Adhesive-Coated Mesh for Printhead Bond Line Control

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Solution Overview

Problem

Conventional printhead designs face challenges with compatibility and durability when using UV inks, as most polymer materials degrade or fail to perform well with these inks, necessitating an improved design that addresses material compatibility and bonding issues.

Innovation Solution

A printhead assembly utilizing a mesh substrate coated with adhesive, which acts as a confinement structure between functional plates, enabling robust bonding and controlling squeeze-out, and using adhesives like thermoplastic polyimide, crosslinkable acrylic, or epoxy to form a strong and chemically resistant bond suitable for UV inks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If polymer materials are used to replace sheet metal components to lower cost, then manufacturing cost is reduced, but material compatibility with UV ink deteriorates causing degradation

Engineering Contradiction:

Improvemanufacturing costVSAvoidmaterial compatibility

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces an adhesive layer as an intermediary between the polymer component and UV ink. This adhesive mediator is specifically selected to be compatible with UV ink while the polymer provides cost benefits, thus resolving the compatibility issue without sacrificing material substitution advantages

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite structure combining polymer materials with adhesive materials that are specifically compatible with UV ink. This composite approach allows the system to benefit from both the cost advantages of polymers and the chemical compatibility requirements for UV ink operation

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional bonding processes are used to join printhead components, then structural integrity is achieved, but adhesive squeeze-out and bond line quality deteriorate

Engineering Contradiction:

Improvestructural integrityVSAvoidbond line quality

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent employs a mesh substrate with adhesive coated on it, creating a flexible yet controlled bonding interface. The mesh structure allows for precise adhesive distribution and prevents excessive squeeze-out while maintaining strong structural bonds between components

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The mesh substrate used in the patent is a porous material that provides controlled pathways for adhesive flow. This porosity allows the adhesive to be contained and distributed evenly during bonding, preventing uncontrolled squeeze-out while ensuring complete coverage and strong adhesion

Inventive Principle:

Principle #31Porous materials

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

The solution provides a robust and chemically resistant bond that prevents material squeeze-out and ensures compatibility with a wide range of ink types, including UV inks, enhancing the durability and performance of printhead assemblies.

Implementation Method 1

adhesive confinement structure comprising an adhesive-coated mesh substrate arranged between adjacent functional plates to provide bonding between the plates

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS8979241B2Using saturated mesh to control adhesive bond line quality

Publication Date: 2015.03.17 XEROX CORP

AI summary

In some aspects of the present application, a printhead assembly is disclosed that comprise a plurality of functional plates stacked together; an adhesive confinement structure comprising an adhesive-coated mesh substrate arranged between adjacent functional plates to provide bonding between the plates.