Method of manufacture of a curling calyx thermoelastic ink jet printer

• US 6,241,905 B1
• Filed: 07/10/1998
• Issued: 06/05/2001
• Est. Priority Date: 07/15/1997
• Status: Expired due to Fees

• Current Assignee: Zamtec Limited (Memjet Limited)
• Original Assignee: Silverbrook Research Pty Limited
• Inventors: Silverbrook, Kia
• Primary Examiner(s): Alanko, Anita
• Application Number:
  US09/113,118
• Time in Patent Office: 1,061 Days
• Field of Search: 216/2, 216/27, 438/21, 347/54, 347/59
• US Class Current: 216/27
• CPC Class Codes: B41J 2/14427 Structure of ink jet print heads with thermal bend detached actuators
• CPC Class Codes: B41J 2/1628 dry etching
• CPC Class Codes: B41J 2/1631 photolithography
• CPC Class Codes: B41J 2/1632 machining
• CPC Class Codes: B41J 2/1635 dividing the wafer into individual chips
• CPC Class Codes: B41J 2/1639 sacrificial molding
• CPC Class Codes: B41J 2/1642 thin film formation by CVD [chemical vapor deposition]
• CPC Class Codes: B41J 2/1648 Production of print heads with thermal bend detached actuators
• CPC Class Codes: B41J 2/16585 for paper-width or non-reciprocating print heads
• CPC Class Codes: B41J 2/17596 Ink pumps, ink valves
• CPC Class Codes: B41J 2002/041 Electromagnetic transducer
• CPC Class Codes: H04N 23/00 Cameras or camera modules comprising electronic image sensors; Control thereof
• CPC Class Codes: H04N 5/2628 Alteration of picture size, shape, position or orientation, e.g. zooming, rotation, rolling, perspective, translation

Abstract

A method of manufacturing an ink jet printhead includes providing an initial semiconductor wafer having an electrical circuitry layer formed thereon. A nozzle ink inlet hole is etched in the circuitry layer. A first sacrificial material layer is deposited over the electrical circuitry layer and is etched to define an actuator anchor area. A first expansion material layer of a material having a desired coefficient of thermal expansion is deposited and etched to define predetermined vias. A first conductive layer is deposited on the first expansion material layer. The first conductive material layer is etched to be conductively interconnected to the electrical circuitry layer. A second expansion material layer of a desired coefficient of thermal expansion is etched to form a disk centered about the vias. A second sacrificial material layer is deposited and etched to form a nozzle chamber mould. An inert material layer is deposited over the second sacrificial material layer and etched to form a nozzle chamber. An ink supply channel is etched through the wafer and the sacrificial layers are etched away.

Claims

1. A method of manufacture of an ink jet printhead, said method comprising the steps of:

(a) providing an initial semiconductor wafer having an electrical circuitry layer formed thereon;

(b) etching a nozzle ink inlet hole in the electrical circuitry layer in addition to a series of vias at predetermined positions interconnecting with the electrical circuitry layer;

(c) depositing a first sacrificial material layer over the electrical circuitry layer including filling said nozzle ink inlet hole, and etching an actuator anchor in the first sacrificial material layer so that the anchor is located around the vias;

(d) depositing a first expansion material layer of a material having a desired coefficient of thermal expansion, and etching predetermined vias in the first expansion material layer;

(e) depositing and etching a first conductive layer on the first expansion material layer, the first conductive material layer being conductively interconnected to the electrical circuitry layer via said vias;

(f) depositing a second expansion material layer of a material having a desired coefficient of thermal expansion, and etching the second expansion material layer to form a disk centered substantially about the vias and incorporating a combination of the first and second expansion material layers and the conductive material layer;

(g) depositing a second sacrificial material layer, and etching the second sacrificial material layer to form a nozzle chamber mould;

(h) depositing an inert material layer over the second sacrificial material layer, etching the inert material layer to form a nozzle chamber around the disk and etching a nozzle ejection port in the inert material layer;

(i) etching an ink supply channel through the wafer; and

(j) etching away the sacrificial layers.

2. A method as claimed in claim 1 which includes etching the disk so that a series of radial slots are defined in the disk.

3. A method as claimed in claim 1 which includes etching a series of small holes in the inert material layer.

4. A method as claimed in claim 1 which includes etching the nozzle chamber mould so that the mould includes a lip around the circumference of the disk.

5. A method as claimed in claim 1 wherein the first and second expansion material layers comprise substantially polytetrafluoroethylene.

6. A method as claimed in claim 1 wherein the inert material layer comprises substantially silicon nitride.

7. A method as claimed in claim 1 wherein the ink supply channel is formed by etching a channel from the back surface of the wafer.

8. A method as claimed in claim 1 further including the step of depositing corrosion barriers over portions of said printhead to reduce corrosion effects.

9. A method as claimed in claim 1 wherein the wafer comprises a double-sided polished CMOS wafer.

10. A method as claimed in claim 1 wherein the wafer is separated into separate printheads.