Metal Flow Channel Plate for High-Density Inkjet Heads
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Solution Overview
Problem
Existing liquid ejection heads face challenges in achieving high nozzle density and long head length at reduced costs, with issues such as material cost increases, warping, cracking, and air bubble dischargeability, particularly for high-density heads above 300 dpi, which affect printing speed and reliability.
Innovation Solution
A liquid ejection head design featuring a flow channel plate formed from a thin metal plate with groove-shaped pressure generating chambers, fluid resistance sections, and nozzle holes, where the pressure generating chamber, nozzle hole, and fluid resistance section are deformed in the thickness direction, allowing for efficient ink flow and air bubble discharge, and a manufacturing method involving press working to form these features without the need for adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the head size exceeds one inch and silicon material is used for the flow channel plate, then manufacturing precision is improved, but material cost increases
Solution Approach 1:
The patent changes the material parameter from silicon to stainless steel thin plate, and changes the processing method parameter from isotropic etching to press working with laser drilling, thereby reducing material cost while maintaining manufacturing precision for pressure generating chambers
Solution Approach 2:
The patent uses inexpensive stainless steel thin plate instead of expensive silicon material, accepting that the material can be processed more simply through press working and laser drilling rather than requiring complex isotropic etching processes
2Productivity
If high temperature hardening is performed to bond the flow channel plate and nozzle plate quickly, then productivity is improved, but reliability deteriorates due to warping or cracking
Solution Approach 1:
The patent changes the bonding parameter from high temperature hardening to room temperature adhesive bonding, eliminating thermal stress that causes warping and cracking, thereby maintaining structural integrity while the adhesive provides strong bonding between plates
Solution Approach 2:
The patent introduces adhesive as an intermediary bonding material between the flow channel plate and nozzle plate, which allows for reliable bonding at room temperature without causing thermal stress, warping, or cracking to the silicon or metal materials
3Reliability
If adhesive bonding is used to prevent warping and cracking, then reliability is improved, but manufacturing precision deteriorates due to adhesive residue affecting nozzle hole positioning
Solution Approach 1:
The patent extracts the bonding process from the nozzle plate assembly area, placing the adhesive bonding operation on the flow channel plate背面 (back side) away from the nozzle holes, thereby preventing adhesive residue from affecting nozzle hole positioning accuracy while maintaining structural integrity through reliable bonding
4Device complexity
If conventional processing methods are used for high-density heads, then manufacturing complexity is reduced, but productivity deteriorates due to air bubble discharge issues
Solution Approach 1:
The patent adds a longitudinal dimension to the pressure generating chamber by extending it in the length direction, creating a longer chamber that enables air bubbles to be discharged more effectively along the length direction, thereby improving productivity through better air bubble discharge without increasing processing complexity
Solution Approach 2:
The patent segments the pressure generating chamber into distinct regions including a liquid introduction section, a liquid ejection section, and an air bubble discharge section, allowing air bubbles to be directed to specific discharge ports, thereby improving air bubble dischargeability and printing speed while maintaining simple processing
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 design enables a longer head length at reduced costs with improved air bubble dischargeability and ink flow efficiency, enhancing printing speed and reliability for high-density heads.
Implementation Method 1
a vibrating plate which forms the wall face of the pressure generating chamber that is deformed by a pressure generating unit such as a piezoelectric element to change the volume within the pressure generating chamber
Data Source
AI summary
A liquid ejection head is disclosed. The liquid ejection includes a flow channel plate, the flow channel plate being formed from one thin plate, the flow channel plate being formed with one or more pressure generating chambers, a fluid resistance section which supplies liquid to the pressure generating chamber, and a nozzle hole which opposes the pressure generating chamber. The flow channel plate is made of a metal material, and wherein the flow plate includes the pressure generating chamber which is formed of a groove-shaped indentation; the nozzle hole which is formed at one end in a longitudinal direction of the groove-shaped indentation; and the fluid resistance section which is formed at the other end in the longitudinal direction of the groove-shaped indentation. The pressure generating chamber, the nozzle head, and the fluid resistance section are formed such that they deform the thin plate in a thickness direction.