Patterned Metallization on Polyimide Aperture Plate for Laser-Ablated Nozzles
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Solution Overview
Problem
Ink jet print heads face challenges in reducing cost and improving performance, with stainless steel aperture plates being expensive to manufacture and polyimide plates experiencing high radiative heat losses due to high emissivity.
Innovation Solution
A method involving a polyimide aperture plate with a low emissivity metal layer, such as aluminum, where the metal layer is patterned to expose the polyimide at nozzle locations, reducing emissivity and preventing metal flaps during nozzle formation, and a low-energy coating is applied to facilitate ink removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polyimide aperture plate is used, then manufacturing cost is reduced, but radiative heat losses increase due to high emissivity
Solution Approach 1:
The patent applies composite materials by combining polyimide and metal layers to create an aperture plate that leverages the low cost and ease of manufacture of polyimide while incorporating the low emissivity properties of metal. The metal layer is deposited on the polyimide substrate, creating a composite structure that simultaneously achieves cost reduction and energy loss reduction.
Solution Approach 2:
The patent applies local quality by selectively removing the metal layer at nozzle locations while maintaining it in other areas. This creates different local properties: areas with metal layer have low emissivity for heat reduction, while nozzle areas expose the polyimide for proper ink ejection. This localized differentiation resolves the contradiction between overall low emissivity and localized nozzle functionality.
2Loss of energy
If a metal layer is added to reduce emissivity, then radiative heat losses decrease, but device complexity increases
Solution Approach 1:
The patent applies the extraction principle by selectively removing the metal layer at nozzle locations. This partial removal simplifies the structure where needed (allowing direct polyimide exposure for nozzle formation) while maintaining the metal layer in areas where heat reduction is critical, thus balancing complexity reduction with energy loss prevention.
Solution Approach 2:
The patent applies preliminary action by depositing the metal layer on the polyimide plate before forming the nozzles. This sequence allows the metal layer to be easily removed at nozzle locations through laser ablation or other methods, simplifying the overall manufacturing process despite the added initial step.
3Manufacturing precision
If the metal layer is patterned to expose polyimide at nozzle locations, then nozzle formation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies mechanics substitution by replacing complex mechanical patterning methods with laser-based ablation or deposition techniques. The metal layer can be precisely removed or deposited at nozzle locations using laser energy, which provides high precision without requiring complex mechanical masking or alignment systems, thus improving nozzle formation while managing manufacturing complexity.
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 solution decreases radiative power losses by 75% compared to stainless steel and 90% compared to raw polyimide, while maintaining low manufacturing costs and improving print head performance by reducing metal exposure and preventing ink interactions.
Implementation Method 1
at least one nozzle is formed through the first layer
Data Source
AI summary
An aperture plate for a print head of a printer can include a first layer having a first emissivity which is covered by a second layer having a second emissivity which is less than the first emissivity. In an embodiment, the second layer can be etched at nozzle locations to form openings in the second layer which have widths/areas greater than widths/areas of nozzles formed in the first layer. In another embodiment, the second layer can have a smaller thickness at the nozzle locations and a larger thickness away from the nozzle locations. Forming the openings in the second layer which are larger than the nozzles, or forming the second layer thinner at the nozzle locations prior to forming the nozzles, can provide a well-formed nozzle and an aperture plate having a low emissivity.