High efficiency, high quality and high reliability
Industrial inkjet printers can print at speeds of hundreds of square meters per hour, but the ever-expanding market for colorful, high-quality and high-durability images for shopping spots, outdoor displays, cars and buildings The requirement of efficiency is pushed to a higher level. Since printheads and ink are key components of any inkjet printer, higher efficiency may ultimately depend on printheads and ink technology that provide reliable performance and high-quality images at high output speeds.
Higher efficiency means printing more square meters per hour, which requires faster delivery of ink to the print media. Higher ink flow can be achieved through a series of methods, including faster inkjet speed, larger inkjet volume, wider print lines, fewer print head round trips, and the use of quick-drying ink. These strategies can be used in combination or individually, but in general, each practical solution will increase the nozzles required for each color and put forward higher requirements on the performance of the print head.
From a practical point of view of manufacturing technology and maintainability, print heads used in industrial inkjet printers are composed of many individual print heads packaged in an array. Depending on the performance requirements, industrial inkjet printers can contain dozens, hundreds, or even thousands of independent printheads. According to this application, each independent printhead must meet the following requirements:
• Compact design The high density of nozzle arrangement per unit printing area reduces the volume and weight of the print head with a large nozzle array.
• High-reliability printheads must be able to resist the chemical corrosion caused by the ink used in industrial inkjet printers, and provide reliable image quality to reduce downtime required for maintenance.
• High-yield printheads should provide high ink flow rates at a drop frequency that enables fast linear printing.
• High image quality The image quality required to meet the application conditions must be provided at the highest printing speed. Ink volume, velocity, and trajectory should be consistent between print heads and print head groups.
• For easy installation and maintenance of mechanical parts, the connection of the ink path and electronic components to the print head must allow for easy installation? 碜 巴 浜 腿? It has consistent and precise properties and quality to ensure consistent ink droplet ejection performance. The manufacturing process should provide high output and production scale suitable for high output.
• Flexibility of printer design The design of the print head should support both fixed or scanning structures and reliably eject ink from industrial inkjet printers under conditions above the industrial temperature range.
The new HP Sai Angel X2 printhead meets these industrial inkjet printing requirements. In this article you will learn how it does this.
Introduction of HP Race Angel X2 Printhead
The HP Race Angel X2 printhead has a compact and modular design and is based on a silicon glass printhead substrate designed, developed and produced by HP.
Piezoelectric inkjet technology provides high-performance imaging at high ink flow rates. The manufacturing process using silicon-based MEMS technology can ensure the design and production of high-performance ink droplet generator architecture to ensure consistent and consistent ink droplet ejection performance.
The printhead substrate has 128 nozzles and 100 nozzles / inch native resolution. It can be assembled into multiple printhead modules and provides up to 800dpi resolution. Because each nozzle can eject 30,000 ink droplets per second and up to 50pl of ink volume, the HP Race Angel X2 print head can supply 10 ml of ink per minute at a linear printing speed of 2 meters per second.
High reliability and chemical resistance to industrial inkjet printer inks are possible because of their design: only silicon, glass, and epoxy resin contact the ink, while the piezoelectric actuators and electrodes are completely isolated from the ink. The print head can provide reliable imaging performance guarantee in the industrial temperature range above 15-45ºC.
The advanced technology contained in the HP Race Angel X2 printhead is protected by a series of patents or patent applications.
Easy installation and maintenance
In an industrial inkjet printer, how to install and maintain hundreds of individual print heads is an issue that must be considered in the design process. The characteristic of HP Sai Angel X2 print head is that the connection of mechanical parts, ink circuit and electronic parts allows the print head to be inserted into place, and only need to be fastened with two screws.
Two mechanical position probes provide positioning accuracy higher than 10 microns without adjustment. The connection of the ink circuit is achieved through two ports, each of which is sealed with an annular ring, so no ink tube needs to be connected and fastened. Power and control signals are provided by a 26-pin connector for transmission.
With HP Sai Angel X2 print head, installation and disassembly become very simple and easy.
Print head substrate
The print head substrate features a unique double-sided "side jet" design. 64 nozzles, ink channels, and piezoelectric actuators are arranged on both sides of the silicon card. With up to 100 nozzles per inch and slim (approximately 1 mm thick), this printhead substrate is ideal for constructing multi-card printhead modules with very high nozzle density. The thin glass plate is permanently bonded to silicon, so there is no need to use an adhesive to seal the ink delivery channel. When a voltage pulse is applied, the piezoelectric actuator deflects the glass plate toward the ink delivery channel by an angle of less than 1 micrometer, thereby ejecting an ink droplet. The nominal speed of the ink droplets is 8 meters per second, which gives accurate ink dot positioning during high-speed linear printing. The piezoelectric actuator and electrodes are placed on the outer surface of the glass plate and are completely isolated from the ink.
On the printhead substrate (as shown), ink is delivered to the entrance of the ink delivery channel along the upper edge. The piezoelectric actuators and their electrodes are golden structures visible in the middle, and the nozzle array is arranged along the lower edge. Because the nozzle is formed in the polished silicon surface layer, there is no need to adjust the nozzle plate or disassemble it during use in the production process of the nozzle.
The HP Race Angel X2 printhead is built with integrated circuit precision using MEMS technology. Because it can define and replicate characteristics in sub-micron specifications, MEMS allows the shape of nozzles and ink delivery channels to be optimized based on ink droplet ejection performance. The highly uniform jet structure inside each print head and between the print heads means continuous and consistent ink droplet volume and velocity, and has a high positioning accuracy in the multiple print head module.
Print head substrate holder
The print head substrate holder is an assembly for supporting and adjusting the print head substrate. The print head is positioned and loaded on the printer, and then connected to the ink supply component to provide the ink separation line and support a solder to the print head substrate Piece of flower line.
The card holder includes four glass-reinforced liquid crystal polymer (LCP) modules. Liquid crystal polymers are very strong, have good dimensional stability and chemical resistance to industrial inkjet inks.
There is a protective LCP sleeve on the front of the print head for adjusting and protecting the nozzle array.
An LCP component supports the mechanical installation and positioning member, the ink supply port is sealed by a ring, and the electronic package (Electronics Package) is adjusted and supported. The ink supply line consists of the print head substrate inserted into it, two glass side plates and two LCP ink accessories. Ink can be delivered through one of the two ports, or flow through both ports to remove air bubbles. These parts are assembled with ink-repellent epoxy resin.
Electronic components
The electronic package (Electronics Package) is used to process the control signals of the print head, adjust the voltage and drive the piezoelectric actuator. It includes two identical electronic boards, which are used for the upper and lower 64 nozzle arrays.
Each side of the cable is wrapped in a thin metal heat sink, and shares a standard 26-pin connector, connected to a power supply and control signal transmission line from the printer. The wire is inserted into the 26-pin connector, and the conductor parts at both ends are welded to the upper and lower arrays of the piezoelectric actuator. The thread is connected with the cast pin on the card holder.
MicroElectromechanical System (MEMS) Technology
MEMS technology is a technology developed for the manufacturing process of integrated circuits. MEMS can simultaneously produce many of the same micro-level electromechanical components on a silicon wafer.
MEMS technology includes many processes. Lithography and etching processes define morphological features on silicon and other materials with sub-micron accuracy. The composite multilayer structure can be accurately calibrated and requires no adhesive for synthesis. Materials can be added in many ways to create metal layers, insulating layers and polymer layers, as well as layers with special properties (such as piezoelectric layers). The material can be thinned or cut through liquid etching, grinding, polishing and sawing to accurately produce the edge, surface and layer thickness.
Silicon-based MEMS technology is very well adapted to the production of printheads in various ways. It can produce the same ink channels, nozzles and piezoelectric actuators in a print head and between the print heads. This means a high degree of consistency in ink drop volume, ink drop rate and ink drop trajectory to ensure high quality printing. MEMS technology provides flexibility in the design of inkjet ink droplet generators, because the ink channel and nozzle size can be modified by changing the characteristics of the photomask and etching parameters to adapt to different performance requirements and ink characteristics.
Like integrated circuits, wafers in MEMS technology are cut from single silicon crystals. The wafer provides a hard, high-strength substrate and is ideal for manufacturing printheads. Silicon is highly resistant to corrosion by industrial inkjet inks and printhead cleaners.
MEMS technology creates value for the manufacturing process by providing high output and adjustable scale output.
Anodic bonding: no adhesive required for printhead assembly
The anodic bonding process is applied to the HP Sai Angel X2 print head, which bonds the thin glass plate and the upper and lower surfaces of the silicon wafer together. This process seals the ink channels without the use of adhesives on the glass.
Anodic bonding is a process that forms a permanent chemical bond and vacuum seal between silicon and glass. Anode bonding can be used at the wafer level, enabling many devices to be produced at the same time. Complex structures can be created by bonding multiple layers of silicon and glass.
Anodic bonding combines a thin glass plate with a silicon wafer between two levels. The glass is doped with metal oxides. Then the glass and silicon are heated to a high temperature to separate the metal oxide, allowing the metal and oxygen ions with opposite charges to move inside the glass. A high DC voltage acts on the stack, and the action of the electric field will cause the metal ions to free the glass-silicon surface. At the same time, oxygen ions flow to the silicon-glass surface, where they oxidize the silicon and form a permanent chemical bond between the silicon and the glass.
This process occurs at the atomic distance, so there is no observable flow of matter in glass or silicon. A vacuum seal can be formed around the ink channel without causing a change in size.
Another contribution of anodic bonding is the production of highly accurate and consistent ink drop generators for the HP Sai Angel X2 printhead.
Technical Specifications: The following table summarizes the key technical specifications of HP Sai Angel X2 print head:
unit
Numerical value
Number of nozzles in each print head
-
128
Original resolution
Dpi
100
Apply print resolution
Dpi
Up to 800
Ink drop frequency
KHz
Up to 30
Ink drop rate (nominal)
m / s
8
Ink volume
Pl
Up to 50
Ink viscosity
cP
Up to 15
Dimensions (H x W)
Mm
8 X 64
Print line height
mm
32.5
Operating temperature
ºC
15-45
to sum up
With its compact design, simple plug-in interface, and uniform droplet ejection characteristics brought about by the MEMS manufacturing technology, the new HP Race Angel X2 printhead is ideally suited for installation into large, high-performance inkjet nozzles Array. The X2 print head, designed and built to work with HP Sai Angel ’s UV-curable inks and wide format printers, will increase production efficiency, reliability, and image quality to a height that meets the needs of the new generation of industrial inkjet printers.
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