1. A method for manufacturing a liquid ejection head including a substrate and a member which is disposed above the substrate and which has passage communicatively connected to discharge port through which a liquid is ejected, the method comprising:
providing first solid layers made of a positive photosensitive resin above the substrate such that outer side surfaces of the first solid layers form an obtuse angle with the substrate;
providing a second solid layer above the substrate such that the second solid layer abuts the outer side surfaces of the first solid layers, the second solid layer being processed into at least one portion of a mold for the passage;
forming at least one portion of the mold for the passage from the second solid layer;
exposing portions of the outer side surfaces of the first solid layers through the second solid layer;
removing the exposed portions from the first solid layers;
providing a cover layer over the portion of the mold for the passage and;
removing at least the portion of the mold to form the passage for forming the member.
2. The method according to claim 1, wherein the second solid layer is provided over the first solid layers.
3. The method according to claim 1, wherein before the first solid layers are exposed, the second solid layer is patterned into a pattern having a shape corresponding to the passage.
4. The method according to claim 1, wherein the outer side surfaces of the first solid layers are shaped by exposing the positive photosensitive resin disposed above the substrate.
5. The method according to claim 2, wherein after the second solid layer is formed over the first solid layers, the second solid layer is polished.
6. The method according to claim 5, wherein the second solid layer is polished such that the first solid layers are uncovered.
7. The method according to claim 1, wherein the second solid layer transmits light used to expose the first solid layers and has a transmittance of 80% or more.
8. The method according to claim 1, wherein the first solid layers are globally exposed.
9. A method for manufacturing a liquid ejection head including a substrate and a member which is disposed above the substrate and which has passage communicatively connected to discharge port through which a liquid is ejected, the method comprising:
providing first solid layers above the substrate such that outer side surfaces of the first solid layers form an obtuse angle with the substrate;
providing a second solid layer, used to form a mold for the passage, above the substrate such that the second solid layer abuts the outer side surfaces of the first solid layers;
forming the mold for the passages from the second solid layer;
removing the first solid layers;
providing a cover layer over the mold; and
forming the passage by removing the mold.
10. A method for forming a structure, comprising:
providing first solid layers above a substrate such that outer side surfaces of the first solid layers form an obtuse angle with the substrate;
providing a second solid layer made of a positive photosensitive resin above the substrate such that the second solid layer abuts the outer side surfaces of the first solid layers; and
removing the first solid layers for forming the structure.
11. A method for forming a structure, comprising:
providing first solid layers made of a positive photosensitive resin above a substrate such that outer side surfaces of the first solid layers form an obtuse angle with the substrate;
providing a second solid layer above the substrate such that the second solid layer abuts the outer side surfaces of the first solid layers;
exposing portions of the outer side surfaces of the first solid layers through the second solid layer; and
removing the exposed portions from the first solid layers.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A ram air fan diffuser for a ram air fan assembly, the diffuser comprising:
a perforated cone having a frustoconical shape symmetrical about an axis of the diffuser with a plurality of perforations between a first end and a second end of the perforated cone;
an inlet ring seal attached to and axially disposed about the first end of the perforated cone; and
an outlet ring seal attached to and axially disposed about the second end of the perforated cone, wherein the outlet ring seal comprises a cylindrical exterior surface symmetrical about the axis of the diffuser, an o-ring channel within the cylindrical exterior surface, and a diffuser rim extending radially beyond the second end of the perforated cone and radially outward in a plane perpendicular from the axis of the diffuser;
wherein an average external diameter of the second end of the perforated cone is greater than an average external diameter of the first end of the perforated cone such that the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser.
2. The diffuser of claim 1, wherein the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser at an angle of between 4.95 degrees and 5.11 degrees from the axis of the diffuser.
3. The diffuser of claim 1, wherein the inlet ring seal and the outlet ring seal are made of fiber-reinforced polymer composite and the perforated cone is made of metal.
4. The diffuser of claim 1, wherein a ratio of a length of the perforated cone to the average external diameter of the second end of the perforated cone is about 0.74, wherein the length of the perforated cone is a distance in a direction parallel to the axis of the diffuser.
5. The diffuser of claim 1, wherein a ratio of a length of the perforated cone to the average external diameter of the second end of the perforated cone is no less than 0.740 and no greater than 0.743, wherein the length of the perforated cone is a distance in a direction parallel to the axis of the diffuser.
6. The diffuser of claim 1, wherein a length of the perforated cone is about 11.730 inches (or about 297.94 mm), the average external diameter of the first end of the perforated cone is about 13.750 inches (or about 349.25 mm), and the average external diameter of the second end of the perforated cone is about 15.815 inches (or about 401.70 mm).
7. The diffuser of claim 1, wherein a length of the perforated cone is between 11.720 inches and 11.740 inches (or between 297.69 mm and 298.20 mm), the average external diameter of the first end of the perforated cone is between 13.735 inches and 13.765 inches (or between 348.87 mm and 349.63 mm), and the average external diameter of the second end of the perforated cone is between 15.800 inches and 15.830 inches (or between 401.32 mm and 402.08 mm).
8. The diffuser of claim 1, wherein the inlet ring seal comprises a fan housing connection having a cylindrical shape; and an internal diameter of the fan housing connection is about 13.950 inches (or about 354.33 mm).
9. The diffuser of claim 1, wherein the inlet ring seal comprises a fan housing connection having a cylindrical shape; and an internal diameter of the fan housing connection is between 13.935 inches and 13.965 inches (or between 353.95 mm and 354.71 mm).
10. The diffuser of claim 1, wherein an average external diameter of the cylindrical exterior surface is about 16.665 inches (or about 423.29 mm); an average external diameter of the o-ring channel is about 16.456 inches (or about 417.98 mm); and an average diameter of the diffuser rim at an outermost radial limit of a radial extension of the diffuser rim is about 16.445 inches (or about 417.70 mm).
11. The diffuser of claim 1, wherein an average external diameter of the cylindrical exterior surface is between 16.650 inches and 16.680 inches (or between 422.91 mm and 423.67 mm) with a maximum external diameter of 16.695 inches (or 424.05 mm); an average external diameter of the o-ring channel is between 16.441 inches and 16.471 inches (or between 417.60 mm and 418.36 mm) with a maximum external diameter of 16.486 inches (or 418.74 mm); and an average diameter of the diffuser rim at an outermost radial limit of a radial extension of the diffuser rim is between 16.430 inches and 16.460 inches (or between 417.32 mm and 418.08 mm) with a maximum external diameter of 16.475 inches (or 418.47 mm).
12. A ram air fan assembly comprising:
a fan housing;
a fan rotor;
a bearing housing attached to the fan housing;
an outer housing connected to the fan housing;
an inner housing attached to the bearing housing; and
a diffuser disposed axially within the outer housing and disposed axially about the bearing housing and at least a portion of each of the fan housing and the inner housing for diffusing fan air from the fan rotor, the diffuser comprising:
a perforated cone having a frustoconical shape symmetrical about an axis of the diffuser with a plurality of perforations between a first end and a second end of the perforated cone;
an inlet ring seal attached to and axially disposed about the first end of the perforated cone; the inlet ring seal comprising a fan housing connection having a cylindrical shape; and
an outlet ring seal for connecting the diffuser to the outer housing; the outlet ring seal attached to and axially disposed about the second end of the perforated cone, wherein the outlet ring seal comprises a cylindrical exterior surface symmetrical about the axis of the diffuser, an o-ring channel within the cylindrical exterior surface, and a diffuser rim extending radially beyond the second end of the perforated cone and radially outward in a plane perpendicular from the axis of the diffuser;
wherein an average external diameter of the second end of the perforated cone is greater than an average external diameter of the first end of the perforated cone such that the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser.
13. The ram air fan assembly of claim 12, wherein the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser at an angle of between 4.95 degrees and 5.11 degrees from the axis of the diffuser.
14. The ram air fan assembly of claim 12, wherein the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser at an angle of about 5 degrees from the axis of the diffuser.
15. The ram air fan assembly of claim 12, wherein the inlet ring seal and the outlet ring seal are made of fiber-reinforced polymer composite and the perforated cone is made of metal.
16. The ram air fan assembly of claim 12, wherein a ratio of a length of the perforated cone to the average external diameter of the second end of the perforated cone is no less than 0.740 and no greater than 0.743, wherein the length of the perforated cone is a distance in a direction parallel to the axis of the diffuser.
17. The ram air fan assembly of claim 12, wherein a length of the perforated cone is between 11.720 inches and 11.740 inches (or between 297.69 mm and 298.20 mm), the average external diameter of the first end of the perforated cone is between 13.735 inches and 13.765 inches (or between 348.87 mm and 349.63 mm), and the average external diameter of the second end of the perforated cone is between 15.800 inches and 15.830 inches (or between 401.32 mm and 402.08 mm).
18. The ram air fain assembly of claim 12 further comprising:
acoustic foam occupying at least most of a volume between the perforated cone and the outer housing.
19. A method for installing a ram air fan diffuser in a ram air fan assembly, the diffuser comprising a perforated cone having a frustoconical shape symmetrical about an axis of the diffuser with a plurality of perforations between a first end and a second end of the perforated cone; an inlet ring seal attached to and axially disposed about the first end of the perforated cone having a fan housing connection; and an outlet ring seal attached to and axially disposed about the second end of the perforated cone, wherein the outlet ring seal comprises a cylindrical exterior surface symmetrical about the axis of the diffuser, an o-ring channel within the cylindrical exterior surface, and a diffuser rim extending radially beyond the second end of the perforated cone and radially outward in a plane perpendicular from the axis of the diffuser; wherein an average external diameter of the second end of the perforated cone is greater than an average external diameter of the first end of the perforated cone such that the perforated cone extends away from the inlet ring seal and radially outward from the axis of the diffuser, the method comprising:
orienting the diffuser such that the fan housing connection of the inlet ring seal faces a fan outlet of the ram air fan assembly;
inserting the diffuser into the fan outlet such that the diffuser axially surrounds a bearing housing and at least a portion of each of a fan housing and an inner housing;
pressing the diffuser toward the fan housing such that the fan housing connection of the inlet ring seal connects to the fan housing and the outlet ring seal connects to an outer housing;
inserting a check valve into a bypass inlet of the ram air fan assembly;
connecting a wire transfer tube to the inner housing;
feeding electrical wires from the inner housing, through the wire transfer tube, to a terminal box;
connecting the electrical wires to the terminal box; and
connecting a motor bearing cooling tube to the inner housing.