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This article has been downloaded from IOPscience. Please scroll down to see the full text article.
2007 J. Micromech. Microeng. 17 1420
(http://iopscience.iop.org/0960-1317/17/8/002)
View the table of contents for this issue, or go to the journal homepage for more
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The article was downloaded on 30/11/2011 at 10:46
IOP PUBLISHING
doi:10.1088/0960-1317/17/8/002
1. Introduction
Inkjet printing is considered one of the most promising printing
technologies that offers several advantages including high
speed, quiet operation and compatibility with a variety of
substrates [1]. The technology has become increasingly
important because of its compatibility with low-cost computer
printers [2]. The initial printers were expensive and had
reliability issues due to difficulties associated with clogging.
A significant improvement in the technology occurred in 1985
with the development of the Thinkjet printer by HewlettPackard, which could be batch fabricated, offering low-cost
and reduced reliability issues [3]. Following this, inkjet
printers have improved continually and established a large
market share due to their low cost, high resolution and low
noise [4]. A variety of inkjet printing mechanisms have
been developed including thermal inkjet (TIJ), piezoelectric
and electrostatic. TIJ has been the preferred method of
inkjet printing due to its low cost and high quality [5].
0960-1317/07/081420+08$30.00
1420
a thermally-driven inkjet print head that consists of domeshaped ink chambers and thin film nozzle guides. Tseng et al
[8] described a thermally driven droplet injector employing
a novel concept of virtual chamber neck. Wang et al
[9] developed a monolithic thermal bubble inkjet print head
based on silicon micromachining technology. Park and Oh
[10] presented a thermally driven monolithic inkjet print
head comprising dome-shaped ink chambers, thin film nozzle
guides and heaters integrated on the top surface of each
chamber. Bae et al [11] proposed a TIJ printer head on a
SOI wafer that comprised two rectangular heaters. Baek et al
[12] proposed a novel high-density TIJ to overcome defects
due to the limitations of the nozzle density in conventional
TIJs. Huang et al [13] designed and fabricated a monolithic
print head that utilizes back-shooting bubble nucleation for
ejection of droplets. Development of a low cost, high
resolution and reliable inkjet print head is critical for the
future of inkjet printing. A high resolution can be achieved
by reducing the nozzle pitch and diameter, hence the droplet
size. Novel design concepts can improve the print quality by
eliminating formation of satellite droplets. The inkjet print
heads can be made cost effective by reducing the overall size
of the print head but the trend goes to larger print heads
for achieving higher printing speed. Most of the existing
inkjet print head designs utilize assembly or bonding processes
for integrating nozzle plates with ink chamber. Simpler
design and fabrication approaches should be adopted to reduce
cost. Monolithic inkjet print heads have been developed with
significant advantages over conventional print heads in terms
of fabrication cost, resolution and reliability [7].
The physics of the TIJ printing process involves many
physical phenomena including heat conduction, bubble
nucleation, two-phase flow, fluid dynamics and surface
chemistry. The most important performance parameters
include droplet speed, droplet volume, operating frequency
and thermal energy. Development of new inkjet devices or
improvements in existing designs require a multiple cycle
of redesign, fabrication and testing to achieve design goals.
As an economical alternative, the performance of inkjet print
heads can be accurately predicted using numerical models.
Numerical simulation can be used to study the effects of design
parameters including heater layer structure, chamber geometry
and operating conditions. A number of studies have been
reported on numerical modeling of ink ejection process in TIJs.
Asai et al [14] reported a one-dimensional linear hydraulic
model to predict bubble-growth and liquid motion coupled
with heat transfer in a side-shooter head. Chen et al [15]
modeled the ink ejection process in a top shooter head using a
lumped model. In this paper, we present the performance of a
monolithic thermal inkjet print head by performing numerical
simulation using FLOW3D. The geometry of the print head
comprises a dome-shaped ink-chamber, a nozzle guide and a
ring-shaped heater integrated on the surface of each chamber.
The print head design eliminates direct contact between the
heater and the ink, thus minimizing heater burnout. The
ink manifold, ink chamber and the nozzle are aligned, thus
facilitating higher nozzle density. A similar inkjet print head
design based on an omega-shaped heater has been reported by
Park and Oh [10], but the goal was to investigate the durability
of the inkjet print head through experiments.
2. Theory
In a TIJ print head, the droplet ejection mechanism involves
coupled interaction between the fluid flow and heat transfer.
The model considers heat transfer from the heater to the
ink present in the ink chamber through a passivation layer.
The temperature dependence of the fluid properties including
viscosity, density and surface tension is taken into account.
Bubble dynamics theory is used to simulate the nucleation
and growth of the thermal bubbles. The flow of ink exiting
the nozzle and its further motion after exiting the nozzle is
simulated. The free surface between the ink and the medium
(air) is tracked using volume of fluid method. The fluid
dynamic behavior of drop ejection in an incompressible,
Newtonian fluid with viscosity , density , is governed by
the continuity and the NS equations with specified boundary
conditions:
u
"=0
d"
u
= p + 2 u
" + g
dt
(1)
(2)
(5)
vap
(6)
T
tv1
$H
where ( pv1, tv1) is a point on the saturation curve, and $H
is latent heat of evaporation. The rate of phase change is
proportional to the deviation from saturation conditions. The
formulation to compute the rate of phase change based on
kinetic theory is [16]
$
%
&
M
P sat
Pv
cevap l ccon
(7)
m=
2R
Tv
Tl
where m is the net mass transfer, M is the molecular
weight of vapor, R is the vapor gas constant, Tl and Tv
are the temperatures in the liquid and vapor. Plsat indicates
1421
Heater
Passivation layer
t
D
Ink chamber
Nozzle guide
Ink channel
L
Figure 2. Computational model of the inkjet print head.
Ink manifold
(9)
(10)
3
Figure 3. Boundaries of the computational domain.
12
Droplet speed
200
175
150
15
20
25
Nozzle length (m)
30
9
8
6
7
3
0
5000
225
10
Droplet volume
Model predictions
250
5
30000
4. Parametric study
This section presents effects of print head geometry,
operational parameters and fluid properties on the device
performance. The geometry of the print head includes nozzle
diameter, heater size and location, chamber size, which can be
1423
900
Heater
t = 2.1 s
Temperature (K)
800
Fluid-film
700
600
500
400
t = 4.5 s
300
0
10
20
30
Time (s)
40
50
t = 15 s
t = 22 s
t = 27 s
t = 31 s
t = 4.5 s
15
Droplet speed
Droplet volume
40
14
30
13
20
12
10
11
t = 2.1 s
50
10
5
15
25
35
Nozzle diameter (m)
45
20
t = 15 s
t = 22 s
T hreshold energy
Droplet diameter
15
6
4
10
2
0
t = 9 s
5
0
10
15
20
Heater width (m)
25
30
15
t = 31 s
30
24
18
12
6
0
20
40
60
80
Chamber diameter (m)
100
volume and speed. The results show that both droplet volume
and speed increase with increase in the thermal energy. A
higher thermal energy results in faster droplets, thus reducing
the printing time but at the same time the droplet volume
1425
SiC
12
SiN
AL
CVD diamond
20
Droplet speed
SiO2
Droplet volume
17
14
11
3
0
400
Droplet volume
12
17
14
11
4
6
Pulse width (s)
10
Density-drop volume
Surface tension- drop volume
Viscosity-drop volume
Density-drop speed
Surface tension-drop speed
Viscosity-droplet speed
8
6
6
9
12
Nozzle guide length (m)
15
Droplet speed
Droplet volume
12
17
14
11
15
5
4
12
16
Thermal energy(J)
20
20
18
16
14
12
0.1
5
0
10
20
Droplet speed
15
100
200
300
Thermal conductivity (W/mK)
5
0
1426
10
15
1
(mPas)
10
100
(mN/m)
10
1000
10000
(kg/m3)
References
75
Density
Surface tension
Viscosity
60
45
30
15
0
0.1
1
(mPas)
10
100
(mN/m)
1000
10000
(kg/m3)
5. Conclusion
The droplet ejection performance of a thermally-driven
monolithic inkjet print head based on a dome-shaped ink
chamber, a nozzle guide and a ring-shaped heater was
simulated. The design employs a passivation layer as an
intermediate layer between the ink and the heater, thus
eliminating heater burnout issues and improving reliability.
The design configuration is such that the ink chamber and
the nozzle are inline, thus higher nozzle density can be
achieved. The numerical model is validated by comparing the
model predictions with experimental results for a previously
reported print head design. The agreement between the
model predictions and the experimental results is within
10%, indicating the validity of the model and modeling
methodology. The droplet ejection performance of the
proposed print head design was simulated including the
nucleation and growth of the thermal bubble. A thermal
pulse was used as the driving mechanism for the droplet
ejection. Coupled flow and energy along with bubble
dynamics equations were solved to predict the time evolution
of the fluid interface, droplet volume and speed, heater and
fluid-film temperature and temperature distribution in the ink
present in the chamber. The model was used to investigate
the effects of print head geometry including nozzle diameter,
nozzle-guide length, chamber size, heater location and thermal
conductivity of the passivation layer, operating conditions
including thermal energy and pulse width, and ink properties
on droplet volume and speed. The influence of ink properties
on tail length was also studied. The results of the parametric
study are expected to facilitate the design and operation of the
proposed print head design.
1427