EP0231790A2 - Process for fabricating laminated structures of improved structural integrity - Google Patents
Process for fabricating laminated structures of improved structural integrity Download PDFInfo
- Publication number
- EP0231790A2 EP0231790A2 EP87100520A EP87100520A EP0231790A2 EP 0231790 A2 EP0231790 A2 EP 0231790A2 EP 87100520 A EP87100520 A EP 87100520A EP 87100520 A EP87100520 A EP 87100520A EP 0231790 A2 EP0231790 A2 EP 0231790A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- pressure
- orifice plate
- substrate
- bonding
- heat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000000034 method Methods 0.000 title claims abstract description 14
- 239000000758 substrate Substances 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims abstract description 17
- 239000011888 foil Substances 0.000 claims abstract description 6
- 239000010409 thin film Substances 0.000 claims abstract description 6
- 230000002706 hydrostatic effect Effects 0.000 claims abstract description 3
- 229920000642 polymer Polymers 0.000 claims abstract description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 11
- 229910052710 silicon Inorganic materials 0.000 claims description 11
- 239000010703 silicon Substances 0.000 claims description 11
- 238000004026 adhesive bonding Methods 0.000 claims description 4
- 239000012790 adhesive layer Substances 0.000 claims 4
- 239000010410 layer Substances 0.000 claims 3
- 239000007788 liquid Substances 0.000 claims 2
- 239000002998 adhesive polymer Substances 0.000 abstract 2
- 230000005540 biological transmission Effects 0.000 abstract 1
- 239000000853 adhesive Substances 0.000 description 11
- 230000001070 adhesive effect Effects 0.000 description 11
- 239000002131 composite material Substances 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004065 semiconductor Substances 0.000 description 2
- 238000003855 Adhesive Lamination Methods 0.000 description 1
- 208000036366 Sensation of pressure Diseases 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000000593 degrading effect Effects 0.000 description 1
- 238000007641 inkjet printing Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000001029 thermal curing Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
- B41J2/135—Nozzles
- B41J2/16—Production of nozzles
- B41J2/1601—Production of bubble jet print heads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
- B41J2/135—Nozzles
- B41J2/16—Production of nozzles
- B41J2/1621—Manufacturing processes
- B41J2/1623—Manufacturing processes bonding and adhesion
Definitions
- the metal nozzle plate 12 is bonded to the underlying silicon substrate 10 by means of an ultraviolet-cured polymer 14 shown in Figure 1b and known generically as a parafilm.
- This parafilm is sold by the DuPont Company of Wilmington, Delaware under the tradename VACREL.
- VACREL The VACREL layer 14 will undergo thermal curing by the application of heat and pressure thereto in a manner to be further described.
- a pressure equalizing composite member 16 is placed on the upper surface of the nozzle plate 12 and includes a pair of outer aluminum foil layers 18 and 20 between which is encapsulated an uncured VACREL or parafilm material 22.
- This parafilm material 22 will liquefy when brought to a predetermined elevated temperature of about 115° - 120°C.
- the pressure equalizing composite structure 16 has also been referred to as a "waterbed sandwich" in that the liquefiable material 22 will conform to the contours of and pressures on the materials 10 and 12 being bonded together.
- FIG. 2a an adhesive failure where the VACREL adhesive is torn away from the nozzle plate.
- Figure 2b the VACREL adhesive is torn away from the underlying silicon substrate
- Figure 2c there is shown a mixed mode failure where the VACREL is torn partially away from the nozzle plate and partially away from the underlying silicon substrate.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Particle Formation And Scattering Control In Inkjet Printers (AREA)
Abstract
Description
- This invention relates generally to the fabrication of laminated structures having improved structural properties especially useful in thermal ink jet print heads. More particularly, the invention is directed to increasing the adhesive forces which bond together adjacent laminated layers without degrading portions of the laminated structure during the process.
- In certain arts such as the manufacture of printheads for thermal ink jet printers, diverse materials are often bonded together in the formation of a unitary composite structure. In such bonding processes, a chosen adhesive material is frequently provided between adjacent layers and thereafter subjected to a predetermined heat and pressure for a time sufficient to produce a good adhesive bond between these layers. An example of such construction is in the fabrication of a thin film resistor thermal ink jet print head where typically a metal orifice plate is adhesively bonded atop a silicon substrate including thermal heater resistors and corresponding ink reservoirs. However, it quite often happens that non-uniform surface irregularities and contours exist on the facing surfaces between which the adhesive is thermal compression bonded. These irregularities and contours may also exist on the surface of the top layer in contact with a member for applying heat and pressure and known in the art as a "heat staker". When such non-uniform surface irregularities and contours are brought together under predetermined conditions of heat and pressure, there are produced corresponding variations in pressure and temperature across the surface areas of the laminated layers. These pressure variations result in weak spots in the cured laminated structure and consequently result in undesirable failures of the laminated structures under conditions of actual use.
- Accordingly, it is an object of this invention to provide a new and improved process for fabricating laminated structures wherein the above problem of adhesion variation with surface contour variation has been substantially eliminated. This object is accomplished by the provision of a pressure equalizing member between the structure undergoing adhesive bonding and lamination and the heat and pressure applicator ("heat staker") therefor. The pressure equalizing member comprises a pair of thin outer flexible foil layers between which is located a liquifiable material of a chosen volume. The liquifiable material is wholly contained within the confines of the pair of thin outer flexible foil layers which are effectively sealed around their outer edges by the unmelted region of the liquifiable material.
- When two adjacent members, such as a thin film resistor semiconductor substrate and a metal orifice plate of the laminated device being constructed are to be adhesively bonded, they are covered with the pressure equalizing member which then is positioned to receive the heat staker on one surface thereof. Upon receiving heat and pressure from the heat staker, the material within the thin flexible foil layers of the pressure equalizing member will liquify and provide a hydrostatic force on the lower flexible layer thereof which then conforms, for example, to the irregular surface contours of the orifice plate and transmits equal pressure over the entire surface area of the laminated structure. Thus, the pressure applied to the adhesive bond is applied with substantial uniformity laterally across the laminated surfaces as compared with known prior art processes. Thus, this invention is capable of producing a composite laminated structure with greater bonding adherence strength.
- The significant advance provided by the present invention will be better understood with reference to the following description of the accompanying drawings.
-
- Figures 1a through 1e are schematic cross-sectional views illustrating the laminating and adhesive bonding process according to the present invention.
- Figures 2a - 2d illustrate various modes of adhesive failure including the cohesive adhesive failure mode in accordance with the present invention.
- Referring now to Figures 1a through 1e, there is shown in Figure 1a a thin film
resistor silicon substrate 10 which will typically provide a support for the ink reservoirs and thermal heater resistors (not shown) of well-known semiconductor device construction for use in a thermal ink jet printer. Each of the resistors and reservoirs (not shown) are associated with nozzle patterns in anozzle plate 12, and thenozzle plate 12, typically fabricated of nickel, as well as thesilicon substrate 10 are generally well-known in the thermal ink jet printing art and will not be described herein in further detail. However, for reference to a thin film resistor print head construction including a description of the various layer materials used therein, reference may be made to the Hewlett Packard Journal, Volume 36, Number 5, May 1985, incorporated herein by reference. This type of printhead construction is also described in U.S. Patent 4,535,343 issued to Conrad L. Wright et al and assigned to the present assignee and also incorporated herein by reference. - The
metal nozzle plate 12 is bonded to theunderlying silicon substrate 10 by means of an ultraviolet-curedpolymer 14 shown in Figure 1b and known generically as a parafilm. This parafilm is sold by the DuPont Company of Wilmington, Delaware under the tradename VACREL. The VACRELlayer 14 will undergo thermal curing by the application of heat and pressure thereto in a manner to be further described. - With the
nozzle plate 12 positioned in place as shown in Figure 1c, a pressure equalizingcomposite member 16 is placed on the upper surface of thenozzle plate 12 and includes a pair of outeraluminum foil layers parafilm material 22. Thisparafilm material 22 will liquefy when brought to a predetermined elevated temperature of about 115° - 120°C. The pressure equalizingcomposite structure 16 has also been referred to as a "waterbed sandwich" in that theliquefiable material 22 will conform to the contours of and pressures on thematerials - This thermal compression bonding is accomplished by first placing the
silicon substrate 10 on asteel holder 24 as shown in Figure 1e. In operation, the heat stakertop element 30 is brought into contact with thecomposite structure 16 under predetermined conditions of heat and pressure and for a time sufficient to provide thermal compression bonding of the VACRELlayer 14 between thenozzle plate 12 and theunderlying silicon substrate 10. We have found that a pressure in the range of 200 - 225 psi applied for between 15 - 20 seconds at a temperature between 115° - 120°C works exceptionally well in practicing this invention. However, the pressure range may if necessary be extended to 20 to 2000 psi, the time extended from 5 to 60 seconds and the temperature extended from 90°C to 160°C. - Referring now to figures 2a - 2d, there is shown in Figure 2a an adhesive failure where the VACREL adhesive is torn away from the nozzle plate. In Figure 2b the VACREL adhesive is torn away from the underlying silicon substrate, and in Figure 2c there is shown a mixed mode failure where the VACREL is torn partially away from the nozzle plate and partially away from the underlying silicon substrate.
- However, in Figure 2d there is shown the optimum and desired cohesive failure of the VACREL made possible by this invention. Here the VACREL is torn from neither the nozzle plate nor the underlying silicon substrate, but rather becomes torn internally across the lateral dimension of the adhesive, indicating the strongest bond possible using this type of adhesive bonding.
- Various modifications may be made in the above described embodiment without departing from the scope of this invention. For example, this invention is not limited to the lamination of printhead devices or to the specific number of layer-members being laminated.
Claims (6)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US82433586A | 1986-01-30 | 1986-01-30 | |
US824335 | 1986-01-30 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0231790A2 true EP0231790A2 (en) | 1987-08-12 |
EP0231790A3 EP0231790A3 (en) | 1989-06-14 |
Family
ID=25241122
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP87100520A Withdrawn EP0231790A3 (en) | 1986-01-30 | 1987-01-16 | Process for fabricating laminated structures of improved structural integrity |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP0231790A3 (en) |
JP (1) | JPH0794165B2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0389738A2 (en) * | 1989-03-27 | 1990-10-03 | Hewlett-Packard Company | Printhead performance tuning via ink viscosity adjustment |
EP0521517A2 (en) * | 1991-07-05 | 1993-01-07 | Canon Kabushiki Kaisha | Ink jet recording head, process for producing the head and ink jet recording apparatus |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2430015B2 (en) * | 1974-06-22 | 1977-08-11 | Th. Goldschmidt Ag, 4300 Essen | PROCESS FOR SURFACE FINISHING OF FLAT MATERIALS WITH ACHIEVING A SURFACE STRUCTURE |
DE2627442A1 (en) * | 1976-06-18 | 1977-12-29 | Becker & Van Huellen | Heating plate press contg. press pad - of synthetic and/or inorganic random fibre web coated with silicone rubber |
DE3150109A1 (en) * | 1980-12-18 | 1982-07-15 | Canon K.K., Tokyo | INK BEAM HEAD |
DE3222874A1 (en) * | 1981-06-18 | 1982-12-30 | Canon K.K., Tokyo | COLOR BEAM HEAD AND METHOD FOR THE PRODUCTION THEREOF |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS533475A (en) * | 1976-06-30 | 1978-01-13 | Dantani Plywood Co | Method of manufacture of decorative plate consisted of plate provided with overrlayer of synthetic resin film |
DE2724056C3 (en) * | 1977-05-27 | 1979-11-22 | Fa. Carl Freudenberg, 6940 Weinheim | Compensation plate for a vulcanizing press or similar presses |
JPS5923693B2 (en) * | 1980-12-08 | 1984-06-04 | 日立化成工業株式会社 | Molding method for laminate products |
JPS5871107A (en) * | 1981-10-23 | 1983-04-27 | 松下電工株式会社 | Manufacture of decorative plywood |
-
1987
- 1987-01-16 EP EP87100520A patent/EP0231790A3/en not_active Withdrawn
- 1987-01-29 JP JP62019598A patent/JPH0794165B2/en not_active Expired - Lifetime
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE2430015B2 (en) * | 1974-06-22 | 1977-08-11 | Th. Goldschmidt Ag, 4300 Essen | PROCESS FOR SURFACE FINISHING OF FLAT MATERIALS WITH ACHIEVING A SURFACE STRUCTURE |
DE2627442A1 (en) * | 1976-06-18 | 1977-12-29 | Becker & Van Huellen | Heating plate press contg. press pad - of synthetic and/or inorganic random fibre web coated with silicone rubber |
DE3150109A1 (en) * | 1980-12-18 | 1982-07-15 | Canon K.K., Tokyo | INK BEAM HEAD |
DE3222874A1 (en) * | 1981-06-18 | 1982-12-30 | Canon K.K., Tokyo | COLOR BEAM HEAD AND METHOD FOR THE PRODUCTION THEREOF |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0389738A2 (en) * | 1989-03-27 | 1990-10-03 | Hewlett-Packard Company | Printhead performance tuning via ink viscosity adjustment |
EP0389738A3 (en) * | 1989-03-27 | 1991-01-09 | Hewlett-Packard Company | Printhead performance tuning via ink viscosity adjustment |
EP0521517A2 (en) * | 1991-07-05 | 1993-01-07 | Canon Kabushiki Kaisha | Ink jet recording head, process for producing the head and ink jet recording apparatus |
EP0521517A3 (en) * | 1991-07-05 | 1993-06-02 | Canon Kabushiki Kaisha | Ink jet recording head, process for producing the head and ink jet recording apparatus |
US5436650A (en) * | 1991-07-05 | 1995-07-25 | Canon Kabushiki Kaisha | Ink jet recording head, process for producing the head and ink jet recording apparatus |
Also Published As
Publication number | Publication date |
---|---|
EP0231790A3 (en) | 1989-06-14 |
JPH0794165B2 (en) | 1995-10-11 |
JPS62181148A (en) | 1987-08-08 |
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18D | Application deemed to be withdrawn |
Effective date: 19890801 |
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RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: STEINFIELD, STEVEN W. Inventor name: CHILDERS, WINTHROP D. |