Molded Nozzle Plate Alignment Features for Print Head Assembly
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Solution Overview
Problem
The alignment between ink outlets of MEMS die and nozzle holes in MEMSJet print heads is challenging due to the assembly method, leading to potential errors and the need for a maintenance wiper system that is not effectively supported by the current nozzle plate design, which is not smooth enough to reliably use a wiper system.
Innovation Solution
A molded nozzle plate with integrated alignment features and side walls surrounding the nozzle holes, allowing for precise positioning of the MEMS die within the cavity, and a smooth outer surface suitable for wiper systems, reducing tolerance errors and improving assembly accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the current assembly method starting with substrate and building up is used, then the assembly process is simple, but the alignment accuracy between ink outlets and nozzle holes deteriorates
Solution Approach 1:
The nozzle plate is pre-formed with integrated alignment features (protrusions or recesses) during the molding process, before assembly occurs. This preliminary incorporation of alignment features eliminates the need for complex post-assembly alignment procedures while ensuring precise positioning of the MEMS die relative to the nozzle holes, thereby resolving the contradiction between assembly simplicity and alignment accuracy.
2Ease of manufacture
If the outer surface of the nozzle plate is not made smooth, then manufacturing is easier, but the reliability of the wiper system deteriorates
Solution Approach 1:
The nozzle plate is designed with differentiated surface qualities: the outer surface is made smooth to enable reliable wiper system operation, while the inner surfaces and features necessary for manufacturing and assembly retain their standard finish. This localized application of smooth surface treatment to only the wiper-contact area resolves the contradiction by providing wiper reliability without compromising manufacturing ease elsewhere on the component.
3Ease of manufacture
If alignment features are not integrated into the nozzle plate, then manufacturing is simpler, but the assembly accuracy deteriorates
Solution Approach 1:
The alignment features are merged with the nozzle plate structure itself, being formed as integral parts of the plate during the molding process. This combining of alignment functionality with the structural component eliminates the need for separate alignment elements or additional manufacturing steps, thereby maintaining manufacturing simplicity while achieving high assembly accuracy through the integrated features.
Data Source
AI summary
An ink jet print head includes a molded nozzle plate, the molded nozzle plate further including molded die alignment features. The molded die alignment features can be registered to the apertures of the print head die.