Inkjet Printhead Aperture Coating for Debris Prevention

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Solution Overview

Problem

Conventional high temperature adhesive bonding processes in jetstack fabrication result in debris particles adhering to the narrow apertures/orifices of inkjet printheads, causing obstructions and requiring labor-intensive post-processing for removal, which is time-consuming and costly, especially as production volume increases.

Innovation Solution

Applying a protective coating, such as a water-soluble material, to fill and obstruct apertures/orifices during bonding to prevent particle intrusion and adhesion, which can be easily removed post-process using a liquid rinse, reducing particle adhesion forces and facilitating debris removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If high temperature adhesive bonding process is used to fabricate jetstack, then bonding strength is improved, but debris particles adhere to aperture/orifice surfaces causing obstructions

Engineering Contradiction:

Improvebonding strengthVSAvoidparticle adhesion

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

A protective coating is applied to the aperture plate before the high temperature bonding process. This coating prevents debris particles from adhering to the aperture/orifice surfaces during bonding, and can be easily removed afterward to leave clean apertures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protective coating acts as an intermediary layer between the aperture surfaces and the bonding environment. It shields the apertures from direct exposure to debris generated during high temperature bonding, preventing particle adhesion while allowing the bonding process to proceed.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional bonding process is used, then fabrication speed is maintained, but labor-intensive post-processing is required for debris removal

Engineering Contradiction:

Improvefabrication speedVSAvoidpost-processing time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The protective coating is applied in advance before bonding, preventing debris adhesion during the process. This eliminates or significantly reduces the need for time-consuming post-bonding cleaning operations, as the coating can be easily removed to leave clean apertures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protective coating temporarily obstructs the apertures during bonding, which seems harmful to productivity. However, this temporary obstruction prevents debris adhesion, and the easy removal of the coating results in net time savings by eliminating complex post-processing cleaning operations.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If protective coating is applied to prevent particle adhesion, then aperture clarity is maintained, but additional process steps are added

Engineering Contradiction:

Improveaperture clarityVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The protective coating is a temporary, disposable layer applied only for the duration of the bonding process. It serves its protective function during bonding, then is easily removed. This disposable approach maintains aperture clarity without requiring permanent complex anti-adhesion mechanisms.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The protective coating changes the surface properties of the aperture plate temporarily during bonding. By modifying the surface characteristics with the coating, debris adhesion is prevented during the high temperature process, and the original surface properties are restored after coating removal.

Inventive Principle:

Principle #35Parameter changes

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

Significantly reduces the occurrence of debris particles adhering to aperture/orifice surfaces, simplifying the fabrication process by allowing for easy removal of the coating, thus maintaining aperture clarity and reducing production delays and costs.

Implementation Method 1

Applying a protective coating, such as a water-soluble material, to fill and obstruct apertures/orifices during bonding to prevent particle intrusion and adhesion

Methodology Applied

Scientific EffectPhysical barrier (protective coating): Coatings

Implementation Method 2

which can be easily removed post-process using a liquid rinse

Methodology Applied

Scientific EffectDissolution (water-soluble material): Solvation

Data Source

PatentUS9073324B2System for fabricating an inkjet printhead

Publication Date: 2015.07.07 XEROX CORP

AI summary

A system for fabricating an inkjet printhead that includes an apparatus for depositing a protective coating on an aperture plate unit, the aperture plate unit including a plurality of outlet apertures in the aperture plate unit, the apparatus including a protective coating source and a protective coating dispensing device, and a processor that is programmed to control an automated process for coating an inner surface of each of the plurality of outlet apertures with the protective coating. The protective coating dispensing device coats the inner surface of each of the plurality of outlet apertures by dispensing a measured amount of the protective coating to completely clog each of the plurality of outlet apertures by at least one of spraying the aperture plate unit with the protective coating and rolling the protective coating onto the aperture plate unit.