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: 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: An ink-jet pen for storing at below-ambient pressure has an orifice formed therein for providing air bubbles to prevent the back pressure from rising above a level that would cause malfunction of the pen. The amount of air drawn into the reservoir is restricted by the reservoir ink that covers the orifice whenever the pen is in an upright position. The valve operates to occlude the orifice whenever the pen is moved into a position, such as inverted, where the reservoir ink no longer covers the orifice. The occlusion of the orifice prevents the unrestricted flow of ambient air into the reservoir that would otherwise eliminate the required back pressure in the reservoir. The valve includes a sealing liquid selected so that the liquid occludes a passage between the orifice and ambient air without flowing through that passage.

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 tapered inkjet orifices. The nozzle member is then mounted to a substrate containing heating elements, each heating element being associated with a single orifice. In a preferred method, the orifices are formed by Excimer laser ablation.In other aspects of the invention, vaporization chambers as well as ink channels, providing fluid communication between an ink reservoir and the orifices, are also formed by Excimer laser ablation.

Abstract: A novel, nozzle member for an inkjet print cartridge and method of forming the nozzle member are disclosed. In this method, the nozzles or orifices are formed in a flexible polymer tape by Excimer laser ablation. In one embodiment, a substrate containing heating elements is mounted on the back of the nozzle member. Conductors for providing electrical signals to the substrate are located inside the flexible polymer tape and end at a via overlying an associated electrode on the substrate. The via electrically connects the conductors to the associated electrode.

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: 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 method for continuously manufacturing parts requiring precision micro-fabrication. According to the method, a surface of a mandrel having a reusable pattern thereon is moved through an electroforming bath. While the mandrel surface moves through the bath, a metal layer is deposited on the mandrel surface to define a pattern. After the metal layer has been deposited to the selected thickness, the metal layer is separated from the mandrel surface.

Abstract: An orifice plate for an ink jet printhead wherein a plurality of elongated isolator slots are adjacent the orifices and in fluid communication therewith, so as to prevent cross-talk between adjacent orifices.

Abstract: An orifice plate is provided of an electroformed material which incorporates an integral ink distribution manifold and integral hydraulic separators between orifices. The general approach to the method of making the orifice plate is to first construct a two-part mandrel made up of a "hard" mandrel which can be reused many times and a "soft" mandrel which is renewed each time the mandrel is used. Typically, the surface of the "hard" mandrel is configured by mask and etch techniques, or by mask and electroplate techniques to define the ink distribution manifold and the hydraulic separators, while the "soft" mandrel is configured by mask and develop techniques to define the orifices and edges between orifice plates. Upon completion of the mandrel, its surface is electroplated with a relatively uniform thickness of metal, and the newly electroplated surface having the orifice plates patterned therein is separated from the mandrel.

Abstract: A method of making a monolithic bubble-driven ink jet print head is provided which eliminates the need for using glue or other adhesives to construct multiple part assemblies. The concept of the method is to provide a layered structure which can be manufactured by relatively standard integrated circuit and printed circuit processing techniques. First, a substrate/resistor combination is manufactured. Then a foundation of conductive material is firmly attached to the substrate and a resist layer is used to define a perimeter/wall combination over the foundation, with the perimeter/wall combination surrounding the resistors and providing hydraulic separation between them. The perimeter/wall combination is then electroplated in place. A flash coat of metal is applied over the resist which is inside the perimeter of the perimeter/wall combination and a second layer of resist is used to define the desired orifices and the external shape of the part.