Sacrificial Form Printhead Fluid Paths
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Solution Overview
Problem
The manufacturing process of piezoelectric ink jet printheads is complex and costly due to the need for multiple layers of materials, which can lead to delamination and premature failure, especially when using adhesives that are not compatible with various inks and have different thermal expansion coefficients.
Innovation Solution
A method involving a sacrificial form is used to simplify the printhead structure by forming a single piece body with internal ink channels, where the sacrificial form is coated with a suitable material and then removed, reducing the number of layers and material interfaces, and using additive manufacturing or injection molding to create the sacrificial form.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple layers of materials are assembled to form printhead fluid paths, then the printhead can achieve complex three-dimensional microfluidic channels, but the manufacturing complexity and cost increase, and delamination may occur
Solution Approach 1:
A sacrificial form is created in advance with the desired negative shape of the fluid channels. This pre-formed template guides the coating process and ensures accurate channel geometry without requiring complex multi-layer assembly during manufacturing
Solution Approach 2:
Multiple functional layers (fluid channels, structural support, nozzle openings) are integrated into a single monolithic printhead body through the coating process, eliminating the need to assemble separate layers and reducing delamination risks
2Adaptability or versatility
If multiple layers of materials are assembled with adhesives, then the printhead can be constructed with different materials, but delamination and premature failure occur due to incompatible thermal expansion coefficients
Solution Approach 1:
The coating process creates a monolithic structure where all materials are bonded at the molecular level during curing, eliminating adhesive interfaces that are prone to delamination due to thermal expansion mismatches
Solution Approach 2:
The printhead body combines the structural integrity of the sacrificial form template with the functional properties of the coating material, creating a composite structure with uniform thermal expansion characteristics
3Strength
If adhesive films are used to bond material layers, then the layers can be joined together, but the adhesive cure cycle requires extended duration and high pressure to minimize delamination
Solution Approach 1:
The coating material is applied directly to the sacrificial form and cured in place, creating immediate bonding without requiring separate adhesive application and extended cure cycles. The coating process itself provides the bonding function
Solution Approach 2:
The adhesive layer is completely removed from the manufacturing process. Instead of using adhesive films that require cure cycles, the coating material bonds directly to the sacrificial form during the coating application, eliminating the need for separate adhesive curing steps
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 results in a printhead with reduced manufacturing complexity and cost, improved yield, and longer lifetime by minimizing delamination risks and simplifying the assembly process, while maintaining the functionality of traditional printheads.
Implementation Method 1
coating a sacrificial form with a coating material
Implementation Method 2
removing the sacrificial form from the coating material
Implementation Method 3
a voltage is applied to a piezoelectric transducer, typically through electrical connection with a flex circuit electrode electrically coupled to a voltage source, which causes the piezoelectric transducer to bend or deflect
Implementation Method 4
Diaphragm flexing by the piezoelectric transducer increases pressure within an ink chamber and expels a quantity of ink from the chamber through a particular nozzle
Data Source
AI summary
A method for forming an ink jet printhead subassembly can include the use of a sacrificial form coated with a coating material to fabricate a printhead subassembly having a plurality of ink channels configured for flowing ink therethrough. The sacrificial form can be manufactured using one or more described techniques. Subsequently, the sacrificial form may be removed from the coating material to provide a printhead subassembly including the coating material and an ink channel through the coating material. The completed printhead subassembly can include a single solid structure manufactured from a single material, or can include more than one solid structures assembled together.