Patent Grant
11597204
Fluid ejection devices selectively ejected droplets of fluid. The fluid may sometimes contain pigments or other particles that may tend to settle. Such settled particles may detrimentally impact the performance of the fluid ejection devices.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. Moreover, the drawings provide examples and/or implementations consistent with the description; however, the description is not limited to the examples and/or implementations provided in the drawings.
Disclosed are example fluid ejection assemblies, fluid ejection assembly components and methods that facilitate recirculation of the fluid to agitate or mix the fluid and reduce settling. The disclosed fluid ejection assemblies, fluid ejection assembly components and methods supply fluid to a fluid ejection die through fan-out fluid passages that converge towards a back face of a smaller dimensioned fluid ejection die. A recirculation passage connects different fan-out fluid passages to recirculate the fluid across a back face of the die. The recirculation passage is formed within a polymeric material. The formation of the recirculation passage in the polymeric material provides for a lower cost recirculation passage and a lower cost fluid ejection assembly. The use of the polymeric material further facilitates a dense arrangement of multiple recirculation passages having reduced pitch while not sacrificing channel depth. In addition to providing a low-cost recirculation passage, the polymeric material in which the recirculation passages formed provides more uniform heat distribution and greater chemical resistance to various fluids as compared to silicon.
In some implementations, a fluid ejection assembly is formed from a fluid ejection die and a single unitary polymeric body. For purposes of this disclosure, a “single unitary polymeric body” refers to a single integral unitary body formed from a single mass of polymeric material, lacking distinct structures that are bonded, welded, fastened or otherwise joined together. The single mass polymeric material may be homogenous or may have different material compositions or mixtures in different portions of the single mass of material.
The single unitary polymeric body is joined to the back face of the fluid ejection die. The single unitary polymeric body includes both the fan-out fluid passages as well as the recirculation passage. In one implementation, the single unitary body comprises a molded polymer in which the fan-out fluid passages and the recirculation passage are molded. In some implementations, the single unitary body comprises a multitude of recirculation passages.
In some implementations, a fluid ejection assembly is formed from a fluid ejection die, a first unitary polymeric body in which the fan-out fluid passages are formed and a second unitary polymeric body sandwiched between and joined to the fluid ejection die in the first unitary polymeric body. The second or intermediate unitary polymeric body provides the recirculation passage or the series of recirculation passages. Examples of polymeric material in which the recirculation passage or passages may be formed include, but are not limited to, epoxy mold compound, or thermoplastic such as polyphenylene sulfide (PPS), polyethylene (PE), polyethylene terephthalate (PET), polyether ether ketone (PEEK), polysulfone (PSU), liquid crystal polymer (LCP), and the like.
Disclosed is an example fluid ejection assembly that may include a fluid ejection die comprising a back face and a front face through which fluid is ejected. The fluid ejection die may further include a fan-out fluid passages converging towards the back face of the fluid ejection die, the fan-out fluid passages comprising a first fan-out fluid passage and a second fan-out fluid passage and a recirculation channel extending within a polymeric material from the first fan-out fluid passage to the second fan-out fluid passage adjacent the back face of the fluid ejection die.
Disclosed is an example fluid ejection assembly component for forming part of a fluid ejection assembly. The component may comprise a unitary polymeric body that comprises converging fan-out fluid passages and recirculation channels. The fan-out fluid passages comprising a first fan-out fluid passage and a second fan-out fluid passage. The recirculation channels extend from the first fan-out fluid passage to the second fan-out fluid passage.
Disclosed is an example method for forming a fluid ejection assembly. The method may comprise providing a fluid ejection die, molding a unitary polymeric body and joining the molded unitary polymeric body adjacent a back face of the fluid ejection die. The polymeric body that is molded may include fan-out fluid passages that converge and a recirculation channel. The fan-out fluid passages comprise a first fan-out fluid passage and a second fan-out fluid passage. The recirculation channel extends within a polymeric material from the first fan-out fluid passage to the second fan-out fluid passage.
Fluid ejection die (FED) 24 comprises a die having a front or fluid ejection face 42 and a rear or back face 44. Die 24 comprises a body formed from a material such as silicon that houses and supports fluid ejection devices that receive fluid from fan-out fluid passage 30-1. Fluid ejection die 24 may include a series of fluid ejection chambers, each chamber having a fluid ejection orifice or nozzle opening. Each fluid ejection device may further include a fluid actuator that displaces fluid within the fluid ejection chamber through the fluid ejection orifice.
In one implementation, the fluid actuator may comprise a thermal resistor which, upon receiving electrical current, heats to a temperature above the nucleation temperature of the solution so as to vaporize a portion of the adjacent solution or fluid to create a bubble which displaces fluid through the orifice. In other implementations, the fluid actuator may comprise other forms of fluid actuators. In other implementations, the fluid actuator may comprise a fluid actuator in the form of a piezo-membrane based actuator, an electrostatic membrane actuator, mechanical/impact driven membrane actuator, a magnetostrictive drive actuator, an electrochemical actuator, and external laser actuators (that form a bubble through boiling with a laser beam), other such microdevices, or any combination thereof.
Fan-out fluid passages 30 comprise fluid passages that converge towards the back face 44 of fluid ejection die 24. Fan-out fluid passages 30 converge towards one another to direct fluid to the generally much smaller dimensioned fluid ejection die 24. As will be described hereafter, in one implementation, fan-out fluid passages 30 are formed within a body distinct from the body in which recirculation channel 40 extends. In other implementations, fan-out fluid passages 30 are formed within a single unitary polymeric body, the same single unitary polymeric body in which recirculation channel 40 extends.
Recirculation channel 40 comprises a passage that extends from fan-out fluid passage 30-1 to fan-out fluid passage 30-2 adjacent the back face 44 of fluid ejection die 24. For purposes of this disclosure, two structures may be considered as “adjacent” to one another despite the provision of an intervening adhesive or other material applied in a viscous state to join the two structures. Recirculation channel 40 facilitates the circulation of fluid across the back face of fluid ejection die 24, between fan-out fluid passages 30. Although not illustrated, in some implementations, fluid ejection assembly 20 may comprise a multitude of recirculation channels that interconnect passages 30 along the back face 44 of fluid ejection die 24.
Recirculation channel 40 extends within a polymeric material 50 (as schematically indicated by stippling). Because recirculation channel 40 is formed within the polymeric material 50, recirculation channel 40 may be provided with more closely controlled shapes and dimensions at a lower cost. The more closely controlled dimensions may facilitate the formation of a larger number or greater density of smaller individually sized recirculation channels which may provide greater circulation velocity for enhanced agitation or mixing. For example, recirculation channel 40 may be molded into the polymeric material 50.
The polymeric material in which recirculation channel 40 extends may define the interior side walls of recirculation channel 40 and may contact or extend adjacent to fluid ejection die 24. As compared to other materials, such as silicon, the polymeric material may have enhanced chemical resistivity to the fluids being circulated. As a result, interior surfaces of the fluid ejection channel 40 have a greater resistance to corrosion caused by the fluid being circulated. Moreover, as compared to other materials such as silicon, the polymeric material may enhance thermal insulative properties, facilitating a more uniform temperature across fluid ejection die 24 and fluid ejection apparatus 20. The more uniform temperature may enhance fluid ejection performance.
In one implementation, the polymeric material 50 in which fluid recirculation channel is formed comprises a molded polymeric material which is shaped while the polymeric material is in a fluid or viscous state and wherein the fluid or liquid polymer material is subsequently hardened or solidified through evaporation or curing. In one implementation, the polymeric material 50 comprises an epoxy mold compound. In another implementation, the polymeric material 50 may be formed from a polymeric material selected from a group of polymeric material such as thermoplastic such as PPS, PE, PET, PEEK, PSU, LCP, and the like, or combinations thereof.
As shown by
As indicated by arrow 60, a portion of the fluid supplied to fan-out fluid passage 30-1 may be circulated through recirculation channel 40, across the back face 44 of fluid ejection die 24. As indicated by arrow 60, the fluid may be circulated through fan-out fluid passage 30-2 out of the recirculation channel 40 and away from the fluid ejection die 24. Such circulated fluid may flow back to a fluid supplier source from which the fluid was provided. As a result, fluid may be recirculated to promote mixing and agitation of the fluid and reduce settling.
As indicated by block 408, a unitary polymeric body, such as body 338 is molded. The molded unitary polymeric body comprises converging fan-out fluid passages, such as fluid passages 30, and a recirculation channel, such as recirculation channel 40, that connect the converging fan-out fluid passages. As indicated by block 412, the molded unitary polymeric body is joined adjacent a back face of the fluid ejection die. Because method 400 molds the polymeric body and correspondingly molds the fan-out fluid passages and the recirculation channel, the location, shape and dimensions of the fan-out fluid passages and recirculation channel may be more precisely controlled and may be fabricated at a lower cost and complexity. In some implementations, the molding of the recirculation channel may facilitate a more dense arrangement of recirculation channels to provide enhanced fluid circulation and agitation. Because the fan-out fluid passages and the circulation channel are concurrently molded in a single unitary polymeric body, individual alignment of the fan-out fluid passages in the circulation channels is automatically achieved as part of the molding operation. Moreover, the use of adhesives may be reduced. As a result, method 400 may facilitate the provision of smaller and more compact ejection assemblies at a reduced cost.
Fan-out body 528, sometimes referred to as a fan-out chiclet, comprises a body extending between fluid supply 522 and recirculation body 538. In the example illustrated, fan-out body 528 is bonded to a larger fluid manifold 523 which directs fluid from fluid supply 522 to body 528. In one implementation, body 528 comprises a single unitary body. In one implementation, body 528 is formed from a single unitary polymeric body. For example, one implementation, body 528 may be formed from a polymer such as PPS, PE, PET, PEEK, PSU, LCP, and so on. Body 528 is joined to circulation body 538 by an intermediate adhesive 539.
Similar to body 228 described above, body 528 comprises fan-out fluid passages 530-1 and 530-2 (collectively referred to as passages 530). Passages 530 are similar to passages 30 described above. Passages 530 converge towards the back face 544 of fluid ejection die 524. Fan-out fluid passages 530 converge towards one another to direct fluid to the generally much smaller dimensioned fluid ejection die 524.
Recirculation body 538 is similar to body 238 described above. Recirculation body 538 is sandwiched between fan-out body 528 and fluid ejection die 524. Recirculation body 538 comprises a single unitary polymeric body. In one implementation, the circulation body 538 may be formed from an epoxy mold compound. In other implementations, recirculation body 53 may be formed from other polymers such as PPS, PE, PET, PEEK, PSU, LCP, and so on.
Body 538 is joined to fluid ejection die 524 by an intermediate adhesive layer 539. In other implementations, body 528 may be joined to body 538 and body 538 may be joined to fluid ejection die 524 in other ways, such as through the use of fasteners, fusing a welding, connectors and the like. In one implementation, bodies 528 and 538 are formed from the same polymeric material 50. In other implementations, bodies 528 and 538 are formed from different polymeric materials.
Body 538 comprises a series of recirculation channels 540 that are formed within and extend within the polymeric material forming body 538. Each of the recirculation channels 540 is similar to recirculation channels 40 described above. Each of the recirculation channels 540 facilitates the circulation of fluid across the back face of fluid ejection die 524, between fan-out fluid passages 530.
Because recirculation channels 540 are formed within polymeric material 50, each recirculation channel 540 may be provided with more closely controlled shape and dimensions at a lower cost. The more closely controlled dimensions may facilitate the formation of a larger number or greater density of smaller individually sized recirculation channels 540 which may provide greater circulation velocity for enhanced agitation or mixing. For example, recirculation channel 540 may be molded into the polymeric material 50.
The polymeric material in which recirculation channel 540 extends may define the interior side walls of each recirculation channel 540 and may contact or extend adjacent to fluid ejection die 524. As compared to other materials, such as silicon, the polymeric material may have enhanced chemical resistivity to the fluids being circulated. As a result, interior surfaces of each fluid ejection channel 540 have a greater resistance to corrosion caused by the fluid being circulated. Moreover, as compared to other materials such as silicon, the polymeric material may enhance thermal insulative properties, facilitating a more uniform temperature across fluid ejection die 524 and fluid ejection apparatus 520. The more uniform temperature may enhance fluid ejection performance.
As further shown by
Fluid supply 722 supplies fluid to fluid ejection die 724 for being ejected. In some implementations, the fluid being supplied comprises an ink. In some implementations, the fluid being supplied comprises a pigment-based ink. In other implementations, fluid supply 722 may supply other types of fluid having particles that may settle. In one implementation, the fluid supply 722 of subsystems 721 supply and eject different types of fluid, such as different colors of ink. In other implementations, the fluid supplies 722 of subsystems 721 supply and eject the same fluids. In some implementations, subsystems 721 may share a single fluid supply 722.
As shown by
Substrate 770 comprises a layer or multiple layers of material, such as silicon, upon which chamber layer 772 and fluid actuators 774 are formed and supported. Substrate 770 comprises ink supply passages 776, in the form of fluid feed holes or slots, that direct fluid through substrate 770 into and out of fluid ejection chambers formed within chamber layer 772.
Chamber layer 772 comprises a layer or multiple layers of material, such as SU8, that form firing chambers 778 having fluid ejection orifices 780. In some implementations, chamber layer 772 may comprise multiple layers such as a first layer forming firing chambers 778 and a second layer, sometimes referred to as an orifice plate, forming orifices 780.
Fluid actuators 774 comprise electrically driven and controlled structures supported by substrate 770 adjacent to the firing chambers 778. Such fluid actuators 774 may be controlled by electrical control signals transmitted to electronic circuitry including transistors and the like, formed on substrate 770, to selectively actuate the fluid actuators 774. Each of such fluid actuators 774, upon being actuated, displaces fluid within the associated ejection chambers 778 so as to displace and eject fluid through the corresponding orifice 780.
In one implementation, each of fluid actuators 774 may comprise a thermal resistor which, upon receiving electrical current, heats to a temperature above the nucleation temperature of the solution so as to vaporize a portion of the adjacent solution or fluid to create a bubble which displaces fluid through the orifice. In other implementations, the fluid actuator may comprise other forms of fluid actuators. In other implementations, each of fluid actuators 774 may comprise a fluid actuator in the form of a piezo-membrane based actuator, an electrostatic membrane actuator, mechanical/impact driven membrane actuator, a magnetostrictive drive actuator, an electrochemical actuator, and external laser actuators (that form a bubble through boiling with a laser beam), other such microdevices, or any combination thereof. It should be appreciated that the described fluid ejection dies 24, 124 and 524 may be similar to fluid ejection die 724.
Body 738 comprises a single unitary polymeric body. In one implementation, body 738 may be formed from an epoxy mold compound. In other implementations, body 738 may be formed from other polymers such as PPS, PE, PET, PEEK, PSU, LCP, and the like. In one implementation, body 738 is molded so as to form fan-out fluid passages 730-1 and 730-2 (collectively referred to as passages 730) and recirculation channels 740. Fan-out fluid passages 730 are similar to fan-out fluid passages 530 described above. Fan-out fluid passages 730 converge towards one another as they approach the back face 744 of fluid ejection die 724.
Recirculation channels 740 are similar to recirculation channels 540 described above. In the example illustrated, recirculation channels 740 are separated by dividers 782. In one implementation, dividers 782 comprise a row or series of pillars extending between channels 740. Such pillars facilitate further crossflow and facilitate mixing. In another implementation, dividers 782 comprise a single elongate rib, a series of end-to-end ribs or staggered and overlapping ribs.
Similar to recirculation channels 740, recirculation channels 940 extend along a length of fluid fan-out passages 730-1 and 730-2, between such passages, and below portion 741 of body 738, as shown in
In the example illustrated, consecutive recirculation channels 940 are separated by dividers in the form of projecting ribs 982. Ribs 982 each have lower surfaces 984 for contacting or supporting fluid ejection die 724 (shown in
Microfluidic die 1024 comprises substrate 1128, chamber layer 1130 and orifice layer 1132. Substrate 1128 comprise a layer of material extending between body 1038 and chamber layer 1130. Substrate 1128 forms an inlet 1152 of fluid supply channel 1136 connected to fan-out fluid passage 730-1. Substrate 1128 further forms an outlet 1154 of fluid discharge channel 1142 connected to fan-out fluid passage 730-2. In one implementation, substrate 1128 is formed from silicon. In other implementations, substrate 1128 may be formed from other materials such as polymers, ceramics, glass and the like.
Chamber layer 1130 comprises a layer of material forming fluid supply channel 1136, fluid discharge channel 1142 and a ceiling or top of ejection chamber 1138 (when assembly 1020 is ejecting fluid in a downward direction).
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Although the present disclosure has been described with reference to example implementations, workers skilled in the art will recognize that changes may be made in form and detail without departing from the disclosed subject matter. For example, although different example implementations may have been described as including features providing benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example implementations or in other alternative implementations. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example implementations and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. The terms “first”, “second”, “third” and so on in the claims merely distinguish different elements and, unless otherwise stated, are not to be specifically associated with a particular order or particular numbering of elements in the disclosure.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2019/039077 | 6/25/2019 | WO |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2020/263235 | 12/30/2020 | WO | A |
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