Piezoelectric Micro-Valve Electrode Structures for Inkjet Dripping Control
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Solution Overview
Problem
Conventional printing technologies, such as continuous inkjet printers, face issues like ink dripping in undesired directions, fluid evaporation leading to continuous replenishment needs, and maintenance costs due to orifice plate degradation.
Innovation Solution
A micro-valve design incorporating a piezoelectric actuating beam with a base layer, electrode layers, and a bonding pad, allowing for precise control of fluid flow through differential electrical signals, and a fluid manifold for ink reservoir management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional continuous inkjet printing is used, then printing capability is provided, but ink dripping in undesired directions occurs leading to maintenance requirements
Solution Approach 1:
The continuous inkjet stream is segmented into discrete droplets through periodic actuation of piezoelectric elements. This segmentation allows individual droplet control, preventing undesired ink dripping while maintaining printing capability. The ink stream is divided into controllable units that can be directed precisely to targets.
Solution Approach 2:
Piezoelectric actuators apply periodic mechanical stress to the ink stream at controlled frequencies to generate droplets at regular intervals. This periodic action enables precise timing and placement of ink droplets, eliminating random dripping while preserving continuous printing operation.
2Productivity
If conventional continuous inkjet printing is used, then printing operation is maintained, but makeup fluid is lost over time as a result of evaporation requiring continuous replenishment
Solution Approach 1:
The system extracts only the necessary amount of ink for each droplet and delivers it directly to the target. By transitioning from continuous ink flow to on-demand droplet generation, excess ink that would otherwise evaporate is eliminated, reducing fluid loss while maintaining continuous printing capability.
Solution Approach 2:
The piezoelectric actuation system generates droplets on-demand based on printing requirements, eliminating the need for continuous ink supply and reducing evaporation losses. The system serves itself by precisely controlling when and where ink is deposited, minimizing waste.
3Ease of manufacture
If conventional continuous inkjet printing is used, then printing function is provided, but orifice plates degrade requiring repair or replacement
Solution Approach 1:
The patent replaces mechanical orifice plates with piezoelectrically actuated channels. The piezoelectric elements control ink flow through field-induced mechanical deformation rather than fixed mechanical openings. This substitution eliminates wear and degradation associated with traditional orifice plates while maintaining printing function.
Solution Approach 2:
The system changes the operating parameters of ink delivery by using dynamic piezoelectric actuation instead of static orifice plates. The piezoelectric elements can rapidly adjust channel dimensions and flow characteristics without physical wear, extending system lifespan while preserving printing capability.
4Reliability
If micro-valves with piezoelectric actuating beams are used, then precise fluid control is achieved, but device complexity increases due to multiple electrode layers and via structures
Solution Approach 1:
The piezoelectric actuating beam structure serves multiple functions simultaneously: it acts as both the structural support element and the actuation mechanism, while integrated electrode layers provide both electrical connection and functional actuation. This multi-functionality reduces overall device complexity despite the presence of multiple layers.
Solution Approach 2:
The patent merges the actuating beam structure with the electrode layers and electrical connection elements into an integrated unit. The via structures serve dual purposes of mechanical support and electrical conduction. This merging of functions reduces the number of separate components while achieving precise fluid control.
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
Enhances the performance and durability of the micro-valves by improving signal transfer rates, reducing maintenance, and preventing ink loss through precise fluid control and efficient ink usage.
Implementation Method 1
A layer of piezoelectric material is disposed on the base layer and extends at least a portion of a distance between the first end and the second end. The cantilevered portion is movable in response to application of a differential electrical signal between the bottom electrode layer and the top electrode layer
Data Source
AI summary
A micro-valve includes an orifice plate including an orifice. The micro-valve further includes an actuating beam having a first end and a second end. The actuating beam also includes a base layer and a layer of piezoelectric material disposed on the base layer, a bottom electrode layer, and a top electrode layer. At an electrical connection portion of the actuating beam, the layer of piezoelectric material includes a first via, and a portion of the top electrode layer disposed within the first via, and a portion of the bottom electrode disposed beneath the first via. The actuating beam includes a base portion extending from the electrical connection portion and a cantilevered portion extending from the base portion. The cantilevered portion is movable in response to application of a differential electrical signal between the bottom electrode layer and the top electrode layer to one of open or close the micro-valve.