Thermoset Flow Path Member for Ink Jet Recording Head
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Solution Overview
Problem
Existing ink jet recording heads face challenges in achieving high-resolution, long-term ink resistance and small linear expansion coefficients, particularly when using resin molding materials, which often result in surface roughening, filler elution, and clogging due to the separation of resin and filler during heat extrusion and long-term ink storage.
Innovation Solution
A thermoset flow path member made from a solid epoxy resin composition combined with a phenolic resin and alumina filler, utilizing injection molding to achieve high-density filling and strong adhesion, reducing filler elution and maintaining surface accuracy, with a small linear expansion coefficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a resin molding material is used for the flow path member, then the manufacturing cost is reduced and ease of manufacture is improved, but the linear expansion coefficient increases and ink resistance deteriorates over time
Solution Approach 1:
The patent uses a composite material consisting of thermosetting resin and alumina filler to create the flow path member. This composite structure combines the manufacturing advantages of resin with the dimensional stability and ink resistance of alumina, achieving both ease of manufacture and long-term reliability.
Solution Approach 2:
The patent modifies the material composition by incorporating alumina filler into the thermosetting resin, changing the physical and chemical parameters of the base material to achieve desired properties including reduced linear expansion coefficient and improved ink resistance.
2Ease of manufacture
If a liquid resin composition is used for injection molding, then the molding process is simplified, but the resin and filler separate during heat extrusion causing surface roughening
Solution Approach 1:
The patent changes the physical state of the resin from liquid to solid form, using solid granules instead of liquid resin. This parameter change prevents separation between resin and filler during heat extrusion while still allowing for injection molding processing.
Solution Approach 2:
The patent uses solid granule molding material that is consumed during the molding process, replacing complex liquid resin systems with a simpler solid material that achieves the desired molding results without separation issues.
3Stability of the object's composition
If alumina filler is added to reduce linear expansion coefficient, then the dimensional stability is improved, but the filler elutes during long-term ink storage causing nozzle clogging
Solution Approach 1:
The patent creates a composite material where alumina filler is embedded in a thermosetting resin matrix. This composite structure provides the dimensional stability of alumina while the cured resin matrix prevents filler elution, eliminating nozzle clogging.
Solution Approach 2:
The thermosetting resin acts as an intermediary material that binds the alumina filler particles together, preventing their direct contact with ink and subsequent elution, while still allowing the composite to achieve low linear expansion coefficient.
4Manufacturing precision
If photolithography is used to manufacture ejection nozzles with high precision, then the manufacturing precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces complex photolithography processes with injection molding technology. The ejection nozzles are formed directly during the injection molding process, substituting mechanical molding for optical lithography and simplifying the manufacturing process.
Solution Approach 2:
The injection molding process serves multiple functions simultaneously: it forms the flow path member structure, creates the ejection nozzles with high precision, and incorporates the alumina filler for dimensional stability, eliminating the need for separate photolithography 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
The solution provides an ink jet recording head with enhanced ink resistance, reduced filler elution, and improved surface accuracy, enabling reliable long-term performance and high-density recording capabilities without the need for expensive alumina materials.
Implementation Method 1
a thermoset flow path member made from a solid epoxy resin composition combined with a phenolic resin and alumina filler, utilizing injection molding
Data Source
AI summary
Provided is an ink jet recording head having a flow path member. The flow path member is made of a thermoset product of a thermosetting molding composition containing a solid epoxy resin composition containing an epoxy resin and a phenolic resin, each solid at ordinary temperatures, and an alumina filler.