Liquid Ejecting Head Resin Molding Warpage Control

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Solution Overview

Problem

The manufacturing process of elongated inkjet printing heads often results in undulation or warpage of resin-formed passage members, leading to variations in adhesion and orientation, which can affect image stability and quality during printing.

Innovation Solution

A method involving resin molding of passage members in a flat plate shape using a mold assembly with a fixed mold, an intermediate movable mold, and a movable mold, where the components are positioned and bonded in a controlled manner to prevent warpage and ensure accurate adhesion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If passage forming layers are stacked and bonded to form a passage member, then complicated passage structures can be realized, but undulation or warpage occurs during demolding or shrinkage causing deformation

Engineering Contradiction:

Improvepassage structure complexityVSAvoidflatness of passage member

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The passage member is divided into multiple passage forming layers that are stacked and bonded together. Each layer can be molded separately and then assembled to form the complete passage structure, enabling complex internal passages while maintaining manufacturing feasibility

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple passage forming layers are stacked and bonded together to form a complete passage member. The layers are combined in a specific sequence to create complicated passage structures that would be difficult to achieve with a single molded piece

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If passage forming layers are stacked and bonded, then passage structures are formed, but adhesion between layers may be damaged due to deformation

Engineering Contradiction:

Improvepassage structure formationVSAvoidadhesion between layers

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Positioning protrusions and recesses are formed on the passage forming layers before stacking and bonding. These preliminary positioning features ensure accurate alignment and proper adhesion when the layers are assembled, preventing deformation that would compromise bond strength

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Positioning protrusions and recesses act as intermediary elements between passage forming layers. These features facilitate precise alignment and ensure proper adhesion during the stacking and bonding process, maintaining both structural integrity and layer alignment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If ejection assembly is attached to deformed passage member, then assembly is completed, but variations in attached orientations occur affecting image quality

Engineering Contradiction:

Improveassembly completionVSAvoidorientation consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Positioning protrusions and recesses are formed on the passage forming layers and ejection assembly before final assembly. These preliminary positioning features ensure accurate orientation and alignment when components are attached, preventing variations that would affect image quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Positioning protrusions and recesses serve as intermediary alignment features between the passage member and ejection assembly. These features ensure consistent orientation during assembly, eliminating variations that would compromise printing precision and image quality

Inventive Principle:

Principle #24Intermediary (Mediator)

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 enables the production of liquid ejecting heads with stable adhesion between the ejection assembly and passage member, maintaining consistent orientation and improving image quality by minimizing deformation and warpage during the molding process.

Implementation Method 1

bond the first member, the second member, and the third member to one another

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS10525711B2Method of manufacturing liquid ejecting head

Publication Date: 2020.01.07 CANON KK

AI summary

A method of manufacturing a liquid ejecting head has a first molding step, a step of performing positioning and a second molding step. In the first molding step, a first member, a second member, and a third member are molded by injecting a resin at different locations inside of a set of a fixed mold, an intermediate movable mold, and a movable mold. In the step of performing positioning, the set is detached in a first direction and the intermediate movable mold and the movable mold are moved in a second direction. In the second molding step, a resin is injected to the inside of the set that is clamped to bond. During a period from the first molding step to completion of the second molding step, the first member, the second member, and the third member are held by insert mold pieces used for molding the members, respectively, in the first molding step.