Multi-Layer Ejection Head for Divergent Fluid Volumes
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Solution Overview
Problem
Conventional fluid ejection heads are optimized for a single type of fluid and are not effective for ejecting different types and volumes of fluids, such as aqueous and non-aqueous fluids, due to their fixed design.
Innovation Solution
A fluid ejection head with multiple fluid ejectors and nozzle configurations, including distinct flow feature layers and nozzle plate layers, allowing for optimized ejection of fluids with varying volumes and properties, with the second fluid ejectors capable of ejecting a volume 2 to 6 times greater than the first, accommodating diverse fluid types and volumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single flow feature layer and single nozzle plate layer are used, then the ejection head is optimized for one type of fluid, but it cannot effectively eject different types and volumes of fluids
Solution Approach 1:
The ejection head is divided into multiple flow feature layers (first flow feature layer and second flow feature layer) and multiple nozzle plate layers (first nozzle plate layer and second nozzle plate layer), with each layer optimized for specific fluid types and volumes. This segmentation allows different regions to handle different fluid characteristics simultaneously.
Solution Approach 2:
Different portions of the ejection head are designed with locally optimized characteristics - the first flow feature layer and first nozzle plate layer are optimized for aqueous fluids, while the second flow feature layer and second nozzle plate layer are optimized for non-aqueous fluids, enabling each region to perform its specific function optimally.
2Quantity of substance
If the ejection head is optimized for ejecting small volumes of fluid (3-6 nanograms), then it cannot effectively eject larger volumes of fluid with ratios from 2:1 to 6:1
Solution Approach 1:
The patent adds a vertical dimension by stacking multiple flow feature layers and nozzle plate layers, allowing different ejection volumes to be achieved through layer selection rather than requiring different ejection head configurations. The second flow feature layer and second nozzle plate layer provide enlarged fluid chambers and expanded nozzle openings for larger volume ejection.
Solution Approach 2:
The multiple flow feature layers are arranged in a nested configuration where the first flow feature layer contains fluid chambers optimized for small volumes, and the second flow feature layer contains enlarged fluid chambers that nest above, providing a hierarchical structure that accommodates different volume requirements.
3Reliability
If an ejection head is designed for aqueous fluids, then it is not optimally designed for ejecting non-aqueous fluids
Solution Approach 1:
The first flow feature layer and first nozzle plate layer are designed with surface properties and geometric characteristics optimized for aqueous fluid ejection, while the second flow feature layer and second nozzle plate layer are designed with different surface properties and geometric characteristics optimized for non-aqueous fluid ejection, allowing each region to reliably handle its designated fluid type.
Solution Approach 2:
The ejection head achieves multi-functionality by integrating multiple flow feature layers and nozzle plate layers that can collectively handle both aqueous and non-aqueous fluids, as well as various fluid volumes, making a single device suitable for diverse applications including vapor therapy, pharmaceutical drug delivery, and assay analysis.
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
Enables a single ejection head to handle widely divergent fluids and fluid volumes, optimizing specific areas for particular fluids, enhancing the ability to manage multiple fluid geometries and volumes effectively.
Implementation Method 1
For thermal actuators, individual heater resistors are defined in the resistive layers and each heater resistor corresponds to a nozzle hole in the nozzle plate for heating and ejecting fluid from the ejection head
Implementation Method 2
Fluid ejection actuators formed on a device surface of the substrate may be thermal actuators, bubble jet actuators, or piezoelectric actuators
Data Source
AI summary
An ejection head. The ejection head includes first fluid ejectors and second fluid ejectors deposited on a semiconductor substrate. A first flow feature layer is attached to the semiconductor substrate to provide a first fluid supply channels and a first fluid chambers and a first portion of second fluid channel and second fluid chambers therein. A second flow feature layer is attached to the first flow feature layer to provide a first portion of first nozzle holes and a second portion of second fluid supply channels and second fluid chambers therein. A first nozzle plate layer is attached to the second flow feature layer to provide a second portion of the first nozzle holes and a first portion of second nozzle holes therein. A second nozzle plate layer is attached to the first nozzle plate layer to provide a second portion of the second nozzle holes therein.