Liquid Ejection Head Resin Layer Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing liquid ejection heads using substrates with through holes often result in resin bending over the supply port, creating air gaps that deform structures during heating, leading to inaccurate formation of ejection orifices and other features.
Innovation Solution
A method involving positioning a first resin layer on a substrate with a through hole, removing the resin portion above the hole before releasing the supporting member, and then applying a second resin layer without an air gap, ensuring accurate processing and preventing deformation during heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If resin layers are applied over through holes during manufacturing, then complete coverage and planarization are achieved, but air gaps form causing deformation during heating
Solution Approach 1:
The resin layer application process is segmented into multiple steps: first applying resin to cover the through hole, then selectively removing the resin portion above the hole, and finally applying additional resin layers. This segmentation prevents air gap formation while maintaining complete coverage elsewhere, resolving the contradiction between coverage and stability.
Solution Approach 2:
The resin portion above the through hole is removed before subsequent resin layers are applied and before heating occurs. This preliminary removal action prevents the formation of enclosed air spaces that would expand during heating, thereby preventing deformation and ensuring reliability.
2Shape
If resin is heated to planarize the surface, then surface flatness is improved, but air gaps expand causing structure deformation
Solution Approach 1:
The resin portion above the through hole is removed before heating occurs. This preliminary action eliminates the source of air gaps that would otherwise expand during heating, allowing the heating process to planarize the surface without causing deformation of precision structures like ejection orifices.
Solution Approach 2:
The heating process, which could potentially cause harm by expanding air gaps, is converted into a beneficial planarization step. By removing the resin above through holes beforehand, the heating process achieves surface flatness improvement without the harmful side effect of deformation, thus converting a potential harm into a pure benefit.
3Strength
If complete resin coverage is maintained over through holes, then structural integrity is preserved, but air gaps form and expand during heating
Solution Approach 1:
The resin coverage is segmented such that resin is present to maintain structural integrity of the channel member, but the resin portion directly above the through hole is selectively removed. This segmentation preserves strength while eliminating air gaps that would cause precision loss during heating.
Solution Approach 2:
Different regions of the resin layer have different qualities: resin in most areas provides structural integrity, while the absence of resin above the through hole prevents air gap formation. This local differentiation of resin presence resolves the contradiction between strength and precision.
Data Source
AI summary
A method of manufacturing a structure includes (1) positioning a first resin layer provided on a first supporting member on a substrate having a through hole, with the first resin layer facing toward the substrate, and releasing the first supporting member from the first resin layer; and (2) positioning a second resin layer provided on a second supporting member on the first resin layer from which the first supporting member has been released, with the second resin layer facing toward the first resin layer, and releasing the second supporting member from the second resin layer. A first resin layer portion that is above the through hole is removed before or simultaneously with the releasing of the first supporting member.