Liquid Ejecting Head Chip Recycling Through Ranked Assembly
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Solution Overview
Problem
Existing liquid ejecting heads are replaced en masse despite varying degrees of failure or deterioration among their head chips, leading to the discarding of usable components.
Innovation Solution
A method for manufacturing a new liquid ejecting head by recycling and selectively embedding used head chips based on ranking and classification, ensuring a mix of chips with different deterioration levels are utilized.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the whole liquid ejecting head is replaced when some head chips are determined to be unusable, then the reliability of the liquid ejecting apparatus is maintained, but the loss of usable head chips increases
Solution Approach 1:
The liquid ejecting head is segmented into multiple independent head chips, each with its own ejection units. This allows individual head chips to be replaced or recycled independently, rather than replacing the entire head assembly. The head chip holder structure enables separate mounting and removal of individual head chips, facilitating selective recycling of functional chips while replacing only the defective ones.
Solution Approach 2:
The patent implements a recycling system where used head chips are collected, evaluated for functionality, and recovered for continued use. Head chips that remain functional after use are extracted from discarded liquid ejecting heads and mounted onto new head holders, creating a recovery loop that reduces waste of usable components while maintaining apparatus reliability.
2Ease of manufacture
If used head chips are randomly assembled into a new liquid ejecting head, then the manufacturing process is simple, but the productivity and quality consistency deteriorate
Solution Approach 1:
Used head chips are evaluated and classified into different ranks based on their functional characteristics before being assembled into new liquid ejecting heads. This preliminary classification ensures that only chips meeting specific performance criteria are selected, guaranteeing quality consistency. The evaluation process includes measuring ejection characteristics and determining suitability for different positions in the new head assembly.
Solution Approach 2:
Different ranks of head chips are assigned to different positions or groups of ejection units within the liquid ejecting head based on their specific performance characteristics. This local quality assignment optimizes the overall head performance by matching chip capabilities with position requirements, rather than using a uniform assembly approach.
Data Source
AI summary
A method of manufacturing a liquid ejecting head includes: first ranking and classifying a plurality of used head chips included in a first liquid ejecting head into a plurality of ranks based on characteristic information of each of the plurality of used head chips included in the first liquid ejecting head; and selecting used head chips to be embedded in the second liquid ejecting head among the plurality of used head chips so that the second liquid ejecting head includes a plurality of used head chips classified in different ranks in the first ranking and classifying. The second liquid ejecting head is manufactured by recycling part of the plurality of used head chips included in the first liquid ejecting heads by embedding the selected used head chips into the second liquid ejecting head.