Monolithic Molding for Printhead Fluid Flow Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reducing the size of printhead dies in inkjet printers to lower costs is hindered by the complexity and increased costs of channeling printing fluid to smaller, more tightly spaced dies, which requires advanced and costly flow structures and fabrication processes.
Innovation Solution
A new process involving the molding of fluid flow channels in a monolithic body surrounding multiple printhead dies, where these channels are formed simultaneously with the body using a transfer molding tool, allowing for direct fluid passage to each die, and enabling the use of smaller, thinner printhead dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the size of printhead dies is reduced to lower costs, then die cost and overall system cost are reduced, but the complexity and cost of fluid flow structures increase
Solution Approach 1:
The patent combines the fluid flow structure and printhead die support into a single monolithic body formed by injection molding. This integration eliminates the need for separate flow structures and complex assembly processes, thereby reducing device complexity while maintaining cost-effective smaller printhead dies
Solution Approach 2:
The monolithic body serves multiple functions simultaneously: it provides structural support for the printhead dies, channels fluid flow to each die, and acts as the housing structure. This multi-functionality reduces the number of components needed and simplifies the overall device architecture
2Ease of manufacture
If smaller printhead dies are used, then cost is reduced, but the fabrication process becomes more complex and costly
Solution Approach 1:
The fluid flow channels are pre-formed within the monolithic body during the injection molding process, before the printhead dies are attached. This preliminary action eliminates the need for complex post-fabrication channel creation and simplifies the overall fabrication process
Solution Approach 2:
The patent replaces complex mechanical fabrication processes (such as drilling, machining, or assembling separate flow components) with a single injection molding operation. This substitution dramatically simplifies the fabrication process while enabling precise channel geometry for smaller dies
3Device complexity
If fluid flow channels are molded simultaneously with the body, then fabrication is simplified and costs are reduced, but precision requirements increase
Solution Approach 1:
The injection molding process allows for precise control of channel dimensions, position, and geometry through parameter optimization (temperature, pressure, mold design). This enables simultaneous formation of the body and channels while maintaining the required manufacturing precision
Solution Approach 2:
The mold cavity acts as an intermediary that pre-defines the exact geometry and position of fluid flow channels before the actual part is formed. This intermediary structure ensures precise channel alignment and dimensions are achieved during the molding process
Data Source
AI summary
In one example, a process for making a micro device structure includes molding a micro device in a monolithic body of material and forming a fluid flow passage in the body through which fluid can pass directly to the micro device.