Abstract: This invention provides an improved ink flow path between an ink reservoir and vaporization chambers in an inkjet printhead. In the preferred embodiment, a barrier layer containing ink channels and vaporization chambers is located between a rectangular substrate and a nozzle member containing an array of orifices. The substrate contains two linear arrays of heater elements, and each orifice in the nozzle member is associated with a vaporization chamber and heater element. The ink channels in the barrier layer have ink entrances generally running along two opposite edges of the substrate so that ink flowing around the edge of the substrate gain access to the ink channels and to the vaporization chambers.

Abstract: A high-durability printhead for an ink cartridge printing system. The printhead includes a substrate having ink ejectors (e.g. resistors) thereon and an orifice plate positioned above the substrate. The orifice plate has a top surface, bottom surface, and a plurality of openings therethrough. The orifice plate is optimally produced from a non-metallic organic polymeric composition. To improve the durability, heat-stability, and ink resistance of the printhead, an intermediate layer manufactured from a thermoplastic polyimide is employed between the orifice plate and the ink ejector-containing substrate. This particular system generally improves the structural integrity of the printhead and provides longer cartridge life.

Abstract: A pagewide printhead for an inkjet printer employs a stretch-to-fit flex circuit with orifices indexed to reference indentations on the flex circuit. Heater resistors disposed on a block of thermally stable insulating material are indexed to reference features accurately located on the block. The reference indentations are fitted to the reference indentations to provide accurate registration of the orifices to the heater resistors.

Abstract: Components of the printing device are attached by a process employing thermo-compressive welding. The process results in a unitary, graded interface between the attached components and eliminates the need for applying thermal-cure adhesives to secure the components.

Abstract: A printhead for an inkjet printer employs an integral pump disposed in an ink feed channel, input well, or output well to circulate ink to the ink expulsion chambers in the printhead.

Abstract: This invention provides an improved ink flow path between an ink reservoir and vaporization chambers in an inkjet printhead. In the preferred embodiment, a barrier layer containing ink channels and vaporization chambers is located between a rectangular substrate and a nozzle member containing an array of orifices. The substrate contains two linear arrays of heater elements, and each orifice in the nozzle member is associated with a vaporization chamber and heater element. The ink channels in the barrier layer have ink entrances generally running along two opposite edges of the substrate so that ink flowing around the edges of the substrate gain access to the ink channels and to the vaporization chambers.

Abstract: Components of the printing device are attached by a process employing thermo-compressive welding. The process results in a unitary, graded interface between the attached components and eliminates the need for applying thermal-cure adhesives to secure the components.

Abstract: An inkjet printhead includes a compact substrate having a pair of elongated edge portions for ink channel architecture, a central interior for substrate circuitry, and a pair of truncated end portions for mounting and for electrical interconnects. The ink channel architecture includes a plurality of ink vaporization chambers each having a firing resistor therein, as well as ink feed channels communicating through an ink passage from an underside of the substrate around both edges of the substrate to the vaporization chambers.

Abstract: This invention provides an apparatus and method of fabrication thereof for an inkjet printhead with an improved ink flow path between an ink reservoir and vaporization chambers in an inkjet printhead. In the preferred embodiment, a barrier layer containing ink channels and vaporization chambers is located between a rectangular substrate and a nozzle member containing an array of orifices. The substrate contains two linear arrays of heater elements, and each orifice in the nozzle member is associated with a vaporization chamber and heater element. The ink channels in the barrier layer have ink entrances generally running along two opposite edges of the substrate so that ink flowing around the edges of the substrate gain access to the ink channels and to the vaporization chambers. The apparatus is fabricated without using ion implant technology.

Abstract: This invention provides an improved ink flow path between an ink reservoir and vaporization chambers in an inkjet printhead. In the preferred embodiment, a barrier layer containing ink channels and vaporization chambers is located between a rectangular substrate and a nozzle member containing an array of orifices. The substrate contains two linear arrays of heater elements, and each orifice in the nozzle member is associated with a vaporization chamber and heater element. The ink channels in the barrier layer have ink entrances generally running along two opposite edges of the substrate so that ink flowing around the edges of the substrate gain access to the ink channels and to the vaporization chambers.

Abstract: A printhead for an inkjet printer employs an ink fill slot having an extended portion disposed as a depression on the primary surface of the printhead substrate. The barrier layer of the printhead forms the walls of the ink ejection chambers, the walls of and constrictions in the ink fill channels, and the contoured barrier lobes between the ink fill channels. The extended portion of the ink fill slot follows the contour of the barrier lobes such that the length of the substrate shelf between the ink fill channel constriction and the extended portion of the ink fill slot is equalized between ink ejection chambers.

Abstract: Selected portions of the orifice plate surfaces are formed to have wetting and non-wetting surface characteristics for minimizing the accumulation of residual ink on the outer surface of the plate and for enhancing the flow of supply ink to the orifices of the plate.

Abstract: A novel, wide inkjet printhead and method of forming said inkjet printhead is disclosed, wherein a pattern of orifices are formed, using a step-and-repeat process, in a flexible tape using laser ablation or other suitable etching devices. The location of the orifices corresponds to where ink will be ejected from the inkjet printhead. The pattern of orifices may extend to any length without difficulty in aligning the orifices, since the tape may be continuous along the entire length of the printhead.

Abstract: In one of the preferred embodiments, an inkjet printhead includes a nozzle member formed of a polymer material that has been laser-ablated to form inkjet orifices. The nozzle member also has formed on it conductive traces for supplying electrical signals to heating elements on a substrate mounted to a surface of the nozzle member. In a preferred method, the orifices are formed by Excimer laser ablation.

Abstract: An ink fill slot can be precisely manufactured in a substrate utilizing photolithographic techniques with chemical etching, plasma etching, or a combination thereof. These methods may be used in conjunction with laser ablation, mechanical abrasion, or electromechanical machining to remove additional substrate material in desired areas. The ink fill slots are appropriately configured to provide the requisite volume of ink at increasingly higher frequency of operation of the printhead by means of an extended portion that results in a reduced shelf length and thus reduced fluid impedance imparted to the ink. The extended portion is precisely etched to controllably align it with other elements of the printhead.

Abstract: Selected portions of the orifice plate surfaces are formed to have wetting and non-wetting surface characteristics for minimizing the accumulation of residual ink on the outer surface of the plate and for enhancing the flow of supply ink to the orifices of the plate.

Abstract: In a print cartridge according to the preferred embodiment of the invention, a polymer tape having orifices formed therein and containing conductive traces has a substrate containing heater elements affixed to a back surface of the tape. Each of the heater elements in the substrate is located substantially behind each of the orifices. The edges of the nozzle member overlap the edges of the substrate, and the back surface of the tape is sealed with respect to an ink reservoir so that a seal substantially circumscribes the substrate. This allows ink to flow around the side edges of the substrate and into vaporization chambers associated with each orifice. The conductive traces on the tape are attached to electrodes along the shorter side edges of the substrate so as not to interfere with the edge-feed of ink along the longer edges of the substrate.

Abstract: A single mask is used to form a tapered nozzle in a polymer nozzle member using laser ablation. In one embodiment of the mask, clear portions of the mask, corresponding to the nozzle pattern to be formed, each incorporate a variable-density dot pattern, where the opaque dots act to partially shield the underlying polymer nozzle member from the laser energy. This partial shielding of the nozzle member under the dot pattern results in the nozzle member being ablated to less of a depth than where there is no shielding. By selecting the proper density of opaque dots around the peripheral portions of the mask openings, the central portion of each nozzle formed in the polymer nozzle member will be completely ablated through, and the peripheral portions of the nozzle will be only partially ablated through. By increasing the density of dots toward the periphery of each mask opening, the resulting nozzle may be formed to have any tapered shape. Other mask patterns are also described.

Abstract: In one of the preferred embodiments, an inkjet printhead includes a nozzle member formed of a polymer material that has been laser-ablated to form inkjet orifices, ink channels, and vaporization chambers in the unitary nozzle member. The nozzle member is then mounted to a substrate containing heating elements associated with each orifice. In a preferred method, the orifices, ink channels, and vaporization chambers are formed using an Excimer laser.

Abstract: A method is provided for assembling thermal ink-jet printheads. The method comprises: (a) providing a circuit layout comprising a first substrate, a plurality of conductive traces thereon in a pre-selected pattern, and a plurality of openings through the substrate defining ink-jet nozzles; (b) providing a die layout comprising (1) a plurality of resistors, each resistor formed on a second substrate and matched to an opening and (2) a plurality of channels formed in a barrier material and matched to a portion of the plurality of conductive traces; (c) interlocking plurality of conductive traces with the plurality of channels to align each resistor with a respective one of the openings; and (d) laminating those portions of the first substrate that contact the barrier to the barrier so as to bond the two layouts together. In one embodiment, the resistors are each formed in a well defined in a layer of the barrier material already on the substrate, which is extended to encompass the resistors.