
Solution Approach 2:
The patent introduces a membrane with controlled thickness (less than 500 microns) as a key parameter. This thin membrane structure allows the integrally connected actuator to vibrate effectively while maintaining the required precision, enabling high jet break-up uniformity without excessive manufacturing complexity.
3Manufacturing precision
If very little stray is permitted in operating parameters, then jet break-up uniformity is improved, but adaptability to varying conditions deteriorates
Solution Approach 1:
The thin membrane (less than 500 microns) acts as a compliant element that allows the integrally connected actuator to adapt to variations in operating parameters such as ink composition and temperature. The membrane's flexibility compensates for parameter variations while maintaining consistent jet break-up uniformity, resolving the contradiction between precision and adaptability.
4Manufacturing precision
If thin membrane is used to connect actuator to mounting plate, then manufacturing precision and tolerance are improved, but structural strength may deteriorate
Solution Approach 1:
The patent employs a thin membrane (less than 500 microns) as a flexible connection between the actuator and mounting plate. This thin film structure provides the necessary compliance for precision and adaptability while the integral connection design ensures sufficient structural strength to maintain the connection under operating conditions.
Solution Approach 2:
The membrane is integrally connected to both the actuator and mounting plate, creating a unified structure that distributes mechanical loads. This integration strengthens the thin membrane connection while maintaining the precision and flexibility benefits of the thin film design.
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 design enhances jet break-up uniformity and reduces manufacturing complexity, enabling higher accuracy and flexibility in ink jet printheads by allowing for thinner features and more flexible operating conditions.
Implementation Method 1
Each of the plurality of actuators is integrally connected to the mounting plate by a membrane, the membrane providing a seal to maintain ink in the cavity
Implementation Method 2
A plurality of actuators is disposed in the cavity to vibrate the ink in the cavity such that each jet breaks up into ink droplets
Implementation Method 3
The mounting plate and integrated actuators are preferably manufactured by laser metal sintering or laser metal melting
Implementation Method 4
The mounting plate and integrated actuators are preferably manufactured by laser metal sintering or laser metal melting
Data Source
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AI summary
A droplet generator for a continuous stream ink jet printhead includes an elongate cavity for containing ink and nozzle orifices in fluid communication with the cavity for passing the ink from the cavity to form jets. The nozzle orifices extend along a length of the cavity. A mounting plate provides a wall of the cavity opposite the nozzle orifices. A plurality of actuators is disposed in the cavity to vibrate the ink in the cavity such that each jet breaks up into ink droplets at substantially a same predetermined distance from the wall. Each of the plurality of actuators is integrally connected to the mounting plate by a membrane.