Liquid Discharge Head Resin Layer Segmentation for Flatness and Strength
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Solution Overview
Problem
Existing methods for manufacturing liquid discharge heads struggle to achieve a balance between the flatness of discharge port surfaces and the mechanical strength of flow path walls, leading to reduced reliability and uniformity in droplet volume discharge.
Innovation Solution
A method involving multiple layers of resin materials is employed, where a first layer forms the flow path pattern, a second layer fills and covers the pattern, and a third layer reinforces the discharge port member, ensuring sufficient mechanical strength and uniformity while maintaining flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the flow path pattern and the peripheral portion pattern material is reduced to make the upper surface of the coating resin layer flatter, then the flatness of the discharge port surface is improved, but the wall thickness of the flow path becomes thin, reducing the mechanical strength of the flow path wall
Solution Approach 1:
The coating resin layer is divided into multiple segments (first coating resin layer and second coating resin layer) that are formed at different stages. The first layer is formed initially, then the peripheral portion pattern material is formed, and finally the second layer is formed to fill the gap and cover the pattern. This segmentation allows each layer to contribute differently to the final structure, enabling both flatness and sufficient wall thickness.
Solution Approach 2:
The first coating resin layer is formed in advance before the peripheral portion pattern material is formed. This preliminary action creates a base layer that will later be combined with the second layer to achieve the desired flatness and structural integrity without compromising wall thickness.
2Manufacturing precision
If the distance between the peripheral portion pattern material and the flow path pattern is reduced to improve flatness, then the discharge port surface becomes flatter, but the contact area between the flow path wall and the substrate becomes small, reducing bonding strength
Solution Approach 1:
The coating resin layer is segmented into first and second layers. The first layer is formed initially with adequate contact area for bonding, then the peripheral portion pattern material is formed, and the second layer is formed to provide the additional flatness. This ensures that bonding strength is established in the first layer while the second layer contributes to surface flatness.
Solution Approach 2:
The first coating resin layer is formed preliminarily before the peripheral portion pattern material is formed. This preliminary formation ensures adequate contact area and bonding strength are established before subsequent processing steps that might reduce contact area.
3Productivity
If liquid discharge ports and liquid flow paths are arranged at high density, then recording speed and image quality are improved, but the walls dividing the flow paths must be relatively thin, reducing the general strength of the flow path walls
Solution Approach 1:
The coating resin layer is segmented into multiple layers (first and second layers) that are formed at different stages. This segmentation allows the flow path walls to achieve sufficient thickness and strength even when walls are thin due to high-density arrangement, because each layer contributes to the overall structural integrity.
Solution Approach 2:
The flow path structure is formed as a composite of multiple coating resin layers (first layer and second layer) that work together to provide both the required thin wall thickness for high-density arrangement and sufficient mechanical strength through the combined structure.
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 results in a highly reliable liquid discharge head with reduced variation in droplet volume and enhanced mechanical strength, capable of stable and uniform droplet discharge at high yield.
Implementation Method 1
providing a second layer so as to fill the gap and to cover the pattern and the member (A)
Data Source
Figure 1
Figure 2A~2J
Figure 3A~3E
AI summary
A method of manufacturing a liquid discharge head having a flow path communicating with a discharge port for discharging liquid includes in the following order: preparing a substrate with an evenly provided first layer as a flat layer; forming, of the first layer, a pattern of the flow path for forming the flow path, and a member (A) provided outside the pattern via a gap; providing a second layer so as to fill the gap and to cover the pattern and the member (A); forming, of the second layer, a member (B) for forming the discharge port on the pattern; and removing the member (A), providing, at least on the substrate, a third layer so as to hold it in intimate contact with the member (B), and removing the pattern to form the flow path.