Metal Member Grain Gradient for Liquid Discharge Head Warpage
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Solution Overview
Problem
Conventional metal members formed by electroforming often suffer from warpage due to differences in average crystal grain sizes between layers, leading to inadequate adhesion and increased delamination, especially in applications like liquid discharge heads.
Innovation Solution
A metal member structure comprising a first layer, a second layer with a different average crystal grain size, and an intermediate layer with a smaller grain size than both, which is interposed between the first and second layers to enhance adhesion and reduce warpage, achieved by controlling current densities during electroforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an intermediate layer with smaller crystal grain size is added between layers with different grain sizes, then interlayer adhesion is improved and delamination is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
An intermediate layer with smaller crystal grain size is inserted between the first layer (larger grain size) and the second layer (different grain size) to act as a mediator that improves interlayer adhesion and reduces delamination. The intermediate layer's fine grain structure provides better bonding interfaces between layers with different crystal grain characteristics.
Solution Approach 2:
The crystal grain size parameter is strategically varied across three layers: the first layer has a larger average grain size, the intermediate layer has a smaller grain size, and the second layer has a different grain size. This parameter change approach optimizes adhesion by creating a gradient structure that reduces stress concentration at layer interfaces.
2Productivity
If electroforming is used to form metal layers, then manufacturing efficiency is high, but warpage occurs due to differences in crystal grain sizes between layers
Solution Approach 1:
The electroforming process parameters are optimized to control crystal grain size in each layer. By adjusting electroforming conditions (current density, electrolyte composition, plating time), the first layer is formed with larger grains while subsequent layers are formed with smaller grains, achieving the desired grain size gradient without sacrificing manufacturing efficiency.
Solution Approach 2:
The metal member is constructed as a composite structure with multiple electroformed layers having different crystal grain sizes. This composite approach combines layers with optimized grain structures to achieve both high productivity through electroforming and reduced warpage through grain size differentiation.
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 intermediate layer improves interlayer adhesion, reducing delamination and stabilizing liquid discharge in applications such as liquid discharge heads by effectively controlling crystal grain sizes and contraction differences.
Implementation Method 1
an average crystal grain size of a first layer is different from an average crystal grain size of a second layer, an intermediate layer having an average crystal grain size smaller than the average crystal grain sizes of the first layer and the second layer is interposed between the first layer and the second layer
Implementation Method 2
to suppress warpage of a metal member formed by electroforming
Data Source
AI summary
A metal member includes a first layer and a second layer. The second layer has an average crystal grain size different from an average crystal grain size of the first layer. An intermediate layer having an average crystal grain size smaller than the average crystal grain sizes of the first layer and the second layer is interposed between the first layer and the second layer.