Abstract: A method for forming an ink jet print head can include attaching a plurality of piezoelectric elements to a diaphragm, dispensing an interstitial layer over the diaphragm, electrically coupling a plurality of conductive elements to the plurality of piezoelectric elements, and curing the interstitial layer. A plurality of electrically isolated conductive particles within the interstitial layer electrically couple the plurality of conductive elements to the plurality of piezoelectric elements. The conductive particles can be evenly distributed throughout the totality of the interstitial layer dielectric, or they can be localized over a top surface of each piezoelectric element and interposed between the plurality of piezoelectric elements and the plurality of conductive elements. The conductive elements can be part of a flex circuit or printed circuit board.

Abstract: A manifold assembly has been constructed that filters ink before the ink enters an inkjet ejector in an inkjet print head. The manifold assembly includes an adhesive layer having openings, an ink manifold layer having a plurality of openings, the openings in the adhesive layer being aligned with the openings in the ink manifold layer, and a polymer layer having a plurality of filter areas, the filter areas being aligned with the openings in the ink manifold layer and the openings in the adhesive layer, the adhesive layer being interposed between the polymer layer and the ink manifold layer.

Abstract: A method and structure for forming an ink jet print head having a dielectric interstitial layer. A flexible top plate attached to a press can be used to apply pressure to an uncured dielectric interstitial layer. The uncured dielectric interstitial layer is cured while contacting the uncured dielectric interstitial layer with the flexible top plate and applying pressure using the press. Using a flexible top plate rather than a rigid top plate has been found to form a cured interstitial layer over an array of piezoelectric elements which has a more uniform or planar upper surface. An interstitial layer so formed can result in decreased processing time, reduced problems with ink communication in the ink jet print head during use, and decreased manufacturing costs.

Abstract: An aperture plate for a print head of a printer can include a first layer having a first emissivity which is covered by a second layer having a second emissivity which is less than the first emissivity. In an embodiment, the second layer can be etched at nozzle locations to form openings in the second layer which have widths/areas greater than widths/areas of nozzles formed in the first layer. In another embodiment, the second layer can have a smaller thickness at the nozzle locations and a larger thickness away from the nozzle locations. Forming the openings in the second layer which are larger than the nozzles, or forming the second layer thinner at the nozzle locations prior to forming the nozzles, can provide a well-formed nozzle and an aperture plate having a low emissivity.

Abstract: A method for assembling an inkjet jet print head enables piezoelectric transducers to be bonded to an inkjet ejector without closing inlets to a pressure chamber within the inkjet ejector. The method includes bonding a polymer layer to a diaphragm layer having a plurality of openings, bonding piezoelectric transducers to the diaphragm layer with a thermoset adhesive, placing thermoset polymer in areas between the piezoelectric transducers on the diaphragm layer, and drilling inlets through the thermoset polymer and the diaphragm at the openings in the diaphragm.

Abstract: A printhead for printing ink includes a particulate filter manufactured from a polymer sheet such as a polyimide sheet. Filter openings within the particulate filter can be formed using a mask and a laser beam to ablate exposed portions of the polymer sheet. Embodiments of the present teachings can result in the formation smaller filter openings at a smaller pitch within the polymer sheet than, for example, stainless steel particulate filters, and thus more openings which cover a larger percentage of the filter surface for a given filter size, which can result in a reduction of fluid pressure within the printhead. Thus smaller filter openings for improved filtering of smaller particulates can be formed while maintaining a sufficient ink flow at a sufficiently low pressure within the printhead during operation.

Abstract: A method for forming an ink jet print head can include attaching a plurality of piezoelectric elements to a diaphragm, dispensing a dielectric fill layer over the diaphragm and the plurality of piezoelectric elements to encapsulate the piezoelectric elements, curing the dielectric fill layer to form an interstitial layer, then removing the interstitial layer from an upper surface of the plurality of piezoelectric elements using a plasma etch.

Abstract: A method of assembly produces a printhead having a polymer aperture plate and outlet plate that are at least 25 mm in length. The method includes bonding the polymer aperture plate to the outlet plate, which is configured with outlets. A laser is aligned with the outlets in the outlet plate to ablate apertures in the polymer aperture plate and the outlet plate is bonded to an inkjet stack to couple the outlets in the outlet plate to pressure chambers in a body plate in the inkjet stack.

Abstract: A method of manufacturing a printhead includes connecting an ink supply and driving electronics to a predetermined number of inkjet ejector sites. Each ejector site includes a fluid inlet and an electrical connector. The predetermined number of ejector sites connected to the ink supply and driving electronics is less than the total number of ejector sites available for use in the printhead.

Abstract: A method for mounting a piezoelectric transducer layer to a diaphragm layer exposes an electrode for each piezoelectric transducer after thermoset polymer filling the interstitial space between the piezoelectric transducers has been cured. The method includes bonding a polymer layer to a diaphragm layer having a plurality of openings, bonding piezoelectric transducers to the diaphragm layer, filling areas between the piezoelectric transducers on the diaphragm layer with thermoset polymer, and removing the thermoset polymer from the piezoelectric transducers with a laser to expose a metal electrode on each piezoelectric transducer.

Abstract: A method for making a plurality of electromechanical transducers includes, depositing a layer of conductive material attached to a first side of a piezoelectric layer to form a laminar structure, attaching the laminar structure to a rigid carrier substrate using a removable double-sided tape, forming piezoelectric transducers, attaching the electromechanical transducer to a fluid channel substructure, and removing the rigid carrier substrate and the double-sided tape.

Abstract: A method includes attaching multiple layers to a back side of at least a portion of a fluid dispensing subassembly having at least one inlet port to form a fluid dispensing assembly, aligning a laser to a region of the fluid dispensing assembly, the region corresponding to the inlet port, and forming at least one hole in the region using a laser, the hole completing a path through the layers to the inlet port. A fluid dispensing assembly has a fluid dispensing subassembly having at least one inlet port, a fluid manifold having at least one outlet, at least two layers between the fluid dispensing subassembly and the manifold, and a fluid path in the at least two layers between the outlet and the inlet port, the fluid path having smooth walls and substantially uniform width.

Abstract: A method and structure for forming an ink jet print head having a dielectric interstitial layer. A flexible top plate attached to a press can be used to apply pressure to an uncured dielectric interstitial layer. The uncured dielectric interstitial layer is cured while contacting the uncured dielectric interstitial layer with the flexible top plate and applying pressure using the press. Using a flexible top plate rather than a rigid top plate has been found to form a cured interstitial layer over an array of piezoelectric elements which has a more uniform or planar upper surface. An interstitial layer so formed can result in decreased processing time, reduced problems with ink communication in the ink jet print head during use, and decreased manufacturing costs.

Abstract: An inkjet array has been developed that enables inlets for one group of inkjet ejectors to be laterally offset from the nozzles of the inkjet ejectors in the group and also enables inlets for another group of inkjet ejectors to be laterally offset from the nozzles of the inkjet ejectors in the other group. The lateral offset distance increases the distance between the inlets of the two groups to provide a wider bonding area between the two groups and improve the fluidic isolation between the two groups of inkjet ejectors.

Abstract: A printhead assembly includes a plurality of functional plates bonded together in a stack by polymeric adhesive(s). The surfaces of the functional plates that contact the polymeric adhesives are subjected to a coating process that includes providing a coating of an adhesion promoter, namely polydopamine, prior to application of the adhesive. The adhesive may be a crosslinkable acrylic adhesive or a thermoplastic polyimide. The polydopamine coating is applied by immersing the functional plate in a buffered dopamine solution for a period sufficient to produce a coating having a pre-determined thickness. The thickness of the coating is controlled by submerging the functional plate in the buffered dopamine solution while the pH value of the dopamine solution is maintained at a value sufficient for polymerization of the dopamine during that time period, and then transferring the plates to a solution having a pH value that is insufficient to sustain the polymerization reaction.

Abstract: A method for assembling an inkjet jet print head enables piezoelectric transducers to be bonded to an inkjet ejector without closing inlets to a pressure chamber within the inkjet ejector. The method includes bonding a polymer layer to a diaphragm layer having a plurality of openings, bonding piezoelectric transducers to the diaphragm layer with a thermoset adhesive, placing thermoset polymer in areas between the piezoelectric transducers on the diaphragm layer, and drilling inlets through the thermoset polymer and the diaphragm at the openings in the diaphragm.

Abstract: An aperture plate for a print head of a printer can include a first layer having a first emissivity which is covered by a second layer having a second emissivity which is less than the first emissivity. In an embodiment, the second layer can be etched at nozzle locations to form openings in the second layer which have widths/areas greater than widths/areas of nozzles formed in the first layer. In another embodiment, the second layer can have a smaller thickness at the nozzle locations and a larger thickness away from the nozzle locations. Forming the openings in the second layer which are larger than the nozzles, or forming the second layer thinner at the nozzle locations prior to forming the nozzles, can provide a well-formed nozzle and an aperture plate having a low emissivity.

Abstract: A method for forming an ink jet print head can include attaching a plurality of piezoelectric elements to a diaphragm, dispensing an interstitial layer over the diaphragm, electrically coupling a plurality of conductive elements to the plurality of piezoelectric elements, and curing the interstitial layer. A plurality of electrically isolated conductive particles within the interstitial layer electrically couple the plurality of conductive elements to the plurality of piezoelectric elements. The conductive particles can be evenly distributed throughout the totality of the interstitial layer dielectric, or they can be localized over a top surface of each piezoelectric element and interposed between the plurality of piezoelectric elements and the plurality of conductive elements. The conductive elements can be part of a flex circuit or printed circuit board.

Abstract: A method of assembly produces a printhead having a polymer aperture plate and outlet plate that are at least 25 mm in length. The method includes bonding the polymer aperture plate to the outlet plate, which is configured with outlets. A laser is aligned with the outlets in the outlet plate to ablate apertures in the polymer aperture plate and the outlet plate is bonded to an inkjet stack to couple the outlets in the outlet plate to pressure chambers in a body plate in the inkjet stack.

Abstract: A fluid dispensing subassembly has a diaphragm arranged to be operated on by a transducer, a body pressure chamber arranged to be operated on by the diaphragm, and an adhesive attachment layer arranged between the diaphragm and the body pressure chamber. A fluid dispensing subassembly has a body pressure chamber formed of either a single plate or set of plates, a diaphragm arranged to operate on the body pressure chamber, and an adhesive layer arranged between the body pressure chamber and the diaphragm. A method of manufacturing a fluid dispensing subassembly includes forming a body pressure chamber from a body plate or a set of plates including a body plate, and adhesively bonding a diaphragm plate to at least the body plate of the fluid dispensing subassembly.