# US 2012/0085842 A1 · Viscous non-contact jetting method and apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2012/0085842 A1 - Document ID: US20120085842A1 - Status: Published application - Kind: A1 - Application number: 12/984,463 - Filed: 2011-01-04 - Published: 2012-04-12 - Earliest claimed: 2010-01-11 - Assignees: Advanjet - Inventors: Robert L. Ciardella; Duong La; Wai Ching Bessie Chin - Web page: https://patentgrep.com/patent/US20120085842A1 ## CPC - B05C 11/1034: {specially designed for conducting intermittent application of small quantities, e.g. drops, of coating material (B05C5/0225, B05C11/1026 take precedence)} - B05C 5/001: {incorporating means for heating or cooling the liquid or other fluent material (B05C11/1042 takes precedence)} - B41J 2/04: generating single droplets or particles on demand - H10P 72/0448: {Apparatus for applying a liquid, a resin, an ink or the like} - B41J 2202/05: Heads having a valve - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) - B41J: TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS - H10P: GENERIC PROCESSES OR APPARATUS FOR THE MANUFACTURE OR TREATMENT OF DEVICES COVERED BY CLASS H10 ## Abstract This invention concerns a method and apparatus for dispensing minute quantities of highly viscous material from a jetting needle when an expelling mechanism is activated using a nozzle plate with a jetting chamber having a top formed by a diaphragm and a bottom in fluid communication with a jetting needle. Fluid enters the chamber from an inlet channel and is jetted from the chamber by deforming the diaphragm to block the channel and expel a drop of fluid from the needle. A diaphragm driven metering chamber and/or reservoir chamber can optionally be used provide fluid to the jetting chamber. ## Claims ### Claim 1 An apparatus for rapidly dispensing minute quantities of a highly viscous material from a jetting needle when an expelling mechanism is activated, comprising: a nozzle plate having opposing first and second surfaces with a jetting chamber formed in the first surface, the jetting chamber having sides, an open top, and a bottom having an opening that is in fluid communication with an outlet on the second surface that is adapted to connect to the needle, the nozzle plate having an inlet channel formed in the first surface and in fluid communication with the jetting chamber, the inlet channel entering a side of the jetting chamber and not extending to the opening in the bottom of the jetting chamber; a flexible diaphragm being sufficiently flexible to deform into the jetting chamber a distance sufficient to block the inlet channel and to provide a fluid seal over the top of the jetting chamber; a support structure located to cooperate with the nozzle plate to compress the diaphragm between the support structure and nozzle plate, the support structure having an opening aligned with the top of the jetting chamber which opening is in sufficient communication with the expelling mechanism to allow the diaphragm over the top of the jetting chamber to deform when the expelling mechanism is activated; and a mechanism holding the diaphragm and nozzle plate together with sufficient force to provide a fluid seal at the top of the jetting chamber. ### Claim 2 (depends on 1) The apparatus of claim 1, wherein the inlet channel is formed in the first surface and the mechanism provides a fluid tight seal with the inlet channel during use and provides an air tight seal with the support structure during use. ### Claim 3 (depends on 1) The apparatus of claim 1, further including a metering device comprising: a metering chamber formed in the first surface and having sides and an open top opposite a closed bottom, the inlet channel being in fluid communication with the metering chamber; a first channel placing the reservoir chamber in fluid communication with a fluid reservoir the flexible diaphragm extending over inlet channel and the metering chamber, the diaphragm being sufficiently flexible to deform into the metering chamber a distance sufficient to block the inlet channel at the metering chamber. ### Claim 4 (depends on 1) The apparatus of claim 1, further including a dual chamber metering device comprising: a reservoir chamber formed in the first surface and having sides and an open top opposite a bottom, the reservoir chamber configured to be placed in fluid communication with a source of highly viscous material to be dispensed by the apparatus; a metering chamber formed in the first surface and having sides and an open top opposite a closed bottom, the inlet channel being in fluid communication with the metering chamber; a first channel formed in the first surface placing the reservoir chamber and metering chamber in fluid communication, the first channel being in fluid communication with the reservoir chamber and the metering chamber; the flexible diaphragm extending over the first channel and the inlet channel and the metering and reservoir chambers, the diaphragm being sufficiently flexible to deform into the metering and reservoir chambers a distance sufficient to block the inlet channel at the metering chamber and to block the first and second ends of the first channel at the metering and reservoir chambers. ### Claim 5 (depends on 3) The apparatus of claim 3, wherein the diaphragm flexibility and the width of the inlet channel are selected so the diaphragm extends into the inlet channel during use. ### Claim 6 (depends on 3) The apparatus of claim 3, further comprising a metering projection urged against the diaphragm and varying the volume between the diaphragm and the bottom of the metering chamber. ### Claim 7 (depends on 1) The apparatus of claim 1, wherein the expelling mechanism produces a force that deforms the diaphragm sufficiently to abut the sides of the jetting chamber between the inlet channel and the bottom of the jetting chamber which is in fluid communication with the outlet. ### Claim 8 (depends on 1) The apparatus of claim 1, wherein the expelling mechanism produces a force that deforms the diaphragm sufficiently to force the diaphragm into a portion of the outlet at the juncture of the outlet with the bottom of the jetting chamber. ### Claim 9 (depends on 1) The apparatus of claim 1, wherein the diaphragm has a hardened insert located over the jetting cavity when the diaphragm is in a relaxed configuration. ### Claim 10 (depends on 1) The apparatus of claim 1, wherein the diaphragm has a thickened protrusion located over and extending partway into the jetting cavity when the diaphragm is in a non jetting configuration during use. ### Claim 11 (depends on 1) The apparatus of claim 1, wherein expelling mechanism includes a solid projection impacting the diaphragm over the jetting chamber and forcing the diaphragm into the jetting chamber so the diaphragm abuts the sides of the jetting chamber. ### Claim 12 (depends on 1) The apparatus of claim 1, further comprising, a position adjustment mechanism interposed between the nozzle plate and the support structure to cause relative movement of the nozzle plate and support structure and vary the compression of the diaphragm. ### Claim 13 (depends on 12) The apparatus of claim 12, wherein the adjustment mechanism comprises a rotating threaded member varying the amount of relative movement. ### Claim 14 (depends on 1) The apparatus of claim 1, further comprising the jetting needle in fluid communication with the outlet of the jetting chamber, the needle having a volume greater than a volume of the jetting chamber measured between a bottom of the inlet channel and the intersection of the outlet with the jetting chamber. ### Claim 15 A nozzle plate for use with an apparatus for jetting highly viscous fluid, the apparatus having an expelling mechanism and a jetting needle from which the highly viscous material is jetted during use and a connecting end adapted to connect to the plate, the needle having a longitudinal axis, the nozzle plate comprising: a plate having opposing first and second surfaces with a jetting chamber formed in the first surface, the jetting chamber having sides encircling the longitudinal axis during use, the jetting chamber having an open top and an opening in a bottom opposite the top which bottom opening is in fluid communication with an outlet opening onto the second surface of the plate and adapted to receive the connecting end of the needle during use, the outlet having a longitudinal axis substantially aligned with a longitudinal axis of the jetting chamber during use, the nozzle plate having an inlet channel in the first surface which is in fluid communication with the jetting chamber, the inlet channel entering a side of the jetting chamber and not extending to the juncture of the chamber sides and outlet, a portion of the jetting chamber defining a minimum expellable volume, the portion located between the bottom of the inlet channel and the juncture of the sides with the outlet, the expellable volume being less than about 1 μl. ### Claim 16 (depends on 15) The nozzle plate of claim 15, further comprising a metering chamber formed in the first surface and having sides and an open top opposite a closed bottom, the inlet channel being in fluid communication with the metering chamber. ### Claim 17 (depends on 16) The nozzle plate of claim 16, further comprising a reservoir chamber formed in the first surface of the plate and having an open top and a bottom, the reservoir chamber being in fluid communication with the metering chamber through a first channel formed in the first surface of the plate, the reservoir chamber being in fluid communication with a second channel formed in the plate and having a distal end adapted to be placed in fluid communication with a fluid reservoir during use, the reservoir chamber having a volume larger than that of the jetting chamber. ### Claim 18 A nozzle plate subassembly for use with a highly viscous jetting apparatus having an expelling mechanism and a jetting needle having a longitudinal axis and an outlet from which the highly viscous material is jetted during use, comprising: a nozzle plate having opposing first and second surfaces with a jetting chamber formed in the first surface, the jetting chamber having sides, an open top, and an opening in a bottom opposite the top which bottom opening is in fluid communication with an outlet that opens onto the second surface of the plate and is configured to be placed in fluid communication with the jetting needle during use, the outlet having a longitudinal axis substantially aligned with a longitudinal axis of the jetting nozzle during use and substantially perpendicular to the first surface, the nozzle plate having an inlet channel in the first surface which is in fluid communication with the jetting chamber, the inlet channel entering a side of the jetting chamber and not extending to the juncture of the chamber sides with the outlet, a portion of the jetting chamber defining an expellable volume of material of about 1 μl or less; a metering chamber formed in the first surface and having sides and an open top opposite a closed bottom, the metering chamber having a volume of between about 1 μl or less, the inlet channel being in fluid communication with the metering chamber. a flexible diaphragm sized to fit over the first surface sufficiently to cover the jetting chamber, metering chamber and inlet channel, the diaphragm having opposing first and second surfaces with the second surface forming a fluid tight seal with the jetting chamber, metering chamber and inlet channel during use and the second surface configured to form an air tight seal with an abutting surface during use. ### Claim 19 (depends on 18) The nozzle subassembly of claim 18, wherein the inlet channel is sized relative to the diaphragm and the material from which the diaphragm is made so that when the diaphragm is pressed against the nozzle plate during use the diaphragm extends into and reduces the volume of the inlet channel and jetting chamber during use of the subassembly to jet highly viscous fluid. ### Claim 20 (depends on 19) The nozzle subassembly of claim 19, further comprising a reservoir chamber formed in the first surface and having sides, and a bottom opposite an open top, the reservoir chamber being in fluid communication with the metering chamber through a first channel formed in the first surface, the reservoir chamber being in fluid communication with a second channel having an inlet end in fluid communication with an exterior of the nozzle plate inlet end is configured to be placed in fluid communication with a fluid reservoir during use of the sub-assembly. ### Claim 21 (depends on 20) The nozzle subassembly of claim 20, wherein the diaphragm covers the reservoir chamber and first channel and provides a fluid tight seal therewith, and wherein the inlet channel and first channel are sized relative to the diaphragm and the material from which the diaphragm is made so that when the diaphragm is pressed against the nozzle plate during use the diaphragm extends into the inlet and first channels to restrict the flow of fluid passing through those channels. ### Claim 22 (depends on 20) The nozzle subassembly of claim 20, wherein the second surface abutting the nozzle plate is substantially flat and the first surface includes raised sealing surfaces. ### Claim 23 A method of dispensing minute quantities of a highly viscous material from an outlet of a jetting needle by an expelling mechanism that deforms a flexible diaphragm into a jetting chamber having sides, an open top covered by the diaphragm and an outlet in the bottom of the jetting chamber that is in fluid communication with the jetting needle, the method comprising: placing the jetting needle, outlet and jetting chamber on a common longitudinal axis; placing an inlet channel in fluid communication with the side of the jetting chamber, the inlet channel not extending to juncture of the chamber sides with the chamber outlet; forcing the highly viscous fluid through the inlet channel into the jetting chamber; deforming the flexible diaphragm into the jetting chamber and against the chamber sides a distance sufficient to block the inlet channel and to abut the chamber sides adjacent to the juncture with the outlet, the deformation occurring with sufficient force to expel a predetermined volume of material from the needle outlet as a drop. ### Claim 24 (depends on 23) The method of claim 23, wherein the inlet channel is formed in the same surface as the jetting chamber and opens onto that surface along a length of the channel, and wherein the diaphragm seals along the length of that channel opening, and wherein the diaphragm is urged against the length of the channel opening and the top of the chamber sufficiently to vary the volume of fluid forced through the inlet channel and into the jetting chamber during the forcing step. ### Claim 25 (depends on 23) The method of claim 23, wherein the chamber outlet comprises a cylindrical channel and the deforming step deforms the diaphragm past the juncture of the chamber sides with the chamber outlet and into the outlet channel. ### Claim 26 (depends on 23) The method of claim 23, further comprising the step of compressing the diaphragm a predetermined amount to vary the volume of the expelled drop. ### Claim 27 (depends on 23) The method of claim 23, wherein the expelling mechanism deforming the diaphragm comprises pressurized air. ### Claim 28 (depends on 23) The method of claim 23, wherein the expelling mechanism deforming the diaphragm includes physically impacting the diaphragm with a solid object which pushes the diaphragm against the chamber sides. ### Claim 29 (depends on 23) The method of claim 23, wherein the diaphragm abuts the juncture of the inlet channel and the outlet. ### Claim 30 An apparatus for jetting highly viscous fluid, comprising: chamber means for holding the highly viscous fluid; inlet channel means for conveying the highly viscous fluid to the chamber means; means for jetting the highly viscous material from the chamber means through the jetting needle with sufficient velocity to form a drop of highly viscous fluid having a volume less than about 250nl and having sufficient velocity to jet that drop from the needle. ### Claim 31 (depends on 30) The apparatus of claim 30, wherein the means for jetting includes a flexible diaphragm, and further including means for adjustably compressing the diaphragm to vary the volume of the expelled drop. ### Claim 32 (depends on 31) The apparatus of claim 31, wherein the means for jetting further includes a pneumatic mechanism deforming the diaphragm into the chamber means. ### Claim 33 (depends on 32) The apparatus of claim 32, wherein the volume of the drop is less than about 100nl. ### Claim 34 (depends on 30) The apparatus of claim 30, wherein the means for jetting deforms a diaphragm into a portion of an outlet in fluid communication with the chamber means. ### Claim 35 (depends on 32) The apparatus of claim 32, further comprising at least one chamber means for metering highly viscous fluid to the chamber means through the inlet channel. ### Claim 36 An apparatus for rapidly dispensing minute quantities of a highly viscous material from a jetting needle when an expelling mechanism is activated, comprising: a nozzle plate having opposing first and second surfaces with a jetting chamber formed in the first surface, the jetting chamber having sides, an open top, and a bottom having an opening that is in fluid communication with an outlet on the second surface that is adapted to connect to the needle, the chamber being in fluid communication with an external fluid reservoir containing said material during use; a flexible diaphragm over the open top of the jetting chamber, the diaphragm having a central protrusion extending toward the opening in the bottom of the chamber, the diaphragm being sufficiently flexible to deform into the jetting chamber a distance sufficient so that the central protrusion blocks the opening in the bottom of the chamber during use; a support structure having an opening aligned with the top of the jetting chamber to allow the diaphragm to deform into the jetting chamber when the expelling mechanism is activated; and a mechanism cooperating with the support structure and providing sufficient force to compress and seal the diaphragm around the top of the jetting chamber. ### Claim 37 (depends on 36) The apparatus of claim 36, wherein the protrusion is integrally molded with the diaphragm. ### Claim 38 (depends on 36) The apparatus of claim 36, wherein the protrusion comprises an insert made of a harder material than the diaphragm and fastened to the diaphragm. ### Claim 39 (depends on 36) The apparatus of claim 36, wherein the protrusion comprises an insert made of a harder material than the diaphragm and molded to the diaphragm. ### Claim 40 (depends on 36) The apparatus of claim 36, wherein the protrusion has a flange on opposing sides of the diaphragm. ### Claim 41 (depends on 39) The apparatus of claim 39, wherein the protrusion has a curved surface facing the opening in the bottom of the chamber and impacting the jetting chamber during use. ### Claim 42 (depends on 39) The apparatus of claim 39, wherein the expelling mechanism deforming the diaphragm is a solid object which pushes the diaphragm against the chamber sides. ### Claim 43 (depends on 39) The apparatus of claim 39, wherein the expelling mechanism delivers an impact force to deform the diaphragm ### Claim 44 A method of dispensing minute quantities of a highly viscous material from an outlet of a jetting needle by an expelling mechanism that deforms a flexible diaphragm into a jetting chamber having sides, an open top, an outlet in the bottom of the jetting chamber that is in fluid communication with the jetting needle, and a diaphragm which is in fluid communication with the jetting chamber, the method comprising: forcing the highly viscous fluid into the jetting chamber through an inlet channel that does not extend to a juncture of the chamber sides with the chamber outlet; deforming the flexible diaphragm into the jetting chamber a distance sufficient to block the inlet fluid flow and to abut the chamber sides adjacent to the juncture of the chamber sides with the outlet, the deformation occurring with sufficient force to expel a predetermined volume of the material from the needle outlet as a drop, the jetting needle, outlet and jetting chamber being on a common longitudinal axis. ### Claim 45 (depends on 44) The method of claim 44, wherein the inlet channel is formed in the same surface as the jetting chamber and opens onto that surface along a length of the channel, and wherein the diaphragm seals along the length of that channel opening, and wherein the deforming step includes urging the diaphragm against the length of the channel opening and the top of the metering chamber sufficiently to vary the volume of fluid forced through the inlet channel and into the jetting chamber during the forcing step. ### Claim 46 (depends on 44) The method of claim 44, wherein the chamber outlet comprises a cylindrical channel and the deforming step deforms the diaphragm past the juncture of the chamber sides with the chamber outlet and into the outlet channel. ### Claim 47 (depends on 44) The method of claim 44, further comprising the step of compressing the diaphragm a predetermined amount to vary the volume of the expelled drop. ### Claim 48 (depends on 44) The method of claim 44, further comprising deforming the diaphragm with pressurized air during the deforming step. ### Claim 49 (depends on 44) The method of claim 44, wherein the deforming step includes physically impacting the diaphragm with a solid object. ### Claim 50 A flexible diaphragm for use with an apparatus for jetting highly viscous fluid, the apparatus having an expelling mechanism, a jetting chamber and a jetting needle from which the highly viscous material is jetted during use, the diaphragm being sufficiently flexible to deform into the jetting chamber a distance sufficient to block the flow of fluid into the jetting chamber and to provide a fluid seal over the top of the jetting chamber. ### Claim 51 (depends on 50) The diaphragm of claim 50, wherein the diaphragm has a thickened protrusion located over and extending partway into the jetting cavity. ### Claim 52 (depends on 50) The diaphragm of claim 50, wherein the diaphragm has a protrusion is integrally molded with the diaphragm. ### Claim 53 (depends on 50) The diaphragm of claim 50, wherein the protrusion comprises an insert made of a harder material than the diaphragm.