1. Field of the Invention
The present invention relates to a method for manufacturing a liquid ejection head composed of a line head in which element substrates provided with liquid supply openings are arranged in a direction crossing a sheet conveying direction on a base plate on which liquid supply slits are formed, for correcting a position of the liquid supply opening to the liquid supply slit, and the liquid ejection head.
2. Description of the Related Art
In general, in a liquid ejection head in which a plurality of element substrates are arranged, the element substrate is positioned and fixed on a support member (base plate) made of aluminum, resin or the like in such manner as to arrange the element substrate in a predetermined position at the time of attaching the liquid ejection head to a liquid ejection apparatus. In this way, there is used a line head in which ejection is made possible on a sheet over an entire region of a sheet width by arranging the element substrates, which are thus positioned and fixed on the base plate, in a zigzag manner. In a case of the liquid ejection head in which such element substrates are arranged on the base plate in a zigzag manner, each of the element substrates is positioned and fixed on the base plate on which liquid supply slits for supplying liquids to the element substrates are each arranged in a predetermined position.
At this time, two lines of the liquid supply slits in the base plate each are linearly formed at an interval in a direction vertical to a sheet conveying direction, and the plurality of element substrates are attached in predetermined positions on the base plate for fixation. Accordingly a position of a liquid supply opening disposed on the element substrate is designed to be adjusted to a predetermined position to a position of the liquid supply slit of the base plate.
However, in a case of an elongated liquid ejection head as the line head, a strain is possibly generated in the base plate, and therefore there are some cases where the position of the liquid supply opening provided on the element substrate does not match the position of the liquid supply slit in the base plate.
Therefore according to Japanese Patent Laid-Open No. 2010-23486, the ink supply member that will be attached to the base plate is divided into a plurality of ink supply members in view of the event that attachment between members different from each other is one cause of generation of the base plate strain, and thus the strain of the base plate is reduced.
The generation of the strain in the base plate is caused not only by the attachment of the different members to each other. In a case of the line head that can eject liquids over an entire region of the sheet in A4 size in the width direction, the base plate having a length of approximately 300 to 400 mm is used. In a case where the base plate of such a length is formed of an aluminum sintered body, a curved warp is generated in the base plate. In regard to an outline of the base plate in which the warp is thus generated, a deformed amount thereof can be removed by cutting work or the like, but in regard to the positions of the plurality of liquid supply slits formed on the base plate, the positional shift of each becomes the larger in the sheet conveying direction from both the ends toward the center of the base plate.
As a result, there are some cases where an opening width of the liquid supply opening of the element substrate is made small. Therefore a refill failure in which liquids are not sufficiently supplied occurs, an adherent for attaching and fixing the element substrate flows into the liquid supply slit, and in the worst case, the liquid supply opening of the element substrate is closed up by the base plate. Therefore the base plate the entirety of which is deformed in a curved shape and in which the liquid supply slit position is out of a predetermined dimension cannot be used, leading to a reduction in production yield rate of the base plate, that is, a cost increase in production thereof.
Therefore, the present invention is made for solving the foregoing problems in the conventional technology, and an object of the present invention is to provide a method for manufacturing a liquid ejection head and a liquid ejection head, which can prevent deterioration in production yield rate of the liquid ejection head to decrease the production cost.
Therefore, a method for manufacturing a liquid ejection head according to an aspect of the present invention including a joint step for jointing a base plate provided with a plurality of supply slits each arranged in a predetermined position and an element substrate provided with a plurality of supply openings each arranged to be adjusted to the predetermined position, comprises an obtaining step for obtaining information in regard to a shift amount between the position of the supply opening and the position of the supply slit at the time of jointing the element substrate and the base plate, a correcting step for, in a case where the information in regard to the shift amount between the position of the supply opening and the position of the supply slit is a predetermined value or more, correcting the element substrate from the predetermined position such that the information in regard to the shift amount is less than the predetermined value, and a position correcting step for correcting the position of the element substrate by an the integral multiple of an image formation minimum pixel pitch in a conveying direction of a sheet, of an image formed on the sheet by liquids ejected from the liquid ejection head, as a unit of a travel distance at the correcting of the element substrate.
According to the aspect of the present invention, it is possible to realize the method for manufacturing the liquid ejection head that can prevent deterioration in production yield rate of the liquid ejection head at the manufacturing to decrease the production cost by adjusting the position of the supply opening in the element substrate to the position of the supply slit in the base plate.
Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
Hereinafter, a first embodiment of the present invention will be in detail explained with reference to the attached drawings.
A liquid ejection head 1000 to which the embodiments of the present invention are applied is provided with an ejection opening line formed therein to cover a range of the maximum width of a sheet supposed to be used, and is a full line type liquid ejection head of an inkjet method that can perform a print in a wide range without the scanning of the liquid ejection head 1000.
The liquid ejection head 1000 includes a plurality of element substrates 1100, a base plate 1200 for supporting the element substrates 1100, an electrical wiring substrate 1300 for electrical connection between the element substrates 1100 and the liquid ejection apparatus, and ink supply members 1500 jointed to the base plate 1200. The plurality of element substrates 1100 are arranged in a direction (arrow Y direction) crossing a sheet conveying direction (arrow X direction) on a main surface 1200a of the base plate 1200 with excellent accuracy, and the ink supply members 1500 are arranged on a surface 1200b of the base plate 1200 at the opposite side to the main surface 1200a.
Next, an explanation will be made of the element substrate 1100 having an ejection opening group for ejecting liquids (hereinafter, referred to as “ink” also).
A plurality of electrodes 1103 are provided at both ends of the Si substrate 1108 in an arrow Y direction for supplying electrical power to the electrical wiring. Further, the ejection opening plate 1110 is provided on the Si substrate 1108, and an ink flow passage 1104 and ejection openings 1105 corresponding to the heat generation resistance elements 1102 are formed in the ejection opening plate 1110 by a photolithographic technique. The ejection opening 1105 is provided to face the heat generation resistance element 1102, and air bubbles are generated from ink supplied from the ink supply opening 1101 by the heat generation resistance element 1102 to eject the ink.
The base plate 1200 for supporting the element substrate 1100 as shown in
The base plate 1200 is provided with the element substrates 1100 each arranged in a zigzag shape with a predetermined position accuracy. The respective element substrates 1100 are arranged such that end portions 1109 of the ejection opening groups 1106 provided in the respective element substrates 1100 overlap with each other in an ejection opening arrangement direction. In this manner, in the joint portion between the element substrates 1100, the end portions 1109 of the ejection opening groups are arranged to overlap with each other. Therefore also in the elongated liquid ejection head, the ejection openings 1105 can be sequentially arranged in the longitudinal direction, and an influence on the image generated at the printing by a positional shift at the arranging or the like can be corrected.
It should be noted that the sheet is not limited to the roll sheet, but may be a cut sheet. Further, the liquid ejection apparatus 2000 is provided with a sub-tank (not shown) for accumulating ink to be supplied to the liquid ejection apparatus 2000. Further, the liquid ejection apparatus 2000 is provided with an ink flow passage, ink accommodated in the sub-tank is supplied to the liquid ejection head 1000, and the ink is recirculated from the liquid ejection head 1000 to the sub-tank through the ink flow passage.
The print unit 2100 is provided with the plurality of liquid ejection heads 1000 each corresponding to a different ink color. In the present embodiment, the liquid ejection heads 1000 comprise four liquid ejection heads corresponding to four colors of cyan C, magenta M, yellow Y and black K, but the numbers of colors may comprise any numbers.
In the manufacture, the image processing technique is first used to measure the positional shift in the sheet conveying direction between the ink supply opening 1101 of the element substrate 1100 arranged on the base plate 1200 and the ink supply slit 1210 of the base plate 1200 (information in regard to the shift amount is obtained). At this time, the position of the ink supply opening 1101 in the element substrate 1100 is measured from a substantially central line of the ink supply opening 1101 in a direction vertical to the sheet conveying direction. In addition, the position of the ink supply slit 1210 in the base plate 1200 is measured from a substantially central line of the ink supply slit 1210 in a direction vertical to the sheet conveying direction.
In a case where the element substrate 1100 is arranged on the base plate 1200 in a state where the shift amount in the sheet conveying direction between the ink supply opening 1101 and the ink supply slit 1201 is less than a half of a width dimension of the ink supply slit 1201 in the short direction (less than a predetermined value), the element substrate 1100 is arranged in a predetermined position without its positional correction. In addition, in a case where the element substrate 1100 is arranged on the base plate 1200 in a state where the shift amount in the sheet conveying direction between the ink supply opening 1101 and the ink supply slit 1201 is a half or more of the width dimension of the ink supply slit 1201 in the short direction (the predetermined value or more), the element substrate 1100 is arranged on the base pate 1200 by adjusting the ink supply opening 1101 to the position of the ink supply slit 1201 for its positional correction.
Specifically the element substrate 1100 is arranged on the base plate 1200 such that a substantially central line of the ink supply opening 1101 in a direction vertical to the sheet conveying direction is substantially in agreement with a substantially central line of the ink supply slit 1210 in a direction vertical to the sheet conveying direction. By arranging the element substrate 1100 with this method, the ink supply opening 1101 the position of which is shifted largely from the ink supply slit 1201 in the sheet conveying direction is corrected in position to be arranged in the substantially central line of the ink supply slit 1201.
When the element substrate 1100 is thus arranged, the element substrates 1100 result in being arranged on the base plate 1200 as shown in
It should be noted that if a production tact time at the manufacturing process is permitted, even when the element substrate 1100 is arranged in a state where the shift amount in the sheet conveying direction between the ink supply opening 1101 and the ink supply slit 1201 is less than a half of the width dimension of the ink supply slit 1201 in the short direction, the element substrate 1100 may be corrected in position in such a manner that the center lines of the ink supply opening 1101 and the ink supply slit 1201 are substantially in agreement with each other. As a result, the element substrates 1100 are arranged on the base plate 1200 as shown in
However, since the opening width of the ink supply slit 1210 is a half or more of the width of itself, a possibility of causing a print failure such as deterioration of ink supply performance or attachment reliability of the element substrate 1100 is extremely low.
Therefore the present embodiment adopts the method where in a case where the ink supply opening 1101 and the ink supply slit 1201 are largely shifted in position from each other as described above, the position of the element substrate 1100 is corrected to the base plate 1200 to arrange the element substrate 1100 thereon. With this correction, the element substrate 1100 arranged to be adjusted (corrected) to the position of the ink supply slit 1201 can form a predetermined image by changing drive timing to the element substrate 1100 arranged in a predetermined position without its positional correction.
Therefore, in a case where the position of the element substrate 1100 is corrected to be arranged to be adjusted to the position of the ink supply slit 1201, the element substrate 1100 may be arranged in a position shifted by an integral multiple of an image formation minimum pixel pitch in the sheet conveying direction (the travel distance is equal to an integral multiple of an image formation minimum pixel pitch), from the predetermined arrangement position of the element substrate 1100. That is, for example, in a case where an image in the sheet conveying direction has a resolution of 1200 dpi, since the image formation minimum pixel pitch is 21.2 μm, the element substrates 1100 each may be arranged in a unit of 21.2 μm
A width dimension of the ink supply slit 1201 is approximately 0.5 to 1 mm. When this accuracy is maintained, even in a case where the element substrate 1100 is arranged in the position of the ink supply slit 1201, the shift amount in the sheet conveying direction between the ink supply opening 1101 and the ink supply slit 1201 can be made less than a half of the width dimension of the ink supply slit 1201.
Therefore according to the manufacturing method by the present embodiment of the present invention, even when the base plate 1200 is warped in a curved shape to cause the ink supply slit 1210 to be arranged in a curved shape, the ink supply can be securely made without a positional shift between the ink supply slit 1210 and the ink supply opening 1101 of the element substrate 1100 to manufacture a highly reliable liquid ejection head.
With this configuration, it is possible to realize the method for manufacturing the liquid ejection head that can prevent deterioration in production yield rate at the manufacturing of the liquid ejection head to decrease the production cost.
Hereinafter, an explanation will be made of a method for manufacturing a liquid ejection head according to a second embodiment of the present invention. It should be noted that since a basic configuration of the present embodiment is the same as that of the first embodiment, hereinafter only a characteristic configuration of the present embodiment will be explained.
Then, with a method similar to that of the first embodiment, each of the element substrates 1100 is arranged such that the ink supply opening 1101 and the ink supply slit 1201 are positioned to be in agreement in the sheet conveying direction. The element substrates 1100 are fine-adjusted to be positioned away from each other by an integral multiple of the image formation minimum pixel pitch in the sheet conveying direction, thus completing the attachment and fixation of the element substrate 1100. That is, according to the manufacturing method in the present embodiment of the present invention, the element substrate 1100 can be arranged following the position of the ink supply slit 1210 in the sheet conveying direction even in this arrangement. Therefore it is possible to realize the highly reliable liquid ejection head in which the positional shift between and the element substrate 1100 and the ink supply slit 1210 cannot nearly occur.
With this configuration, it is possible to realize the method for manufacturing the liquid ejection head that can prevent deterioration in production yield rate at the manufacturing of the liquid ejection head to decrease the production cost.
Hereinafter, an explanation will be made of a method for manufacturing a liquid ejection head according to a third embodiment of the present invention. It should be noted that since a basic configuration of the present embodiment is the same as that of the first embodiment, hereinafter only a characteristic configuration of the present embodiment will be explained.
Since the method for positioning the ink supply slit 1210 and the element substrate 1100 is the same as the content explained in the first embodiment and the second embodiment, herein an explanation will be made of disposition of a center line and a positional shift in a case where the ink supply slit 1210 comprises a plurality of the ink supply slits.
Here, in a case where an end portion of the ink supply slit 1210 is round, as shown in
Next, an explanation will be made of a positional shift in the sheet conveying direction between the ink supply slit 1210 and the ink supply opening 1101.
In this state, securement of an opening area between the ink supply opening 1101 and the ink supply slit 1210 and reliability on leakage or the like of an adherent at the jointing between the element substrate 1100 and the base plate 1200 can be maintained.
According to the manufacturing method in the present embodiment of the present invention, in the arrangement configuration thus requiring the high accuracy, the element substrate 1100 can be arranged following the position of the ink supply slit 1210 in the sheet conveying direction. Therefore it is possible to realize the liquid ejection head with high reliability in which in regard to all the element substrates 1100, the positional shift between the element substrate 1100 and the ink supply slit 1210 does not nearly exist as shown in
Thereby it is possible to realize the method for manufacturing the liquid ejection head with high reliability that can prevent a deterioration in production yield rate at the manufacturing of the liquid ejection head to perform a cost decrease in production thereof.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2014-023562, filed Feb. 10, 2014, which is hereby incorporated by reference wherein in its entirety.
Number | Date | Country | Kind |
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2014-023562 | Feb 2014 | JP | national |