Polyimide Printhead Coverlay Reduces Nozzle Deformation

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Solution Overview

Problem

Conventional ink jet printheads made from stainless steel are expensive to manufacture due to the costly processes of forming apertures or nozzles using chemical or mechanical etch techniques, and they suffer from deformation during assembly, leading to misdirectional jetting and poor print quality.

Innovation Solution

A method using a polyimide aperture plate with an anti-wetting coating and a coverlay with an elastic modulus of at least 0.5 GPa is applied, where the coverlay contacts the anti-wetting coating during a press operation to reduce deformation and improve print quality, and the anti-wetting coating is formed by coating a substrate with an isocyanate compound and hydroxyl functionalized fluoro-crosslinking material and subjecting it to curing treatments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If stainless steel aperture plates with chemical or mechanical etching are used, then manufacturing precision and durability are improved, but manufacturing cost increases

Engineering Contradiction:

Improvenozzle formation precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from stainless steel to polyimide, and changes the nozzle formation method from chemical/mechanical etching to laser ablation. This parameter change enables lower manufacturing cost while maintaining precision through the laser ablation process that creates clean, precise nozzle openings in the polyimide material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical and chemical etching system with a laser ablation system. Laser ablation uses optical energy to directly remove material and form nozzles, eliminating the need for chemical etchants and mechanical tools, thereby reducing manufacturing cost and complexity while maintaining precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If stainless steel aperture plates are used, then structural strength is improved, but deformation during assembly occurs leading to poor print quality

Engineering Contradiction:

Improveaperture plate strengthVSAvoidnozzle alignment precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent uses a composite structure consisting of polyimide aperture plate with anti-wetting coating and a coverlay layer. This composite material combination provides the necessary structural strength to prevent deformation during assembly while the coverlay protects the anti-wetting coating, maintaining nozzle alignment precision and print quality.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies a coverlay to the aperture plate before assembly to protect the anti-wetting coating and prevent deformation during the pressing operation. This beforehand protection ensures that the nozzle structure remains intact and properly aligned, preventing misdirectional jetting.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If polyimide material is used instead of stainless steel, then manufacturing cost is reduced, but material strength decreases

Engineering Contradiction:

Improvemanufacturing costVSAvoidaperture plate strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent creates a composite structure by combining polyimide material with a coverlay layer. The polyimide provides cost advantages and good laser ablation characteristics, while the coverlay reinforces the structure and protects the anti-wetting coating, together achieving both low cost and sufficient strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different properties to different parts of the aperture plate assembly. The polyimide base material provides cost-effectiveness and laser processability, while the added coverlay provides localized reinforcement and protection where needed, achieving optimal balance between cost and strength.

Inventive Principle:

Principle #3Local quality

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 approach reduces deformation around the nozzle, enhances ink jetting precision, and lowers manufacturing costs by using a more affordable polyimide material while maintaining high print quality and compliance with energy efficiency standards.

Implementation Method 1

an anti-wetting coating on a surface of the ink jet printhead aperture plate assembly

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Implementation Method 2

The coverlay can include a layer having an elastic modulus of at least 0.5 GPa

Methodology Applied

Scientific EffectElastic modulus: Elasticity

Data Source

PatentUS9096062B2Manufacturing process for an ink jet printhead including a coverlay

Publication Date: 2015.08.04 XEROX CORP

AI summary

A method for forming an ink jet printhead can include interposing a coverlay between a press plate of a press and an ink jet printhead aperture plate assembly, such that the coverlay physically contacts an anti-wetting coating on a surface of the aperture plate assembly. With the coverlay contacting the anti-wetting coating, a force is applied to the aperture plate assembly using the press. The coverlay is separated from the aperture plate assembly, wherein the coverlay includes a layer having an elastic modulus of at least 0.5 GPa.