Liquid Supply Unit Flatness Control via Segmented Molding
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Solution Overview
Problem
Resin molding of flat plate-shaped liquid supply units for inkjet printing apparatuses often results in undulation and warpage due to demolding and shrinkage, leading to potential leakage issues when connected to other components.
Innovation Solution
A method involving multiple molding and bonding steps using a disassemblable mold assembly with a die slide mold to maintain contact portions on specific surfaces throughout the process, ensuring precise positioning and bonding of intermediate passage members between first and second members, thereby minimizing deformation and enhancing flatness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resin molding is used to manufacture flat plate-shaped liquid supply units, then cost is reduced and manufacturing efficiency is improved, but undulation and warpage occur due to demolding and shrinkage
Solution Approach 1:
The liquid supply unit is divided into multiple separate members (first member, second member, intermediate passage member) that are molded individually using resin molding, then bonded together. This segmentation allows each member to be manufactured efficiently through molding while the assembly process maintains overall flatness by bonding contact portions that remain on the same surfaces.
Solution Approach 2:
The mold assembly is designed with predetermined positions for contact portions before the molding process begins. By pre-positioning these contact portions on specific surfaces of the mold, the method ensures that when members are molded and subsequently bonded, the contact portions align correctly without requiring post-molding adjustments, thus maintaining flatness while enabling efficient resin molding production.
2Shape
If layers are stacked and bonded after resin molding, then a flat plate-shaped liquid supply unit is formed, but deformation occurs during stacking and bonding
Solution Approach 1:
The mold assembly pre-positions contact portions on specific surfaces before molding. This preliminary positioning ensures that when multiple members are stacked and bonded, the contact portions align correctly without causing deformation, as the bonding process occurs at predetermined locations that maintain the flat plate shape.
Solution Approach 2:
The contact portions act as intermediary elements between the multiple molded members. By bonding these specific contact portions that remain on the same surfaces throughout the process, the members are connected in a way that minimizes deformation and maintains the overall flat plate shape of the liquid supply unit.
3Reliability
If contact portions are deformed during molding, then connection to other components is compromised, but maintaining deformation-free contact portions requires precise control
Solution Approach 1:
The liquid supply unit is segmented into multiple members with specifically designated contact portions. By separating the contact portions from other structural elements and positioning them on specific surfaces of the mold, the design ensures that these critical connection points remain undeformed during molding, maintaining connection reliability despite the multi-step process complexity.
Solution Approach 2:
The contact portions serve as intermediary connection points between the liquid supply unit and other components. The mold assembly is designed to keep these contact portions on the same surfaces throughout molding, ensuring they remain flat and undeformed for reliable connection, while the complexity of the molding process is managed through systematic disassembly and reassembly steps.
Data Source
AI summary
A method of manufacturing a liquid supply unit includes a first molding step and a second molding step. In a first molding step, a resin is injected into different positions inside a mold assembly and a first member having a first contact portion, a second member having a second contact portion and an intermediate passage member having a passage structure to connect the first contact portion to the second contact portion are molded. In a second molding step, the mold assembly is disassembled, a die slide mold disposed inside the mold assembly is moved for positioning the members. Then, the mold assembly is clamped again and a resin is injected into the mold assembly. The first contact portion and the second contact portion are respectively held on the same surfaces inside the mold assembly during a period from the first molding step to completion of the second molding step.