Polymer Laser-Ablated Filter for Inkjet Printhead Pressure
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Solution Overview
Problem
High-resolution ink jet printheads face contamination issues due to the limitations of stainless steel particulate filters, which restrict ink flow and increase pressures as nozzle sizes decrease, making them costly and prone to premature failure.
Innovation Solution
A polymer particulate filter is formed using laser ablation, with precise openings that allow for improved filtration without constricting ink flow, reducing the need for expensive cleanroom manufacturing and minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel particulate filters are used to filter contaminants in the printhead, then contamination removal is achieved, but ink flow is restricted and pressures increase
Solution Approach 1:
The patent changes the material parameter from stainless steel to polymer, which fundamentally alters the filtration characteristics. The polymer material allows for smaller opening sizes while maintaining lower flow resistance, thereby removing contaminants effectively without significantly increasing ink flow pressure.
Solution Approach 2:
The patent employs a composite structure combining polymer material with precisely controlled opening patterns. This composite approach enables optimization of both filtration efficiency and flow characteristics, achieving contamination removal while maintaining acceptable ink flow pressures.
2Manufacturing precision
If nozzle sizes are decreased to increase printer resolution, then print quality improves, but contamination blocking becomes more likely
Solution Approach 1:
The patent changes the filter material parameter to polymer, enabling the use of smaller opening sizes that match the reduced nozzle dimensions in high-resolution printers. This parameter change allows the filter to effectively block contaminants without interfering with the reduced ink flow required for high-resolution printing.
Solution Approach 2:
The patent uses a patterned mask during polymer sheet formation to create opening patterns that replicate the precise geometric requirements of high-resolution printing. This copying approach ensures the filter openings are precisely sized and positioned to match the nozzle array, enabling effective filtration without compromising print resolution.
3Reliability
If stainless steel filters are used to maintain filtration effectiveness, then contamination removal is achieved, but manufacturing costs increase
Solution Approach 1:
The patent replaces expensive stainless steel filters with more economical polymer filters. The polymer material is less costly to manufacture, and the filters can be produced using standard laser ablation or photolithography processes, significantly reducing manufacturing costs while maintaining adequate filtration effectiveness for the application.
Solution Approach 2:
The patent changes the material parameter from expensive stainless steel to cost-effective polymer, reducing manufacturing costs while maintaining filtration performance. The polymer material can be processed using conventional manufacturing techniques, further lowering production expenses.
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 polymer filter provides effective contamination removal with reduced pressure constraints and lower manufacturing costs, enabling higher print quality and longer printhead lifespan.
Implementation Method 1
a laser beam can be directed through the openings in the mask and onto a surface of the polymer sheet to heat and ablate portions of the polymer sheet
Data Source
AI summary
A printhead for printing ink includes a particulate filter manufactured from a polymer sheet such as a polyimide sheet. Filter openings within the particulate filter can be formed using a mask and a laser beam to ablate exposed portions of the polymer sheet. Embodiments of the present teachings can result in the formation smaller filter openings at a smaller pitch within the polymer sheet than, for example, stainless steel particulate filters, and thus more openings which cover a larger percentage of the filter surface for a given filter size, which can result in a reduction of fluid pressure within the printhead. Thus smaller filter openings for improved filtering of smaller particulates can be formed while maintaining a sufficient ink flow at a sufficiently low pressure within the printhead during operation.