EP0321075A2 — Integrated thermal ink jet printhead and method o…

Claim 1

Independent Claim 188 words

A self-aligning process for manufacturing a thermal ink jet printhead including the steps of: a. providing a reusable substrate (10); b. forming an orifice plate (18) on said substrate; c. forming a first barrier (20) layer on said orifice plate; d. forming heater resistors (22) on said first barrier layer in a predefined configuration and spacing relative to openings (16) in said orifice plate; e. forming a second barrier layer (30) on said first barrier layer (20) and extending over said heater resistors (22) to protect said heater resistors from ink corrosion and cavitation wear; f. forming an ink reservoir-defining layer (38) on said second barrier layer (30) and having a plurality of ink reservoir openings (40,42) aligned with openings (16) in said orifice plate (18); g. providing passages (44,46) through said first and second barrier layers (20,30) and extending from said reservoirs (40,42) and to openings (16) in said orifice plate (18), whereby said ink reservoir layer (38) may be secured to an ink supply chamber (48) for supplying ink to said plurality of ink reservoirs; and h. removing said reusable substrate (10) from said orifice plate.

Claim 2

Dependent Claim 188 words

A self-aligning process for manufacturing a thermal ink jet printhead including the steps of: a. providing a reusable substrate (10); b. forming an orifice plate (18) on said substrate; c. forming a first barrier (20) layer on said orifice plate; d. forming heater resistors (22) on said first barrier layer in a predefined configuration and spacing relative to openings (16) in said orifice plate; e. forming a second barrier layer (30) on said first barrier layer (20) and extending over said heater resistors (22) to protect said heater resistors from ink corrosion and cavitation wear; f. forming an ink reservoir-defining layer (38) on said second barrier layer (30) and having a plurality of ink reservoir openings (40,42) aligned with openings (16) in said orifice plate (18); g. providing passages (44,46) through said first and second barrier layers (20,30) and extending from said reservoirs (40,42) and to openings (16) in said orifice plate (18), whereby said ink reservoir layer (38) may be secured to an ink supply chamber (48) for supplying ink to said plurality of ink reservoirs; and h. removing said reusable substrate (10) from said orifice plate.

Claim 3

Dependent Claim 35 words

The process defined in claim 1 which further includes affixing an ink supply chamber (48) to said reservoir-defining layer (38) for providing ink to each of said reservoirs from a common source of ink supply.

Claim 4

Dependent Claim 40 words

The process defined in claim 1 which includes forming heater resistors (22) integral with lead-in conductors (24,26,28) on the surface of said first barrier layer (20) and controlling the resistor/conductor resistance by controlling the cross-section areas of the resistor/conductor material.

Claim 5

Dependent Claim 40 words

The process defined in claim 2 which includes forming heater resistors (22) integral with lead-in conductors (24,26,28) on the surface of said first barrier layer (20) and controlling the resistor/conductor resistance by controlling the cross-section areas of the resistor/conductor material.

Claim 6

Dependent Claim 76 words

A process for manufacturing an ink jet pen which includes: a. forming a thin film transducer structure on a reusable substrate (10) and including conductors (24,26,28) leading into heat generating transducers (22); b. forming ink-reservoir defining walls (38) adjacent to said transducers (22); c. removing said substrate (10); d. bonding said walls to an ink supply container (48); and e. electrically connecting said conductors to mating leads on said container for providing current to said transducers.

Claim 7

Dependent Claim 76 words

A process for manufacturing an ink jet pen which includes: a. forming a thin film transducer structure on a reusable substrate (10) and including conductors (24,26,28) leading into heat generating transducers (22); b. forming ink-reservoir defining walls (38) adjacent to said transducers (22); c. removing said substrate (10); d. bonding said walls to an ink supply container (48); and e. electrically connecting said conductors to mating leads on said container for providing current to said transducers.

Claim 8

Dependent Claim 33 words

The process defined in claim 5 wherein said ink reservoir defining walls (38) are electroformed in a pattern on said thin film transducer structure and subsequently bonded to said ink supply container (48).

Claim 9

Dependent Claim 28 words

The process defined in claim 6 wherein orifice openings (16) in said thin film transducer structure are made by selective electroforming on top of said reusable substrate (10).

Claim 10

Dependent Claim 45 words

The process defined in claim 5 wherein said transducers are formed by depositing a plurality of resistors (22) in partially encircling geometry surrounding a corresponding plurality of orifices (16) in said thin film transducer structure and integrally joined with a plurality of lead-in conductors (24,26,28).

Claim 11

Dependent Claim 22 words

The process defined in claim 8 wherein said walls are electroformed to partially surround said resistors (22) and provide ink flow thereto.

Claim 12

Dependent Claim 201 words

An integrated thermal ink jet printhead comprising: a. an orifice plate (18) having plurality of openings (16) therein; b. a first barrier layer (20) disposed on said orifice plate; c. a plurality of heater resistors (22) arranged in a predefined configuration on said first barrier layer (20) and positioned adjacent said openings (16) in said orifice plate; d. a second barrier layer (30) disposed on said first barrier layer (20) and covering said heater resistors (22) and protecting same from ink corrosion and cavitation wear; e. an ink reservoir-defining layer (38) disposed on said second barrier (30) layer and having a plurality of ink reservoirs (40,42) therein aligned with said openings (16) in said orifice plate; and f. said first and second barrier layers (20,30) having a passageway (44,46) extending therethrough at each opening in said orifice plate for providing an ink flow path from said reservoirs (40,42) in said reservoir-defining layer and through openings (16) in said orifice plate, whereby said ink reservoir defining layer (38) may be secured to an ink supply chamber (48) or housing for supplying ink to said reservoirs (40,42) and through said openings (16) in said orifice plate (18) during an ink jet printing operation.

Claim 13

Dependent Claim 201 words

An integrated thermal ink jet printhead comprising: a. an orifice plate (18) having plurality of openings (16) therein; b. a first barrier layer (20) disposed on said orifice plate; c. a plurality of heater resistors (22) arranged in a predefined configuration on said first barrier layer (20) and positioned adjacent said openings (16) in said orifice plate; d. a second barrier layer (30) disposed on said first barrier layer (20) and covering said heater resistors (22) and protecting same from ink corrosion and cavitation wear; e. an ink reservoir-defining layer (38) disposed on said second barrier (30) layer and having a plurality of ink reservoirs (40,42) therein aligned with said openings (16) in said orifice plate; and f. said first and second barrier layers (20,30) having a passageway (44,46) extending therethrough at each opening in said orifice plate for providing an ink flow path from said reservoirs (40,42) in said reservoir-defining layer and through openings (16) in said orifice plate, whereby said ink reservoir defining layer (38) may be secured to an ink supply chamber (48) or housing for supplying ink to said reservoirs (40,42) and through said openings (16) in said orifice plate (18) during an ink jet printing operation.

Claim 14

Dependent Claim 37 words

The structure defined in claim 10 which further includes an ink supply chamber (48) affixed to said ink reservoir-defining layer (38) for supplying ink from a common source of ink supply to each of said reservoirs (40,42).

Claim 15

Dependent Claim 32 words

The structure defined in claim 10 wherein said heater resistors (22) are formed integral with lead-in conductors (24,26,28), the resistance of which is controlled in accordance with their established cross sectional area.

Claim 16

Dependent Claim 32 words

The structure defined in claim 11 wherein said heater resistors (22) are formed integral with lead-in conductors (24,26,28), the resistance of which is controlled in accordance with their established cross sectional area.

Claim 17

Dependent Claim 80 words

An ink jet pen including in combination: a. a thin film transducer structure having conductors (24,26,28) thereon leading into heat generating transducers (22) and further having ink ejection orifices (16) associated with said transducers; b. annular walls (38) adjacent said transducers and defining ink reservoirs (40,42) therefor; c. an ink container (48) bonded to said annular walls (38); and d. means (50,52) on said container for providing an external electrical connection to said conductors on said thin film transducer structure.

Claim 18

Dependent Claim 80 words

An ink jet pen including in combination: a. a thin film transducer structure having conductors (24,26,28) thereon leading into heat generating transducers (22) and further having ink ejection orifices (16) associated with said transducers; b. annular walls (38) adjacent said transducers and defining ink reservoirs (40,42) therefor; c. an ink container (48) bonded to said annular walls (38); and d. means (50,52) on said container for providing an external electrical connection to said conductors on said thin film transducer structure.

Claim 19

Dependent Claim 24 words

The pen defined in claim 14 wherein said walls (38) are electroformed to have ink flow ports therein for supplying ink to said transducers.

Claim 20

Dependent Claim 25 words

The pen defined in claim 14 wherein said transducers are heater resistors (22) which partially surround said orifices (16) in said thin film transducer structure.

Claim 21

Dependent Claim 35 words

The pen defined in claim 16 wherein said walls (38) are electroformed to have ink flow ports therein for supplying ink to said heater resistors (22) and which partially surround (Fig. 9B) said heater resistors.

Claim 22

Dependent Claim 19 words

The pen defined in claim 17 wherein said heater resistors (22) are integrally joined to lead in conductors (24,26,28).

Claim 23

Dependent Claim 29 words

The pen defined in claim 14 wherein said transducers are heater resistors (22) which partially encircle (Fig. 9B) said orifices and which are integrally joined to lead-in conductors (24,26,28).

Integrated thermal ink jet printhead and method of manufacturing

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