US4694308A
Expired / Lapsed
US
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Barrier layer and orifice plate for thermal ink jet printhead assembly
Assignee: HP Inc
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Filing: 1986-12-04
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Granted: 1987-09-15
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Expires: 2006-12-04
Abstract
Abstract This application discloses a thermal ink jet printhead and method of manufacture featuring an improved all-metal orifice plate and barrier layer assembly. This assembly includes constricted ink flow ports to reduce cavitation damage and smooth contoured convergent ink ejection orifices to prevent "gulping" of air during an ink ejection process. Both of these features extend the maximum operating frequency, fmax, of the printhead. The nickle barrier layer and the underlying thin film resistor substrate are gold plated and then soldered together to form a good strong solder bond at the substrate-barrier layer interface.
Inventors
- 👤 C. S. Chan
- 👤 Robert R. Hay
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 18:39
CPC Classifications
C; C25; C25D; C25D1/00; C25D1/02; B; B41; B41J; B41J2/00; B41J2/005; B41J2/01; B41J2/135; B41J2/14; B41J2/14016; B41J2/14088; B41J2/14112; B41J2/14129; B41J2/14145; B41J2/16; B41J2/1601; B41J2/1603; B41J2/1621; B41J2/1623; B41J2/1625; B41J2/1631; B41J2/164; B41J2/1643; B41J2202/00; B41J2202/01; B41J2202/11; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49401
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
198 words
In a thermal ink jet print head assembly including a plurality of resistive heater elements located on a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice layer structure and geometry including a discontinuous layer of metal having a plurality of interrupted sections therein defining a corresponding plurality of cavity regions axially aligned with said heater elements and with respect to the direction of ink flow; each of said cavity regions being connected to constricted ink flow ports having widths substantially smaller than the diameters of said cavities, and a continuous layer of metal joining said discontinuous layer and having a plurality of output orifices axially aligned with said cavities and having output openings smaller than the diameters of said cavities; said output orifices further including, smooth contoured walls extending from the peripheries of said cavities to said output openings and operative to minimize the turbulance of ink flow through said cavities and exiting said output orifices and thereby increasing the maximum achievable frequency of operation.
Claim 2
Dependent Claim
198 words
In a thermal ink jet print head assembly including a plurality of resistive heater elements located on a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice layer structure and geometry including a discontinuous layer of metal having a plurality of interrupted sections therein defining a corresponding plurality of cavity regions axially aligned with said heater elements and with respect to the direction of ink flow; each of said cavity regions being connected to constricted ink flow ports having widths substantially smaller than the diameters of said cavities, and a continuous layer of metal joining said discontinuous layer and having a plurality of output orifices axially aligned with said cavities and having output openings smaller than the diameters of said cavities; said output orifices further including, smooth contoured walls extending from the peripheries of said cavities to said output openings and operative to minimize the turbulance of ink flow through said cavities and exiting said output orifices and thereby increasing the maximum achievable frequency of operation.
Claim 3
Dependent Claim
24 words
The improvement defined in claim 1 wherein said discontinuous layer has scalloped outer walls which serve to reduce cross talk and reflective acoustic waves.
Claim 4
Dependent Claim
16 words
The improvement defined in claim 1 wherein said continuous and discontinuous layers are electroformed of nickel.
Claim 5
Dependent Claim
16 words
The improvement defined in claim 2 wherein said continuous and discontinuous layers are electroformed of nickel.
Claim 6
Dependent Claim
183 words
In a thermal ink jet printhead assembly including a plurality of resistor heater elements located on a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop and aligned with the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice plate structure including a metal barrier layer having cavities therein defining ink reservoirs aligned with said heater resistors and secured to said thin film resistor structure and further having ink flow ports therein for receiving ink from an ink source, and a metal orifice plate layer joined to said barrier layer and having ink passageways therein coaxially aligned with said cavities in said barrier layer, said ink passageways being defined by contoured and curved interior walls which converge from a point of maximum diameter adjacent said barrier layer to a point of minimum diameter at the outer surface of said orifice plate layer, whereby the convergent geometry of said passageways minimizes turbulance and cavitation wear caused by ink flowing through said passageways.
Claim 7
Dependent Claim
183 words
In a thermal ink jet printhead assembly including a plurality of resistor heater elements located on a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop and aligned with the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice plate structure including a metal barrier layer having cavities therein defining ink reservoirs aligned with said heater resistors and secured to said thin film resistor structure and further having ink flow ports therein for receiving ink from an ink source, and a metal orifice plate layer joined to said barrier layer and having ink passageways therein coaxially aligned with said cavities in said barrier layer, said ink passageways being defined by contoured and curved interior walls which converge from a point of maximum diameter adjacent said barrier layer to a point of minimum diameter at the outer surface of said orifice plate layer, whereby the convergent geometry of said passageways minimizes turbulance and cavitation wear caused by ink flowing through said passageways.
Claim 8
Dependent Claim
28 words
The structure defined in claim 5 wherein said barrier layer is gold plated nickel and is well suited for strong solder bonding to said thin film resistor substrate.
Claim 9
Dependent Claim
46 words
The structure defined in claim 6 wherein said barrier layer and orifice plate layer are joined together by the electroforming of nickel, and the contour of said passageways in said orifice plate layer is defined by the masking on said barrier layer during an electroforming process.
Claim 10
Dependent Claim
29 words
The structure defined in claim 7 wherein said barrier layer is gold plated nickel and is well suited for the strong solder bonding to said thin film resistor substrate.
Claim 11
Dependent Claim
169 words
In a thermal ink jet printhead assembly including a plurality of resistive heater elements and a corresponding plurality of individual ink reservoirs constructed atop the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer structure and geometry including a first layer of material having a plurality of interrupted sections therein defining a corresponding plurality of cavity regions aligned with respect to said heater elements; each of said cavity regions being connected to ink flow ports, and a second layer of material joining said first layer of metal and having a plurality of output orifices aligned with respect to said cavities and having output openings smaller than the diameters of said cavities; said output orifices further including smooth, convergent contoured walls extending from the peripheries of said cavities to said output openings and operative to minimize the turbulance of ink flow and air gulping through said cavities and thereby increasing the maximum achievable frequency of operation.
Claim 12
Dependent Claim
169 words
In a thermal ink jet printhead assembly including a plurality of resistive heater elements and a corresponding plurality of individual ink reservoirs constructed atop the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer structure and geometry including a first layer of material having a plurality of interrupted sections therein defining a corresponding plurality of cavity regions aligned with respect to said heater elements; each of said cavity regions being connected to ink flow ports, and a second layer of material joining said first layer of metal and having a plurality of output orifices aligned with respect to said cavities and having output openings smaller than the diameters of said cavities; said output orifices further including smooth, convergent contoured walls extending from the peripheries of said cavities to said output openings and operative to minimize the turbulance of ink flow and air gulping through said cavities and thereby increasing the maximum achievable frequency of operation.
Claim 13
Dependent Claim
24 words
The improvement defined in claim 9 wherein said first material layer has scalloped outer walls which serve to reduce crosstalk and reflective acoustic waves.
Claim 14
Dependent Claim
17 words
The improvement defined in claim 9 wherein said first and second metal layers are electroformed of nickel.
Claim 15
Dependent Claim
17 words
The improvement defined in claim 10 wherein said first and second metal layers are electroformed of nickel.
Claim 16
Dependent Claim
180 words
In a thermal jet printhead assembly including a plurality of resistor heater elements within a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop and aligned with respect to the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice plate structure including a barrier layer having cavities therein defining ink reservoirs, said cavities aligned with respect to said heater resistors and further having ink flow ports therein for receiving ink from an ink source, and an orifice plate layer joined to said barrier layer and having ink passageways therein aligned with respect to said cavities in said barrier layer, said ink passageways being defined by contoured and curved interior walls which converge from a point of maximum diameter adjacent said barrier layer to a point of minimum diameter at the outer surface of said orifice plate layer, whereby the convergent geometry of said passageways minimizes turbulance, air gulping, and cavitation wear caused by ink flowing through said passageways.
Claim 17
Dependent Claim
180 words
In a thermal jet printhead assembly including a plurality of resistor heater elements within a thin film resistor structure and further having a plurality of individual ink reservoirs constructed atop and aligned with respect to the plurality of resistive heater elements, respectively, for receiving thermal energy therefrom during an ink jet printing operation, the improvement comprising: a barrier layer and orifice plate structure including a barrier layer having cavities therein defining ink reservoirs, said cavities aligned with respect to said heater resistors and further having ink flow ports therein for receiving ink from an ink source, and an orifice plate layer joined to said barrier layer and having ink passageways therein aligned with respect to said cavities in said barrier layer, said ink passageways being defined by contoured and curved interior walls which converge from a point of maximum diameter adjacent said barrier layer to a point of minimum diameter at the outer surface of said orifice plate layer, whereby the convergent geometry of said passageways minimizes turbulance, air gulping, and cavitation wear caused by ink flowing through said passageways.
Claim 18
Dependent Claim
28 words
The assembly defined in claim 13 wherein said barrier layer is gold plated nickel and is well suited for strong solder bonding to said thin film resistor structure.
Claim 19
Dependent Claim
46 words
The assembly defined in claim 14 wherein said barrier layer and orifice plate layer are joined together by the electroforming of nickel, and the contour of said passageways in said orifice plate layer is defined by the masking on said barrier layer during an electroforming process.
Claim 20
Dependent Claim
29 words
The assembly defined in claim 15 wherein said barrier layer is gold plated nickel and is well suited for the strong solder bonding to said thin film resistor structure.
Claim 21
Dependent Claim
24 words
The assembly defined in claim 16 wherein said first metal layer has scalloped outer walls which serve to reduce crosstalk and reflective acoustic waves.
References Cited (Backward Citations)
US4558333A
Cited
US4513298A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-09-14 | 1991-03-16 | 1991-09-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-09-14 | 1995-03-16 | 1995-09-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-09-14 | 1999-03-16 | 1999-09-15 | $7700.00 | Window Closed / Lapsed |