Laser Drilling Ink Inlets in Multi-Layer Fluid Dispensing Assemblies
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Solution Overview
Problem
The challenge in fluid dispensing assemblies, such as print heads, is maintaining precise alignment and uniform fluid flow across multiple layers with a high density of ink inlets, which is difficult due to the small dimensions and tight tolerances, leading to potential misalignment and non-uniform fluid characteristics that can result in lower quality prints and increased manufacturing costs.
Innovation Solution
The solution involves assembling the layers without full alignment and then forming the ink inlets using laser drilling or ablation after assembly, allowing for relaxed tolerances during layer alignment and using flexible circuit substrates and polymers to facilitate precise and uniform hole formation, ensuring consistent fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a high density of ink inlets is used to achieve high density fluid dispensing, then the fluid transfer efficiency is improved, but the alignment precision deteriorates due to small dimensions and tight tolerances across multiple layers
Solution Approach 1:
The patent applies preliminary action by assembling all layers (diaphragm, actuators, circuit board, heaters) before forming the ink inlets. This sequence allows the layers to be positioned and secured without the constraint of pre-aligned inlet holes, enabling relaxed tolerances during assembly while maintaining high inlet density for efficient fluid transfer
Solution Approach 2:
The patent replaces mechanical alignment systems with laser drilling or ablation to form ink inlets after assembly. This substitution eliminates the need for mechanical alignment fixtures and precision positioning mechanisms, allowing layers to be assembled with relaxed tolerances while achieving precise inlet formation through controlled energy removal
2Stability of the object's composition
If tight alignment tolerances are maintained across multiple layers, then the fluid flow uniformity is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by assembling all layers (diaphragm, actuators, circuit board, heaters) before forming the ink inlets. This sequence allows the layers to be positioned and secured without the constraint of pre-aligned inlet holes, enabling relaxed tolerances during assembly while maintaining high inlet density for efficient fluid transfer
Solution Approach 2:
The patent replaces mechanical alignment systems with laser drilling or ablation to form ink inlets after assembly. This substitution eliminates the need for mechanical alignment fixtures and precision positioning mechanisms, allowing layers to be assembled with relaxed tolerances while achieving precise inlet formation through controlled energy removal
3Stability of the object's composition
If tight alignment tolerances are maintained across multiple layers, then the fluid flow uniformity is improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent applies preliminary action by assembling all layers (diaphragm, actuators, circuit board, heaters) before forming the ink inlets. This sequence allows the layers to be positioned and secured without the constraint of pre-aligned inlet holes, enabling relaxed tolerances during assembly while maintaining high inlet density for efficient fluid transfer
Solution Approach 2:
The patent replaces mechanical alignment systems with laser drilling or ablation to form ink inlets after assembly. This substitution eliminates the need for mechanical alignment fixtures and precision positioning mechanisms, allowing layers to be assembled with relaxed tolerances while achieving precise inlet formation through controlled energy removal
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 ensures precise and uniform ink inlet formation, improving print quality by maintaining consistent fluid characteristics and reducing manufacturing costs through relaxed alignment tolerances and efficient laser-based hole formation methods.
Implementation Method 1
forming the ink inlets with a laser
Data Source
AI summary
A method includes attaching multiple layers to a back side of at least a portion of a fluid dispensing subassembly having at least one inlet port to form a fluid dispensing assembly, aligning a laser to a region of the fluid dispensing assembly, the region corresponding to the inlet port, and forming at least one hole in the region using a laser, the hole completing a path through the layers to the inlet port. A fluid dispensing assembly has a fluid dispensing subassembly having at least one inlet port, a fluid manifold having at least one outlet, at least two layers between the fluid dispensing subassembly and the manifold, and a fluid path in the at least two layers between the outlet and the inlet port, the fluid path having smooth walls and substantially uniform width.