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.

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.