Printhead Top Hat Layer Support to Prevent Tape Removal Damage
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Solution Overview
Problem
The removal of adhesive tape from printheads can cause damage to the top hat layer, leading to leakage of printing fluid due to deflection and stress on the printhead components.
Innovation Solution
The design of the printhead minimizes beam length where taping begins, and incorporates pillars to provide additional support, reducing deflection and stress when the tape is removed, thus preventing damage to the top hat layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to seal printhead to prevent printing fluid leakage, then sealing effectiveness is improved, but the top hat layer may be damaged during tape removal causing leakage
Solution Approach 1:
The patent performs preliminary reinforcement of the top hat layer by forming a support structure (second layer of photo definable material) beneath the top hat layer before the taping process. This preliminary action ensures that when adhesive tape is applied and later removed, the reinforced top hat layer can withstand the deflection and stress without damage, thus preventing printing fluid leakage while maintaining sealing effectiveness.
2Object-generated harmful factors
If tape is applied over printhead to prevent printing fluid leakage, then sealing is achieved, but deflection and stress during tape removal can damage the top hat layer
Solution Approach 1:
The patent applies beforehand cushioning by depositing a second layer of photo definable material that forms a support structure directly beneath the top hat layer. This support structure acts as a cushion that absorbs and distributes the stress and deflection forces generated during tape application and removal, preventing damage to the top hat layer while maintaining the sealing function against printing fluid leakage.
3Strength
If the beam length of unsupported top hat layer is reduced, then deflection during taping is minimized, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by providing targeted reinforcement only in the specific region where the top hat layer is unsupported and most vulnerable to deflection. The second layer of photo definable material is selectively formed to create pillars or support structures at critical locations beneath the top hat layer, rather than uniformly thickening the entire layer. This localized approach minimizes deflection during taping while avoiding unnecessary increase in overall device complexity.
Data Source
AI summary
In example implementations, a printhead die is provided. The printhead die includes a substrate, a chamber layer formed on the substrate, a plurality of printing fluid ejection chambers coupled to opposite sides of the chamber layer and along a length of the chamber layer, and a top hat layer formed on the chamber layer and the plurality of printing fluid ejection chambers. The chamber layer includes a void to store printing fluid. The top hat layer includes an initial unsupported top hat layer portion over the void, wherein the initial unsupported top hat layer portion comprises a first end that is narrower than a second end.