Piezoelectric Drop Generator Array Manufacturing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current drop-on-demand ink jet technologies face challenges in efficiently manufacturing arrays of piezoelectric drop generators for high-quality ink jet printheads, particularly in the integration and manufacturing processes of piezoelectric transducers and electrodes.

Innovation Solution

The development of a drop-on-demand printing apparatus that employs a controller to selectively energize drop generators with piezoelectric transducers, utilizing a flexible diaphragm actuated by electrodes and a piezo element, and a manufacturing process involving laminar piezoelectric assemblies, metal deposition, and adhesive layers to form arrays of drop generators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional manufacturing processes are used for piezoelectric drop generators, then manufacturing simplicity is maintained, but manufacturing efficiency and quality are insufficient for high-quality ink jet printheads

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufacturing process is divided into distinct segments: forming the piezoelectric layer, depositing metal electrodes, creating adhesive layers, and forming the array structure. Each segment can be optimized independently while contributing to the overall manufacturing efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The piezoelectric layer and metal electrodes are prepared and positioned in advance before final assembly into the drop generator array. This preliminary preparation enables more efficient manufacturing by pre-processing components rather than assembling them step-by-step during final production.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If integrated manufacturing of piezoelectric transducers and electrodes is used, then manufacturing efficiency is improved, but manufacturing precision and alignment quality may deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidalignment precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Different regions of the manufacturing process are optimized for different qualities: the piezoelectric layer formation focuses on precision and uniformity, while the metal deposition focuses on electrical conductivity and pattern accuracy. Each local process is tuned to achieve the specific quality requirements of that component.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Adhesive layers are used as intermediaries between the piezoelectric transducers and the substrate, and between metal electrodes and their respective components. These intermediary layers provide tolerance for alignment variations while ensuring secure bonding and electrical connectivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If arrays of drop generators are formed with multiple layers, then functionality and quality are improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveprinting qualityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The multi-layer structure is organized with the piezoelectric layer nested within the overall drop generator structure, metal electrodes nested on and around the piezoelectric elements, and adhesive layers nested between components. This nested arrangement consolidates multiple functions into a compact integrated structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The piezoelectric layer serves multiple functions: it acts as the active transducer element, provides structural support, and serves as a substrate for metal electrode deposition. Similarly, the adhesive layers provide both bonding and electrical insulation functions. This multi-functionality reduces the need for separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This solution enables efficient and effective production of arrays of piezoelectric drop generators, enhancing the manufacturing efficiency of ink jet printheads and improving the quality of ink jet printing by precise control and efficient ink drop emission.

Implementation Method 1

drop generators with piezoelectric transducers, utilizing a flexible diaphragm actuated by electrodes and a piezo element

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

manufacturing process involving laminar piezoelectric assemblies, metal deposition, and adhesive layers

Methodology Applied

Scientific EffectMetal deposition: Deposition (physical)

Data Source

PatentUS8006356B2Method of forming an array of drop generators

Publication Date: 2011.08.30 GENESEE VALLEY INNOVATIONS LLC

AI summary

A method for making an electromechanical device including forming an electromechanical transducer that includes a deposited metallic diaphragm, and attaching the electromechanical transducer to a fluid channel substructure.