Masking Material for Laser Nozzle Plate Fabrication
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Solution Overview
Problem
The existing methods for producing ink-jet heads with multiple nozzles are time-consuming and labor-intensive, requiring significant effort as the number of nozzles increases, making it difficult to efficiently form nozzle rows and rows in a nozzle plate.
Innovation Solution
A method involving a substrate and a masking material with aligned mask holes, where the masking material is moved and laser irradiation is applied to form nozzle row groups with nozzles arranged in an array, using ultraviolet lasers to achieve uniform energy density and efficient formation of nozzle rows, allowing for the simultaneous creation of multiple nozzle rows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If nozzles are formed one by one separately by laser machining, then each nozzle can be precisely formed, but it requires much time and labor
Solution Approach 1:
The patent combines multiple nozzle formation operations into a single laser irradiation step by using a masking material with multiple mask holes arranged in different directions. This allows simultaneous formation of multiple nozzle rows (first nozzle rows in the first direction and second nozzle rows in the second direction) from a single substrate, thereby improving productivity while maintaining precision through the masking approach.
Solution Approach 2:
The masking material is prepared in advance with pre-formed mask holes arranged in specific patterns and directions. This preliminary preparation of the masking material allows the subsequent laser irradiation to efficiently form multiple nozzle rows simultaneously without requiring repeated positioning and irradiation operations, thus resolving the contradiction between precision and productivity.
2Quantity of substance
If the number of nozzles and nozzle rows is increased, then the jetting capability is improved, but more time and labor is required for forming the nozzles
Solution Approach 1:
The patent merges the formation of multiple nozzle rows with different orientations into a single processing step. By arranging mask holes in both the first direction (forming first nozzle rows) and second direction (forming second nozzle rows) within the same masking material, the system can create a large number of nozzles simultaneously, thereby increasing nozzle quantity without proportionally increasing formation time.
Solution Approach 2:
The masking material is segmented into multiple regions with mask holes arranged in different directions. This segmentation allows different sets of nozzles (first nozzle rows and second nozzle rows) to be formed in different regions simultaneously during a single laser irradiation process, enabling high nozzle counts to be achieved efficiently.
3Manufacturing precision
If laser irradiation is performed to form nozzles, then nozzles can be precisely formed in the substrate, but the process becomes time-consuming when done separately for each nozzle
Solution Approach 1:
The patent combines multiple laser irradiation targets into a single irradiation operation by using a masking material that contains mask holes for both first nozzle rows and second nozzle rows. This merging approach maintains the precision of laser-formed nozzles while reducing process complexity by eliminating the need for separate irradiation steps for different nozzle groups.
Solution Approach 2:
The masking material serves as an intermediary between the laser source and the substrate. It pre-defines the positions and orientations of all mask holes, allowing the laser to precisely form nozzles in multiple directions simultaneously without requiring complex positioning control or multiple irradiation operations, thus simplifying the overall process.
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 method simplifies the production process, enabling the easy formation of nozzle plates with multiple nozzle rows and reducing the time and labor required, while ensuring accurate and efficient nozzle formation, even for longer nozzle row groups.
Implementation Method 1
a laser irradiation sub-step for irradiating a laser onto the surface of the substrate from a side of a surface of the masking material opposite to the substrate, and forming, in the substrate, a plurality of nozzle row groups
Implementation Method 2
in the nozzle row group forming step, the nozzle row groups may be formed by an ultraviolet laser
Data Source
AI summary
For forming a group or rows of nozzles in a substrate of an ink-jet head, firstly, a laser irradiation source and a masking material in which a plurality of holes arranged in two rows are formed, are arranged on an upper side of a position at which one group of rows of nozzles of the substrate is formed. Next, an ultraviolet laser is irradiated from an upper side of the masking material, and a laser which has passed through the masking material is irradiated on the substrate. Two rows of nozzles are formed in a portion of the substrate at which the ultraviolet laser is irradiated. Accordingly, by irradiation of the laser once, it is possible to form a plurality of nozzles arranged in a row.