Abstract: A print head for a printer includes a jet stack for passage of ink to media to form an image on the media. The jet stack includes a substrate having a micro actuator. The substrate has an opening through the substrate that is proximate to the micro actuator and a diaphragm bonded to the substrate. The diaphragm has an opening through the diaphragm that is configured for fluid communication with the opening through the substrate. The diaphragm opening has a width that is larger than a width of the opening in the substrate.

Abstract: Exemplary embodiments provide interconnects and methods for interconnecting an electrical device array with a flexible circuit by filling a chemically-etched or laser-ablated integral stencil with conductive materials.

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: Provided are free-standing ductile composites and methods of making free-standing ductile composites. The method of making a free-standing ductile composite can include providing a substrate and releasably bonding one or more piezoelectric elements to the substrate. The method can also include kerfing the piezoelectric elements in a predetermined pattern to form a kerfed pattern, filling the kerfed pattern with a polymer to form a polymer-piezoelectric composite, and lapping the polymer-piezoelectric composite. The method can further include releasing the polymer-piezoelectric composite from the substrate.

Abstract: An inkjet external ink manifold is provided that allows for use of a jet stack that does not internally contain ink manifolds. The external ink manifold has a manifold body that includes one or more ink manifold chambers and includes ports arranged to connect the chambers to one or more ink reservoirs. The external ink manifold further includes an adhesive layer overlying and sealing the ink manifold chambers. The adhesive layer includes a plurality of ports arranged to connect the external ink manifold chambers to the jet stack.

Abstract: A system for fabricating a transducer for an ink jet imaging device comprises a transducer assembly including a transducer overlying at least a portion of a flexible carrier. The transducer has a top surface extending a first distance from the carrier. A spacer overlies a portion of the carrier not covered by the transducer. The spacer has a top surface extending a second distance form the carrier. The second distance is less than the first distance and corresponds to a target thickness for the transducer. A lapping tool is configured to lap the top surface of the transducer. The system includes a detector for detecting when the lapping tool contacts the lapping spacer.

Abstract: In accordance with the invention, there are jet stacks, ink jet print heads, and methods of making jet stacks and ink jet print heads. The method of making an ink jet print head can include providing a partial jet stack including a diaphragm, a plurality of port holes, and having an ink outlet side and providing a polymer planarized piezoelectric array. The method can also include bonding the polymer planarized piezoelectric array to a side opposite to the ink outlet side of the partial jet stack using an adhesive, wherein the partial jet stack is aligned such that the planarized polymer covers the plurality of port holes, and using the partial jet stack as a mask to extend the port holes through the polymer by ablating the polymer and an excess portion of the adhesive from the ink outlet side using a laser.

Abstract: A method for assembling a micro-fluidic device better preserves the integrity of a filter in a filter layer and simplifies the bonding of the filter layer to the channel layers on each side of the filter layer. The method includes aligning a polymer layer having a plurality of filter elements and a plurality of fluid passages arranged between the filter elements between two substrates of a micro-fluidic device, and bonding the polymer layer between the two substrates to seal an area between the filter elements and the fluid passages to enable fluid flow through the filter elements to be segregated from fluid flow through the fluid passages.

Abstract: Exemplary embodiments provide interconnects and methods for interconnecting an electrical device array with a flexible circuit by filling a chemically-etched or laser-ablated integral stencil with conductive materials

Abstract: A method processes electrical connections in a micro-fluidic device to reduce mechanical cross-talk and improve actuator performance. The method includes applying conductive adhesive to an electrode overlying a piezoelectric material, contacting the conductive adhesive with an electrical contact pad mounted to a support member to cover the electrode and piezoelectric material with the support member, and removing a portion of the support member that covers the electrical contact pad, the electrode, and the actuator.

Abstract: A method for assembling a micro-fluidic device better preserves the integrity of a filter in a filter layer and simplifies the bonding of the filter layer to the channel layers on each side of the filter layer. The method includes aligning a polymer layer having a plurality of filter elements and a plurality of fluid passages arranged between the filter elements between two substrates of a micro-fluidic device, and bonding the polymer layer between the two substrates to seal an area between the filter elements and the fluid passages to enable fluid flow through the filter elements to be segregated from fluid flow through the fluid passages.

Abstract: A method processes electrical connections in a micro-fluidic device to reduce mechanical cross-talk and improve actuator performance. The method includes applying conductive adhesive to an electrode overlying a piezoelectric material, contacting the conductive adhesive with an electrical contact pad mounted to a support member to cover the electrode and piezoelectric material with the support member, and removing a portion of the support member that covers the electrical contact pad, the electrode, and the actuator.

Abstract: An inkjet external ink manifold is provided that allows for use of a jet stack that does not internally contain ink manifolds. The external ink manifold has a manifold body that includes one or more ink manifold chambers and includes ports arranged to connect the chambers to one or more ink reservoirs. The external ink manifold further includes an adhesive layer overlying and sealing the ink manifold chambers. The adhesive layer includes a plurality of ports arranged to connect the external ink manifold chambers to the jet stack.

Abstract: An inkjet external ink manifold is provided that allows for use of a jet stack that does not internally contain ink manifolds. The external ink manifold has a manifold body that includes one or more ink manifold chambers and includes ports arranged to connect the chambers to one or more ink reservoirs. The external ink manifold further includes an adhesive layer overlying and sealing the ink manifold chambers. The adhesive layer includes a plurality of ports arranged to connect the external ink manifold chambers to the jet stack.

Abstract: A print head for a printer includes a jet stack for passage of ink to media to form an image on the media. The jet stack includes a substrate having a micro actuator. The substrate has an opening through the substrate that is proximate to the micro actuator and a diaphragm bonded to the substrate. The diaphragm has an opening through the diaphragm that is configured for fluid communication with the opening through the substrate.

Abstract: A system for fabricating a transducer for an ink jet imaging device comprises a transducer assembly including a transducer overlying at least a portion of a flexible carrier. The transducer has a top surface extending a first distance from the carrier. A spacer overlies a portion of the carrier not covered by the transducer. The spacer has a top surface extending a second distance form the carrier. The second distance is less than the first distance and corresponds to a target thickness for the transducer. A lapping tool is configured to lap the top surface of the transducer. The system includes a detector for detecting when the lapping tool contacts the lapping spacer.

Abstract: In accordance with the invention, there are free-standing ductile composites, liquid dispensing devices, and methods of making free-standing ductile composites, liquid dispensing devices. The method of making a free-standing ductile composite can include providing a substrate and releasably bonding one or more piezoelectric elements to the substrate. The method can also include kerfing the piezoelectric elements in a predetermined pattern to form a kerfed pattern, filling the kerfed pattern with a polymer to form a polymer-piezoelectric composite, and lapping the polymer-piezoelectric composite. The method can further include releasing the polymer-piezoelectric composite from the substrate.

Abstract: In accordance with the invention, there are jet stacks, ink jet print heads, and methods of making jet stacks and ink jet print heads. The method of making an ink jet print head can include providing a partial jet stack including a diaphragm, a plurality of port holes, and having an ink outlet side and providing a polymer planarized piezoelectric array. The method can also include bonding the polymer planarized piezoelectric array to a side opposite to the ink outlet side of the partial jet stack using an adhesive, wherein the partial jet stack is aligned such that the planarized polymer covers the plurality of port holes, and using the partial jet stack as a mask to extend the port holes through the polymer by ablating the polymer and an excess portion of the adhesive from the ink outlet side using a laser.

Abstract: A pin holder for a microarraying apparatus comprising at least one group of bodies of circular cross-section packed together to form a network of pathways in gaps between the bodies; and an array of pins slidably arranged in the pathways. The pins are held in parallel to each other automatically as a result of the self organized packing of the circular cross-section bodies, which may be spheres, for example ball bearings, or cylindrical, for example needle roller bearings. The pin holder provides for very accurate parallel alignment of the pins, low pin friction, as well as low cost and complexity of manufacture.

Abstract: Segmented heater configurations for ejecting fluid on to a medium having heater segments, where area and power level dissipation of each heater segment in the heater configuration are chosen such that different sized drops of fluid are ejected depending on the pulse voltage and/or pulse width used. As the pulse voltage and/or pulse width applied to a particular channel is increased, more heating segments in that ejection channel nucleate bubbles and produce larger drops. As a result, drop volume and spot size of the ejected fluid can be increased as pulse voltage and/or pulse width increase. For side-shooting devices, the heaters and power densities are configured such that the segment closest to the orifice nucleates its bubble first. For devices which eject droplets perpendicular to the plane of the heater, the heater segments can be arranged into a two-dimensional array. Each segment has a different power density.