Abstract: A charge plate for an ink jet printer comprises a rigid support plate provided with a medially extending elongated slot and an electrode support structure cast in place adheringly against the walls of the slot. The electrode support structure is fabricated from a nonconductive casting resin which is cast against a silicone elastomer mold having a series of upstanding pegs coated with a release agent and an overcoating of conductive epoxy. The casting resin flows around the peg structure and bonds itself to the conductive epoxy coating. The conductive epoxy material transfers from the mold surface to the electrode support structure upon mold separation, so that the casting process produces a series of cylindrical charging electrodes cast in place within charging tunnels in the electrode support structure. The resulting product is subjected to a finishing operation, and flexible printed circuit leads are thereafter attached to the charging electrodes.

Abstract: Connection of electrical leads to individual charge electrodes in a charge plate structure is facilitated by the formation of conductive pads extending from each charge electrode to the corresponding electrical lead. The conductive pads are formed by applying a mask, containing open areas corresponding to areas between individual charge electrodes and electrical leads, to the charge plate structure and spraying a conductive epoxy resin onto the mask. Electrical connections between the leads and charge electrodes are rapidly and reliably made in this manner.

Abstract: Connection of electrical leads to individual charge electrodes in a charge plate structure is facilitated by the integral formation of such leads during the mold stage of formation of a charge plate. An elastomeric mold is formed from a charge plate master coated with a photoresist material and having base area corresponding to the placement of the electrical leads. The elastomeric mold is coated with an electrically conductive resin, and a charge plate is cast in the mold. Upon separation, the conductive resin transfers to the charge plate structure forming charge electrodes. Lapping or grinding the surface of the structure removes excess resin and leaves the electrical leads intact.

Abstract: A charge plate for an ink jet printer comprises a rigid support plate provided with a medially extending elongated slot and an electrode support structure cast in place adheringly against the walls of the slot. The electrode support structure is fabricated from a non-conductive casting resin which is cast against a silicone elastomer mold having a series of upstanding pegs coated with a release agent and an overcoating of conductive epoxy. The casting resin flows around the peg structure and bonds itself to the conductive epoxy coating. The conductive epoxy material transfers from the mold surface to the electrode support structure upon mold separation, so that the casting process produces a series of cylindrical charging electrodes cast in place within charging tunnels in the electrode support structure. The resulting product is subjected to a finishing operation, and flexible printed circuit leads are thereafter attached to the charging electrodes.