U.S. patent application number 11/213837 was filed with the patent office on 2006-03-02 for working method for forming minute holes, tool used in the method, method and apparatus for manufacturing liquid ejecting head.
This patent application is currently assigned to SEIKO EPSON CORPORATION. Invention is credited to Hideyuki Ogawa, Katsunori Ono, Koichi Saito, Nobuyuki Soma, Nagamitsu Takashima.
Application Number | 20060042435 11/213837 |
Document ID | / |
Family ID | 35941166 |
Filed Date | 2006-03-02 |
United States Patent
Application |
20060042435 |
Kind Code |
A1 |
Ogawa; Hideyuki ; et
al. |
March 2, 2006 |
Working method for forming minute holes, tool used in the method,
method and apparatus for manufacturing liquid ejecting head
Abstract
A punching apparatus forms a hole at a bottom portion of each of
recesses which are formed in a metal plate in advance and arrayed
in a first direction. A female die supports the metal plate. A male
die is opposed to the recess and provided with a punch array in
which a plurality of punches in the first direction. The male die
is movable in a second direction perpendicular to the first
direction to form the hole with each of the punches. The punches
include first punches each having a distal end face which is slant
in the second direction. A slant angle of the distal end face
corresponds to a warp of the plate member due to the formation of
the recesses.
Inventors: |
Ogawa; Hideyuki; (Nagano,
JP) ; Saito; Koichi; (Nagano, JP) ; Takashima;
Nagamitsu; (Nagano, JP) ; Soma; Nobuyuki;
(Nagano, JP) ; Ono; Katsunori; (Nagano,
JP) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W.
SUITE 800
WASHINGTON
DC
20037
US
|
Assignee: |
SEIKO EPSON CORPORATION
|
Family ID: |
35941166 |
Appl. No.: |
11/213837 |
Filed: |
August 30, 2005 |
Current U.S.
Class: |
83/13 |
Current CPC
Class: |
Y10T 83/04 20150401;
B41J 2/1632 20130101; B41J 2/1433 20130101; B41J 2/162 20130101;
Y10T 29/494 20150115; Y10T 29/49401 20150115 |
Class at
Publication: |
083/013 |
International
Class: |
B26D 1/00 20060101
B26D001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 30, 2004 |
JP |
P2004-249598 |
Sep 1, 2004 |
JP |
P2004-253846 |
Claims
1. A punching apparatus for forming a hole at a bottom portion of
each of recesses which are formed in a metal plate in advance and
arrayed in a first direction, the punching apparatus comprising: a
female die, adapted to support the metal plate; and a male die,
adapted to be opposed to the recess and comprising a punch array in
which a plurality of punches in the first direction, wherein: the
male die is movable in a second direction perpendicular to the
first direction to form the hole with each of the punches; the
punches include first punches each having a distal end face which
is slant in the second direction; and a slant angle of the distal
end face corresponds to a warp of the plate member due to the
formation of the recesses.
2. The punching apparatus as set forth in claim 1, wherein the
recesses and the punches are arrayed with a fixed pitch.
3. The punching apparatus as set forth in claim 1, wherein the
first punches are provided at least in both ends of the punch
array.
4. The punching apparatus as set forth in claim 1, wherein a cross
section of each of the punches in the first direction is
rectangular.
5. The punching apparatus as set forth in claim 1, wherein a first
part of the distal end face which is closer to an end of the punch
array is closer to the female die than a second part of the distal
end face which is closer to a center of the punch array.
6. The punching apparatus as set forth in claim 5, wherein: the
punches are arrayed such that a contour line of the punch array
defined by connecting respective distal end faces of the punches
includes first parts assuming straight lines; and a first portion
of each of the straight lines which is closer to the end of the
punch array is closer to the female die than a second portion of
each of the straight lines which is closer to the center of the
punch array.
7. The punching apparatus as set forth in claim 6, wherein the
contour line includes a second part located between the first parts
and assuming a straight line extending in the first direction.
8. The punching apparatus as set forth in claim 7, wherein the
second part of the contour line is closer to the female die than
the second portion of each of the first part.
9. The punching apparatus as set forth in claim 5, wherein: the
punches are arrayed such that a contour line of the punch array
defined by connecting respective distal end faces of the punches
includes parts assuming curved lines; and a first portion of each
of the curved lines which is closer to the end of the punch array
is closer to the female die than a second portion of each of the
curved lines which is closer to the center of the punch array.
10. The punching apparatus as set forth in claim 9, wherein the
contour line includes a second part located between the first parts
and assuming a straight line extending in the first direction.
11. The punching apparatus as set forth in claim 10, wherein the
second part of the contour line is closer to the female die than
the second portion of each of the first part.
12. The punching apparatus as set forth in claim 1, wherein a first
part of the distal end face which is closer to an end of the punch
array is farther from the female die than a second part of the
distal end face which is closer to a center of the punch array.
13. The punching apparatus as set forth in claim 12, wherein: the
punches are arrayed such that a contour line of the punch array
defined by connecting respective distal end faces of the punches
includes first parts assuming straight lines; and a first portion
of each of the straight lines which is closer to the end of the
punch array is farther from the female die than a second portion of
each of the straight lines which is closer to the center of the
punch array.
14. The punching apparatus as set forth in claim 13, wherein the
contour line includes a second part located between the first parts
and assuming a straight line extending in the first direction.
15. The punching apparatus as set forth in claim 12, wherein: the
punches are arrayed such that a contour line of the punch array
defined by connecting respective distal end faces of the punches
includes parts assuming curved lines; and a first portion of each
of the curved lines which is closer to the end of the punch array
is farther from the female die than a second portion of each of the
curved lines which is closer to the center of the punch array.
16. The punching apparatus as set forth in claim 15, wherein the
contour line includes a second part located between the first parts
and assuming a straight line extending in the first direction.
17. A punching apparatus for forming a hole at a bottom portion of
each of recesses which are formed in a metal plate in advance and
arrayed in a first direction, the punching apparatus comprising: a
female die, adapted to support the metal plate; and a male die,
adapted to be opposed to the recess and comprising a punch array in
which a plurality of punches in the first direction, wherein: the
male die is movable in a second direction perpendicular to the
first direction to form the hole with each of the punches; a
contour line of the punch array defined by connecting respective
distal end faces of the punches includes a plurality of parts
assuming straight lines extending in the first direction; and one
of straight lines which is closer to an end of the punch array is
farther from the female die than one of the straight lines which is
closer to a center of the punch array, in accordance with a warp of
the plate member due to the formation of the recesses.
18. A method of manufacturing a liquid ejection head, comprising:
providing a first metal plate; supporting the first metal plate on
a female die; forming a plurality of recesses in the first metal
plate so as to be arrayed in a first direction; opposing a male die
to the recess, the male die comprising a punch array in which a
plurality of punches arrayed in the first direction; actuating the
male die in a second direction perpendicular to the first direction
to form a through hole at a bottom portion of each of the recesses
with each of the punches; providing a second metal plate formed
with a plurality of nozzle orifices; and joining the first metal
plate and the second metal plate such that each of the nozzle
orifices is communicated with one of the recesses, wherein: the
punches include first punches each having a distal end face which
is slant in the second direction; and a slant angle of the distal
end face corresponds to a warp of the plate member due to the
formation of the recesses.
19. A method of manufacturing a liquid ejection head, comprising:
providing a first metal plate; supporting the first metal plate on
a female die; forming a plurality of recesses in the first metal
plate so as to be arrayed in a first direction; opposing a male die
to the recess, the male die comprising a punch array in which a
plurality of punches arrayed in the first direction; actuating the
male die in a second direction perpendicular to the first direction
to form a through hole at a bottom portion of each of the recesses
with each of the punches; providing a second metal plate formed
with a plurality of nozzle orifices; and joining the first metal
plate and the second metal plate such that each of the nozzle
orifices is communicated with one of the recesses, wherein: a
contour line of the punch array defined by connecting respective
distal end faces of the punches includes a plurality of parts
assuming straight lines extending in the first direction; and one
of straight lines which is closer to an end of the punch array is
farther from the female die than one of the straight lines which is
closer to a center of the punch array, in accordance with a warp of
the plate member due to the formation of the recesses.
20. A method of punching a metal plate, comprising: supporting the
metal plate on a female die; forming a plurality of recesses in the
metal plate so as to be arrayed in a first direction; opposing a
male die to the recess, the male die comprising a punch array in
which a plurality of punches arrayed in the first direction; and
actuating the male die in a second direction perpendicular to the
first direction to form a hole at a bottom portion of each of the
recesses with each of the punches, wherein: the punches include
first punches each having a distal end face which is slant in the
second direction; and a slant angle of the distal end face
corresponds to a warp of the plate member due to the formation of
the recesses.
21. The punching method as set forth in claim 20, wherein a cross
section of the bottom portion of each of the recesses in the first
direction is V-shaped.
22. A method of punching a metal plate, comprising: supporting the
metal plate on a female die; forming a plurality of recesses in the
metal plate so as to be arrayed in a first direction; opposing a
male die to the recess, the male die comprising a punch array in
which a plurality of punches arrayed in the first direction; and
actuating the male die in a second direction perpendicular to the
first direction to form a hole at a bottom portion of each of the
recesses with each of the punches, wherein: a contour line of the
punch array defined by connecting respective distal end faces of
the punches includes a plurality of parts assuming straight lines
extending in the first direction; and one of straight lines which
is closer to an end of the punch array is farther from the female
die than one of the straight lines which is closer to a center of
the punch array, in accordance with a warp of the plate member due
to the formation of the recesses.
23. The punching method as set forth in claim 22, wherein a cross
section of the bottom portion of each of the recesses in the first
direction is V-shaped.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a working method for
forming circular, rectangular, or-shaped minute holes of about 0.5
mm or less in diameter or longer-side length in a metal plate by
press working, and a tool used in the method. The present invention
also relates to an apparatus and method for manufacturing a liquid
ejecting head incorporating the worked metal plate.
[0002] An ink jet recording head (hereinafter, referred to as
"recording head") used as an example of a liquid ejecting head is
provided with a plurality of series of flow paths reaching nozzle
orifices from a common ink reservoir via pressure generating
chambers in correspondence with the orifices. Further, the
respective pressure generating chambers need to form by a fine
pitch in correspondence with a recording density to meet a request
of downsizing. Therefore, a wall thickness of a partition wall for
partitioning contiguous ones of the pressure generating chambers is
extremely thinned. Further, an ink supply port for communicating
the pressure generating chamber and the common ink reservoir is
more narrowed than the pressure generating chamber in a flow path
width thereof in order to use ink pressure at inside of the
pressure generating chamber efficiently for ejection of ink
drops.
[0003] The pressure generating chambers and communicating ports
etc. that connect the pressure chambers to the nozzle orifices,
respectively, are formed by performing plastic working on a metal
plate (see Japanese Patent Publication 2004-98164A, for example).
In particular, since the communicating ports are formed after
forming the pressure generating chambers, the working for forming
the communicating ports is required to be suitable for the state of
deformation of a chamber formation plate that has occurred at the
time of formation of the pressure generating chambers.
[0004] When a male die and a female die are returned to original
positions from a state that the operation strokes of the male die
and the female die have taken maximum values and plastic
deformation of a chamber formation plate (metal plate) placed
between the male die and the female die has completed, the chamber
formation plate that has been released from the male die and the
female die is gently warped in the arrayed direction of elongated
recess portions which are to be pressure generating chambers due to
internal stress. If the chamber formation plate is placed generally
horizontally with the openings of the elongated recess portions
located above and the bottoms of the elongated recess portions
located below, the warped shape is such that the ends in the
arrayed direction of the elongated recess portions are highest and
the height decreases gradually as the position goes from the ends
to the center.
[0005] To form communicating ports in the bottom portions of the
elongated recess portions that are arranged along such a warped
shape, an array of punches having the same pitch as the arrayed
pitch of the pressure generating chambers is prepared. However,
since the tips of the large number of punches are arranged in a
row, as the punches are moved in the depth direction of the
elongated recess portions, the end punches or punches close to
those first dig into the bottom portions of the end elongated
recess portions or elongated recess portions close to those and
then the remaining punches dig into the corresponding elongated
recess portions in order from the outside to the center.
[0006] As the punches dig into the bottom portions, forces act on
the end punches or punches close to those in such directions as to
move those punches toward the center of the punch array. Therefore,
the end punches or punches close to those may be bent toward the
center of the punch array or broken. If punches are bent in such a
manner, the corresponding communicating port working positions are
deviated, which means reduction in working accuracy. In addition,
the durability of the end punches or punches close to those is
lowered and their lives are shortened, which is uneconomical. If a
punch is broken, production is suspended for its replacement and
various processing costs occur, which is also uneconomical.
Further, since the communicating ports to be formed in the pressure
generating chambers are very minute, the punches are long and very
narrow and accordingly their rigidity tends to be insufficient for
the working resistance. The above problems are more serious in this
respect.
[0007] The above problems relate to the rigidity of each punch in
the arrayed direction of the elongated recess portions. On the
other hand, it is also important to secure sufficient rigidity of
each punch in the longitudinal direction of the associated
elongated recess portion, that is, pressure generating chamber.
SUMMARY OF THE INVENTION
[0008] It is an object of the invention to provide a working method
capable of forming minute holes in a metal plate with high accuracy
by plastic working, and a tool used in the method.
[0009] It is also an object of the invention to provide, an
apparatus and a method for manufacturing a liquid ejecting head
incorporating the worked metal plate.
[0010] In order to achieve the above object, according to the
invention, there is provided a punching apparatus for forming a
hole at a bottom portion of each of recesses which are formed in a
metal plate in advance and arrayed in a first direction,
comprising: [0011] a female die, adapted to support the metal
plate; and [0012] a male die, adapted to be opposed to the recess
and comprising a punch array in which a plurality of punches in the
first direction, wherein: [0013] the male die is movable in a
second direction perpendicular to the first direction to form the
hole with each of the punches; [0014] the punches include first
punches each having a distal end face which is slant in the second
direction; and [0015] a slant angle of the distal end face
corresponds to a warp of the plate member due to the formation of
the recesses.
[0016] The recesses and the punches may be arrayed with a fixed
pitch.
[0017] The first punches may be provided at least in both ends of
the punch array.
[0018] A cross section of each of the punches in the first
direction may be rectangular.
[0019] A first part of the distal end face which is closer to an
end of the punch array may be closer to the female die than a
second part of the distal end face which is closer to a center of
the punch array.
[0020] Here, the punches may be arrayed such that a contour line of
the punch array defined by connecting respective distal end faces
of the punches includes first parts assuming straight lines. Here,
a first portion of each of the straight lines which is closer to
the end of the punch array is closer to the female die than a
second portion of each of the straight lines which is closer to the
center of the punch array.
[0021] Here, the contour line may include a second part located
between the first parts and assuming a straight line extending in
the first direction.
[0022] Here, the second part of the contour line may be closer to
the female die than the second portion of each of the first
part.
[0023] The punches may be arrayed such that a contour line of the
punch array defined by connecting respective distal end faces of
the punches includes parts assuming curved lines. Here, a first
portion of each of the curved lines which is closer to the end of
the punch array is closer to the female die than a second portion
of each of the curved lines which is closer to the center of the
punch array.
[0024] Here, the contour line may include a second part located
between the first parts and assuming a straight line extending in
the first direction.
[0025] Here, the second part of the contour line may be closer to
the female die than the second portion of each of the first
part.
[0026] A first part of the distal end face which is closer to an
end of the punch array may be farther from the female die than a
second part of the distal end face which is closer to a center of
the punch array.
[0027] Here, the punches may be arrayed such that a contour line of
the punch array defined by connecting respective distal end faces
of the punches includes first parts assuming straight lines. Here,
a first portion of each of the straight lines which is closer to
the end of the punch array is farther from the female die than a
second portion of each of the straight lines which is closer to the
center of the punch array.
[0028] Here, the contour line may include a second part located
between the first parts and assuming a straight line extending in
the first direction.
[0029] The punches may be arrayed such that a contour line of the
punch array defined by connecting respective distal end faces of
the punches includes parts assuming curved lines. Here, a first
portion of each of the curved lines which is closer to the end of
the punch array is farther from the female die than a second
portion of each of the curved lines which is closer to the center
of the punch array.
[0030] Here, the contour line may include a second part located
between the first parts and assuming a straight line extending in
the first direction.
[0031] According to the invention, there is also provided a
punching apparatus for forming a hole at a bottom portion of each
of recesses which are formed in a metal plate in advance and
arrayed in a first direction, comprising: [0032] a female die,
adapted to support the metal plate; and [0033] a male die, adapted
to be opposed to the recess and comprising a punch array in which a
plurality of punches in the first direction, wherein: [0034] the
male die is movable in a second direction perpendicular to the
first direction to form the hole with each of the punches; [0035] a
contour line of the punch array defined by connecting respective
distal end faces of the punches includes a plurality of parts
assuming straight lines extending in the first direction; and
[0036] one of straight lines which is closer to an end of the punch
array is farther from the female die than one of the straight lines
which is closer to a center of the punch array, in accordance with
a warp of the plate member due to the formation of the
recesses.
[0037] According to the invention, there is also provided a method
of manufacturing a liquid ejection head, comprising: [0038]
providing a first metal plate; [0039] supporting the first metal
plate on a female die; [0040] forming a plurality of recesses in
the first metal plate so as to be arrayed in a first direction;
[0041] opposing a male die to the recess, the male die comprising a
punch array in which a plurality of punches arrayed in the first
direction; [0042] actuating the male die in a second direction
perpendicular to the first direction to form a through hole at a
bottom portion of each of the recesses with each of the punches;
[0043] providing a second metal plate formed with a plurality of
nozzle orifices; and [0044] joining the first metal plate and the
second metal plate such that each of the nozzle orifices is
communicated with one of the recesses, wherein: [0045] the punches
include first punches each having a distal end face which is slant
in the second direction; and [0046] a slant angle of the distal end
face corresponds to a warp of the plate member due to the formation
of the recesses.
[0047] According to the invention, there is also provided a method
of manufacturing a liquid ejection head, comprising: [0048]
providing a first metal plate; [0049] supporting the first metal
plate on a female die; [0050] forming a plurality of recesses in
the first metal plate so as to be arrayed in a first direction;
[0051] opposing a male die to the recess, the male die comprising a
punch array in which a plurality of punches arrayed in the first
direction; [0052] actuating the male die in a second direction
perpendicular to the first direction to form a through hole at a
bottom portion of each of the recesses with each of the punches;
[0053] providing a second metal plate formed with a plurality of
nozzle orifices; and [0054] joining the first metal plate and the
second metal plate such that each of the nozzle orifices is
communicated with one of the recesses, wherein: [0055] a contour
line of the punch array defined by connecting respective distal end
faces of the punches includes a plurality of parts assuming
straight lines extending in the first direction; and [0056] one of
straight lines which is closer to an end of the punch array is
farther from the female die than one of the straight lines which is
closer to a center of the punch array, in accordance with a warp of
the plate member due to the formation of the recesses.
[0057] According to the invention, there is also provided a method
of punching a metal plate, comprising: [0058] supporting the metal
plate on a female die; [0059] forming a plurality of recesses in
the metal plate so as to be arrayed in a first direction; [0060]
opposing a male die to the recess, the male die comprising a punch
array in which a plurality of punches arrayed in the first
direction; and actuating the male die in a second direction
perpendicular to the first direction to form a hole at a bottom
portion of each of the recesses with each of the punches, wherein:
[0061] the punches include first punches each having a distal end
face which is slant in the second direction; and [0062] a slant
angle of the distal end face corresponds to a warp of the plate
member due to the formation of the recesses.
[0063] A cross section of the bottom portion of each of the
recesses in the first direction may be V-shaped.
[0064] According to the invention, there is also provided a method
of punching a metal plate, comprising: [0065] supporting the metal
plate on a female die; [0066] forming a plurality of recesses in
the metal plate so as to be arrayed in a first direction; [0067]
opposing a male die to the recess, the male die comprising a punch
array in which a plurality of punches arrayed in the first
direction; and actuating the male die in a second direction
perpendicular to the first direction to form a hole at a bottom
portion of each of the recesses with each of the punches, wherein:
[0068] a contour line of the punch array defined by connecting
respective distal end faces of the punches includes a plurality of
parts assuming straight lines extending in the first direction; and
[0069] one of straight lines which is closer to an end of the punch
array is farther from the female die than one of the straight lines
which is closer to a center of the punch array, in accordance with
a warp of the plate member due to the formation of the
recesses.
[0070] A cross section of the bottom portion of each of the
recesses in the first direction may be V-shaped.
[0071] With some of the above configurations, since the bending
force generated by the warped metal plate against the punches is
canceled or considerably reduced, no inclinations etc. occur in the
punches at and near the ends of the punch array, and hence an array
of minute holes can be formed in the metal plate correctly at
prescribed positions.
[0072] Therefore, reduction in working accuracy due to the warp of
the metal plate can be prevented and high quality can be attained
in accuracy. In addition, since the bending loads on the punches at
and near the ends are reduced, an event that punches at particular
positions are bent or broken does not occur and hence the
durability of the punches can be increased. The above advantages
are particularly effective in forming an array of minute holes in a
liquid ejecting head, for example.
[0073] With some of the above configurations, since the punches of
the punch array are dug into the bottom portions of the recesses
almost simultaneously, the working shapes of the respective
recesses are made uniform. That is, reduction in working accuracy
due to the warp of the metal plate can be prevented and high
quality can be attained in accuracy. Further, since no unevenness
occurs in the working loads on the respective punches, there does
not occur an event that punches at particular positions are bent or
broken. The durability of the punches can thus be increased. The
above advantages are particularly effective in forming an array of
minute holes in a liquid ejecting head, for example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] The above objects and advantages of the present invention
will become more apparent by describing in detail preferred
exemplary embodiments thereof with reference to the accompanying
drawings, wherein:
[0075] FIG. 1 is a perspective view of a disassembled ink jet
recording head according to a first embodiment of the
invention;
[0076] FIG. 2 is a sectional view of the ink jet recording
head;
[0077] FIGS. 3A and 3B are views for explaining a vibrator
unit;
[0078] FIG. 4 is a plan view of a chamber formation plate;
[0079] FIG. 5A is a view enlarging an X portion in FIG. 4;
[0080] FIG. 5B is a sectional view taken along a line VB-VB of FIG.
5A;
[0081] FIG. 5C is a sectional view taken along a line VC-VC of FIG.
5A;
[0082] FIG. 6 is a plan view of an elastic plate;
[0083] FIG. 7A is a view enlarging a Y portion of FIG. 6;
[0084] FIG. 7B is a sectional view taken along a line VIIB-VIIB of
FIG. 7A;
[0085] FIGS. 8A and 8B are views for explaining a first die used in
forming an elongated recess portion;
[0086] FIGS. 9A and 9B are views for explaining a second die used
in forming the elongated recess portion;
[0087] FIGS. 10A to 10C are views for explaining steps of forming
the elongated recess portion;
[0088] FIG. 10D is a section view showing a metal plate warped by
the formation of the elongated recess portion;
[0089] FIG. 11A is a section view for explaining a second male die
used in forming first communicating ports, according to a first
embodiment of the invention;
[0090] FIG. 11B is a section view for explaining a third male die
used in forming second communicating ports, according to the first
embodiment of the invention;
[0091] FIG. 11C is a section view for explaining a grinding
step;
[0092] FIG. 11D is a section view showing a comparative example of
a distal end of a first punch in the second male die;
[0093] FIG. 11E is a section view showing a distal end of a first
punch in the second male die of FIG. 11A;
[0094] FIG. 11F is a diagram showing a part in the vicinity of an
end of a first punch array in the second male die of FIG. 11A;
[0095] FIG. 11G is a section view for explaining how the distal end
of the first punch of FIG. 11E cuts into the metal plate;
[0096] FIG. 11H is a side view of a first modified example of the
first punch of the second male die of FIG. 11A;
[0097] FIG. 11I is a side view of the first punch of the second
male die of FIG. 11A;
[0098] FIG. 11J is a side view of a second modified example of the
first punch of the second male die of FIG. 11A;
[0099] FIG. 11K is a side view of a third modified example of the
first punch of the second male die of FIG. 11A;
[0100] FIG. 11L is a side view of a fourth modified example of the
first punch of the second male die of FIG. 11A;
[0101] FIG. 11M is a side view of a fifth modified example of the
first punch of the second male die of FIG. 11A;
[0102] FIG. 11N is a side view of a first punch of a second male
die according to a second embodiment of the invention;
[0103] FIG. 11O is a side view of a comparative example for the
second male die of FIG. 11N;
[0104] FIG. 11P is a side view of a first modified example of the
first punch of the second male die of FIG. 11N;
[0105] FIG. 11Q is a side view of a second modified example of the
first punch of the second male die of FIG. 11N;
[0106] FIG. 11R is a side view of a third modified example of the
first punch of the second male die of FIG. 11N;
[0107] FIG. 12A is a perspective view showing a state that the
first punch or the second punch is held between guide members;
[0108] FIG. 12B is a perspective view of the first punch of FIG.
11I held between the guide members;
[0109] FIG. 12C is a perspective view of the first punch of FIG.
11N held between the guide members;
[0110] FIG. 13A is a horizontal section view of the state shown in
FIG. 12;
[0111] FIG. 13B is a vertical section view of the state shown in
FIG. 12;
[0112] FIG. 14 is a horizontal section view of the punches;
[0113] FIG. 15 is a view showing a first modified example of the
guide members;
[0114] FIG. 16 is a horizontal section view showing a second
modified example of the guide members;
[0115] FIG. 17 is a horizontal section view showing a third
modified example of the guide members;
[0116] FIG. 18 is a sectional view for explaining an ink jet
recording head incorporating heat generating elements;
[0117] FIG. 19 is a partially sectional view showing an apparatus
for manufacturing a liquid ejecting head;
[0118] FIG. 20 is a plan view taken along a line XX-XX in FIG.
19;
[0119] FIG. 21 is a section view taken along a line XXI-XXI in FIG.
20;
[0120] FIG. 22 is a perspective view of a male die incorporated in
the manufacturing apparatus and corresponding to the second male
die of FIG. 11I;
[0121] FIG. 23 is an enlarged perspective view showing a distal end
portion of the male die of FIG. 22;
[0122] FIG. 24 is a perspective view showing a first modified
example of the male die of FIG. 22;
[0123] FIG. 25A is a perspective view of a male die incorporated in
the manufacturing apparatus and corresponding to the second male
die of FIG. 11N;
[0124] FIG. 25B is an enlarged perspective view showing a distal
end portion of the male die of FIG. 25A;
[0125] FIG. 25C is a perspective view showing a modified example of
the male die of FIG. 25A;
[0126] FIG. 26A is a plan view for explaining how to form a
communicating hole in an elongated recess portion;
[0127] FIG. 26B is a sectional view for explaining how to form the
communicating hole in the elongated recess portion; and
[0128] FIG. 27 is a section view for explaining a second modified
example of the male die of FIG. 22.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0129] Embodiments of the invention will be described below with
reference to the accompanying drawings. Firstly, the constitution
of a liquid ejecting head will be described.
[0130] Since it is preferable to apply the invention to a recording
head of an ink jet recording apparatus, as an example
representative of the liquid ejecting head, the above recording
head is shown in the embodiment.
[0131] As shown in FIGS. 1 and 2, a recording head 1 is roughly
constituted by a casing 2, a vibrator unit 3 contained at inside of
the casing 2, a flow path unit 4 bonded to a front end face of the
casing 2, a connection board 5 arranged onto a rear end face of the
casing 2, a supply needle unit 6 attached to the rear end face of
the casing 2.
[0132] As shown in FIGS. 3A and 3B, the vibrator unit 3 is roughly
constituted by a piezoelectric vibrator group 7, a fixation plate 8
bonded with the piezoelectric vibrator group 7 and a flexible cable
9 for supplying a drive signal to the piezoelectric vibrator group
7.
[0133] The piezoelectric vibrator group 7 is provided with a
plurality of piezoelectric vibrators 10 formed in a shape of a row.
The respective piezoelectric vibrators 10 are constituted by a pair
of dummy vibrators 10a disposed at both ends of the array and a
plurality of drive vibrators 10b arranged between the dummy
vibrators 10a. Further, the respective drive vibrators 10b are cut
to divide in a pectinated shape having an extremely slender width
of, for example, about 50 .mu.m through 100 .mu.m, so that 180
pieces are provided.
[0134] Further, the dummy vibrator 10a is provided with a width
sufficiently wider than that of the drive vibrator 10b and is
provided with a function for protecting the drive vibrator 10b
against impact or the like and a guiding function for positioning
the vibrator unit 3 at a predetermined position.
[0135] A free end portion of each of the piezoelectric vibrators 10
is projected to an outer side of a front end face of the fixation
plate 8 by bonding a fixed end portion thereof onto the fixation
plate 8. That is, each of the piezoelectric vibrators 10 is
supported on the fixation plate 8 in a cantilevered manner.
Further, the free end portions of the respective piezoelectric
vibrators 10 are constituted by alternately laminating
piezoelectric bodies and inner electrodes so that extended and
contracted in a longitudinal direction of the elements by applying
a potential difference between the electrodes opposed to each
other.
[0136] The flexible cable 9 is electrically connected to the
piezoelectric vibrator 10 at a side face of a fixed end portion
thereof constituting a side opposed to the fixation plate 8.
Further, a surface of the flexible cable 9 is mounted with an IC 11
for controlling to drive the piezoelectric vibrator 10 or the like.
Further, the fixation plate 8 for supporting the respective
piezoelectric vibrators 10 is a plate-shaped member having a
rigidity capable of receiving reaction force from the piezoelectric
vibrators 10, and a metal plate of a stainless steel plate or the
like is preferably used therefor.
[0137] The casing 2 is a block-shaped member molded by a
thermosetting resin of an epoxy species resin or the like. Here,
the casing 2 is molded by the thermosetting resin because the
thermosetting resin is provided with a mechanical strength higher
than that of a normal resin, a linear expansion coefficient is
smaller than that of a normal resin so that deformability depending
on the environmental temperature is small. Further, inside of the
casing 2 is formed with a container chamber 12 capable of
containing the vibrator unit 3, and an ink supply path 13
constituting a portion of a flow path of ink. Further, the front
end face of the casing 2 is formed with a recess 15 for
constituting a common ink reservoir 14.
[0138] The container chamber 12 is a hollow portion having a size
of capable of containing the vibrator unit 3. At a portion of a
front end side of the container chamber 12, a step portion is
formed such that a front end face of the fixation plate 8 is
brought into contact therewith.
[0139] The recess 15 is formed by partially recessing the front end
face of the casing 2 so has to have a substantially trapezoidal
shape formed at left and right outer sides of the container chamber
12.
[0140] The ink supply path 13 is formed to penetrate the casing 2
in a height direction thereof so that a front end thereof
communicates with the recess 15. Further, a rear end portion of the
ink supply path 13 is formed at inside of a connecting port 16
projected from the rear end face of the casing 2.
[0141] The connection board 5 is a wiring board formed with
electric wirings for various signals supplied to the recording head
1 and provided with a connector 17 capable of connecting a signal
cable. Further, the connection board 5 is arranged on the rear end
face of the casing 2 and connected with electric wirings of the
flexible cable 9 by soldering or the like. Further, the connector
17 is inserted with a front end of a signal cable from a control
apparatus (not illustrated).
[0142] The supply needle unit 6 is a portion connected with an ink
cartridge (not illustrated) and is roughly constituted by a needle
holder 18, an ink supply needle 19 and a filter 20.
[0143] The ink supply needle 19 is a portion inserted into the ink
cartridge for introducing ink stored in the ink cartridge. A distal
end portion of the ink supply needle 19 is sharpened in a conical
shape to facilitate to insert into the ink cartridge. Further, the
distal end portion is bored with a plurality of ink introducing
holes for communicating inside and outside of the ink supply needle
19. Further, since the recording head according to the embodiment
can eject two kinds of inks, two pieces of the ink supply needles
19 are provided.
[0144] The needle holder 18 is a member for attaching the ink
supply needle 19, and a surface thereof is formed with base seats
21 for two pieces of the ink supply needles 19 for fixedly
attaching proximal portions of the ink supply needles 19. The base
seat 21 is fabricated in a circular shape in compliance with a
shape of a bottom face of the ink supply needle 19. Further, a
substantially central portion of the bottom face of the base seat
is formed with an ink discharge port 22 penetrated in a plate
thickness direction of the needle holder 18. Further, the needle
holder 18 is extended with a flange portion in a side
direction.
[0145] The filter 20 is a member for hampering foreign matters at
inside of ink such as dust, burr in dieing and the like from
passing therethrough and is constituted by, for example, a metal
net having a fine mesh. The filter 20 is adhered to a filter
holding groove formed at inside of the base seat 21.
[0146] Further, as shown in FIG. 2, the supply needle unit 6 is
arranged on the rear end face of the casing 2. In the arranging
state, the ink discharge port 22 of the supply needle unit 6 and
the connecting port 16 of the casing 2 are communicated with each
other in a liquid tight state via a packing 23.
[0147] Next, the above-described flow path unit 4 will be
explained. The flow path unit 4 is constructed by a constitution in
which a nozzle plate 31 is bonded to one face of a chamber
formation plate 30 and an elastic plate 32 is bonded to other face
of the chamber formation plate 30.
[0148] As shown in FIG. 4, the chamber formation plate 30 is a
plate-shaped member made of a metal formed with an elongated recess
portion 33, a communicating port 34 and an escaping recess portion
35. According to the embodiment, the chamber formation plate 30 is
fabricated by working a metal substrate made of nickel having a
thickness of 0.35 mm.
[0149] An explanation will be given here of reason of selecting
nickel of the metal substrate. First reason is that the linear
expansion coefficient of nickel is substantially equal to a linear
expansion coefficient of a metal (stainless steel in the embodiment
as mentioned later) constituting essential portions of the nozzle
plate 31 and the elastic plate 32. That is, when the linear
expansion coefficients of the chamber formation plate 30, the
elastic plate 32 and the nozzle plate 31 constituting the flow path
unit 4 are substantially equal, in heating and adhering the
respective members, the respective members are uniformly expanded.
Therefore, mechanical stress of warping or the like caused by a
difference in the expansion rates is difficult to generate. As a
result, even when the adhering temperature is set to high
temperature, the respective members can be adhered to each other
without trouble. Further, even when the piezoelectric vibrator 10
generates heat in operating the recording head 1 and the flow path
unit 4 is heated by the heat, the respective members 30, 31 and 32
constituting the flow path unit 4 are uniformly expanded.
Therefore, even when heating accompanied by activating the
recording head 1 and cooling accompanied by deactivating are
repeatedly carried out, a drawback of exfoliation or the like is
difficult to be brought about in the respective members 30, 31 and
32 constituting the flow path unit 4.
[0150] Second reason is that nickel is excellent in corrosion
resistance. That is, aqueous ink is preferably used in the
recording head 1 of this kind, it is important that alteration of
rust or the like is not brought about even when the recording head
1 is brought into contact with water over a long time period. In
this respect, nickel is excellent in corrosion resistance similar
to stainless steel and alteration of rust or the like is difficult
to be brought about.
[0151] Third reason is that nickel is rich in ductility. That is,
in manufacturing the chamber formation plate 30, as mentioned
later, the fabrication is carried out by plastic working (for
example, forging). Further, the elongated recess portion 33 and the
communicating port 34 formed in the chamber formation plate 30 are
of extremely small shapes and high dimensional accuracy is
requested therefor. When nickel is used for the metal substrate,
since nickel is rich in ductility, the elongated recess portion 33
and the communicating port 34 can be formed with high dimensional
accuracy even by plastic working.
[0152] Further, with regard to the chamber formation plate 30, the
chamber formation plate 30 may be constituted by a metal other than
nickel when the condition of the linear expansion coefficient, the
condition of the corrosion resistance and the condition of the
ductility are satisfied.
[0153] The elongated recess portion 33 is a groove-shaped recess
portion constituting a pressure generating chamber 29 and is
constituted by a groove in a linear shape as shown to enlarge in
FIG. 5A. According to the embodiment, 180 pieces of grooves each
having a width of about 0.1 mm, a length of about 1.5 mm and a
depth of about 0.1 mm are aligned side by side. A bottom face of
the elongated recess portion 33 is recessed in a V-shaped shape by
reducing a width thereof as progressing in a depth direction (that
is, depth side). The bottom face is recessed in the V-shaped shape
to increase a rigidity of a partition wall 28 for partitioning the
contiguous pressure generating chambers 29. That is, by recessing
the bottom face in the V-shaped shape, a wall thickness of the
proximal portion of the partition wall 28 is thickened to increase
the rigidity of the partition wall 28. Further, when the rigidity
of the partition wall 28 is increased, influence of pressure
variation from the contiguous pressure generating chamber 29 is
difficult to be effected. That is, a variation of ink pressure from
the contiguous pressure generating chamber 29 is difficult to
transmit. Further, by recessing the bottom face in the V-shaped
shape, the elongated recess portion 33 can be formed with excellent
dimensional accuracy by plastic working (to be mentioned later).
Further, an angle between the inner faces of the recess portion 33
is, for example, around 90 degrees although prescribed by a working
condition.
[0154] Further, since a wall thickness of a distal end portion of
the partitioning wall 28 is extremely thin, even when the
respective pressure generating chambers 29 are densely formed, a
necessary volume can be ensured.
[0155] Both longitudinal end portions of the elongated recess
portion 33 are sloped downwardly to inner sides as progressing to
the depth side. The both end portions are constituted in this way
to form the elongated recess portion 33 with excellent dimensional
accuracy by plastic working.
[0156] Further, contiguous to the elongated recess portion 33 at
the both ends of the row, there are formed single ones of dummy
recesses 36 having a width wider than that of the elongated recess
portion 33. The dummy recess portion 36 is a recess portion in a
groove-shaped shape constituting a dummy pressure generating
chamber which is not related to ejection of ink drops. The dummy
recess portion 36 according to the embodiment is constituted by a
groove having a width of about 0.2 mm, a length of about 1.5 mm and
a depth of about 0.1 mm. Further, a bottom face of the dummy recess
portion 36 is recessed in a W-shaped shape. This is also for
increasing the rigidity of the partition wall 28 and forming the
dummy recess portion 36 with excellent dimensional accuracy by
plastic working.
[0157] Further, an array of recesses is constituted by the
respective elongated recess portions 33 and the pair of dummy
recess portions 36. According to the embodiment, two rows of the
recesses are formed as shown in FIG. 4.
[0158] The communicating port 34 is formed as a small through hole
penetrating from one end of the elongated recess portion 33 in a
plate thickness direction. The communicating ports 34 are formed
for respective ones of the elongated recess portions 33 and are
formed by 180 pieces in a single recess portion array. The
communicating port 34 of the embodiment is in a rectangular shape
in an opening shape thereof and is constituted by a first
communicating port 37 formed from a side of the elongated recess
portion 33 to a middle in the plate thickness direction in the
chamber formation plate 30 and a second communicating port 38
formed from a surface thereof on a side opposed to the elongated
recess portion 33 up to a middle in the plate thickness
direction.
[0159] Further, sectional areas of the first communicating port 37
and the second communicating port 38 differ from each other and an
inner dimension of the second communicating port 38 is set to be
slightly smaller than an inner dimension of the first communicating
port 37. This is caused by manufacturing the communicating port 34
by pressing. The chamber formation plate 30 is fabricated by
working a nickel plate having a thickness of 0.35 mm, a length of
the communicating port 34 becomes equal to or larger than 0.25 mm
even when the depth of the recess portion 33 is subtracted.
Further, the width of the communicating port 34 needs to be
narrower than the groove width of the elongated recess portion 33,
set to be less than 0.1 mm. Therefore, when the communicating port
34 is going to be punched through by a single time of working, a
male die (punch) is buckled due to an aspect ratio thereof.
[0160] Therefore, in the embodiment, the working is divided into
two steps. In the first step, the first communicating port 37 is
formed halfway in the plate thickness direction, and in the second
step, the second communicating port 38 is formed. The working
process of this communicating port 34 will be described later.
[0161] Further, the dummy recess portion 36 is formed with a dummy
communicating port 39. Similar to the above-described communicating
port 34, the dummy communicating port 39 is constituted by a first
dummy communicating port 40 and a second dummy communicating port
41 and an inner dimension of the second dummy communicating port 41
is set to be smaller than an inner dimension of the first dummy
communicating port 40.
[0162] Further, although according to the embodiment, the
communicating port 34 and the dummy communicating port 39 opening
shapes of which are constituted by small through holes in a
rectangular shape are exemplified, the invention is not limited to
the shape. For example, the shape may be constituted by a through
hole opened in a circular shape or a through hole opened in a
polygonal shape.
[0163] The escaping recess portion 35 forms an operating space of a
compliance portion 46 (described later) in the common ink reservoir
14. According to the embodiment, the escaping recess portion 35 is
constituted by a recess portion in a trapezoidal shape having a
shape substantially the same as that of the recess 15 of the casing
2 and a depth equal to that of the elongated recess portion 33.
[0164] Next, the above-described elastic plate 32 will be
explained. The elastic plate 32 is a kind of a sealing plate of the
invention and is fabricated by, for example, a composite material
having a two-layer structure laminating an elastic film 43 on a
support plate 42. According to the embodiment, a stainless steel
plate is used as the support plate 42 and PPS (polyphenylene
sulphide) is used as the elastic film 43.
[0165] As shown in FIG. 6, the elastic plate 32 is formed with a
diaphragm portion 44, an ink supply port 45 and the compliance
portion 46.
[0166] The diaphragm portion 44 is a portion for partitioning a
portion of the pressure generating chamber 29. That is, the
diaphragm portion 44 seals an opening face of the elongated recess
portion 33 and forms to partition the pressure generating chamber
29 along with the elongated recess portion 33. As shown in FIG. 7A,
the diaphragm portion 44 is of a slender shape in correspondence
with the elongated recess portion 33 and is formed for each of the
elongated recess portions 33 with respect to a sealing region for
sealing the elongated recess portion 33. Specifically, a width of
the diaphragm portion 44 is set to be substantially equal to the
groove width of the elongated recess portion 33 and a length of the
diaphragm portion 44 is set to be a slight shorter than the length
of the elongated recess portion 33. With regard to the length, the
length is set to be about two thirds of the length of the elongated
recess portion 33. Further, with regard to a position of forming
the diaphragm portion 44, as shown in FIG. 2, one end of the
diaphragm portion 44 is aligned to one end of the elongated recess
portion 33 (end portion on a side of the communicating port
34).
[0167] As shown in FIG. 7B, the diaphragm portion 44 is fabricated
by removing the support plate 42 at a portion thereof in
correspondence with the elongated recess portion 33 by etching or
the like to constitute only the elastic film 43 and an island
portion 47 is formed at inside of the ring. The island portion 47
is a portion bonded with a distal end face of the piezoelectric
vibrator 10.
[0168] The ink supply port 45 is a hole for communicating the
pressure generating chamber 29 and the common ink reservoir 14 and
is penetrated in a plate thickness direction of the elastic plate
32. Similar to the diaphragm portion 44, also the ink supply port
45 is formed to each of the elongated recess portions 33 at a
position in correspondence with the elongated recess portion 33. As
shown in FIG. 2, the ink supply port 45 is bored at a position in
correspondence with other end of the elongated recess portion 33 on
a side opposed to the communicating port 34. Further, a diameter of
the ink supply port 45 is set to be sufficiently smaller than the
groove width of the elongated recess portion 33. According to the
embodiment, the ink supply port 45 is constituted by a small
through hole of 23 .mu.m.
[0169] Reason of constituting the ink supply port 45 by the small
through hole in this way is that flow path resistance is provided
between the pressure generating chamber 29 and the common ink
reservoir 14. That is, according to the recording head 1, an ink
drop is ejected by utilizing a pressure variation applied to ink at
inside of the pressure generating chamber 29. Therefore, in order
to efficiently eject an ink drop, it is important that ink pressure
at inside of the pressure generating chamber 29 is prevented from
being escaped to a side of the common ink reservoir 14 as less as
possible. From the view point, the ink supply port 45 is
constituted by the small through hole.
[0170] Further, when the ink supply port 45 is constituted by the
through hole as in the embodiment, there is an advantage that the
working is facilitated and high dimensional accuracy is achieved.
That is, the ink supply port 45 is the through hole, can be
fabricated by laser machining. Therefore, even a small diameter can
be fabricated with high dimensional accuracy and also the operation
is facilitated.
[0171] The compliance portion 46 is a portion for partitioning a
portion of the common ink reservoir 14. That is, the common ink
reservoir 14 is formed to partition by the compliance portion 46
and the recess 15. The compliance portion 46 is of a trapezoidal
shape substantially the same as an opening shape of the recess 15
and is fabricated by removing a portion of the support plate 42 by
etching or the like to constitute only the elastic film 43.
[0172] Further, the support plate 42 and the elastic film 43
constituting the elastic plate 32 are not limited to the example.
Further, polyimide may be used as the elastic film 43. Further, the
elastic plate 32 may be constituted by a metal plate provided with
a thick wall and a thin wall at a surrounding of the thick wall for
constituting the diaphragm portion 44 and a thin wall for
constituting the compliance portion 46.
[0173] Next, the above-described nozzle plate 31 will be explained.
The nozzle plate 31 is a plate-shaped member made of a metal
aligned with a plurality of nozzle orifices 48 at a pitch in
correspondence with a dot forming density. According to the
embodiment, a nozzle array is constituted by aligning a total of
180 pieces of the nozzle orifices 48 and two rows of the nozzles
are formed as shown in FIG. 2.
[0174] Further, when the nozzle plate 31 is bonded to other face of
the chamber formation plate 30, that is, to a surface thereof on a
side opposed to the elastic plate 32, the respective nozzle
orifices 48 face the corresponding communicating ports 34.
[0175] Further, when the above-described elastic plate 32 is bonded
to one surface of the chamber formation plate 30, that is, a face
thereof for forming the elongated recess portion 33, the diaphragm
portion 44 seals the opening face of the elongated recess portion
33 to form to partition the pressure generating chamber 29.
Similarly, also the opening face of the dummy recess portion 36 is
sealed to form to partition the dummy pressure generating chamber.
Further, when the above-described nozzle plate 31 is bonded to
other surface of the chamber formation plate 30, the nozzle orifice
48 faces the corresponding communicating port 34. When the
piezoelectric vibrator 10 bonded to the island portion 47 is
extended or contracted under the state, the elastic film 43 at a
surrounding of the island portion is deformed and the island
portion 47 is pushed to the side of the elongated recess portion 33
or pulled in a direction of separating from the side of the
elongated recess portion 33. By deforming the elastic film 43, the
pressure generating chamber 29 is expanded or contracted to provide
a pressure variation to ink at inside of the pressure generating
chamber 29.
[0176] When the elastic plate 32 (that is, the flow path unit 4) is
bonded to the casing 2, the compliance portion 46 seals the recess
15. The compliance portion 46 absorbs the pressure variation of ink
stored in the common ink reservoir 14. That is, the elastic film 43
is deformed in accordance with pressure of stored ink. Further, the
above-described escaping recess portion 35 forms a space for
allowing the elastic film 43 to be expanded.
[0177] The recording head 1 having the above-described constitution
includes a common ink flow path from the ink supply needle 19 to
the common ink reservoir 14, and an individual ink flow path
reaching each of the nozzle orifices 48 by passing the pressure
generating chamber 29 from the common ink reservoir 14. Further,
ink stored in the ink cartridge is introduced from the ink supply
needle 19 and stored in the common ink reservoir 14 by passing the
common ink flow path. Ink stored in the common ink reservoir 14 is
ejected from the nozzle orifice 48 by passing the individual ink
flow path.
[0178] For example, when the piezoelectric vibrator 10 is
contracted, the diaphragm portion 44 is pulled to the side of the
vibrator unit 3 to expand the pressure generating chamber 29. By
the expansion, inside of the pressure generating chamber 29 is
brought under negative pressure, ink at inside of the common ink
reservoir 14 flows into each pressure generating chamber 29 by
passing the ink supply port 45. Thereafter, when the piezoelectric
vibrator 10 is extended, the diaphragm portion 44 is pushed to the
side of the chamber formation plate 30 to contract the pressure
generating chamber 29. By the contraction, ink pressure at inside
of the pressure generating chamber 29 rises and an ink drop is
ejected from the corresponding nozzle orifice 48.
[0179] According to the recording head 1, the bottom face of the
pressure generating chamber 29 (elongated recess portion 33) is
recessed in the V-shaped shape. Therefore, the wall thickness of
the proximal portion of the partition wall 28 for partitioning the
contiguous pressure generating chambers 29 is formed to be thicker
than the wall thickness of the distal end portion. Thereby, the
rigidity of the thick wall 28 can be increased. Therefore, in
ejecting an ink drop, even when a variation of ink pressure is
produced at inside of the pressure generating chamber 29, the
pressure variation can be made to be difficult to transmit to the
contiguous pressure generating chamber 29. As a result, the
so-called contiguous cross talk can be prevented and ejection of
ink drop can be stabilized.
[0180] According to the embodiment, the ink supply port 45 for
communicating the common ink reservoir 14 and the pressure
generating chamber 29 is constituted by the small hole penetrating
the elastic plate 32 in the plate thickness direction, high
dimensional accuracy thereof is easily achieved by laser machining
or the like. Thereby, an ink flowing characteristic into the
respective pressure generating chambers 29 (flowing velocity,
flowing amount or the like) can be highly equalized. Further, when
the fabrication is carried out by the laser beam, the fabrication
is also facilitated.
[0181] According to the embodiment, there are provided the dummy
pressure generating chambers which are not related to ejection of
ink drop contiguously to the pressure generating chambers 29 at end
portions of the array (that is, a hollow portion partitioned by the
dummy recess portion 36 and the elastic plate 32), with regard to
the pressure generating chambers 29 at both ends, one side thereof
is formed with the contiguous pressure generating chamber 29 and an
opposed thereof is formed with the dummy pressure generating
chamber. Thereby, with regard to the pressure generating chambers
29 at end portions of the row, the rigidity of the partition wall
partitioning the pressure generating chamber 29 can be made to be
equal to the rigidity of the partition wall at the other pressure
generating chambers 29 at a middle of the row. As a result, ink
ejection characteristics of all the pressure generating chambers 29
of the one array can be made to be equal to each other.
[0182] With regard to the dummy pressure generating chamber, the
width on the side of the aligning direction is made to be wider
than the width of the respective pressure generating chambers 29.
In other words, the width of the dummy recess portion 36 is made to
be wider than the width of the elongated recess portion 33.
Thereby, ejection characteristics of the pressure generating
chamber 29 at the end portion of the array and the pressure
generating chamber 29 at the middle of the array can be made to be
equal to each other with high accuracy.
[0183] According to the embodiment, the recess 15 is formed by
partially recessing the front end face of the casing 2, the common
ink reservoir 14 is formed to partition by the recess 15 and the
elastic plate 32, an exclusive member for forming the common ink
reservoir 14 is dispensed with and simplification of the
constitution is achieved. Further, the casing 2 is fabricated by
resin dieing, fabrication of the recess 15 is also relatively
facilitated.
[0184] Next, a method of manufacturing the recording head 1 will be
explained. Since the manufacturing method is characterized in steps
of manufacturing the chamber formation plate 30, an explanation
will be mainly given for the steps of manufacturing the chamber
formation plate 30.
[0185] The chamber formation plate 30 is fabricated by forging by a
progressive die. Further, a metal plate 55 (referred to as "strip
55" in the following explanation) used as a material of the chamber
formation plate 30 is made of nickel as described above.
[0186] The steps of manufacturing the chamber formation plate 30
comprises steps of forming the elongated recess portion 33 and
steps of forming the communicating port 34 which are carried out by
a progressive die.
[0187] In the elongated recess portion forming steps, a first male
die 51 shown in FIGS. 8A and 8B and a female die shown in FIGS. 9A
and 9B are used. The first male die 51 is a die for forming the
elongated recess portion 33. The male die is aligned with
projections 53 for forming the elongated recess portions 33 by a
number the same as that of the elongated recess portions 33.
Further, the projections 53 at both ends in an aligned direction
are also provided with dummy projections (not illustrated) for
forming the dummy recess portions 36. A distal end portion 53a of
the projection 53 is tapered from a center thereof in a width
direction by an angle of about 45 degrees as shown in FIG. 8B.
Thereby, the distal end portion 53a is sharpened in the V-shaped
shape in view from a longitudinal direction thereof. Further, both
longitudinal ends 53b of the distal end portions 53a are tapered by
an angle of about 45 degrees as shown in FIG. 8A. Therefore, the
distal end portion 53a of the projection 53 is formed in a shape of
tapering both ends of a triangular prism.
[0188] Further, the female die 52 is formed with a plurality of
projections 54 at an upper face thereof. The projection 54 is for
assisting to form the partition wall partitioning the contiguous
pressure generating chambers 29 and is disposed between the
elongated recess portions 33. As shown in FIG. 10A, the projections
54 extend parallel with the longitudinal direction of the
projections 53 and are located at such positions as to be opposed
to the corresponding projections 53. As shown in FIGS. 9B and 10A,
each projection 54 has a wedge-shaped cross section and its
sharpened portion is opposed to the distal end portion 53a of the
corresponding projection 53. The length of the projections 54 is
set approximately the same as that of the elongated recess portions
33 (projections 53).
[0189] In the elongated recess portion forming steps, first, as
shown in FIG. 10A, the strip 55 is mounted at an upper face of the
female die 52 and the first male die 51 is arranged on an upper
side of the strip 55. Next, as shown in FIG. 10B, the first male
die 51 is moved down to push the distal end portion of the
projection 53 into the strip 55. At this occasion, since the distal
end portion 53a of the projection 53 is sharpened in the V-shaped
shape, the distal end portion 53a can firmly be pushed into the
strip 55 without buckling. Pushing of the projection 53 is carried
out up to a middle in a plate thickness direction of the strip 55
as shown in FIG. 10C.
[0190] By pushing the projection 53, a portion of the strip 55
flows to form the elongated recess portion 33. In this case, since
the distal end portion 53a of the projection 53 is sharpened in the
V-shaped shape, even the elongated recess portion 33 having a small
shape can be formed with high dimensional accuracy. That is, the
portion of the strip 55 pushed by the distal end portion 53a flows
smoothly, the elongated recess portion 33 to be formed is formed in
a shape following the shape of the projection 53. Further, since
the both longitudinal ends 53b of the distal end portion 53a are
tapered, the strip 55 pushed by the portions also flows smoothly.
Therefore, also the both end portions in the longitudinal direction
of the elongated recess portion 33 are formed with high dimensional
accuracy.
[0191] As the distal end portions 53a are dug into the strip 55 in
the above manner, the metal material is pressed between the distal
end portions 53a and the projections 54 opposed to the distal end
portions 53a and thereby flows into the gaps between the
projections 53.
[0192] Since pushing of the projection 53 is stopped at the middle
of the plate thickness direction, the strip 55 thicker than in the
case of forming a through hole can be used. Thereby, the rigidity
of the chamber formation plate 30 can be increased and improvement
of an ink ejection characteristic is achieved. Further, the chamber
formation plate 30 is easily dealt with and the operation is
advantageous also in enhancing plane accuracy.
[0193] A portion of the strip 55 is raised into a space between the
contiguous projections 53 by being pressed by the projections 53.
In this case, the projection 54 provided at the female die 52 is
arranged at a position in correspondence with an interval between
the projections 53, flow of the strip 55 into the space is
assisted. Thereby, the strip 55 can efficiently be introduced into
the space between the projections 53 and the protrusion (i.e., the
partition wall 28) can be formed highly.
[0194] Next, a description will be made of how the strip 55 is
deformed when a large number of recessed portions are formed in the
strip 55.
[0195] FIG. 10C shows a state that the first male die 51 has been
advanced fully (maximum stroke). In this state, the strip 55 is
confined completely between the first male die 51 and the female
die 52. When the first male die 51 is returned to the original
position from this state, the strip 55 is released. At this time,
as shown in FIG. 10D, due to the internal stress of the strip 55,
the strip 55 is deformed so as to assume a smooth curve in which a
center portion is low and end portions are high. The reason why the
strip 55 is warped in this manner is considered due to combined
occurrence of a phenomenon that thick portions 55a of the strip 55
expand in the arrayed direction of the elongated recess portions 33
due to the internal stress and a phenomenon that the elongated
recess portions 33 above the thick portions 55a are gaps and hence
cannot suppress their expansion in the arrayed direction.
[0196] In other words, as described above, if the strip 55 is
placed generally horizontally with the openings of the elongated
recess portions 33 located above and the bottoms of the elongated
recess portions 33 located below, the warped shape is such that the
ends in the arrayed direction of the elongated recess portions 33
are highest and the height decreases gradually as the position goes
from the ends to the center.
[0197] After the elongated recess portions 33 have been formed in
the above-described manner, a transition is made to the
communicating ports forming process to form minute communicating
ports 34 in the bottom portions of the elongated recess portions
33.
[0198] As shown in FIGS. 11A and 11B, according to a first
embodiment of the invention, a second male die 57 and a third male
die 59 are used in the communicating ports forming process. The
second male die 57 is configured such that plural
rectangular-prism-shaped first punches 56 that conform in shape to
intended first communicating ports 37 are arrayed on a base member
at a prescribed pitch. The third male die 59 is configured such
that plural rectangular-prism-shaped second punches 58 that conform
in shape to intended second communicating ports 38 are arrayed on a
base member at a prescribed pitch. The second punches 58 are one
size narrower than the first punches 56.
[0199] Since the bottom portions of the elongated recess portions
33 are gently slant as shown in FIG. 10D, the center line O2 of
each of the end elongated recess portions 33 is inclined from the
digging direction line O1 of the first punches 56 by an angle
.theta. as shown in FIG. 11D. If the distal end faces 56f of the
first punches 56 are perpendicular to the digging direction line O1
and the first punches 56 are dug along the digging direction line
O1 in this condition, the only one side of each distal end face 56f
is pressed against the one slant surface of the V-shaped bottom
portion of the associated elongated recess portion 33. Hence,
bending force represented by arrow P1 acts on the first punch 56.
The bending force P1 acts in the direction from the end of the
first punch array 56a to its center. Therefore, bending stress is
concentrated at the proximal end of each first punch 56.
[0200] Because of the above bending force P1, the position of
digging of each first punch 56 into the bottom portion of the
associated elongated recess portion 33 is deviated rightward in
FIG. 11D, as a result of which the accuracy of the positions of
formation of the first communicating ports 37 is lowered. This
phenomenon is remarkable at locations where the angle .theta. is
large, that is, the phenomenon becomes more remarkable as the
position goes closer to the ends of the array of elongated recess
portions 33. Conversely, the phenomenon is negligible around the
center of the first punch array 56a. That is, since the angle
.theta. is large at and near the end elongated recess portions 33,
the problem of the deviation of the punch digging position is
serious there. As the position goes closer to the center of the
array of elongated recess portions 33, the angle .theta. decreases
gradually and hence the bending force P1 also decreases gradually.
The deviation of the punch digging position occurs in either of a
case that the first punches 56 are deformed elastically and a case
that they are deformed plastically. In either case, the accuracy of
the positions of formation of the first communicating ports 37 is
lowered. Since this phenomenon is most remarkable at and near the
ends of the first punch array 56a, the first punches 56 are prone
to wear there, which lowers the durability of the tool.
[0201] To solve the above problem, in this embodiment, the distal
end faces of first punches 56 at and near the ends of the first
punch array 56a are shaped into slant faces 56g as shown in FIG.
11E. More specifically, the slant faces 56g are configured such
that the position thereof recedes more in the punch digging
direction as the position goes closer to the center of the first
punch array 56a. As shown in FIG. 11F, a contour line 56b formed by
the slant faces 56g of the first punches 56 at and near the ends of
the first punch array 56a is inclined so that the slant distal end
face 56g projects more in the advancement direction of the second
male die 57 as the position goes closer to the ends of the first
punch array 56a. A dashed chain line in FIG. 11F indicates an
imaginary plane S that is perpendicular to the punch (male die)
digging direction. The interval between the imaginary plane S and
the slant distal end face 56g increases as the position goes closer
to the center of the first punch array 56a (goes rightward in FIG.
11F). Reference numeral 56b represents a contour line formed by
connecting the distal end faces 56g of the first punches 56. In
this case, as shown in FIG. 11, the contour line 56b is defined by
two slant straight lines 56c connected by a horizontal straight
line 56d located therebetween. In this diagram, the first punches
56 and the elongated recess portions 33 formed in the strip 55 in
advance are drawn simply as fine short lines.
[0202] As shown in FIG. 11G, because of the formation of the slant
distal end face 56g, the one edge of the tip portion of each first
punch 56 is shaped into an acute angle portion 56h. When the acute
angle portion 56h hits the slant surface of the bottom portion of
the corresponding elongated recess portion 33, bending force P1 of
the same kind as described above is generated. At the same time,
bending force P2 that counters the bending force P1 is generated
because the acute angle portion 56h digs into the bottom portion of
the elongated recess portion 33. The bending force P2 cancels out
the bending force P1 entirely or partially, and hence the total
bending force of moving the first punch 56 toward the center of the
first punch array 56a is canceled or is weakened. It is considered
that the bending force P2 originates from reaction force that the
slant distal end face 56g that has cut into the strip 55 receives
from the strip 55.
[0203] The first punches 56 shown in FIG. 11F have the same pitch
as the arrayed pitch of the elongated recess portions 33, and are
dug into the bottom portions of the corresponding elongated recess
portions 33 at the prescribed positions as the second male die 57
is advanced. As described above, the contour line 56b formed by the
slant faces 56g of the first punches 56 at and near the ends of the
first punch array 56a is inclined so that the slant distal end face
56g projects more in the advancement direction of the second male
die 57 as the position goes closer to the ends of the first punch
array 56a.
[0204] According to this rule, the shape of the contour line 56b
may be modified in various manners described below. For example,
the contour line 56b may assume a smooth curve (circular arc).
[0205] The slant straight parts 56c of the contour line 56b shown
in FIG. 11I may be curved. As shown in FIG. 11J, the center
horizontal part 56d of the contour line 56b may be projected toward
the strip 55. As shown in FIG. 11K, the slant straight parts 56c of
the contour line 56b shown in FIG. 11J may be provided as curved
slant parts 56i. As shown in FIG. 11L, the contour line 56b may be
formed only with slant straight parts 56c.
[0206] The lengths of the first punches 56 are set according to the
shape of the contour line 56b. That is, the length of the first
punches 56 at and near the ends of the first punch array 56a
increases as the position goes closer to the ends, and the first
punches 56 at and near the ends of the first punch array 56a are
longer than the central first punches 56, in the examples of FIGS.
11H, 11I and 11K. Alternatively, the length of the first punches 56
at and near the ends of the first punch array 56a increases as the
position goes closer to the ends, and the central first punches 56
project in the punch digging direction, in the examples of FIGS.
11J and 11K.
[0207] Further, the above-described bending force P2 may be
obtained even in a case where the lengths of the first punches 56
are determined such that the lowermost positions of the respective
slant faces 56g are arranged on the imaginary plane S.
[0208] In order to form the communicating ports 34, as shown in
FIG. 11A, unpierced recesses as first communicating ports 37 are
first formed by digging the first punches 56 of the second male die
57 into the bottom portions of the elongated recess portions 33 of
the strip 55 halfway in the thickness direction. Incidentally, as
shown in FIG. 11G, the bending forces P1 and P2 counter each other,
whereby the bending of the first punches 56 and the deviation of
the punch digging positions can be prevented.
[0209] Since as described above the bending forces P1 and P2
counter each other and the bending of the first punches 56 and the
deviation of the punch digging positions can thereby be prevented,
communicating ports 34 can be formed correctly at the prescribed
positions. In addition, since the total force of bending each first
punch 56 is canceled or weakened greatly because the bending forces
P1 and P2 counter each other, the durability of the first punches
56 is increased.
[0210] As shown in FIG. 11B, in the second punches 58 of the third
male die 59, a second punch array 58a and a contour line 58b (a
line connecting the distal end faces of the second punches 58) are
formed in the same manner as in the first punches 56. The shape of
the contour line 58b and the lengths of the second punches 58 are
set in the same manners as the shape of the contour line 56b and
the lengths of the first punches 56. After the recesses as the
first communicating ports 37 have been formed in the
above-described manner, as shown in FIG. 11B the second punches 58
of the third male die 59 are dug into the bottom portions of the
first communicating ports 37 from the side of the elongated recess
portions 33, whereby unpierced recesses as second communicating
ports 38 are formed. Incidentally, the back surface of the strip 55
is formed with bulges 38a.
[0211] Then, the bulges 38a are ground away to an imaginary plane
30a indicated by a dashed chain line in FIG. 11B, whereby the
second communicating ports 38 are given openings on the back
surface side of the strip 55.
[0212] The advantages of the above working method according to the
first embodiment are as follows.
[0213] For example, when an array of elongated recess portions 33
is formed in a strip 55 at a prescribed pitch, there may occur, for
a certain reason, an event that internal stresses etc. occurring at
local forming positions of the strip 55 are accumulated in the
arrayed direction. As a result, the strip 55 may be warped.
However, in the working method of this embodiment, since the distal
end faces of at least first punches 56 at and near the ends of the
first punch array 56a are shaped into the slant faces 56g in which
the lowermost position recedes more in the punch digging direction
as the position goes closer to the center of the first punch array
56a, bending force P2 is generated because of the warp of the strip
55 so as to counter bending force P1 that is directed toward the
center of the first punch array 56a when the bending force P1 acts
on each of the first punches 56 at and near the ends of the first
punch array 56a. Since the bending force P2 generated by the slant
distal end face 56g cancels out the bending force P1 entirely or in
a large part, the total bending force acting on each first punch 56
can be weakened to a negligible level. As a result, no inclinations
etc. occur in the first punches 56 at and near the ends of the
first punch array 56a, and hence an array of communicating ports 34
can be formed in the bottom portions of the elongated recess
portions 33 correctly at the prescribed positions.
[0214] Therefore, reduction in working accuracy due to the abnormal
arrangement form can be prevented and high quality can be attained
in accuracy. In addition, since the bending loads on the first
punches 56 at and near the ends are reduced, an event that punches
at particular positions are bent or broken does not occur and hence
the durability of the punching tool can be increased. The above
advantages are particularly effective in forming an array of
communicating ports 34 in a liquid ejecting head, for example.
[0215] An array of elongated recess portions 33 is formed at a
prescribed pitch in a strip 55 and the first punches 56 having the
same pitch as the elongated recess portions 33 are dug into the
bottom portions of the elongated recess portions 33. Therefore,
communicating ports 34 can be formed correctly relatively to the
prescribed positions of densely arranged elongated recess portions
33 even if they are located at and near the ends of the array.
[0216] The contour line 56b of first punches 56 at and near the
ends of the first punch array 56a is inclined so that the slant
distal end face 56g projects more in the advancement direction of
the second male die 57 as the position goes closer to the ends.
Therefore, the first punches 56 at and near the ends of the first
punch array 56a can be caused to perform initial-stage working with
high accuracy as the second male die 57 is advanced. Even if
bending force P1 toward the center of the first punch array 56a
acts on each of the first punches 56 at and near the ends of the
first punch array 56a as the second male die 57 is advanced or the
first punches 56 at and near the ends of the first punch array 56a
are involved in working for a longer time and receive heavier
working loads because they are first dug into the bottom portions
of the corresponding elongated recess portions 33, the
communicating ports 34 can be formed correctly at the prescribed
positions of the elongated recess portions 33 because the total
bending force acting on each of the first punches 56 at and near
the ends of the first punch array 56a is weakened by the slant
distal end face 56g. An event that only the first punches 56 at and
near the ends of the first punch array 56a wear early does not
occur, and the durability of the punching tool can be
increased.
[0217] The contour line 56b of the first punch array 56a projects
more in the advancement direction of the second male die 57 in end
portions of the first punch array 56a than in its central portion.
Therefore, even if the strip 55 is warped as mentioned the above,
the first punches 56 in the end portions of the first punch array
56a start working earlier than the first punches 56 in the central
portion and then the entire first punch array 56a performs working,
whereby the communicating ports 34 can be formed correctly at the
prescribed positions of the elongated recess portions 33.
[0218] In a case where the contour line 56b is configured as shown
in FIG. 11I, after the first punches 56 at the ends of the first
punch array 56a have started working, the first punches 56 that
start working move toward the center of the first punch array 56a
gradually according to the gradient of the straight portions 56c.
Therefore, the working loads on the first punches 56 at and near
the ends of the first punch array 56a can be set according to the
durability of the first punches 56 and the working depth by setting
the gradient (i.e., angle) of the straight parts 56c at a proper
value, which is effective in increasing the durability of the
punching tool.
[0219] In a case where the contour line 56b is configured as shown
in FIG. 11H, the first punches 56 at and near the ends of the first
punch array 56a first performs hole formation working correctly and
then a transition is made continuously and gradually to hole
formation working by the central first punches 56. As a result, the
working can be performed continuously and smoothly, which is
effective in increasing the durability of the first punches 56.
[0220] In a case where the contour line 56b is configured as shown
in FIG. 11J, after the first punches 56 at the ends of the first
punch array 56a have started working, the first punches 56 that
start working move toward the center of the first punch array 56a
gradually according to the gradient of the straight parts 56c.
Therefore, the working loads on the first punches 56 at and near
the ends of the first punch array 56a can be set according to the
durability of the first punches 56 and the working depth by setting
the gradient (i.e., angle) of the straight parts 56c at a proper
value. In addition, since the horizontal straight part 56d start
working after the slant straight parts 56c, the entire first punch
array 56a can perform working smoothly.
[0221] In a case where the contour line 56b is configured as shown
in FIG. 11K, after the first punches 56 at the ends of the first
punch array 56a have started working, the first punches 56 that
start working move toward the center of the first punch array 56a
gradually in accordance with the curved slant parts 56i. Therefore,
the working loads on the first punches 56 at and near the ends of
the first punch array 56a can be set according to the durability of
the first punches 56 and the working depth by suitably setting the
curvature of the curved slant parts 56i. In addition, since the
horizontal straight part 56d start working after the curved slant
parts 56i, the entire first punch array 56a can perform working
smoothly.
[0222] The lengths of the first punches 56 at and near the ends of
the first punch array 56a are set in such a manner that the length
increases as the position goes closer to the ends of the first
punch array 56a. Therefore, even if bending force P1 toward the
center of the first punch array 56a acts on each of the first
punches 56 at and near the ends of the first punch array 56a as the
second male die 57 is advanced or the first punches 56 at and near
the ends of the first punch array 56a are involved in working for a
longer time and receive heavier working loads because they are
first dug into the strip 55, the communicating ports 34 can be
formed correctly at the prescribed positions of the strip 55
because the total bending force acting on each of the first punches
56 at and near the ends of the first punch array 56a is weakened by
the slant distal end face 56g. An event that only the first punches
56 at and near the ends of the first punch array 56a wear early
does not occur, and the durability of the punching tool can be
increased.
[0223] The lengths of the first punches 56 at and near the ends of
the first punch array 56a are set longer than the lengths of the
central first punches 56. Therefore, even if the strip 55 is warped
as mentioned the above, the first punches 56 in the end portions of
the first punch array 56a start working earlier than the first
punches 56 in the central portion and then the entire first punch
array 56a performs working, whereby the communicating ports 34 can
be formed in the bottom portions of the elongated recess portions
33 correctly at the prescribed positions.
[0224] The lengths of the first punches 56 at and near the ends of
the first punch array 56a are set in such a manner that the length
increases as the position goes closer to the ends of the first
punch array 56a, and the lengths of the first punches 56 are set in
such a manner that the central first punches 56 project more in the
punch digging direction than the other first punches 56. Therefore,
even if bending force P1 toward the center of the first punch array
56a acts on each of the first punches 56 at and near the ends of
the first punch array 56a as the second male die 57 is advanced or
the first punches 56 at and near the ends of the first punch array
56a are involved in working for a longer time and receive heavier
working loads because they are first dug into the strip 55, the
communicating ports 34 can be formed in the bottom portions of the
elongated recess portions 33 correctly at the prescribed positions
because the total bending force acting on each of the first punches
56 at and near the ends of the first punch array 56a is weakened by
the slant distal end face 56g. An event that only the first punches
56 at and near the ends of the first punch array 56a wear early
does not occur, and the durability of the punching tool can be
increased. In addition, since the lengths of the first punches 56
are set in such a manner that the central first punches 56 project
more in the punch digging direction than the other first punches
56, the central first punches 56 start working almost immediately
after the end of working by the first punches 56 at and near the
ends of the first punch array 56a, which enables working that is
free of unevenness over the entire first punch array 56a.
[0225] Even if the first punches 56 have a rectangular cross
section with which prescribed shape accuracy is hard to attain,
rectangular communicating ports 34 can be obtained with high shape
accuracy because the first punches 56 at and near the ends of the
first punch array 56a perform high-precision working at the initial
working stage.
[0226] The process for forming the communicating ports 34 includes
the first process for forming unpierced recesses 37 in the strip 55
using the first punches 56, the second process for forming
unpierced recesses 38 while causing the bottom portions of the
recesses 37 to bulge using the second punches 58, and the third
process for removing bulges 38a. Since the workings with the
punches 56 and 58 at and near the ends of the punch arrays 56a and
58a are performed first with high accuracy, the recesses 37 or 38
are formed correctly in the first or second process and the bulging
lengths of the bulges 38a are made almost uniform. Therefore, the
thicknesses of the portions that are removed in the third step are
constant among the recesses 38, whereby the removing process is
simplified and the lengths of resulting communicating ports 34 are
made uniform.
[0227] Since the above recessed portions are elongated recess
portions 33, a procedure is possible that hole formation working by
the first punches 56 at and near the ends of the first punch array
56a is performed first with high accuracy on the elongated recess
portions 33 and subsequently the arrayed communicating ports 34 are
formed correctly at the prescribed positions of the elongated
recess portions 33 at the same pitch as the pitch of the elongated
recess portions 33.
[0228] The elongated recess portions 33 have V-shaped bottom
portions. When the communicating ports 34 are formed in the
V-shaped bottom portions of the elongated recess portions 33 under
a condition that the strip 55 is warped, the first punches 56 are
prone to be bent or escape due to the V-shaped slant surfaces,
resulting in reduction in working accuracy. However, this problem
relating to the working accuracy can be solved because correct hole
formation working is performed in advance at the prescribed
positions on V-shaped slant surfaces having abnormal inclination
angles in the elongated recess portions 33 corresponding to the
first punches 56 at and near the ends of the first punch array
56a.
[0229] Next, a second embodiment of the invention will be
described. Components similar to those in the first embodiment will
be designated by the same reference numerals and repetitive
explanations for those will be omitted.
[0230] In this embodiment, as shown in FIG. 11N, distal end faces
of a first punch array 56a of first punches 56 are made slant such
that a contour line 56b generally assumes a circular arc shape that
is approximately the same as the warped shape of the strip 55.
[0231] With this configuration, when the communicating ports 34 are
formed, the distal end faces of the first punches 56, is dug into
the bottom portions of the elongated recess portions 33 almost
simultaneously.
[0232] Therefore, the working loads imposed on the respective first
punches 56 are made uniform and hence there does not occur an event
that a particular portion of the contour line 56b wears early. In
addition, since the digging depths at the respective working
positions are uniform, the working accuracy can be increased.
[0233] In the second punches 58 of the third male die 59, a second
punch array 58a is formed and a contour line 58b can be defined in
the same manner as in the first punches 56. The contour line 58b
generally assumes a circular arc shape that is approximately the
same as the warped shape of the strip 55.
[0234] FIG. 11O shows a comparative example in which the contour
line 56b assumes a horizontal straight line. In this case, first
punches 56 at and near the ends of the contour line 56b are first
dug into the bottom portions of the corresponding elongated recess
portions 33 and the digging positions shift in order toward the
center of the array of elongated recess portions 33. Therefore, the
time in which the first punches 56 at and near the ends of the
contour line 56b serve to deform the material is long, as a result
of which they receive heavy working loads and wear early.
[0235] Although it is most desirable that the contour line 56b is
the same as the warped shape of the strip 55 in their arrayed
direction of the elongated recess portions 33 as shown in FIG. 11N,
the problems can be solved as long as they approximate each
other.
[0236] For example, as shown in FIG. 11P as a first modified
example, the contour line 56b may have slant straight parts 56c
connected by a horizontal straight part 56d located
therebetween.
[0237] As shown in FIG. 11Q as a second modified example, the
contour line 56b may be projected stepwise toward the strip 55 as
being closer to the center thereof.
[0238] As shown in FIG. 11R as a third modified example, the
contour line 56b may be formed only with slant straight parts
56c.
[0239] The advantages of the above working method according to the
second embodiment are as follows.
[0240] For example, when an array of elongated recess portions 33
is formed in a strip 55 at a prescribed pitch, there may occur, for
a certain reason, an event that internal stresses etc. occurring at
local forming positions of the strip 55 are accumulated in the
arrayed direction. As a result, the strip 55 may be warped.
However, according to the working method of this embodiment, the
punches 56 or 58 of the punch array 56a or 58a are dug into the
bottom portions of the elongated recess portions 33 almost
simultaneously. Therefore, the working shapes of the respective
elongated recess portions 33 are made uniform; that is, reduction
in working accuracy due to the warp of the strip 55 can be
prevented and high quality can be attained in accuracy. Further,
since no unevenness occurs in the working loads on the respective
punches 56 or 58, there does not occur an event that punches at
particular positions are bent or broken. The durability of the
punches 56 or 58 can thus be increased. The above advantages are
particularly effective in forming an array of minute holes in a
liquid ejecting head, for example.
[0241] The contour line 56b or 58b of the punch array 56a or 58a is
configured such that the distal end faces of the central punches 56
or 58 project more in the advancement direction of the male die 57
or 59 than those of the punches 56 or 58 at and near the ends of
the punch array 56a or 58a. Therefore, even if the strip 55 is
warped by the formation of the elongated recess portions 33, the
punches 56 or 58 can be dug into the bottom portions of the
elongated recess portions 33 almost simultaneously by making the
shape of the contour line 56b or 58b identical or approximately
identical to the warped shape of the strip 55.
[0242] In a case where the contour line 56b or 58b is configured as
shown in FIG. 11N, since the shape of the contour line 56b or 58b
can be made the same as the warped shape of the strip 55, the
punches 56 or 58 can be dug into the bottom portions of the
elongated recess portions 33 simultaneously.
[0243] In a case where the contour line 56b or 58b is configured as
shown in FIGS. 11P and 11R, since the shape of the contour line 56b
or 58b can be made approximately the same as the warped shape of
the strip 55, the punches 56 or 58 can thus be dug into the bottom
portions of the elongated recess portions 33 almost
simultaneously.
[0244] A mass-production-level durability test showed that the
contour line 56b or 58b of FIG. 11P provides about five times
higher durability than other contour lines.
[0245] In a case where the contour line 56b or 58b is configured as
shown in FIG. 11R, since the shape of the contour line 56b or 58b
can be made approximately the same as the warped shape of the strip
55, the punches 56 or 58 can thus be dug into the bottom portions
of the elongated recess portions 33 almost simultaneously.
[0246] The punches 56 or 58 at and near the ends of the first punch
array 56a or 58a are set shorter than the central punches 56 or 58.
Therefore, even if the working loads on the punches 56 or 58 at and
near the ends of the first punch array 56a or 58a are heavy, an
event can be prevented that the durability of those punches 56 or
58 becomes lower than that of the central punches 56 or 58.
[0247] Since the punches 56 or 58 having a rectangular cross
section are dug into the bottom portions of the elongated recess
portions 33 almost simultaneously, rectangular minute holes can be
formed with high shape accuracy.
[0248] Communication holes 34 are formed by the process including
the first process for forming unpierced recesses in a strip 55
using the first punches 56, the second process for forming
unpierced recesses while causing the bottom portions of the
recesses to bulge using the second punches 58, and the third
process for removing bulges 38a by grinding. Since the punches 56
or 58 are dug into the bottom portions of the elongated recess
portions 33 almost simultaneously and the digging lengths of the
respective punches 56 or 58 are almost uniform, the recesses formed
in the first and second processes are given correct shapes and the
bulging lengths of the bulges 38a are made almost uniform.
Therefore, the grinding lengths of the grinding in the third step
are constant among the recesses, whereby the third process is
simplified and the lengths of resulting minute holes are made
uniform.
[0249] The elongated recess portions 33 have V-shaped bottom
portions. When communicating ports 34 are formed in the V-shaped
bottom portions of the elongated recess portions 33, if the strip
55 is warped by the formation of the elongated recess portions 33,
first punches 56 for forming first communicating ports 37 are prone
to be bent or escape due to the V-shaped slant surfaces, resulting
in reduction in working accuracy. However, this problem relating to
the working accuracy can be solved by making the first punches 56
to be dug almost simultaneously in view of the warped shape of the
strip 55.
[0250] In the tool that is used for the working for formation of
minute holes, the first punch array 56a or 58a is formed by
providing, at the prescribed pitch, the punches 56 or 58 as tip
portions of the male die 57 or 59 and the contour line 56b or 58b
of the first punch array 56a or 58a is configured such that the
distal end faces of the central punches 56 or 58 project more in
the advancement direction of the male die 57 or 59 than those of
the punches 56 or 58 at and near the ends of the first punch array
56a or 58a.
[0251] Therefore, even if the strip 55 is warped by the formation
of the elongated recess portions 33, the punches 56 or 58 can be
dug into the bottom portions of the elongated recess portions 33
almost simultaneously by making the shape of the contour line 56b
or 58b identical or approximately identical to the warped shape.
Further, since the working loads on the respective punches 56 or 58
are almost uniform, there does not occur an event that punches 56
or 58 at particular positions are damaged early. The life of the
expensive tool can thus be elongated, which is economical.
[0252] Incidentally, as shown in FIG. 12A, the above working is
carried out while the first punches 56 and the second punches 58
are respectively guided by guide members 70a and 70b. A detailed
explanation will be given of the point as follows.
[0253] As shown in FIG. 12B, the first punches 56 and second
punches 58 according to the first embodiment are respectively held
between the guide members 70a and 70b.
[0254] As shown in FIG. 12C, the first punches 56 and second
punches 58 according to the second embodiment are respectively held
between the guide members 70a and 70b.
[0255] FIGS. 13A and 13B schematically shows the guide members 70a
and 70b for guiding the respective punches 56, 58. Although only
five sets of the punches 56, 58 are shown in the drawings,
actually, the punches 56, 58 are aligned by a number as same as
that of the elongated recess portions 33 for constituting the
pressure generating chambers 29.
[0256] As shown in FIG. 14, respective sectional shapes of the
first and the second punches 56, 58 are rectangular and faces A and
B including two parallel sides of the rectangular shape are aligned
respectively along the aligning direction L at the predetermined
pitch. Further, the two side faces A and B along the aligning
direction of the respective aligned punches 56, 58 are guided by
the guide members 70a and 70b from two directions.
[0257] The guide members 70a and 70b are in a shape of a pair of
square rods extended in the aligning direction L of the punches 56,
58 and the two side faces A and B along the aligning direction of
the respective punches 56, 58 are guided by inner side faces of the
guide members 70a and 70b opposed to each other.
[0258] The respective guide members 70a and 70b are provided with
projections 71 for guiding faces C and D of the punches 56, 58
facing a clearance 72 between the aligned punches 56, 58 (see FIG.
14). The projections 71 are formed to extend in the vertical
direction over from upper ends to lower ends of the guide members
70a and 70b at inner side faces thereof. As shown in FIG. 13A, the
projections 71a, for guiding outer side faces in the aligning
direction L of the punches 56, 58 disposed at both end portions of
the aligned punches 56, 58, are formed as a stepped shape.
[0259] Grinding the inner side faces of the guide members 70a and
70b so as to form grooves, the projections 71 and 71a are defined
by the grooves. Since such a grinding work is relatively
inexpensive means, the manufacturing cost can be reduced. Further,
such a grinding work can provide the projections 71 and 71a with
high accuracy, the guiding preciseness of the guide members 70a and
70b can be secured. The processing accuracy of the communicating
port 34 can be accordingly secured.
[0260] As shown in FIG. 13A, the projections 71 are provided at
every other clearance 72 between the aligned punches 56, 58 in the
guide member 70a on one side and provided at every other clearance
72 also in the guide member 70b on other side. Therefore, two
punches 56, 58 are placed between a pair of projections 71 in
either guide member 70a or 70b. Further, the projections 71 are
alternately arranged such that each punch 56, 58 is guided by a
pair of projections 71 respectively provided on the guide members
70a and 70b.
[0261] In the one guide member 70a, two punches 56 or 58 are
disposed between the adjacent projections 71. In the other guide
member 70b, two punches 56 or 58 are disposed between the adjacent
projections 71 at positions that are shifted by the pitch of the
punches 56 or 58 from the positions of the nearest pair of punches
56 or 58 that are disposed between the adjacent projections 71 of
the one guide member 70a.
[0262] Not only can an even superior method and tool for formation
of minute holes be obtained but also a recording head 1 that is
stable in quality can be manufactured and a manufacturing apparatus
therefor can be obtained by combining the above-described workings
and advantages of the punch arrays 56a and 58a, the contour lines
56b and 58b, etc. according to the invention with the following
advantages of the guide members 70a and 70b.
[0263] By arranging the projections 71 in this way,
four-directional guidance can be attained, so that bending or
escaping of the punches 56, 58 in the midst of working can
significantly be restrained. Accordingly, the shape accuracy, the
dimensional accuracy and the alignment accuracy of each
communicating port 34 can remarkably be promoted.
[0264] Further, since the projections 71 are provided at every
other clearances 72 between the punches 56 and 57, numbers of the
projections 71 formed at each of the guide members 70a and 70b can
be reduced. Accordingly, the grinding work of the guide members 70a
and 70b for forming the projections 71 can be simplified, so that
the working cost can further be reduced.
[0265] In a state that the four side faces of each of the punches
56, 58 are guided by the inner side faces of the guide members 70a
and 70b and projections 71 and 71a, the punches 56, 58 are pressed
into the strip 55 to form the communicating ports 34 aligned in a
row.
[0266] Since working can be carried out in a state of preventing
bending or escaping of the punches 56, 58, wear or damage of the
punches 56, 58 can significantly be reduced, so that tool life can
significantly be prolonged. Accordingly, the accuracy of the
communicating port 34 can be maintained over a long time period,
which is advantageous in view of the quality control of the
process.
[0267] Further, in this stage, the small communicating port 34 is
formed by punching through the V-shaped bottom portion of the
elongated recess portion 33 which has been plastically worked by
pressing. Since such a portion has relatively higher hardness and
workability is deteriorated, it is difficult to attain the working
accuracy at the time of forming the small communicating port 34.
However, according to the above configuration, since the bending or
escaping of the punches are prevented by the guide members 70a and
70b, the working can be carried out with high accuracy while
prolonging the lifetime of the dies.
[0268] FIG. 15 shows a first modified example of the guide member
for holding the punches in which the punch 56, 58 having a
rectangular cross section is guided by guide portions 75 defined by
quasi-circular holes 74. In such a case, since a guidance area of
the guide portions 75 with respect to the punch is extremely small,
wear or damage of the guide portion 75 is remarkable and the
lifetime of the guide member 73 becomes short. On the other hand,
according to the above guidance configuration, the guidance area
can be widely secured, so that the lifetime of the guide members
70a and 70b can significantly be prolonged.
[0269] Further, in the case of FIG. 15, a certain pitch dimension P
is needed so that it is difficult to simultaneously form minute
holes aligned with a relatively small pitch. However, according to
the invention, even in a case where the pitch P becomes small,
since the punches 56, 58 can stably be guided, high working
accuracy can be ensured.
[0270] The invention is effective when the pitch P is set to be 0.3
mm or less to form the communicating ports 34 aligned with the
pitch. The invention is more effective when the pitch dimension P
is 0.25 mm or less, and further effective when the pitch dimension
is 0.2 mm or less.
[0271] Further, the invention is particularly effective when
forming the communicating port 34 having the size of the opening of
0.2 mm or less, or when forming the minute hole in which a ratio of
a thickness, that is, the penetrated dimension of the strip 55 with
respect to the opening dimension of the communicating port 34 is
0.5 or more. Further, the invention is more effective in forming
the minute hole having the ratio is 0.8 or more, and further
effective when forming the minute hole having the ratio is 1 or
more. In the embodiment, the opening dimension of the communicating
port 34 is a rectangular shape of 0.095 mm.times.0.16 mm.
[0272] In the embodiment, since the communicating port 34 is
fabricated by working at a plurality of times by using the punches
56, 58 having different thicknesses, even the extremely small
communicating port 34 can be fabricated with excellent dimensional
accuracy. Further, since the first communicating port 37 fabricated
from the side of the elongated recess portion 33 is formed only up
to the middle in the plate thickness direction, it is prevented a
drawback that the partition wall portion 28 or the like of the
pressure generating chamber 29 is excessively pulled downward.
Thereby, the communicating port 34 can be fabricated with excellent
dimensional accuracy without deteriorating the shapes of the
V-shaped bottom portion of the elongated recess portion 33 and the
partition wall portion 28.
[0273] Although steps of manufacturing the communicating ports 34
by two times of working are exemplified, the communicating ports 34
may be fabricated by working of three times or more. Further, when
the above-described drawback is not brought about, the
communicating port 34 may be fabricated by a single working.
[0274] After the communicating ports 34 are fabricated, both
surfaces of the strip 55 are polished to flatten along the chain
lines shown in FIG. 11C, so that the plate thickness is adjusted to
a predetermined thickness (0.3 mm, in the embodiment).
[0275] The step of forming the elongated recess portions and the
step of forming the communicating ports may be carried out by
separate stages or carried out by the same stage. In a case where
the steps are carried out by the same stage, since the strip 55
remains unmoved at both stages, the communicating port 34 can be
fabricated in the elongated recess portion 33 with excellent
positional accuracy.
[0276] After the chamber formation plate 30 is fabricated by the
above-described steps, the flow path unit 4 is fabricated by
bonding the elastic plate 32 and the nozzle plate 71 which are
fabricated separately. In the embodiment, bonding of the respective
members is carried out by adhering. Since the both surfaces of the
chamber formation plate 30 are flattened by the above-described
polishing, the elastic plate 32 and the nozzle plate 31 can firmly
be adhered thereto.
[0277] Since the elastic plate 32 is the composite material
constituting the support plate 42 by the stainless steel plate, the
linear expansion rate is prescribed by stainless steel constituting
the support plate 42. The nozzle plate 31 is also fabricated by the
stainless steel plate. As described above, the linear expansion
rate of nickel constituting the chamber formation plate 30 is
substantially equal to that of stainless steel. Therefore, even
when adhering temperature is elevated, warping caused by the
difference between the linear expansion rates is not brought about.
As a result, the adhering temperature can be set higher than a case
where a silicon substrate is used, so that adhering time can be
shortened and fabrication efficiency is promoted.
[0278] After the flow path unit 4 is fabricated, the vibrator unit
3 and the flow path unit 4 are bonded to the case 2 fabricated
separately. Also in this case, bonding of the respective members is
carried out by adhering. Therefore, even when the adhering
temperature is elevated, warping is not brought about in the flow
path unit 4, so that adhering time is shortened.
[0279] After the vibrator unit 3 and the flow path unit 4 are
bonded to the case 2, the flexible cable 9 of the vibrator unit 3
and the connection board 5 are soldered, thereafter, the supply
needle unit 6 is attached thereto to thereby provide the liquid
ejecting head.
[0280] FIG. 16 shows a second modified example of the guide
members. In this case, the projections 71 at the inner side faces
of the guide members 70a and 70b are provided at all of the
clearances 72. By constituting in this way, the four side faces of
the respective punches 56, 58 can firmly be guided and working with
higher accuracy can be carried out.
[0281] FIG. 17 shows a second modified example of the guide
members. In this case, the projections 71 are not formed at the
inner side faces of the guide members 70a and 70b and only the two
faces A and B of the respective punches 56, 58 are guided. With
such a configuration, cost can be saved by simplifying the shapes
of the guide members 70a and 70b while ensuring the guiding
effect.
[0282] A manufacturing method of the recording head 1 according to
the invention is performed in such a manner that an array of
elongated recess portions 33 are formed in a strip 55 and
communicating ports 34 are formed in the elongated recess portions
33 by one of the above working methods. Therefore, even if the
strip 55 is warped by the formation of the elongated recess
portions 33, the communicating ports 34 can be formed with very
high accuracy in the elongated recess portions 33 as precise
structures. The ink ejection characteristic of the recording head 1
can be kept good.
[0283] Next, an explanation will be given of an apparatus for
manufacturing a liquid ejecting head using the method of punching
the communicating port.
[0284] As shown in FIG. 19, the manufacturing apparatus 76 is
roughly constituted by: an upper operation unit 77; a lower
operation unit 78; a first die 79 fixed to the lower operating
portion 78; a second die 80 fixed to the upper operation unit 77; a
male die 81 fixed to the second die 80; and a guide member 82
attached to the second die 80 for guiding the male die 81.
[0285] In the apparatus, the upper operation unit 77 is operated to
move vertically by a driving device (not illustrated).
[0286] In the first die 79, the chamber formation plate 30
corresponding to the above described strip 55 is placed at a
predetermined position defined by reference pins 83. The first die
79 is formed with openings 84 for each receiving the male die 81.
The chamber formation plate 30 is previously formed with the
elongated recess portions 33 by the steps shown in FIGS. 10A to
10C.
[0287] The second die 80 is constituted by a base member 85 coupled
to the upper operation unit 77 and a punch plate 86 coupled to the
base member 85. The punch plate 86 is attached with the male die 81
via a fixing piece 87. Two male dies 81 are provided in association
with two rows of elongated recess portions 33 to form the
communicating ports 34 therein.
[0288] The guide member 82 is integrally formed with a guide plate
88 and a guide base member 89, and is provided with a space 90 for
avoiding interference with the fixing piece 87 and allowing
relative displacement, mentioned later. The guide member 82
corresponds to the above-described guide member 70a or 70b and is
constructed by a structure of integrating the guide plate 88 and
the guide base member 89 by illustrated bolts, however, these
members may be constituted by a single member, or may be
constituted by three or more members.
[0289] The guide member 82 is attached to the second die 80 while
being able to move relative to the actuating direction of the male
die 81. Actuating shafts 91 are fixed to the guide base member 89
while being extended in parallel with the actuating direction of
the upper operation unit 77. An upper end portion of each actuating
shaft 91 is extended into a chamber 92 formed in the base member
85. The chamber 92 is a cylinder-shaped space having a circular
cross section whose inner diameter is larger than a diameter of the
actuating shaft 91 also having a circular cross section. A stopper
93 is fixed to an upper end of the actuating shaft 91, so that the
stopper 93 is capable of moving vertically in the chamber 92 like a
piston. A compression coil spring 94 is inserted into the chamber
92 to urge the stopper 93 in a direction that the guide member 82
is separated from the second die 80. A bolt 96 is provided to
adjust a position of a spring seat 95 to thereby adjust the urging
force of the coil spring 94 acting on the stopper 93. The
compression coil spring 94 may be replaced with a rubber piece.
[0290] In order to move the guide member 82 relative to the second
die 80, a displacement space S is provided between the second die
80 and the guide member 82. Also in the space 90, a similar
displacement space is provided between a lower face of the fixing
piece 87 and an upper face of the guide plate 88.
[0291] FIGS. 22 and 23 are perspective views respectively showing
an entire shape and a punch portion of the male die 81. The male
die 81 corresponds to the second male die 57 or the third male die
59 according to the first embodiment, and a number of punches 97
are arranged in a row at a distal end portion thereof. Similarly,
FIGS. 25A and 25B are perspective views respectively showing an
entire shape and a punch portion of the male die 81 which
corresponds to the second male die 57 or the third male die 59
according to the second embodiment.
[0292] The punches 97 are continued from a high rigidity portion 98
such that a sectional area of the high rigidity portion is larger
than a total sectional area of the punches 97. Further, the high
rigidity portion 98 is continued from a base portion 99 having a
higher sectional area than that of the high rigidity portion
98.
[0293] Further, the base portion 99 is formed with a flange 100 in
a direction substantially orthogonal to the actuating direction of
the male die 81. The fixing piece 87 is provided with an elongated
hole 101 into which the base portion 99 is inserted and a retaining
face 102 which abuts against the flange 100. The punches 97 and the
high rigidity portion 98 or the high rigidity portion 98 and the
base portion 99 are smoothly connected by curved faces 103 and
104.
[0294] As shown by FIGS. 23 and 25B, a slit 105 is provided between
the contiguous punches 97 and a pitch of the respective punches 97
are as same as a pitch of the elongated recess portions 33.
[0295] The male die 81 is placed at a such a position that each of
the punches 97 arrayed in a direction perpendicular to the
longitudinal direction of each elongated recess portion 33 opposes
to one longitudinal end portion of each elongated recess portion
33. In the embodiment, the guide member 82 guides a portion of the
male die 81 where the punches 97 are provided, and the guide member
82 is formed with a slit hole 106 through which the punches 97 are
allowed to penetrate, as shown in FIG. 20. Inner faces of the slit
hole 106 opposed to each other serve as control faces 107a and 107b
for restraining the punches 97 from displacing in the longitudinal
direction of the elongated recess portion 33. The control faces
107a and 107b are brought into a sliding contact with both side
portions of the punches 97. Alternatively, small clearances may be
provided between the control faces 107a and 107b and the both side
portions of the punches 97. In FIGS. 19 and 21, although the
clearance is illustrated to be considerably large, the actual
clearance is provided such an extent that the above-described
sliding contact may be established. The guide plate 88 is formed
with a slender recess groove 108 continued from the slit hole 106,
for receiving the high rigidity portion 98, as shown in FIG.
21.
[0296] FIG. 19 shows a state before the forging work for forming
the communicating ports 34 is started. In this state, the stopper
93 is brought into close contact with the lower face of the chamber
92 by the spring force of the compression coil spring 94 to define
a relative position between the guide plate 88 and the punches 97.
Further, in this state, the lower face of the guide plate 88 and
the distal end faces of the punches 97 are made flush with each
other.
[0297] FIG. 24 shows a first modified example of the male die 81
corresponding to the first embodiment in which the flange 100 is
formed on both side end faces of the male die 81.
[0298] FIG. 25C shows a first modified example of the male die 81
corresponding to the second embodiment in which the flange 100 is
formed on both side end faces of the male die 81.
[0299] Operation of the apparatus 76 of manufacturing the recording
head will be explained.
[0300] When the second die 80 is lowered from the state shown in
FIG. 19, the guide plate 88 and the punches 97 are also lowered
while maintaining their relative position relationship. Then the
guide plate 88 is first brought into close contact with the chamber
formation plate 30 so that the guide member 82 is stopped.
Thereafter, when the second die 80 is lowered further, the punches
97 are projected from the guide plate 88 while the compression coil
spring 94 are cut into the end portions of the elongated recess
portions 33. When a press length of the punches 97 reaches a
predetermined level, the second die 80 is lifted up so that the
punches 97 are retracted from the chamber formation plate 30 while
the guide plate 88 is pressing the chamber formation plate 30 by
the compression coil spring 94.
[0301] In the manufacturing apparatus 76, the punches 56 and 58
according to the first embodiment in which the distal end faces 56g
of at least punches 56 and 58 located at and near the ends of the
punch arrays 56a and 58a are slant faces in which the lowermost
position recedes more in the punch digging direction as the
position goes closer to the center of the punch arrays 56a and 58a
are dug into the bottom portions of the elongated recess portions
33. Therefore, even if the chamber formation plate 30 is warped by
the formation of the elongated recess portions 33, the punches 56
and 58 at and near the ends of the punch arrays 56a and 58a can
first be dug into the bottom portions of the elongated recess
portions 33. As a result, the communicating ports 34 can be formed
with very high accuracy in the elongated recess portions 33 that
are precise structures and the ink discharge characteristic of the
recording head 1 can be kept good.
[0302] In the manufacturing apparatus 76, the punches 56 or 58
according to the second embodiment are dug into the bottom portions
of the elongated recess portions 33 in a state that the shape of
the contour line 56b or 58b of the first punch array 56a or 58a is
made identical or approximately identical to the warped shape of
the strip 55. Therefore, even if the strip 55 is warped by the
formation of the elongated recess portions 33, the punches 56 or 58
can be dug into the bottom portions of the elongated recess
portions 33 uniformly. As a result, communicating ports 34 can be
formed with very high accuracy in the elongated recess portions 33
as precise structures. The ink ejection characteristic of the
recording head 1 can be kept good.
[0303] Owing to the structure that the press work is carried out
while guiding the both side portions of the punches 97 by the
control faces 107a and 107b in the slit hole 106 formed at the
guide plate 88, bending or escape of the punches 97 by stresses
produced by working is prevented. Accordingly, the shape,
dimensional and alignment accuracy of each communicating port 34
are enhanced. Further, wear or damage of the punches 97 can
considerably be reduced and tool life can considerably be
prolonged, the accuracy of the communicating port 34 can be
maintained over a long time period. Further, the communicating port
34 can be worked with excellent dimensional accuracy without
deteriorating contiguous ones of the communicating ports 34 even in
a case where the communicating ports 34 which are aligned at a
relatively small pitch.
[0304] Since the elongated recess portion 33, which has been
subjected to the plastic working in advance, has relatively higher
hardness and workability is deteriorated, it is difficult to attain
the working accuracy at the time of forming the small communicating
port 34. However, according to the above configuration, since the
bending or escaping of the punches 97 are prevented by the guide
member 82, the working can be carried out with high accuracy while
prolonging the lifetime of the dies.
[0305] Even in a case where the press length of the punches 97 to
the chamber formation plate 30 is prolonged, since the guide plate
88 is brought into close contact with the surface of the chamber
formation plate 30 or disposed at the extreme vicinity of the
chamber formation plate 30, the guiding function of the guide plate
88 is achieved at the location as proximate as possible to the
portion of generating stresses produced by working, so that the
bending or escape of the punches 97 by working stresses can further
securely be prevented.
[0306] Although the punches 97 are more liable to be bent or
escaped in the longitudinal direction substantially orthogonal to
the aligning direction than in the aligning direction, by
restraining the displacement of the punches 97 by the control faces
107a and 107b, bending or escape of the punches 97 are prevented so
that the communicating ports 34 are formed with high accuracy.
[0307] Since the control faces 107a and 107b are defined by the
inner faces of the slit hole 106 formed in the guide plate 88, such
inner faces has high rigidity capable of withstanding large load.
Therefore, the control faces 107a and 107b can be made to carry out
stable guiding function. Further, since the control faces 107a and
107.b can be ensured immediately by forming the slit hole 106, the
control faces 107a and 107b can be provided by simple
constitution.
[0308] The relative positions of the guide plate 88 and the punches
97 before starting the punching work are accurately set by the
actuating shaft 91, the stopper 93, the compression coil spring 94
and the like. That is, it is surely possible to determine the
proper relative positions of the punches 97 and the guide plate 88
in which the punches 97 abnormally projected from the guide plate
88. Further, when the punches 97 are pressed, since the guide plate
88 is pressed onto the chamber formation plate 30 by the
compression coil spring 94, the guiding function of the guide plate
88 is achieved at the location most proximate to the punching
portion, so that bending or escape of the punches 97 can be
prevented at the optimum location.
[0309] The sectional areas of the punches 97, the high rigidity
portion 98 and the base portion 99 are successively increased and
the rigidity of the total of the male die 81 is set to be the
largest at the base portion 99. Therefore, since the rigidity of
the male die 81 is increased gradually toward the fixed side,
stresses are not abnormally concentrated on a particular location
of the male die 81 when the punches 97 are actuated. Accordingly,
the durability of the total structure of the male die 81 can be
enhanced. Further, the rigidity of attaching the male die 81 to the
second die 80 can be ensured in the stable state, so that
durability sufficient for frequent punching operation can be
attained.
[0310] Since the male die 81 is attached to the fixing piece 87
while the flange 100 is firmly retained, the rigidity of attaching
the male die 81 to the second die 80 can be increased.
Particularly, when the punches 97 pressed into the chamber
formation plate 30 is withdrawn, it is necessary to transmit the
large withdrawing force from the second die 80 to the male die 81.
In such an occasion, since the flange 100 is pressed by the
retaining face 102 of the fixing piece 87, the male die 81 and the
second die 80 can be withdrawn with firm integrity, so that the
manufacturing apparatus 76 having excellent operational stability
is provided.
[0311] By a plurality of the male dies 81, the communicating ports
34 can be formed by one operation at the respective elongated
recess portions 33 so that the productivity can be promoted.
Further, even when two of the male dies are arranged to be able to
form two rows of the communicating ports in parallel, promotion of
productivity is also achieved.
[0312] Further, the guide plate 88 is provided with a simple
structure while realizing multi-function. That is, the slit hole
106 achieving guiding function and a bottom face for pressing the
chamber formation plate 30.
[0313] An slope face 109 is formed at a longitudinal end portion of
the elongated recess portion 33 and the punches 97 are pressed into
the slope face 109. In order to form the slope face 109, as shown
in FIG. 8A, the both longitudinal end portions 53b of the distal
end portion 53a of each projection 53 are tapered. When the
projection 53 is pressed into the chamber formation plate 30, the
elongated recess portion 33 having the slope face 109 is formed at
the longitudinal end portion. Relative positions of the punches 97
and the chamber formation plate 30 are set such that the punches 97
are pressed to the inclined plate 109 while the pressure generating
forming plate 30 is supported at the predetermined position of the
first die 79. The communicating port 34 is formed at the slope face
109 by lifting down the male die 81. Others are similar to the
above-described embodiment and similar portions are designated with
the same reference numerals.
[0314] The distal end portion of the punch 97 is pressed to the
slope face 109 at the initial stage so that large bending moment is
act on the punch 97. However, since the punches 97 are guided by
the guide plate 88, the bending moment can firmly be received by
the guide plate 88 so that the communicating port 34 can be formed
without bringing about bending or escape at the punches 97 even in
such a case. Further, the punch 97 is accurately pressed into the
slope face 109, and the material flow smoothly accompanies with the
punch 97. Therefore, burrs projecting into the elongated recess
portion 33 can be prevented from being formed. Accordingly, bubbles
in liquid flow will not stay in the flow path so that the ejection
property of liquid ejecting head can normally be maintained.
[0315] Since the elongated recess portion 33 is constituted by the
V-shaped bottom faces, when the punch 97 having a rectangular cross
section is pressed into the longitudinal end portion of the
elongated recess portion 33, the distal end portion of the punch 97
is pressed onto both of the V-shaped bottom faces and the slope
face 109 as shown in FIG. 26A. Therefore, the above-described burrs
or the like can be prevented from being brought about also in the
V-shaped bottom faces.
[0316] FIG. 27 shows a second modified example of the male die 81.
This configuration is applicable for the second male die 57 or the
third male die 59 according to both of the first embodiment and the
second embodiment.
[0317] In this case, the high rigidity portion 98 is guided by the
guide plate 88. Others are similar to the above-described
respective embodiments and similar portions are designated with the
same reference numerals.
[0318] Since the high rigidity portion 98 having a relatively high
rigidity is guided, the state of guiding the male die 81 is
stabilized. Further, only a length of the punch 97 required for
realizing the punching work may be ensured at the punch portion
without ensuring a length required for guiding. Therefore, the
length of the punches 97 can substantially be shortened and
rigidity against bending or escape or the like of the punches 97
per se can be enhanced. Otherwise, the operation and the obtained
advantages are similar to those of the above embodiments.
[0319] Meanwhile, the invention is not limited to the
above-described embodiments but can variously be modified based on
the description of the appended claims.
[0320] For example, with regard to the partition wall portion 28,
when the proximal portion is more thick-walled than the distal end
portion, the rigidity of the partition wall portion 28 can be
increased and the volume necessary for the pressure related chamber
29 can be ensured. From the view point, the shape of the bottom of
the elongated recess portion is not limited to V-shaped. For
example, the bottom face of the elongated recess portion 33 may
have an arcuate cross section. Further, in order to fabricate the
elongated recess portion 33 having such a bottom shape, the first
male die 51 having the projection 53 the distal end portion of
which is arcuately chamfered.
[0321] With regard to a pressure generating element, an element
other than the piezoelectric vibrator 10 may be adopted. For
example, an electromechanical conversion element of an
electrostatic actuator, a magnetorestrictive element or the like
may be used. Further, a heat generating element may be used as a
pressure generating element.
[0322] Specifically, a recording head 1' shown in FIG. 18 comprises
a heat generating element 61 as the pressure generating element.
According to the embodiment, in place of the elastic plate 32, a
sealing board 62 provided with the compliance portion 46 and the
ink supply port 45 is used and the side of the elongated recess
portion 33 of the chamber formation plate 30 is sealed by the
sealing board 62. Further, the heat generating element 61 is
attached to a surface of the sealing board 62 at inside of the
pressure generating chamber 29. The heat generating element 61
generates heat by feeding electricity thereto via an electric
wiring.
[0323] Since other constitutions of the chamber formation plate 30,
the nozzle plate 31 and the like are similar to those of the
above-described embodiments, explanations thereof will be
omitted.
[0324] In the recording head 1', by feeding electricity to the heat
generating element 61, ink at inside of the pressure generating
chamber 29 is bumped and bubbles produced by the bumping presses
ink at inside of the pressure generating chamber 29, so that ink
drops are ejected from the nozzle orifice 48.
[0325] Even in the case of the recording head 1', since the chamber
formation plate 30 is fabricated by plastic working of metal,
advantages similar to those of the above-described embodiments are
achieved.
[0326] With regard to all the above-described plastic workings, in
order to achieve desired accuracy, cold working is preferably
performed. More preferably, temperature control is conducted such
that temperature of a worked object falls within a constant
range.
[0327] With regard to the material for manufacturing the chamber
formation plate 30, in the view point of forming the proximal
portion of the partition wall 28 to be thick-walled than the distal
end portion, the material is not limited to that of a single metal
plate. For example, a laminated plate material fabricated by
laminating a plurality of plate materials may be used, and the
chamber formation plate 30 may be fabricated by a coating plate
coated with a resin on a surface of a metal board.
[0328] With regard to the communicating port 34, although according
to the above-described embodiments, an example of providing the
communicating port 34 at one end portion of the elongated recess
portion 33 has been explained, the invention is not limited
thereto. For example, the communicating port 34 may be formed
substantially at center of the elongated recess portion 33 in the
longitudinal direction and the ink supply ports 45 and the common
ink reservoirs 14 communicated therewith may be arranged at both
longitudinal ends of the elongated recess portion 33. Thereby,
stagnation of ink at inside of the pressure generating chamber 29
reaching the communicating port 34 from the ink supply ports 45 can
be prevented.
[0329] Further, although according to the above-described
embodiments, an example of applying the invention to the recording
head used in the ink jet recording apparatus has been shown, an
object of the liquid ejecting head to which the invention is
applied is not constituted only by ink of the ink jet recording
apparatus but glue, manicure, conductive liquid (liquid metal) or
the like can be ejected.
[0330] For example, the invention is applicable to a color filter
manufacturing apparatus to be used for manufacturing a color filter
of a liquid-crystal display. In this case, a coloring material
ejection head of the apparatus is an example of the liquid ejecting
head. Another example of the liquid ejection apparatus is an
electrode formation apparatus for forming electrodes, such as those
of an organic EL display or those of a FED (Field Emission
Display). In this case, an electrode material (a conductive paste)
ejection head of the apparatus is an example of the liquid ejecting
head. Still another example of the liquid ejection apparatus is a
biochip manufacturing apparatus for manufacturing a biochip. In
this case, a bio-organic substance ejection head of the apparatus
and a sample ejection head serving as a precision pipette
correspond to examples of the liquid ejecting head. The liquid
ejection apparatus of the invention includes other industrial
liquid ejection apparatuses of industrial application.
[0331] Further, the above-described punching method according to
the invention is not limited to the application for the case of
manufacturing a liquid ejecting head.
* * * * *