Jet Stack Diaphragm Opening Width for Ink Droplet Control
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Solution Overview
Problem
The manufacturing of high-density ink jet print heads with precise ink channels is challenging due to the need for tight tolerances and uniform nozzle performance, which affects the quality of images produced by ink jet printers.
Innovation Solution
A jet stack design featuring a substrate with micro actuators and a diaphragm, where the diaphragm openings are wider than the substrate openings, allowing for fluid communication and precise control of ink droplet size through laser-ablated passageways in the substrate, ensuring consistent inlet resistance and improved image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser ablation is used to create substrate openings, then manufacturing precision of opening width is improved, but device complexity increases due to additional processing steps
Solution Approach 1:
The diaphragm is pre-formed with openings of a first width before bonding to the substrate. This preliminary action allows the substrate openings to be laser-ablated to a second, more precise width without requiring the entire assembly to be reworked, thereby achieving high precision while managing process complexity through staged manufacturing.
Solution Approach 2:
The opening formation process is segmented into two distinct stages: first forming the diaphragm openings with a preliminary width, then separately laser-ablating the substrate openings to the final precise width. This segmentation allows each component to be optimized independently, improving overall manufacturing precision while containing complexity to specific processing steps.
2Reliability
If diaphragm openings are made wider than substrate openings, then fluid communication is improved, but manufacturing precision requirements increase for the smaller substrate openings
Solution Approach 1:
The diaphragm serves as an intermediary component with openings that are deliberately made wider than the final substrate openings. This intermediary structure ensures reliable fluid communication while the subsequent laser ablation of the substrate openings to a precise second width maintains manufacturing precision, effectively decoupling the two requirements.
Solution Approach 2:
The diaphragm openings are formed preliminarily at a wider first width to ensure adequate fluid communication. The substrate openings are then laser-ablated to a precise second width that is smaller but still maintains proper fluid flow. This preliminary action allows the system to meet both the fluid communication requirement and the precision requirement without compromising either.
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 enables precise control of ink droplet size and uniform performance across ink jet nozzles, enhancing the quality of images generated by improving the consistency of ink flow and pressure, thereby addressing the challenges of manufacturing high-density ink jet print heads.
Implementation Method 1
laser ablating the substrate to form passageways through the substrate that are in fluid communication with the openings in the diaphragm
Data Source
AI summary
A print head for a printer includes a jet stack for passage of ink to media to form an image on the media. The jet stack includes a substrate having a micro actuator. The substrate has an opening through the substrate that is proximate to the micro actuator and a diaphragm bonded to the substrate. The diaphragm has an opening through the diaphragm that is configured for fluid communication with the opening through the substrate. The diaphragm opening has a width that is larger than a width of the opening in the substrate.