Plasma Polymerized Nozzle Plate for Stable Ink Discharge

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Solution Overview

Problem

The existing droplet discharge devices, such as ink-jet printers, face challenges in achieving stable ink discharge due to ink attachment on nozzle plate surfaces, leading to curved discharge paths and uneven ink distribution, which degrades printing quality. Additionally, the precision in adhesive application between the nozzle plate and substrate is difficult to control, resulting in uneven ink chamber volumes and dimensional inaccuracies.

Innovation Solution

A nozzle plate with a liquid-repellent film and a bonding film, both comprising plasma polymerized films with a Si skeleton and elimination groups, is used. The liquid-repellent film is formed by bonding a coupling agent with the plasma polymerized film, and the bonding film develops adhesiveness through energy application, ensuring strong bonding and uniformity between the nozzle plate and substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a liquid-repellent treatment is performed on the nozzle plate surface to prevent ink attachment, then ink discharge stability is improved, but printing quality cannot be sufficiently improved due to dimensional inaccuracy from adhesive application issues

Engineering Contradiction:

Improveink discharge stabilityVSAvoiddimensional accuracy of droplet discharge head

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the physical and chemical parameters of the nozzle plate surface by forming a plasma polymerized film with specific properties (Si skeleton structure, elimination groups). This film provides both liquid repellency and controlled adhesiveness, allowing precise control of bonding characteristics while maintaining ink discharge stability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite structure consisting of a plasma polymerized film formed on the nozzle plate, combining organic (elimination groups) and inorganic (Si skeleton) components. This composite material simultaneously provides liquid repellency, adhesiveness to the substrate, and dimensional stability, resolving the contradiction between ink discharge reliability and manufacturing precision.

Inventive Principle:

Principle #40Composite materials

2Strength

If adhesive is supplied between the nozzle plate and substrate to bond them, then bonding strength is achieved, but uniform adhesive amount cannot be controlled resulting in uneven ink chamber volumes and dimensional inaccuracy

Engineering Contradiction:

Improvebonding strength between nozzle plate and substrateVSAvoiduniformity of ink chamber volume and dimensional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The plasma polymerized film on the nozzle plate provides self-adhesiveness to the substrate through its elimination groups that react with the substrate surface. This self-service bonding mechanism eliminates the need for external adhesive application, ensuring uniform bonding across the entire surface without the variability associated with manual or automated adhesive dispensing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the mechanical adhesive application system with a chemical bonding mechanism. The plasma polymerized film's elimination groups chemically react with the substrate surface, providing strong bonding without requiring physical adhesive materials. This substitution eliminates the dimensional variability inherent in adhesive-based bonding systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If photosensitive or elastic adhesive is used to bond the nozzle plate and substrate, then assembly is achieved, but adhesive runs out of the bonding part and uniform bulks cannot be achieved among ink chambers or droplet discharge heads

Engineering Contradiction:

Improveassembly capability of droplet discharge headVSAvoiduniformity of ink chamber bulks and dimensional accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The plasma polymerized film provides self-adhesiveness that activates upon contact with the substrate, eliminating the need for separate adhesive application steps. The bonding occurs uniformly across the entire interface through the film's inherent chemical reactivity, preventing adhesive overflow and ensuring consistent ink chamber volumes across multiple devices.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent extracts the adhesive function from the assembly process and integrates it into the nozzle plate structure itself through the plasma polymerized film. This extraction eliminates the harmful effects of running adhesive while maintaining the essential bonding function, resulting in uniform dimensional accuracy across all ink chambers and devices.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS8128202B2Nozzle plate, method for manufacturing nozzle plate, droplet discharge head, and droplet discharge device

Publication Date: 2012.03.06 SEIKO EPSON CORP

AI summary

A nozzle plate includes: a nozzle for discharging a liquid as droplets; a liquid-repellent film suppressing attachment of the droplets on one surface of the nozzle plate; and a first bonding film formed on the other surface of the nozzle plate and bonded with a substrate. In the nozzle plate, the liquid-repellent film includes a first plasma polymerized film having a Si skeleton, which includes a siloxane (Si—O) bond and has a random atomic structure, and an elimination group bonded with the Si skeleton.