EP0498292B1 - Integrally formed bubblejet print device - Google Patents
Integrally formed bubblejet print device Download PDFInfo
- Publication number
- EP0498292B1 EP0498292B1 EP92101475A EP92101475A EP0498292B1 EP 0498292 B1 EP0498292 B1 EP 0498292B1 EP 92101475 A EP92101475 A EP 92101475A EP 92101475 A EP92101475 A EP 92101475A EP 0498292 B1 EP0498292 B1 EP 0498292B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- nozzle
- heater
- ink
- chip
- zbj
- 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.)
- Expired - Lifetime
Links
- 238000000034 method Methods 0.000 claims abstract description 69
- 239000000758 substrate Substances 0.000 claims abstract description 56
- 238000004519 manufacturing process Methods 0.000 claims abstract description 31
- 239000004065 semiconductor Substances 0.000 claims abstract description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 36
- 229910052710 silicon Inorganic materials 0.000 claims description 36
- 239000010703 silicon Substances 0.000 claims description 36
- 230000017525 heat dissipation Effects 0.000 claims description 15
- 238000007639 printing Methods 0.000 abstract description 15
- 230000015572 biosynthetic process Effects 0.000 abstract description 12
- 238000003491 array Methods 0.000 abstract description 6
- 238000010438 heat treatment Methods 0.000 abstract description 6
- 235000012431 wafers Nutrition 0.000 description 88
- 239000010410 layer Substances 0.000 description 54
- 229910052751 metal Inorganic materials 0.000 description 44
- 239000002184 metal Substances 0.000 description 44
- 239000011521 glass Substances 0.000 description 43
- 230000008569 process Effects 0.000 description 37
- 238000005530 etching Methods 0.000 description 35
- 239000004411 aluminium Substances 0.000 description 20
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 20
- 229910052782 aluminium Inorganic materials 0.000 description 20
- 229910021420 polycrystalline silicon Inorganic materials 0.000 description 20
- 229920005591 polysilicon Polymers 0.000 description 20
- 238000001020 plasma etching Methods 0.000 description 16
- 229910003862 HfB2 Inorganic materials 0.000 description 15
- 238000013461 design Methods 0.000 description 15
- 238000012545 processing Methods 0.000 description 15
- 238000001125 extrusion Methods 0.000 description 13
- 239000007943 implant Substances 0.000 description 13
- 150000002500 ions Chemical class 0.000 description 13
- 238000009792 diffusion process Methods 0.000 description 12
- 238000002161 passivation Methods 0.000 description 12
- 238000010276 construction Methods 0.000 description 11
- 238000005755 formation reaction Methods 0.000 description 11
- 229910052581 Si3N4 Inorganic materials 0.000 description 9
- 230000008901 benefit Effects 0.000 description 9
- 238000001816 cooling Methods 0.000 description 9
- 239000002245 particle Substances 0.000 description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 9
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 9
- 229910052715 tantalum Inorganic materials 0.000 description 9
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 9
- 229910052785 arsenic Inorganic materials 0.000 description 8
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 8
- 239000007788 liquid Substances 0.000 description 8
- 230000005499 meniscus Effects 0.000 description 8
- 230000002441 reversible effect Effects 0.000 description 8
- 239000000523 sample Substances 0.000 description 8
- 239000002918 waste heat Substances 0.000 description 8
- 239000004593 Epoxy Substances 0.000 description 7
- 230000009471 action Effects 0.000 description 7
- 230000008878 coupling Effects 0.000 description 7
- 238000010168 coupling process Methods 0.000 description 7
- 238000005859 coupling reaction Methods 0.000 description 7
- 238000011161 development Methods 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 230000037452 priming Effects 0.000 description 7
- 101100269850 Caenorhabditis elegans mask-1 gene Proteins 0.000 description 6
- 239000003086 colorant Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 150000004767 nitrides Chemical class 0.000 description 6
- 230000009467 reduction Effects 0.000 description 6
- VZGDMQKNWNREIO-UHFFFAOYSA-N tetrachloromethane Chemical compound ClC(Cl)(Cl)Cl VZGDMQKNWNREIO-UHFFFAOYSA-N 0.000 description 6
- 238000000151 deposition Methods 0.000 description 5
- 238000011049 filling Methods 0.000 description 5
- 238000004528 spin coating Methods 0.000 description 5
- 238000005229 chemical vapour deposition Methods 0.000 description 4
- 238000011109 contamination Methods 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- 229910052796 boron Inorganic materials 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 238000010304 firing Methods 0.000 description 3
- 238000003384 imaging method Methods 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 239000012528 membrane Substances 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- 238000009835 boiling Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 230000001186 cumulative effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000002513 implantation Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- LRTTZMZPZHBOPO-UHFFFAOYSA-N [B].[B].[Hf] Chemical compound [B].[B].[Hf] LRTTZMZPZHBOPO-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000012993 chemical processing Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 238000013016 damping Methods 0.000 description 1
- 238000012217 deletion Methods 0.000 description 1
- 230000037430 deletion Effects 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000007496 glass forming Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 238000001459 lithography Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 230000000873 masking effect Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012544 monitoring process Methods 0.000 description 1
- VXAPDXVBDZRZKP-UHFFFAOYSA-N nitric acid phosphoric acid Chemical compound O[N+]([O-])=O.OP(O)(O)=O VXAPDXVBDZRZKP-UHFFFAOYSA-N 0.000 description 1
- 238000000206 photolithography Methods 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000003134 recirculating effect Effects 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000004611 spectroscopical analysis Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000012876 topography Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 230000007723 transport mechanism Effects 0.000 description 1
- 238000010407 vacuum cleaning Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 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
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2/14016—Structure of bubble jet print heads
- B41J2/14032—Structure of the pressure chamber
- B41J2/1404—Geometrical characteristics
-
- 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
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2/14016—Structure of bubble jet print heads
- B41J2/14032—Structure of the pressure chamber
- B41J2/14056—Plural heating elements per ink chamber
-
- 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
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2/14016—Structure of bubble jet print heads
- B41J2/14088—Structure of heating means
- B41J2/14112—Resistive element
- B41J2/14137—Resistor surrounding the nozzle opening
-
- 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
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2/14016—Structure of bubble jet print heads
- B41J2/14145—Structure of the manifold
-
- 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
- B41J2/1603—Production of bubble jet print heads of the front shooter type
-
- 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
-
- 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
- B41J2/1626—Manufacturing processes etching
- B41J2/1628—Manufacturing processes etching dry etching
-
- 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
- B41J2/1626—Manufacturing processes etching
- B41J2/1629—Manufacturing processes etching wet etching
-
- 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
- B41J2/1631—Manufacturing processes photolithography
-
- 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
- B41J2/1632—Manufacturing processes machining
-
- 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
- B41J2/1635—Manufacturing processes dividing the wafer into individual chips
-
- 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
- B41J2/164—Manufacturing processes thin film formation
- B41J2/1642—Manufacturing processes thin film formation thin film formation by CVD [chemical vapor deposition]
-
- 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
- B41J2/164—Manufacturing processes thin film formation
- B41J2/1643—Manufacturing processes thin film formation thin film formation by plating
-
- 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
- B41J2/164—Manufacturing processes thin film formation
- B41J2/1645—Manufacturing processes thin film formation thin film formation by spincoating
-
- 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
- B41J2/17—Ink jet characterised by ink handling
- B41J2/175—Ink supply systems ; Circuit parts therefor
- B41J2/17563—Ink filters
-
- 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
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2002/1437—Back shooter
-
- 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
- B41J2202/00—Embodiments of or processes related to ink-jet or thermal heads
- B41J2202/01—Embodiments of or processes related to ink-jet heads
- B41J2202/11—Embodiments of or processes related to ink-jet heads characterised by specific geometrical characteristics
-
- 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
- B41J2202/00—Embodiments of or processes related to ink-jet or thermal heads
- B41J2202/01—Embodiments of or processes related to ink-jet heads
- B41J2202/13—Heads having an integrated circuit
Definitions
- the present invention relates a method of fabricating a bubblejet print device using semiconductor fabrication techniques, according to claim 1.
- Bubblejet print heads are known in the art and have recently become available commercially as portable, relatively low-cost printers generally used with personal computers. Examples of such devices are those made by HEWLETT-PACKARD as well as the CANON BJ10 printer.
- Figs. 1 and 2 show schematic perspective views of prior art bubblejet print heads representative of those used by CANON and HEWLETT-PACKARD, respectively.
- the prior art bubblejet (BJ) head 1 is formed by a BJ semiconductor chip device 2 abutting a laser etched cap 3.
- the cap 3 acts as a guide for the inward flow of ink (indicated in the drawing by arrows) into the head 1 via an inlet 4, and the outward ejection of the ink from the head 1 via a plurality of nozzles 5.
- the nozzles 5 are formed as the open ends of channels in the cap 3.
- On the BJ chip 2 are arranged one or more (generally 64) heater elements (not shown) which are energized so as to cause ink to be ejected from each of the nozzles 5 by a bubble of vapourised ink formed within the corresponding channel.
- the BJ chip 2 also includes a semiconductor diode matrix (not illustrated) which acts to supply energy to the heater elements arranged adjacent the channels.
- HEWLETT-PACKARD thermal ink jet head 10 as seen in Fig. 2, a two part configuration is also used, however ink enters the cap 12 through an inlet 13 arranged in the side of the cap 12 which supplies an array of nozzles 14 arranged perpendicular to the inlet 13. Ink exits through the face of the cap 12. A flat heater 15 is arranged immediately beneath each nozzle 14 so as to cause ejection of ink from the inlet channel 13 into the nozzles.
- JP-A-60-8076 discloses a bubble jet print device comprising heating resistors and electrical connections to the heating resistors, both being formed on a substrate. Nozzles are formed through the substrate, wherein one end of each nozzle is disposed adjacent to the respective heating resistor, and the other end of each nozzle forms an outlet for ejecting ink.
- the substrate is directly connected to an ink box and the nozzles are erected when not in use, so that no ink is left in the nozzles and no blocking of the nozzles occurs.
- the EP-A-0 339 926 discloses a drop-on-demand ink drop jet printhead comprising layers of like print modules of which adjacent layers are equally laterally offset.
- the modules are formed each with a row of parallel equally spaced ink drop ejectors in form of piezo-electrical transducers arranged in one or more groups.
- the ejector groups in each layer are laterally spaced by the same amount and corresponding segments of the groups in different layers are together capable of depositing drops of ink in a particular segment of the print line at a density equal to the product of the drop density capability of each group and the number of groups having segments corresponding to the associated print line segment.
- the EP-A-0 352 726 discloses a liquid-jet recording head comprising a substrate on which a plurality of energy-generating elements is disposed, and a cover plate covering the substrate.
- the substrate and the cover plate together define a liquid chamber as well as liquid paths each communicating the liquid chamber with a corresponding ejecting outlet.
- the liquid paths are provided in correspondence with the energy-generating elements.
- the object of the present invention is to provide a bubblejet print device which is capable of printing images of high image density in high quality.
- the method of fabricating a bubblejet print device comprises the steps of providing a substrate member having a heater means, electrodes electrically connected to the heater means, and an overcoat for protecting the heater means, forming a first hole into the substrate member adjacent to the heater means from one side on which the overcoat is provided, forming a second hole into the substrate member from the other side, the second hole being communicated with the first hole, thereby forming a passageway through the substrate member.
- a Z-Axis bubble jet chip (ZBJ chip) is used to describe a chip lying in the x y plane in which ink flows both into and out of the chip in the z direction.
- a Z-axis bubblejet (ZBJ) chip 40 which includes an ink inlet arranged on one (underside as illustrated) plane surface of the chip 40, and a plurality of nozzles 41 which provide for outlets of ink on the opposite side. It is readily apparent from a direct comparison of Figs. 1 and 2 with Fig. 3 that the ZBJ chip 40 has a single, monolithic, integrally formed structure as opposed to the two part structure of the prior art.
- the chip 40 is formed using semiconductor fabrication techniques. Furthermore, ink is ejected from the nozzles 41 in the same direction in which ink is supplied to the chip 40.
- a cross-section of a first embodiment of a stationary (i.e. non-moving) ZBJ printhead 50 is shown which is configured for the production of full length A4 continuous tone colour images at an image density of 1600 dpi or 400 pixels per inch.
- the head 50 is provided with a ZBJ chip 70 having four nozzle arrays, one for each of cyan 71, magenta 72, yellow 73 and black 74.
- the nozzle arrays 71-74 are formed from nozzle vias 77 with four nozzles per pixel giving a total of 51,200 nozzles per chip 70.
- FIG. 4 shows the basic nozzle cross-section which is formed in a silicon substrate 76 over which a layer 78 of thermal Si0 2 is formed.
- a heater element 79 is provided about the nozzle 77, which is capped by an overcoat layer 80 of chemical vapour deposited (CVD) glass.
- CVD chemical vapour deposited
- Each of the nozzles 77 communicates with a common ink supply channel 75 for that particular colour of ink.
- the ZBJ chip 70 is positionable upon a channel extrusion 60 which has ink channels 61 communicating with the channels 75 so as to provide for a continuous flow of ink to the chip 70.
- a membrane filter 54 is provided between the extrusion 60 and the chip 70.
- Two power bus bars 51 and 52 are provided which electrically connect to the chip 70.
- the bus bars 51 and 52 also act as heat sinks for the dissipation of heat from the chip 70.
- Fig. 5 shows a second embodiment of a ZBJ head 200 similar in configuration to that shown in Fig. 4.
- the head 200 has a ZBJ chip 100 including nozzle arrays 102, 103, 104 and 105 for each of cyan, magenta, yellow and black, respectively.
- the chip 100 has ink channels 101 which communicate with ink reservoirs 211, 212, 213 and 214, respectively for the above colours, in a channel extrusion 210.
- the channel extrusion 210 has an alternate geometry of higher volumetric capacity than that shown in Fig. 4 for the same size of the chip 100. Also illustrated are tab connections 203 and 204 which connect the power bus bars 201 and 202 to the chip 100. A membrane filter 205 is also provided as before.
- the head 200 is required to be about 220 mm long, by 15 mm across, by 9 mm deep. Using the foregoing as a standard arrangement, many configurations of ZBJ heads are possible. The actual size and the number of nozzles per chip depend solely on the required performance of the printer application.
- Table 1 lists seven applications of ZBJ printheads and the various requirements for each application considered necessary.
- Application one is considered suitable for low cost full colour printers, portable computers, low cost colour copiers and electronic still photography.
- Application two is considered suitable for personal printers, and personal computers, whilst application three is useful in electronic still photography, video printers and workstation printers.
- the fourth application finds use in colour copiers, full colour printers, colour desktop publishing and colour facsimile.
- the fifth application is for a monochrome device which sees application in digital black and white copiers, high resolution printers, portable computers, and plain paper facsimiles.
- Applications six and seven show respectively high speed and medium speed A3 continuous tone applications useful in colour copiers and colour desktop publishing.
- the high speed version of application six finds use in small run commercial printing and the medium speed version in colour facsimile.
- the ZBJ chip 100 has four nozzle arrays 102-105, each comprising four rows of nozzle vias 110 (Figs. 6-9).
- the nozzle vias 110 are formed by etching through a substrate 130 of the chip 100.
- the substrate 130 is generally about 500 microns deep and, depending on the required application, can be 220 mm long by 4 mm wide.
- Figs. 6 to 9 illustrate the etching of the nozzle vias 110 through the substrate 130. So that the ZBJ chip 100 can eject a drop of 3 pl, it is necessary for the diameter of each nozzle 110 to be approximately 20 microns.
- a four stage process is used commencing with a 500 micron deep substrate 300 having an overlying glass (SiO 2 ) layer 142 enclosing a heater 120 within as seen in Fig. 5.
- the step as seen in Fig. 6 is a plasma etch of a 20 micron straight-walled round hole, through the glass overcoat 142 and at least 10 microns into the substrate 130. This forms the nozzle tip 111.
- the next step as seen in Fig. 7 requires the etching of a large channel (approximately 100 microns wide by 300 microns deep) in the rear of the chip 100. This forms nozzle channels 114 that supply ink flow to the nozzles 110.
- the next step, as seen in Fig. 8, is to print nozzle barrel patterns at the bottom of the channels 114 formed in Fig. 7.
- the nozzle barrels 113 are approximately 40 microns in diameter and are plasma etched to within 10 microns of the front of the chip 100. As the isotropic plasma etch is relatively non-selective, this method cannot be used to etch the entire cavity without also etching through, and destroying the heater 120.
- an isotropic etch is used on the wall exposed silicon to a depth of 10 microns from the front of the chip 100.
- This step acts to widen the nozzles 110 and undercut the Si02 layer 142 containing the heater 120.
- This step forms the nozzle cavity 112.
- the step also ensures that the tip 111 joins the barrel 113 without risking plasma etched damage to the heater 120.
- the front to back surface etching should be aligned to better than 10 microns and the etch depth control should also be better than 10 microns.
- the complete nozzle via 110 is formed including its tip 111, cavity 112, barrel 113 and channel 114.
- the formation of the nozzle tip 11, the nozzle cavity 112 which acts as a thermal chamber, the nozzle barrel 113 and the nozzle channel 114 creates a passageway for the flow of ink through the substrate 100 for ejection.
- the thermal chamber 115 which surrounds the nozzle tip 111 is arranged as a cylinder, with the heater 120 deposited in the walls of the cylinder.
- This arrangement has several disadvantages, including:
- the thermal chamber 115 is arranged as a cone. This is to allow the heater 120 to be etched to increase its resistance. This arrangement has the following difficulties:
- Fig. 12 shows a quasi-hemispherical chamber in which the heater 120 is formed on a frusto-conical section which faces into a substantially hemispherical chamber.
- Figs. 13 to 18 show six preferred nozzle structures which permit monolithic construction, a small drop size of 3 picolitres thus permitting 1600 dpi printing, a fault tolerant heater design, a nozzle spacing anywhere on the surface of the substrate, and the use in multi-colour print devices.
- Fig. 13 illustrates a substantially hemispherical thermal chamber 115 which is formed by applying an undercutting isotropic plasma etch of silicon before reactive ion etching (RIE) of the nozzle barrel 113.
- RIE reactive ion etching
- This configuration is characterised by a reverse action in which the formation of the bubble 116 is in the direction opposite to the ejection of the ink drop 108.
- the thermal shunt 140 conducts heat away from the nozzle area into the substrate 130 to reduce the time taken for the thermal chamber 115 to cool sufficiently prior to the ejection of the next ink drop 108.
- This configuration has advantages of planar construction of the heater 120 whereby accurate control of the heater shape and size can be achieved. Also, the thermal coupling between the heater 120 and the ink is significant, because the heater 120 is isolated from the ink by the thermal SiO2 layer 132 which is more thermally conductive than CVD glass. Also, this layer can be manufactured thinner than a corresponding layer of CVD glass, as it is not prone to pinholes. Depending on the slope of the barrel 113 as it enters the thermal chamber 115, and the contact angle of the ink with a passivation layer, this nozzle geometry will permit automatic filling by capillary action.
- Fig. 14 is similar to the configuration of Fig. 13 except that in this geometry, the direction of flow of ink 106 through the chip 100 is reversed, giving a reversed nozzle arrangement in which bubble formation is in the same direction as ink drop ejection.
- ink 106 enters the nozzle passageway through an aperture 484 and a meniscus 107 is formed at the nozzle tip 486 boundary between the barrel 487 and the channel 489. Formation of bubbles 116 acts to expel an ink drop 108 through the channel 489 and onto a medium such as paper 220.
- the configuration of the reverse nozzle arrangement differs in one significant way from the earlier configurations described.
- the earlier configurations e.g. Fig. 13
- a thermal shunt 140 which acts to shunt heat away from the heater 120 and into the substrate 130.
- immediately adjacent the heaters 120 is an underlying reservoir of ink 106.
- a thermal diffuser 491 is used to increase the area of heat transport from the heater 120 through the overcoat 142 and into the ink 106 reservoir.
- heat conductive path is much shorter than that of Fig. 13, greater heat dissipation can be achieved.
- heat dissipation can be further enhanced by re-circulating the ink 106 through a heat exchanger using a supply pump (not illustrated).
- This configuration has the advantages of planar construction, good thermal coupling and heat dissipation. Also, bubble direction is in the direction of ink ejection which reduces kinetic losses.
- a disadvantage of this configuration is that the nozzle is not self priming, and must be initially primed using positive pressure. Once primed, the shrinking bubble will draw ink into the thermal chamber 488 after the drop 108 has been fired. Also, the cantilevered section supporting the heaters 120 must be sufficiently thick to withstand the shock from collapsing bubbles 116.
- a nozzle arrangement which includes a trench implanted heater 493.
- the nozzle cavity 112 is formed as a straight cylinder communicating with the nozzle barrel 113 and the optionally etched nozzle channel 114.
- An annular trench 492 is etched into the silicon, and a layer of SiO2 is grown adjacent and about the nozzle cavity 112.
- the annular heater 493 is plated on the trench 492 which acts to form vapourised bubbles 116 which expand across the cavity 112 transverse the direction of drop ejection. Advantages of this configuration include good thermal coupling and self-priming.
- Disadvantages include poor heat dissipation because liquid cooling by forced ink flow is not effective as the bulk of the ink is isolated from the bubble generating surface by 600 microns of substrate 130. Also, it is difficult to obtain adequate nozzle length as this must be generated by very thick layers of CVD glass forming the overcoat 142. Additionally, bubble formation being transverse permits non-optimal motion coupling. Also, thermal conduction into the substrate 130 is high causing heat to be wasted therethrough. Finally, the length of the heater 493 is constrained by the circumference of the nozzle, or half the circumference if fault tolerance is employed, and so it is difficult to obtain a high resistance heater 493.
- Fig. 16 illustrates the annular trench configuration of Fig. 15 shown in the reversed arrangement.
- the annular trench 492 extends towards the nozzle tip 486 as does the diffused heater 493 therein.
- a thermal diffuser 491 is also provided in the previous manner.
- the nozzle length can be easily varied. Advantages of this configuration reside in thermal coupling, ease of heat dissipation, self priming and ease of manufacture. Disadvantages include the bubble direction being transverse to the direction of ink drop ejection, and difficulty in controlling the length of the heater 493. Also, thermal conduction to the silicon substrate 130 is high which causes heat to be wasted.
- Fig. 17 shows a further configuration utilising an elbow heater.
- a cylindrical nozzle passageway is formed between the nozzle tip 111 and the barrel 113.
- Thermally grown SiO2 is provided as a layer 494 which extends into the barrel 113.
- An elbow oriented heater 495 is then plated onto the layer 494, and an electrical contact is made on the top surface of the heater 495.
- Overcoat layer 142 of CVD SiO 2 is then provided over the contact and heater, and extends into the nozzle barrel 113. Advantages of this configuration are self priming and thermal insulation of the heater 495 from the substrate 130.
- Disadvantages include poor heat dissipation, difficulties in controlling the nozzle length by varying the thickness of the overcoat 142, transverse bubble direction, poor thermal coupling due to the heater 495 being isolated from the ink 106 by a layer of amorphous CVD glass, difficulties in controlling heater length, and manufacturing complexity.
- Fig. 18 illustrates the reverse arrangement of the elbow connected heater 495 which is manufactured in a similar manner.
- Advantages include heat dissipation through the ink reservoir, self priming and the heater 495 being thermally insulated from the substrate 130.
- Disadvantages include transverse bubble direction, poor thermal coupling through the amorphous CVD glass between the heater 495 and the ink 106, and constraints to the heater length.
- Fig. 19 illustrates a nozzle arrangement similar to that of Fig. 14, however the relative sizes of the nozzle aperture 484 and the nozzle tip 486 have been varied to improve capillary action for the filling of the nozzle and the formation of the meniscus 107.
- One disadvantage of the configuration of Fig. 14 is that the nozzle aperture 484 and the nozzle tip 486 have equal diameters. The diameter of the nozzle tip 486 varies depending on a number of design criteria such as the desired drop size.
- the ink 106 In order to prime the nozzle and provided the meniscus 107 as illustrated, the ink 106 must flow through the aperture 484 but then stop at the tip 486. Generally, if both are of the same size, the ink will either form a meniscus at the aperture 484, or drip through the tip 486 depending on the priming pressure. Neither of these conditions are desired. What is specifically desired is that the aperture 484 be of sufficient diameter to allow for priming of the nozzle, and that the tip 486 be of a different, smaller diameter to provide for the formation of the meniscus 107. The nozzle is then primed using a pressure greater than the "bubble pressure" of the aperture 484, but less than the "bubble presure" of the nozzle 486.
- the configuration of Fig. 19 which illustrates a suitable arrangement in which the diameter of the aperture 484 is approximately 50% larger than that of the tip 486. This configuration also provides for accurate control of the drop size whilst maintaining high refilling rates of the nozzle.
- the operation of the ZBJ chip 100 differs from that of prior art bubblejet heads in the use of an alternate drop ejection mechanism which is illustrated in Figs. 20 to 27.
- a single nozzle 110 of the ZBJ print head 100 is shown in its quiescent state where the heater 120 is off.
- Ink 106 within the nozzle 110 forms a meniscus 107.
- the heater 120 is turned on thus heating the surrounding substrate 130 and the thermal layer 132 which in turn heats the ink 106 within the nozzle 110. Some of the ink 106 evaporates to form small bubbles 116.
- the heater 120 is turned off which acts to contract the bubble 116 and draw ink 106 from the drop 108 that is formed.
- the drop 108 separates from the ink 106 within the nozzle 110 and the contracting bubble 116 draws an ink meniscus 107 backwards into the nozzle 110.
- the ink 106 oscillates, and eventually returns to the quiescent state.
- the oscillating damping time is one factor which determines the maximum dot repetition rate.
- Fig. 29 illustrates the super heating of ink in which a thin layer of superheated ink 109 forms adjacent the passivation layer 144 within the nozzle cavity 112.
- the waste heat is removed by three separate paths. Firstly, heat is removed through the ink which acts to raise its temperature slightly. However, the thermal conductivity of ink is low, so the amount of heat removed by this path is also low.
- the walls of the nozzle 110 are made of silicon from the substrate 130, and have high thermal conductivity, heat dissipation through the walls is fast. However, not all of the bubble 116 will be in contact with the side walls of the nozzle 110.
- Fig. 30 illustrates the heat flow from the cooling bubble 116 as described above.
- Fig. 31 also shows waste heat removal paths 125 in which heat will flow through the substrate 130 as the main thermal conduit away from the heater 120. Some of this heat will flow back into the ink 106 and eventually be ejected with subsequent drops 108. The remainder of the heat will flow through the substrate 130 and into the aluminium heat sink (51,52), seen in Fig. 4.
- Fig. 32 illustrates the macroscopic heat dissipation for the ZBJ head 200 with 51,200 nozzles printing four colours. If the heater action does not raise the average temperature of the entire head assembly 200 more than about 10°C to 20°C above that of the incoming ink 106, it is not necessary to provide an external cooling mechanism. In this manner, the ZBJ head 200 can be effectively cooled by a steady flow of ink 106 from ink reservoirs 215, 216, 217 and 218 as illustrated. The quantity of ink flow is in direct proportion to the heat generated, as ink 106 is expelled every time the heaters are turned on.
- nozzle efficiency thermal and the substantially smaller kinetic output compared with electrical input
- more heat will be generated than can be expelled with the drops without raising the ink temperature excessively.
- other heat sinking methods such as forced air cooling or liquid cooling using the ink
- the operating temperature of the ZBJ heater elements 120 is above 300°C. It is important that the active elements (drive transistors and logic) of the ZBJ chip 100 do not experience this temperature extreme. This can be achieved by locating the drive transistors and logic as far from the heater elements 120 as possible. These active elements can be located at the edges of the chip 100, leaving only the heaters 120 and the aluminium connecting lines in the high temperature region.
- the ZBJ chip 100 is susceptible to blockage by particulate contamination of the ink 106. Any particle of a size between 20 microns and 60 microns will permanently lodge in the nozzle cavity 112, as it cannot be ejected with the ink drop 108.
- a filter such as the membrane filter 205, is included in the ink path to remove all particles larger than 10 microns. This can be a 10 micron bonded fibreglass absolute filter and preferably has a relatively large area to allow sufficient ink flow.
- the continuous tone ZBJ chip 100 with four nozzles 110 per pixel has a degree of tolerance of blocked nozzles 110.
- a blocked nozzle 110 will result in a 25% reduction of colour intensity for that pixel rather than a complete absence of colour.
- cap and substrate are made of differing materials.
- One solution to this problem is to make the cap out of the same material as the substrate, usually silicon. Even if this is done, differences in temperature between the silicon substrate and the silicon cap (caused by waste heat from the heaters) can be sufficient to cause mis-registration.
- the ZBJ chip 100 does not suffer from these problems, as the heaters 120, nozzles 110 and ink paths 101 are all fabricated using a single silicon substrate 130. Nozzle to heater registration is determined by the accuracy of the photolithography with which the ZBJ chip 100 is manufactured. Due to the relatively large feature sizes of this configuration, there is little difficulty in ensuring that the nozzles are correctly aligned as the ZBJ chip 100 is a monolithic chip capable of being manufactured using a 2 micron semiconductor processes.
- 16 drops per pixel are used to create an image density of 400 pixels per inch. This gives 16 levels of grey tone per pixel.
- the tonal subtleties required to produce continuous tone images can be produced by standard digital dot or line screening methods or by error diffusion of the least significant 4 bits of an 8 bit colour intensity value. This results in a perceived colour resolution of 256 levels per colour, while maintaining a spacial resolution of 400 pixels per inch.
- the head assembly 200 must deal with several specific requirements: ink supply; ink filtration; power supply; power dissipation; signal connection; and mechanical support.
- the ZBJ head 200 with 51,200 nozzles, each of which can eject a 3 pl ink drop every 200 microseconds, can use a maximum of 1.28 ml of ink per second. This occurs when the head 200 is printing a solid four-colour black. As there are four colours, the maximum flow is 0.23 ml per colour per second. If the ink speed is to be limited to around 20 mm per second, then the ink channels 211-214 must have a cross- sectional area of 16 mm 2 each.
- any particles carried in the ink that are less than 60 microns in diameter will be carried into the nozzle channel 114. Any of these particles which are greater than 20 microns in diameter cannot be ejected from the nozzle 110. Even if pre-filtered ink is supplied to the user, there is a possibility of particle contamination when the ink is re- filled. Therefore, the ink must be effectively filtered to eliminate any particles between 20 and 60 microns.
- the peak current consumption of the full width colour ZBJ head 200 is about several amperes. This must be supplied to the entire length of the chip 100 with insignificant voltage drop. Also, the ZBJ head has more than 35 signal connections, the exact number depending upon the chosen circuit design, and accordingly insignificant voltage drop is also required.
- the ink channel extrusion 210 has three functions: to provide the ink paths and keep the four colours separate; to provide mechanical support for the ZBJ chip 110; and to assist in dissipating the waste heat to the ink 106.
- the ink channel extrusion 210 be extruded from aluminium, and anodised to provide electrical insulation from the busbars 201 and 202. Manufacturing accuracy of the extrusion 210 need only be maintained to approximately ⁇ 50 microns, as the extrusion 210 is not in contact with the nozzles 110. The edges of the channel extrusion 210 should be sealed against the ZBJ chip 100 to prevent air from entering the head assembly 200. This can be achieved with the same epoxy as that used to glue the assembly 200.
- One way of supplying the necessary power to the chip 110 is by power connections which run the full length of the chip 110. These can be connected using tape automated bonding (TAB) to the busbars 201 and 202 which form part of the head assembly 200.
- TAB tape automated bonding
- the signal connections to the ZBJ chip 100 can be formed using the same TAB tapes as are used to supply power to the ZBJ chip 100.
- the busbars 201,202 can be configured as heat sink elements surrounding the extrusion 210.
- the A4 full width continuous tone ZBJ head 200 has a high current consumption of several amperes when operating. The distribution of this current to and across the chip 100 is not possible using standard integrated circuit construction. However, the geometry of the ZBJ chip 100 leads to a simple solution. The entire edge of the chip 100 can be used to supply power, with connections being made to a wide aluminium trace along both of the long edges of the chip 100. Power can be supplied by the busbars 201 and 202 along both sides of the chip 100 connected to the chip by tape automated bonding (TAB), compressible solder bumps, spring leaf connection to gold plated traces, a large number of wire bonds, or other connection technology.
- TAB tape automated bonding
- the full length full colour head can have a power dissipation of up to 500 watts when all nozzles are printing, depending on the nozzle efficiency.
- the ZBJ head 200 is essentially a single piece construction and the head cost will consist almost entirely of the ZBJ chip 100 itself.
- the ZBJ chip 100 cost is determined by processing cost per wafer, number of heads per wafer, and yield. Assuming that the processing costs per wafer is about $800, and the number of heads per wafer is 25, the pre-yield cost per head is $32.
- the mature-process yield must be about 30%.
- the chip area for the full colour full length ZBJ heads 200 is of the order of 8.8 cm 2 .
- the fault tolerance redundancy of the ZBJ head is preferably provided to improve the yield. This can allow a large number of defects to exist on the chip without affecting the operation of any of the nozzles. Furthermore, it is not necessary to incorporate 100% redundancy, but it is necessary to reduce the non-redundant region of the ZBJ head to a size consistent with an adequate yield. Even with fault tolerance, there are several factors which can act to reduce yields below reasonable levels. Some of these factors are:
- fault tolerance is included in the ZBJ chip 100 so as to improve yield as well as to improve head life.
- the provision of fault tolerance is considered essential so as to achieve low manufacturing costs of the ZBJ chips 100.
- the fault tolerance concept described herein is specifically applied to the ZBJ chip 100, the same concept can be used for other types of BJ heads if a configuration with two heaters per nozzle is created.
- fault tolerance is that chip complexity is doubled. However, due to the topography of the nozzles 110, there is only a slight (about 10%) increase in chip area. The yield decrease this causes is dwarfed by the yield increase provided by fault tolerance.
- each heater 120 is provided with two heater elements on opposite sides of the nozzle 110 and preferably having identical geometries.
- the heater elements are termed a main heater and a redundant heater. Accordingly, the ink drop fired from the nozzle tip 111 by either heater is essentially the same.
- Control of the redundant heater for fault tolerance is provided by sensing the voltage at the drive transistor to the main heater drive.
- This node makes a high-to-low transition every time the nozzle 110 is fired. Three faults are detected by the behaviour of this node:
- the ZBJ chip 100 is very long and thin, and has many holes etched through it, the mechanical strength of the chip 100 is insufficient to allow high yield dicing in the conventional manner.
- FIG. 33 A simple solution using a diced back etch is illustrated in Fig. 33 where channels 147 are etched in the back surface of the wafer 149, most of the way through the wafer 149.
- the wafer 149 is then scored 145 on the front surface.
- the channels 147 can be etched using the same processes that are used to etch the ink channels 101 and nozzle vias 110.
- the spacing of vias 146 along the dice line 145 can be adjusted to give the optimum trade-off between strength for handling and ease of dicing.
- tags 148 (Fig. 34) can be left along the edges of the wafers 149. These tags 148 must be diced off before the ZBJ chips 100 are separated.
- the wafer length for 220 mm heads must be 230 mm.
- the wafers 149 can also be supported by these tags 148 during the various chemical processing steps to prevent processing "shadows" from affecting the regions of the ZBJ chip 100.
- the full width colour ZBJ chip 110 has dimensions of approximately 220 mm ⁇ 4 mm, yet requires very fine line widths, such as 3 microns for the one nozzle per pixel design, and 2 microns for the four nozzle per pixel design. To maintain focus and resolution when imaging the resist patterns is difficult, but is within the limits of current technology.
- Either full wafer projection printing or an optical stepper can be used. In both cases, the projection equipment requires modification to the stage to allow for 220 mm travel in the long axis.
- a scanning projection printer is modified to match the mask transport mechanism to permit very long masks. Defects caused by particles on the mask are projected at a 1:1 ratio and are in focus, so cleaner conditions are required to achieve the same defect level.
- a 1:1 projection printer also requires a mask of an image area of 220 mm ⁇ 104 mm. This requires modification to the mask fabrication process. The manufacturing of 2 micron resolution masks of this size is viable for high volume production, but the masks are very expensive in small volumes. For these reasons, a stepper configuration should also be considered.
- 5:1 reduction stepper reduces some of the problems associated with a scanning projection printer, particularly those associated with the production of very large masks, and the particle contamination of the mask.
- some new problems are introduced. Firstly, a different imaging area of 10 mm ⁇ 8 mm is used. Then the full size wafer can be imaged in 22 ⁇ 13 steps. This provides a total of 286 steps which generally takes about 250 seconds to print. As there are approximately 10 imaging steps required for the manufacture of the ZBJ chip 100, total exposure time per wafer can be about 2,500 seconds which substantially reduces the production rate of such devices. Also, the use of the wafer stepper introduces the following two problems which effect the ZBJ chip design:
- the first of these problems can be countered by using a repeating design, and ensuring that alignment at the perimeters of that repeating block is not critical.
- the repeating block does not have to be rectangular, but can avoid critical features such as nozzles.
- the left hand and right hand edges of the mask pattern can be quite irregular, provided they match each other.
- each signal line must terminate at the bonding pads 207,223 (Fig. 35), which are typically arranged at the side edges of the chip 100. This normally requires that the side edges of the chip 100 be imaged with a different pattern than that of the centre of the ZBJ chip 100. This can be achieved by blading the mask to obscure the bonding pads and associated circuitry on all but the first exposure of the chip.
- Fig. 35 shows a basic floor plan or chip layout of a stepper mask for a full width continuous tone colour ZBJ chip 100, including complete redundancy for full fault tolerance.
- the magnified portion of the drawing illustrates an irregular mask boundary 258.
- the ZBJ chips 100 can be processed in a manner very similar to standard semiconductor processing. There are however, some extra processing steps required. These are: accurate wafer thickness control, deposition of a HfB 2 heater element; etching of the nozzle tip; back etching of the ink channels; and back etching of the nozzle barrels.
- NMOS process with two level metal is assumed as this is the basis of the four nozzle per pixel design.
- CMOS or bipolar processes can also be used.
- Wafer preparation for scanning BJ heads is similar to that for standard semiconductor devices, except that the back surface must also be accurately ground and polished, and wafer thickness maintained at better than 5 microns. This is because both sides of the wafer are photolithographically processed, and etch depth from the reverse side is critical.
- Full width fixed ZBJ chips require different wafer preparation than do those used in scanning heads, as the ZBJ chip must be at least 210 mm long in order to be able to print an A4 page, and at least 297 mm long for a A3 pages. This is much wider than the typical silicon crystalline cylinder. Wafers can be sliced longitudinally from the cylinder to accommodate the long chips required.
- the resultant wafer When the wafer has been ground and polished the resultant wafer should generally be about 600 microns thick.
- the resultant wafer is a rectangular shape approximately 230 mm ⁇ 104 mm ⁇ 600 microns thick. On this wafer, approximately 25 full colour heads can be processed. Such a wafer will appear similar to that of Fig. 34.
- a 230 mm long 6 inch cylinder can be used to produce up to 2,600 full width, full colour heads before yield losses.
- wafer flatness requirements are no more severe than those of the transistor fabrication processes.
- the wafer can be gettered using back-side phosphorous diffusion, but back-side damage can result.
- Wafer processing of the ZBJ chip 100 uses a combination of special processes required for heater deposition and nozzle formations, and standard processes used for drive electronics fabrication. As the size of the ZBJ chip 100 is largely determined by the nozzles 110 and not by the drive transistors, there is little size advantage in using a very fine process.
- the process disclosed here is based on a 2 micron self-aligned polysilicon gate NMOS process, but other processes such as CMOS or bipolar can be used.
- the process size disclosed here is the largest size compatible with the interconnect density required to the nozzles 113 of the high density four colour ZBJ head. This also requires two levels of metal. Two levels of metal can be required for simpler heads, as high current tracks run across the chip, and very long clock tracks run along the chip.
- the wafer processing steps required for the formation of the ZBJ nozzles 110 are intermingled with the steps required for the drive transistors.
- the process used for the drive transistors can be standard as known to those skilled in the art, there is no requirement to specify such steps in this specification.
- Figs. 36 to 45 show the cross section for a single nozzle.
- Figs. 36 to 45 also illustrate the corresponding and simultaneous construction of transistors arranged outboard of the nozzle arrays.
- a 0.5 micron layer 132 of thermal SiO 2 is grown on the P-type doped substrate 130. This is patterned with the driver circuit requirements as well as with the thermal shunt vias 400.
- a thin gate oxide is thermally grown on the substrate 130. This will also affect the electrical connections of the thermal shunt 140 to the substrate 130, but will have an insignificant effect on thermal conduction.
- Polysilicon is deposited to form the gates 403 and interconnects of the transistors. The drain and source of the transistors are N-type doped using the polysilicon gate 403 as a mask. This will also dope the thermal shunt connection 403 to the substrate 130.
- a 0.05 micron layer of HfB 2 is deposited to form the heater 120.
- a 0.5 micron layer of aluminium is deposited over the substrate 130 to form the first level of metal 134.
- a resist is patterned with the sum of the heater and the first level metal 134, and wet etched with a phosphoric acid-nitrate etchant.
- the HfB 2 layer is reactive ion etched using the aluminium as a mask.
- the etch is performed with a halogenic gas such as CCl 4 (carbon tetrachloride), as described in US Patent No. 4,889,587.
- the wafer is then at the stage illustrated in Fig. 37.
- the mask shows the ground common track 405 and the V+ common track 405.
- a resist is then patterned with a pattern which exposes the heater element 120, and wet etched with a phosphoric acid-nitric etchant.
- the wafer then corresponds to that illustrated in Fig. 38, also showing a heater connection electrode 407, and HfB 2 408 under aluminium.
- Fig. 39 illustrates the provision of the interlevel oxide 136.
- This is a layer of CVD SiO 2 or PECVD SiO 2 , approximately 1 micron thick. The thickness of this layer can be determined by the thermal lag required between the heater 120 and the thermal shunt 140.
- Fig. 39 shows the cross-section of the wafer after this step in which 410 is a thermal shunt via, 411 represents the nozzle cavity, 412 a via for connection to the transistor and 413 the heater connection vias.
- the second level metal 138 is formed as a layer of 0.5 micron aluminium which forms both the thermal shunt 140 and the second level of interconnects 144 to the heaters 120, heater connection 416 and connection 415 for the drive circuitry.
- Two levels of metal are unlikely to be necessary for ZBJ heads with one nozzle per pixel, but are likely to be required for high speed colour heads with four nozzles per pixel.
- the thickness and material of this layer can be changed to suit the thermal requirements of the heater chamber depending on the specific application.
- a CVD glass overcoat 142 is applied, approximately 4 microns thick.
- a low temperature CVD process such as PECVD, can be used. This layer is very thick and provides mechanical strength for the nozzle tip 417, as well as environmental protection.
- a 17 micron diameter hole is RIE etched through the 4 micron glass overcoat with an SiO 2 etching species. This forms the top of the nozzle tip 417 and completes the configuration illustrated in Fig. 41.
- the hole (417) formed by a RIE of SiO 2 is extended at least 30 microns into the silicon by further RIE, using a silicon etching gas.
- the SiO 2 overcoat is used as the RIE mask.
- RIE is relatively unselective, a substantial amount of the SiO 2 overcoat will be sacrificed.
- the etch rate is 5:1 (Si:SiO 2 )
- the CVD glass overcoat is deposited to a depth of 10 microns so that 4 microns remains after etching the silicon.
- This hole (417) can be etched as deeply as possible to minimise accuracy requirements in the depth of back etching of the nozzle barrel (113). Reactive ion etching is used to obtain near vertical side walls, to ensure that the ink flows to the end of the nozzle by surface tension.
- the wafer is back-etched to a thickness of approximately 200 microns.
- the actual thickness is not critical, but the variation in thickness is, however.
- the wafer must be etched such that the thickness variation is less than ⁇ 2 microns over the wafer. If this is not achieved, it is difficult to subsequently ensure that the process of back etching the nozzles does not over-etch and destroy the heaters.
- the next step for a four colour head is to RIE etch ink channels 101 in the reverse side of the surface of the chip 100 in the manner illustrated in Figs. 6 to 9.
- These channels 101 (Fig. 5) are approximately 600 microns wide ⁇ 100 microns deep.
- These channels 101 are not essential to the operation of the ZBJ chip 100, but have two advantages. Namely, the channels 101 reduce the ink flow rate through the filter from approximately 8 mm per second to 2 mm per second. This flow rate reduction can alternatively be achieved by locating the filter differently in the ZBJ head 200. Also, the channels reduce the depth that the nozzles 110 need to be etched from 190 microns to 90 microns. As the nozzle barrels 113 are 40 microns in diameter, this has a major effect on the ratio of length to diameter of the barrels 113.
- the ink channel back-etching process can also be used to thin the wafer along the dice lines in the manner earlier described with reference to Fig. 33.
- the etch depth of the next step, nozzle barrel back- etching 419, is critical to ensure that the nozzle barrel 113 properly joins with the nozzle tip 417 (111) to form the thermal chamber.
- a solution to this problem is to incorporate end point detection using optical spectroscopy.
- a chemical etch stop signal can be created by filling the nozzle tips 417 previously etched from the front surface of the substrate with a detectable chemical signature, and monitoring the exhaust gases with an emission spectroscope.
- the nozzle barrels 113 are formed with an anisotropic reactive ion etch of silicon. Holes 40 microns in diameter (later widened to 60 microns with an isotropic plasma etch), are etched 70 microns into the silicon from the reverse side of the wafer. These holes are at the bottom of the previously etched ink channels, which are 100 microns deep. As the wafer is thinned to 200 microns, these holes etch to within 30 microns of the front surface of the silicon.
- etch can be stopped, even if some of the nozzles have not joined up to the tips. This is because the next step (10 micron isotropic etching of all exposed silicon) joins up any that are within about 12 microns.
- Fig. 42 shows the ZBJ chip at the end of this step.
- Etch depth uniformity over the entire wafer surface is critical. The tolerance depends largely on the depth of each etch achievable with the 18 micron hole etched from the front of the chip. Given that the front etched hole is etched 30 ⁇ 2 microns, wafer thickness is 200 ⁇ 2 microns, ink channel back etch depth is 100 ⁇ 4 microns, overall isotropic etch of silicon is 10 ⁇ 1 microns, maximum joining distance is 12 microns, and the minimum between the nozzle barrel and the heater is 10 microns, cumulative tolerances mean that the nozzle barrel etch must be 70 ⁇ 4 microns. All of these tolerances can be loosened if the front etch can be deeper than 30 microns. The accuracy of alignment of the back-etching process to the front surface processes need only be to within ⁇ 10 microns, as alignment of the barrel and tip is not critical.
- Fig. 43 The cumulative effect of these tolerances is illustrated in Fig. 43.
- the cross-hatched area 424 seen in Fig. 43 shows the region of uncertainty in the final nozzle geometry, and the single-hatched area 423 shows the safety margin for the nozzle barrel to nozzle tip join using these tolerances. This safety margin is required because the reactive ion etches will not leave perfectly flat bottomed holes.
- the uncertainty of the wafer thickness (200 ⁇ 2 microns) and the channel etch (100 ⁇ 4 microns) are combined into one thickness figure of 100 ⁇ 6 microns as the channels are too large to be shown in this figure.
- the resist must be very thick to be maintained for 70 microns of RIE; the etch is deep and narrow, giving problems with removal of spent etchant; shadowing of the projection pattern by the walls of the ink channels must be avoided; and adequate resist coverage of the stepped surface must be achieved. This is not critical as etching of the ink channel walls can be tolerated.
- the entire ZBJ wafer is then subjected to a 10 ⁇ 1 micron isotropic plasma etch of all exposed silicon.
- This has two purposes. Firstly, this forms the thermal chamber 115 by undercutting 425 the thermal silicon dioxide 132 in the region of the heater 120. This is also to ensure that the nozzle barrels 113 join with the nozzle tips 111 resulting from a widening 426 of the barrels 113. As the wafer is etched from both sides, any non-joining barrels 113 and tips 111 that are within 18 microns (twice (10 - 1) microns) should join up. Non-joining barrels and tips within approximately 12 microns will behave essentially similarly to joined barrels and tips. This reduces the accuracy requirements of the barrel back-etch 419.
- the etch must be highly selective towards silicon, and have a negligible etch rate with thermal silicon dioxide, otherwise the heater insulation layer 132 will be destroyed. This results in the configuration illustrated in Fig. 44.
- the 4 micron glass overcoat 142 must now be etched to expose the bonding pads. This is not performed before the nozzle tip silicon etch because poor selectivity can cause the 30 micron RIE silicon etch to etch through the aluminium layer 139.
- the ZBJ chip 100 can then be passivated with a 0.5 micron layer 144 of tantalum or other suitable material. It can be difficult to achieve a highly conformal coating, but irregularities in the passivation thickness will not substantially affect the performance of the ZBJ chip 100.
- the ZBJ chip 100 has no electrical output, and therefore true functional testing can only be achieved by loading the device with ink into printing and printing patterns which exercise each individual nozzle 110. This cannot be performed at multi-probe time.
- An effective method of functional testing the chips 100 at multi-probe time is to test the power consumption in the V+ to ground path as each heater 120 is turned on in sequence. Each time a heater 120 is fired, a current pulse should occur. As this is a separate circuit with negligible quiescent current, these pulses are readily detected.
- the entire pattern of operational heaters and redundant circuits can be determined in approximately 1 second with inexpensive equipment. Therefore, the entire wafer can be multi-probed in under one minute.
- the pattern of functional and non-functional heaters can be read into a computer and be used for compiling process statistics and detecting local quality control problems.
- Scribing is along the top surface of the etched dice channels 147 (see Fig. 33).
- the end tabs 148 for handling must be diced off before the ZBJ chips 100 can be separated.
- the chips 100 can be glued in place in the head assemblies 200 and connected using tape automated bonding, with one tape along each edge of the chip. Alternatively, standard wire bonding can be used, as long as enough wires are bonded to meet the high current requirements of the chip 100.
- Fig. 45 illustrates the cross-section of the completed device.
- Fig. 47 is a plan view of typical components used in a ZBJ chip of the structure shown in Fig. 14.
- Figs. 48 to 78 are vertical cross-sections through the centre line of Fig. 47 at various manufacturing stages.
- Fig. 48 The manufacturing process commences with a standard silicon wafer of P-type doping with a resistivity of approximately 25 ohm cm.
- Fig. 49 A layer of silicon nitride 501 approximately 0.15 microns thick is grown on the wafer 500. This is a standard NMOS process .
- Fig. 50 A first mask 501 is used to pattern the silicon nitride 501 to prepare for boron implantation.
- Fig. 51 The wafer 500 is implanted with a field 503 of boron to eliminate the formation of spurious transistors.
- Fig. 52 A thermal oxide layer 504 approximately 0.8 microns thick is grown on the boron implanted field 503.
- Fig. 53 The remaining silicon nitride 501 is removed.
- Fig. 54 This is a standard NMOS process which implants arsenic to form regions 505 for deletion mode transistors. This step involves the spin deposition of a resist, exposure of the resist to the second mask, development of the resist, arsenic implantation, and resist removal.
- Fig. 55 A 0.1 micron gate oxide 506 is thermally grown. This is part of a standard NMOS process and increases the field oxide thickness to 0.9 microns.
- Fig. 56 A 1 micron layer of polysilicon 507 is deposited over the entire wafer 500 using chemical vapour deposition.
- Fig. 57 The polysilicon 507 is patterned using a third mask 508.
- the wafer 500 is spin coated with resist.
- the resist is exposed using the third mask and is developed.
- the polysilicon 507 is then etched using an anisotropic ion enhanced etching to reduce undercutting.
- Fig. 58 The gate oxide 506 is etched where exposed by the polysilicon etch of the third mask. This results in etch diffusion windows 509 being formed and will also thin the field oxide 504 leaving a thickness of 0.8 microns.
- Fig. 59 N+ diffusion regions 510 approximately 1 micron deep are formed in the diffusion windows 509.
- Fig. 60 A 1 micron layer of glass 511 is deposited using chemical vapour deposition.
- Fig. 61 The CVD glass 511 is etched where contacts are required to the polysilicon 507, the diffusions 510 and in the heater region. Contact regions 512 are formed. This process differs from the standard NMOS process in that the depth of etch is controlled so that there is an appropriate amount of thermal SiO 2 504 remaining under the heaters.
- Fig. 62 A 0.05 micron layer 513 of HfB 2 is deposited over the wafer 500. This is not a standard NMOS process.
- Fig. 63 A HfB 2 layer 513 is etched using ion enhanced etching with CCl 4 as the etchant. This exposes the heaters 514. This step requires spin coating of resist, exposure to a fifth level mask, development of resist, ion enhanced etching, and resist stripping.
- Fig. 64 A 1 micron first metal level 515 of aluminium is evaporated over the wafer 500.
- Fig. 65 The first metal level 515 is etched using a sixth level mask. This step requires spin coating of resist, exposure to the sixth mask, development of resist, plasma etching, and resist stripping. The etch must be strongly selective over HfB 2 , as the HfB 2 layer is only 0.05 microns and will be exposed when the metal 515 is etched.
- Fig. 66 A 1 micron layer 516 of glass is deposited using chemical vapour deposition.
- Pattern contacts for the seventh level mask are made using a standard contact etch for 2 micron NMOS with double level metal. This step requires spin coating of resist, exposure to the seventh mask, development of resist, ion enhanced etching, and resist stripping.
- Fig. 68 A 1 micron second level metal layer 517 of aluminium is evaporated over the wafer 500.
- This metal layer 517 provides the second level of contacts. This is required because a high wiring density is required to the heaters 514, which must be metal for low resistance.
- This layer also provides the thermal diffuser or thermal shunt as described in the earlier embodiments.
- Fig. 69 The second level metal 517 is etched using an eighth mask. This step requires spin coating of resist, exposure to the eighth mask, development of the resist, plasma etching, and resist stripping. This is a normal NMOS step.
- the isolated metal disk above the heaters 514 is the thermal diffuser used to distribute waste heat to avoid hot-spots.
- Fig. 70 A thick layer 518 of glass is deposited over the wafer 500.
- the layer 518 must be thick enough to provide adequate mechanical strength to resist the shock of imploding bubbles. Also, enough glass must be deposited to diffuse the heat over a wide enough area so that the ink does not boil when in contact with it. 4 micron thickness is considered adequate, but can be easily varied if desired.
- Fig. 71 This step requires etching using a ninth level mask of a cylindrical barrel 519 into the overcoat 518, through the thermal oxide layer 504 down to the implanted field 503. Both CVD glass and thermal quartz are etched. This step requires spin coating of resist, exposure to a ninth level mask, development of resist, and anisotropic ion enhanced etching, and resist stripping.
- the thermal chamber 520 is formed by an isotropic plasma etch of silicon, highly selective over SiO 2 . This is essential, as otherwise the protective layer of SiO 2 separating the heater 514 from the passivation will be etched.
- the previously etched barrel 519 acts as the mask for this step. In this case, an isotropic etch of 17 microns is used. Care must be taken not to fully etch the thermal SiO 2 layer 504.
- Nozzle channels 521 are etched from the reverse side of the wafer 500 by an anisotropic ion enhanced etching.
- the channels 521 are about 60 microns in diameter, and about 500 microns deep.
- the depth of the channels 521 is such that the distance between the top of the channel and the bottom of the thermal chamber 520 is the required nozzle length.
- the etching place through a layer of resist 522.
- Fig. 74 The nozzle via is etched from the front side of the wafer 500 using a highly anisotropic ion enhanced etching. This etch is from the bottom of the the thermal chamber 520 to the top of the back etched nozzle channels 521, and is about 20 microns in length, and 20 microns in diameter.
- the nozzle barrels 523 are formed therefrom.
- Fig. 75 A 0.5 micron passivation layer 524 of tantalum is conformably coated over the entire wafer 500.
- Fig. 76 In this step, windows are opened for the bonding pads 525. This requires a resist coating, exposure to a twelfth level mask, resist development, etching of the tantalum passivation layer 524, ion enhance etching of the overcoat 518, and resist stripping. As 2 microns of aluminium is available in the pad regions, it is easy to avoid etching through the pads formed by the second level metal 517.
- Fig. 77 After probing of the wafer 500, the ZBJ chip is mounted into a frame or support extrusion as earlier described and glued into place. Wires 526 are bonded to the pads formed by the second level metal 525 at the ends of the chip. Power rails are bonded along the two long edges of the chip. Connections are then potted in epoxy resin.
- Fig. 78 This shows a forward ejection type ZBJ nozzle filled with ink 527. In this case, the droplet is ejected downwards when the nozzle fires.
- This type of head requires priming of ink using positive pressure, as it will not be filled by capillary action.
- a similar head construction can be used for reverse firing nozzles by filling the head heat chip from the other side.
- the ZBJ printhead 200 incorporating the ZBJ chip 100 is useful in a variety of printing applications either printing across the page in the traditional manner, as a scanning print head, or as a stationary full width print head.
Abstract
Description
- The present invention relates a method of fabricating a bubblejet print device using semiconductor fabrication techniques, according to
claim 1. - Bubblejet print heads are known in the art and have recently become available commercially as portable, relatively low-cost printers generally used with personal computers. Examples of such devices are those made by HEWLETT-PACKARD as well as the CANON BJ10 printer.
- Figs. 1 and 2 show schematic perspective views of prior art bubblejet print heads representative of those used by CANON and HEWLETT-PACKARD, respectively.
- As seen in Fig. 1 the prior art bubblejet (BJ)
head 1 is formed by a BJsemiconductor chip device 2 abutting a laser etchedcap 3. In this configuration, thecap 3 acts as a guide for the inward flow of ink (indicated in the drawing by arrows) into thehead 1 via aninlet 4, and the outward ejection of the ink from thehead 1 via a plurality ofnozzles 5. Thenozzles 5 are formed as the open ends of channels in thecap 3. On theBJ chip 2 are arranged one or more (generally 64) heater elements (not shown) which are energized so as to cause ink to be ejected from each of thenozzles 5 by a bubble of vapourised ink formed within the corresponding channel. TheBJ chip 2 also includes a semiconductor diode matrix (not illustrated) which acts to supply energy to the heater elements arranged adjacent the channels. - In the prior art HEWLETT-PACKARD thermal
ink jet head 10 as seen in Fig. 2, a two part configuration is also used, however ink enters thecap 12 through aninlet 13 arranged in the side of thecap 12 which supplies an array ofnozzles 14 arranged perpendicular to theinlet 13. Ink exits through the face of thecap 12. Aflat heater 15 is arranged immediately beneath eachnozzle 14 so as to cause ejection of ink from theinlet channel 13 into the nozzles. - Further, the JP-A-60-8076 discloses a bubble jet print device comprising heating resistors and electrical connections to the heating resistors, both being formed on a substrate. Nozzles are formed through the substrate, wherein one end of each nozzle is disposed adjacent to the respective heating resistor, and the other end of each nozzle forms an outlet for ejecting ink. The substrate is directly connected to an ink box and the nozzles are erected when not in use, so that no ink is left in the nozzles and no blocking of the nozzles occurs.
- Furthermore, the EP-A-0 339 926 discloses a drop-on-demand ink drop jet printhead comprising layers of like print modules of which adjacent layers are equally laterally offset. The modules are formed each with a row of parallel equally spaced ink drop ejectors in form of piezo-electrical transducers arranged in one or more groups. The ejector groups in each layer are laterally spaced by the same amount and corresponding segments of the groups in different layers are together capable of depositing drops of ink in a particular segment of the print line at a density equal to the product of the drop density capability of each group and the number of groups having segments corresponding to the associated print line segment.
- Moreover, the EP-A-0 352 726 discloses a liquid-jet recording head comprising a substrate on which a plurality of energy-generating elements is disposed, and a cover plate covering the substrate. The substrate and the cover plate together define a liquid chamber as well as liquid paths each communicating the liquid chamber with a corresponding ejecting outlet. The liquid paths are provided in correspondence with the energy-generating elements.
- Problems exist with these prior art devices due to their two-part construction with respect to an accurate registration between the two parts. Even if accurate registration is initially achieved, differing rates of thermal expansion or contraction may prevent this accuracy being maintained over appreciable dimensions during operation. Such registration problems limit the performance of the prior art devices to image densities generally lower than 400 dots per inch (dpi), and scanning or moving print heads rather than fixed print heads.
- In view of the above state of the art, the object of the present invention is to provide a bubblejet print device which is capable of printing images of high image density in high quality.
- This object is solved by the method set forth in
claim 1. - According to the invention, the method of fabricating a bubblejet print device comprises the steps of providing a substrate member having a heater means, electrodes electrically connected to the heater means, and an overcoat for protecting the heater means, forming a first hole into the substrate member adjacent to the heater means from one side on which the overcoat is provided, forming a second hole into the substrate member from the other side, the second hole being communicated with the first hole, thereby forming a passageway through the substrate member.
- As a result, high accuracy of the device is initially achieved, wherein thermal expansion or contraction does not prevent this accuracy from being maintained during the operation of the device. This is because of the one-part construction of the device in which the nozzles or passageways incorporating the heater means and including the nozzle tips as well as the nozzle barrels between which the heater means are located, are formed integrally.
- Advantageously developed embodiments of the invention are subject-matter of
claims 2 to 11. - As used herein, the term "a Z-Axis bubble jet chip (ZBJ chip)" is used to describe a chip lying in the x y plane in which ink flows both into and out of the chip in the z direction.
- The above and other features and advantages of the present invention will become more apparent from the following description of embodiments thereof taken in conjunction with the accompanying drawings.
- A number of preferred embodiments of the present invention will now be described with reference to the drawings in which:
- Figs. 1 and 2 are representations of prior art BJ print heads;
- Fig. 3 is a representation of a ZBJ chip of the present invention;
- Fig. 4 is a cut-away isometric view of a first embodiment of a ZBJ print head;
- Fig. 5 is a view similar to Fig. 4 but of a second embodiment;
- Figs. 6 to 9 illustrate one etching process which can be used to create the ZBJ nozzles;
- Figs. 10 to 19 show various alternate nozzle configurations;
- Figs. 20 to 27 show the manner of expulsion of ink from one nozzle of the ZBJ chip;
- Figs. 28 to 32 illustrate the transfer of heat in the ZBJ chip;
- Figs. 33, 34 and 35 illustrate preferred configurations for the manufacture of multiple ZBJ heads on a single silicon wafer;
- Figs. 36 to 45 illustrate the various stages used in wafer processing of the ZBJ chip;
- Fig. 46 is a cross-sectional schematic view through a wide hole which incorporates several nozzles; and
- Figs. 47 to 78 show the manufacturing stages of a preferred embodiment.
- Referring firstly to Fig. 3, the general configuration of a Z-axis bubblejet (ZBJ)
chip 40 is shown which includes an ink inlet arranged on one (underside as illustrated) plane surface of thechip 40, and a plurality ofnozzles 41 which provide for outlets of ink on the opposite side. It is readily apparent from a direct comparison of Figs. 1 and 2 with Fig. 3 that the ZBJchip 40 has a single, monolithic, integrally formed structure as opposed to the two part structure of the prior art. Thechip 40 is formed using semiconductor fabrication techniques. Furthermore, ink is ejected from thenozzles 41 in the same direction in which ink is supplied to thechip 40. - Referring now to Fig. 4, a cross-section of a first embodiment of a stationary (i.e. non-moving) ZBJ
printhead 50 is shown which is configured for the production of full length A4 continuous tone colour images at an image density of 1600 dpi or 400 pixels per inch. Thehead 50 is provided with a ZBJchip 70 having four nozzle arrays, one for each ofcyan 71, magenta 72, yellow 73 and black 74. The nozzle arrays 71-74 are formed fromnozzle vias 77 with four nozzles per pixel giving a total of 51,200 nozzles perchip 70. The magnified portion of Fig. 4 shows the basic nozzle cross-section which is formed in asilicon substrate 76 over which alayer 78 of thermal Si02 is formed. Aheater element 79 is provided about thenozzle 77, which is capped by anovercoat layer 80 of chemical vapour deposited (CVD) glass. Each of thenozzles 77 communicates with a commonink supply channel 75 for that particular colour of ink. The ZBJchip 70 is positionable upon achannel extrusion 60 which hasink channels 61 communicating with thechannels 75 so as to provide for a continuous flow of ink to thechip 70. Amembrane filter 54 is provided between theextrusion 60 and thechip 70. - Two
power bus bars chip 70. Thebus bars chip 70. - Fig. 5 shows a second embodiment of a
ZBJ head 200 similar in configuration to that shown in Fig. 4. - The
head 200 has aZBJ chip 100 includingnozzle arrays chip 100 hasink channels 101 which communicate withink reservoirs channel extrusion 210. - The
channel extrusion 210 has an alternate geometry of higher volumetric capacity than that shown in Fig. 4 for the same size of thechip 100. Also illustrated aretab connections power bus bars chip 100. Amembrane filter 205 is also provided as before. - So as to be able to print an A4 page, the
head 200 is required to be about 220 mm long, by 15 mm across, by 9 mm deep. Using the foregoing as a standard arrangement, many configurations of ZBJ heads are possible. The actual size and the number of nozzles per chip depend solely on the required performance of the printer application. - Table 1 lists seven applications of ZBJ printheads and the various requirements for each application considered necessary. Application one is considered suitable for low cost full colour printers, portable computers, low cost colour copiers and electronic still photography. Application two is considered suitable for personal printers, and personal computers, whilst application three is useful in electronic still photography, video printers and workstation printers. The fourth application finds use in colour copiers, full colour printers, colour desktop publishing and colour facsimile. The fifth application is for a monochrome device which sees application in digital black and white copiers, high resolution printers, portable computers, and plain paper facsimiles. Applications six and seven show respectively high speed and medium speed A3 continuous tone applications useful in colour copiers and colour desktop publishing. The high speed version of application six finds use in small run commercial printing and the medium speed version in colour facsimile.
- It will be appreciated by those skilled in the art that the foregoing applications are configured for ZBJ heads with a drop size of 3 pl (pico-litres). Other configurations are possible and higher operating speeds can be achieved at the expense of image quality, by using larger drop sizes.
- The physical structure of the
ZBJ chip 100 will now be described in detail. TheZBJ chip 100, as illustrated in Fig. 5, for example, has four nozzle arrays 102-105, each comprising four rows of nozzle vias 110 (Figs. 6-9). The nozzle vias 110 are formed by etching through asubstrate 130 of thechip 100. Thesubstrate 130 is generally about 500 microns deep and, depending on the required application, can be 220 mm long by 4 mm wide. Figs. 6 to 9 illustrate the etching of the nozzle vias 110 through thesubstrate 130. So that theZBJ chip 100 can eject a drop of 3 pl, it is necessary for the diameter of eachnozzle 110 to be approximately 20 microns. In one possible manufacturing method a four stage process is used commencing with a 500 microndeep substrate 300 having an overlying glass (SiO2)layer 142 enclosing aheater 120 within as seen in Fig. 5. Firstly, the step as seen in Fig. 6 is a plasma etch of a 20 micron straight-walled round hole, through theglass overcoat 142 and at least 10 microns into thesubstrate 130. This forms thenozzle tip 111. - The next step as seen in Fig. 7 requires the etching of a large channel (approximately 100 microns wide by 300 microns deep) in the rear of the
chip 100. This formsnozzle channels 114 that supply ink flow to thenozzles 110. The next step, as seen in Fig. 8, is to print nozzle barrel patterns at the bottom of thechannels 114 formed in Fig. 7. The nozzle barrels 113 are approximately 40 microns in diameter and are plasma etched to within 10 microns of the front of thechip 100. As the isotropic plasma etch is relatively non-selective, this method cannot be used to etch the entire cavity without also etching through, and destroying theheater 120. - Accordingly, as seen in Fig. 9, an isotropic etch is used on the wall exposed silicon to a depth of 10 microns from the front of the
chip 100. This step acts to widen thenozzles 110 and undercut theSi02 layer 142 containing theheater 120. This step forms thenozzle cavity 112. The step also ensures that thetip 111 joins thebarrel 113 without risking plasma etched damage to theheater 120. It will be apparent to those skilled in the art that the above mentioned dimensions are only approximate and show a general concept only. However, the front to back surface etching should be aligned to better than 10 microns and the etch depth control should also be better than 10 microns. In this way, the complete nozzle via 110 is formed including itstip 111,cavity 112,barrel 113 andchannel 114. - It will be apparent that the formation of the
nozzle tip 11, thenozzle cavity 112 which acts as a thermal chamber, thenozzle barrel 113 and thenozzle channel 114 creates a passageway for the flow of ink through thesubstrate 100 for ejection. - In Fig. 10, the
thermal chamber 115 which surrounds thenozzle tip 111 is arranged as a cylinder, with theheater 120 deposited in the walls of the cylinder. This arrangement has several disadvantages, including: - (1) the heater film must be deposited vertically inside the cylinder and whilst this can be achieved by chemical vapour deposition (CVD), it is then very difficult to etch the
heater 120 into the required size and shape; - (2) it is difficult to achieve a redundant heater configuration for fault tolerance;
- (3) the
heater 120 must be buried below the surface so that there is ink to eject, or the vapour will simply vent out of thetip 111; and - (4) the ink is separated from the
heater 120 by CVD Si02 instead of crystalline Si02, which has a higher thermal conductivity. - In Fig. 11, the
thermal chamber 115 is arranged as a cone. This is to allow theheater 120 to be etched to increase its resistance. This arrangement has the following difficulties: - (1) if the cone angle is made too shallow, the
nozzle 110 will not fill with ink by capillary action. - (2) if the cone angle is made too steep, like the cylindrical chamber it is still difficult to etch the
heater 120; and - (3) the
nozzle barrel 123 is very narrow, thus increasing the ink refill time. - Fig. 12 shows a quasi-hemispherical chamber in which the
heater 120 is formed on a frusto-conical section which faces into a substantially hemispherical chamber. - Figs. 13 to 18 show six preferred nozzle structures which permit monolithic construction, a small drop size of 3 picolitres thus permitting 1600 dpi printing, a fault tolerant heater design, a nozzle spacing anywhere on the surface of the substrate, and the use in multi-colour print devices.
- Fig. 13 illustrates a substantially hemispherical
thermal chamber 115 which is formed by applying an undercutting isotropic plasma etch of silicon before reactive ion etching (RIE) of thenozzle barrel 113. This configuration is characterised by a reverse action in which the formation of thebubble 116 is in the direction opposite to the ejection of theink drop 108. Thethermal shunt 140 conducts heat away from the nozzle area into thesubstrate 130 to reduce the time taken for thethermal chamber 115 to cool sufficiently prior to the ejection of thenext ink drop 108. - This configuration has advantages of planar construction of the
heater 120 whereby accurate control of the heater shape and size can be achieved. Also, the thermal coupling between theheater 120 and the ink is significant, because theheater 120 is isolated from the ink by thethermal SiO2 layer 132 which is more thermally conductive than CVD glass. Also, this layer can be manufactured thinner than a corresponding layer of CVD glass, as it is not prone to pinholes. Depending on the slope of thebarrel 113 as it enters thethermal chamber 115, and the contact angle of the ink with a passivation layer, this nozzle geometry will permit automatic filling by capillary action. - Disadvantages of this configuration reside in the reversed operation by which bubble formation is in the opposite direction to ink ejection which reduces efficiency. Also, the thick CVD glass overcoat is required which forms the nozzle region. Finally, waste heat must be dissipated via a long path through approximately 600 microns of
silicon substrate 130. This limits the nozzle density and/or the maximum firing rate of the nozzles. Other disadvantages relate to potential difficulties with thenozzle 111 filling with ink, by capillary action, if the angle of thebarrel 113 and thethermal chamber 115 is not closely monitored. - Fig. 14 is similar to the configuration of Fig. 13 except that in this geometry, the direction of flow of
ink 106 through thechip 100 is reversed, giving a reversed nozzle arrangement in which bubble formation is in the same direction as ink drop ejection. - As seen in Fig. 14,
ink 106 enters the nozzle passageway through anaperture 484 and ameniscus 107 is formed at thenozzle tip 486 boundary between thebarrel 487 and thechannel 489. Formation ofbubbles 116 acts to expel anink drop 108 through thechannel 489 and onto a medium such aspaper 220. - The configuration of the reverse nozzle arrangement differs in one significant way from the earlier configurations described. The earlier configurations (e.g. Fig. 13) utilise a
thermal shunt 140 which acts to shunt heat away from theheater 120 and into thesubstrate 130. However, in the configuration of Fig. 14, immediately adjacent theheaters 120 is an underlying reservoir ofink 106. Accordingly, athermal diffuser 491 is used to increase the area of heat transport from theheater 120 through theovercoat 142 and into theink 106 reservoir. In this configuration, because the heat conductive path is much shorter than that of Fig. 13, greater heat dissipation can be achieved. Also, heat dissipation can be further enhanced by re-circulating theink 106 through a heat exchanger using a supply pump (not illustrated). - This configuration has the advantages of planar construction, good thermal coupling and heat dissipation. Also, bubble direction is in the direction of ink ejection which reduces kinetic losses. A disadvantage of this configuration is that the nozzle is not self priming, and must be initially primed using positive pressure. Once primed, the shrinking bubble will draw ink into the
thermal chamber 488 after thedrop 108 has been fired. Also, the cantilevered section supporting theheaters 120 must be sufficiently thick to withstand the shock from collapsingbubbles 116. - Turning now to Fig. 15, a nozzle arrangement is shown which includes a trench implanted
heater 493. In this embodiment, thenozzle cavity 112 is formed as a straight cylinder communicating with thenozzle barrel 113 and the optionally etchednozzle channel 114. Anannular trench 492 is etched into the silicon, and a layer of SiO2 is grown adjacent and about thenozzle cavity 112. Theannular heater 493 is plated on thetrench 492 which acts to formvapourised bubbles 116 which expand across thecavity 112 transverse the direction of drop ejection. Advantages of this configuration include good thermal coupling and self-priming. Disadvantages include poor heat dissipation because liquid cooling by forced ink flow is not effective as the bulk of the ink is isolated from the bubble generating surface by 600 microns ofsubstrate 130. Also, it is difficult to obtain adequate nozzle length as this must be generated by very thick layers of CVD glass forming theovercoat 142. Additionally, bubble formation being transverse permits non-optimal motion coupling. Also, thermal conduction into thesubstrate 130 is high causing heat to be wasted therethrough. Finally, the length of theheater 493 is constrained by the circumference of the nozzle, or half the circumference if fault tolerance is employed, and so it is difficult to obtain ahigh resistance heater 493. - Fig. 16 illustrates the annular trench configuration of Fig. 15 shown in the reversed arrangement. Here the
annular trench 492 extends towards thenozzle tip 486 as does the diffusedheater 493 therein. Athermal diffuser 491 is also provided in the previous manner. Unlike Fig. 15, due to the configuration of thechannel 489 the nozzle length can be easily varied. Advantages of this configuration reside in thermal coupling, ease of heat dissipation, self priming and ease of manufacture. Disadvantages include the bubble direction being transverse to the direction of ink drop ejection, and difficulty in controlling the length of theheater 493. Also, thermal conduction to thesilicon substrate 130 is high which causes heat to be wasted. - Fig. 17 shows a further configuration utilising an elbow heater. In this embodiment, a cylindrical nozzle passageway is formed between the
nozzle tip 111 and thebarrel 113. Thermally grown SiO2 is provided as alayer 494 which extends into thebarrel 113. An elbow orientedheater 495 is then plated onto thelayer 494, and an electrical contact is made on the top surface of theheater 495.Overcoat layer 142 of CVD SiO2 is then provided over the contact and heater, and extends into thenozzle barrel 113. Advantages of this configuration are self priming and thermal insulation of theheater 495 from thesubstrate 130. Disadvantages include poor heat dissipation, difficulties in controlling the nozzle length by varying the thickness of theovercoat 142, transverse bubble direction, poor thermal coupling due to theheater 495 being isolated from theink 106 by a layer of amorphous CVD glass, difficulties in controlling heater length, and manufacturing complexity. - Fig. 18 illustrates the reverse arrangement of the elbow connected
heater 495 which is manufactured in a similar manner. Advantages include heat dissipation through the ink reservoir, self priming and theheater 495 being thermally insulated from thesubstrate 130. Disadvantages include transverse bubble direction, poor thermal coupling through the amorphous CVD glass between theheater 495 and theink 106, and constraints to the heater length. - Fig. 19 illustrates a nozzle arrangement similar to that of Fig. 14, however the relative sizes of the
nozzle aperture 484 and thenozzle tip 486 have been varied to improve capillary action for the filling of the nozzle and the formation of themeniscus 107. One disadvantage of the configuration of Fig. 14 is that thenozzle aperture 484 and thenozzle tip 486 have equal diameters. The diameter of thenozzle tip 486 varies depending on a number of design criteria such as the desired drop size. - In order to prime the nozzle and provided the
meniscus 107 as illustrated, theink 106 must flow through theaperture 484 but then stop at thetip 486. Generally, if both are of the same size, the ink will either form a meniscus at theaperture 484, or drip through thetip 486 depending on the priming pressure. Neither of these conditions are desired. What is specifically desired is that theaperture 484 be of sufficient diameter to allow for priming of the nozzle, and that thetip 486 be of a different, smaller diameter to provide for the formation of themeniscus 107. The nozzle is then primed using a pressure greater than the "bubble pressure" of theaperture 484, but less than the "bubble presure" of thenozzle 486. The configuration of Fig. 19 which illustrates a suitable arrangement in which the diameter of theaperture 484 is approximately 50% larger than that of thetip 486. This configuration also provides for accurate control of the drop size whilst maintaining high refilling rates of the nozzle. - The operation of the
ZBJ chip 100 differs from that of prior art bubblejet heads in the use of an alternate drop ejection mechanism which is illustrated in Figs. 20 to 27. In Fig. 20, asingle nozzle 110 of theZBJ print head 100 is shown in its quiescent state where theheater 120 is off.Ink 106 within thenozzle 110 forms ameniscus 107. - In Fig. 21, the
heater 120 is turned on thus heating the surroundingsubstrate 130 and thethermal layer 132 which in turn heats theink 106 within thenozzle 110. Some of theink 106 evaporates to formsmall bubbles 116. - As seen in Fig. 22, as the evaporated
ink 106 is heated, it expands and coalesces intolarge bubbles 116. - In Fig. 23, pressure from the expanding
gas bubbles 116forces ink 106 out of thenozzle tip 111 at high speed. - In Fig. 24, the
heater 120 is turned off which acts to contract thebubble 116 and drawink 106 from thedrop 108 that is formed. - In Fig. 25, the
drop 108 separates from theink 106 within thenozzle 110 and thecontracting bubble 116 draws anink meniscus 107 backwards into thenozzle 110. - As seen in Fig. 26, surface tension causes the
nozzle 110 to refill withink 106 from the underlying reservoir in which the velocity ofink 106 causes overfilling. - Finally, in Fig. 27 the
ink 106 oscillates, and eventually returns to the quiescent state. The oscillating damping time is one factor which determines the maximum dot repetition rate. - As depicted in Fig. 28, when the
heater 120 is turned on, a portion of the heat will flow into theink 106, and the remainder flows into the material surrounding the nozzle in the manner indicated. - Fig. 29 illustrates the super heating of ink in which a thin layer of
superheated ink 109 forms adjacent thepassivation layer 144 within thenozzle cavity 112. - Excess heat must be rapidly removed after the
heater 120 is turned off. Within 200 microseconds of theheater 120 being energized, there should be noink 106 remaining at a temperature above 100°C, at which bubbles 116 form due to theink 106 being substantially composed of water. If this is not achieved, thenext ink drop 108 will not fire correctly as there will be an insulating layer of vapour between theheater 120 and theink 106. - The waste heat is removed by three separate paths. Firstly, heat is removed through the ink which acts to raise its temperature slightly. However, the thermal conductivity of ink is low, so the amount of heat removed by this path is also low.
- Because the walls of the
nozzle 110 are made of silicon from thesubstrate 130, and have high thermal conductivity, heat dissipation through the walls is fast. However, not all of thebubble 116 will be in contact with the side walls of thenozzle 110. - Also, waste heat is removed through the
heater element 120. Heat dissipation through theheater element 120 is important, as no ink vapour must be in contact with theheater 120 when the next drop is fired. Because the bulk of material around theheater 120 is glass, with low thermal conductivity, thethermal shunt 140 is included, to shunt waste heat to thesubstrate 130. If the removal of this heat can be achieved within approximately 200 microseconds, then it is not necessary to include thethermal shunt 140. Fig. 30 illustrates the heat flow from thecooling bubble 116 as described above. - Fig. 31 also shows waste
heat removal paths 125 in which heat will flow through thesubstrate 130 as the main thermal conduit away from theheater 120. Some of this heat will flow back into theink 106 and eventually be ejected withsubsequent drops 108. The remainder of the heat will flow through thesubstrate 130 and into the aluminium heat sink (51,52), seen in Fig. 4. - Fig. 32 illustrates the macroscopic heat dissipation for the
ZBJ head 200 with 51,200 nozzles printing four colours. If the heater action does not raise the average temperature of theentire head assembly 200 more than about 10°C to 20°C above that of theincoming ink 106, it is not necessary to provide an external cooling mechanism. In this manner, theZBJ head 200 can be effectively cooled by a steady flow ofink 106 fromink reservoirs ink 106 is expelled every time the heaters are turned on. - Generally, about 50 watts of
electrical power 126 is supplied to thehead 200 which outputs aspray 117 of 12,800 drops per colour per 200 µs use. This represents anoutput 127 of about 1.28 ml of ink drops per second at ambient temperature plus 10-20°C. It should also be noted that the driver circuit on thechip 100 also dissipates some power but this is minor compared to that dissipated by theheaters 120 themselves. - However, if the nozzle efficiency (thermal and the substantially smaller kinetic output compared with electrical input) is less than that indicated above, more heat will be generated than can be expelled with the drops without raising the ink temperature excessively. In this case, other heat sinking methods (such as forced air cooling or liquid cooling using the ink) can also be used.
- While the average temperature of the
ZBJ print head 200 is low, the operating temperature of theZBJ heater elements 120 is above 300°C. It is important that the active elements (drive transistors and logic) of theZBJ chip 100 do not experience this temperature extreme. This can be achieved by locating the drive transistors and logic as far from theheater elements 120 as possible. These active elements can be located at the edges of thechip 100, leaving only theheaters 120 and the aluminium connecting lines in the high temperature region. - Two potential sources of blocked heads exist and these are dried ink and contamination.
- When the
print head 200 is not in use, the exposed surface will dry out. If it dries too much, the pressure of abubble 116 will be insufficient to dislodge any dried ink. This problem can be alleviated by: - 1. Automatically capping the
head 200 with an air tight seal when not in use; - 2. Applying a solvent to the front surface of the
ZBJ head 200 during a cleaning cycle; - 3. The use of a self-skinning ink; and/or
- 4. A vacuum cleaning system.
- The
ZBJ chip 100 is susceptible to blockage by particulate contamination of theink 106. Any particle of a size between 20 microns and 60 microns will permanently lodge in thenozzle cavity 112, as it cannot be ejected with theink drop 108. A filter such as themembrane filter 205, is included in the ink path to remove all particles larger than 10 microns. This can be a 10 micron bonded fibreglass absolute filter and preferably has a relatively large area to allow sufficient ink flow. - The continuous
tone ZBJ chip 100 with fournozzles 110 per pixel has a degree of tolerance of blockednozzles 110. A blockednozzle 110 will result in a 25% reduction of colour intensity for that pixel rather than a complete absence of colour. - The existing prior art bubblejet technologies of Canon and Hewlett-Packard's thermal ink jet systems use a two-piece construction to form the nozzles. The heaters are formed on a silicon chip whereas the nozzles are formed using a cap manufactured of a different material. This technique has proven to be highly successful for the production of scanning thermal ink jet heads with moderate numbers of nozzles. However, to achieve full-width A4 printing (i.e. with a stationary head) with very small drop sizes, this technique becomes more difficult. With nozzle pitches of 64 microns and head lengths of 220 mm, differences in thermal expansion between the substrate and the nozzle cap as small as 0.02% are sufficient to cause malfunction. Even small ambient temperature changes will cause this degree of differential thermal expansion if the cap and substrate are made of differing materials. One solution to this problem is to make the cap out of the same material as the substrate, usually silicon. Even if this is done, differences in temperature between the silicon substrate and the silicon cap (caused by waste heat from the heaters) can be sufficient to cause mis-registration.
- The
ZBJ chip 100 does not suffer from these problems, as theheaters 120,nozzles 110 andink paths 101 are all fabricated using asingle silicon substrate 130. Nozzle to heater registration is determined by the accuracy of the photolithography with which theZBJ chip 100 is manufactured. Due to the relatively large feature sizes of this configuration, there is little difficulty in ensuring that the nozzles are correctly aligned as theZBJ chip 100 is a monolithic chip capable of being manufactured using a 2 micron semiconductor processes. - As it is difficult to vary the size of drops from a bubblejet head, continuous tone operation is achieved by varying the number of drops.
- In the present case, 16 drops per pixel are used to create an image density of 400 pixels per inch. This gives 16 levels of grey tone per pixel. The tonal subtleties required to produce continuous tone images can be produced by standard digital dot or line screening methods or by error diffusion of the least significant 4 bits of an 8 bit colour intensity value. This results in a perceived colour resolution of 256 levels per colour, while maintaining a spacial resolution of 400 pixels per inch. There are two nozzle configuration considered herein: one nozzle per pixel; and four nozzles per pixel. In both cases, the drop size is assumed to be approximately 3 pl.
- There are several factors which affect the optimum configuration of the
nozzles 110. These include: - (1) For a print resolution of 400 dpi, 64 micron square pixels are required;
- (2) The number of nozzles per pixel has a different effect on the nozzle configuration;
- (3) The
nozzle barrel 113 diameter affects the nozzle layout because thebarrel 113 is larger than the diameter of thedrop 108. In thepreferred embodiment 100, thebarrel 113 is 60 microns in diameter. To maintain mechanical strength of thechip 100, it is assumed that eachnozzle 110 must be at least 80 microns from its nearest neighbour; - (4) The firing duty cycle, which is 1:32, allows a 6.25 microsecond heater pulse every 200 microseconds. This gives time for the
ink meniscus 107 to stabilise before thenext drop 108 is fired; - (5) To prevent major variations in the supply current energizing the
heaters 120, all of the 32 available time slots allowed by the 1:32 duty cycle are used by an equal number ofnozzles 110. This means that: - (6) If
adjacent nozzles 110 are fired in order, then the heat from onenozzle 110 can interfere with the next, and an area may become too hot. To minimise this problem, widely spacednozzles 110 are fired in sequence; and - (7) The optimum arrangement for a colour head is not simply a monochrome head repeated four times. The extra nozzles of the colour head can be used to achieve better thermal distribution.
- It should be noted that although the detailed description of this specification concentrates on the four nozzle per pixel configuration, as this is the most difficult, a one nozzle per pixel configuration can be readily derived.
- The
head assembly 200 must deal with several specific requirements:
ink supply; ink filtration; power supply; power dissipation; signal connection; and mechanical support. - The
ZBJ head 200 with 51,200 nozzles, each of which can eject a 3 pl ink drop every 200 microseconds, can use a maximum of 1.28 ml of ink per second. This occurs when thehead 200 is printing a solid four-colour black. As there are four colours, the maximum flow is 0.23 ml per colour per second. If the ink speed is to be limited to around 20 mm per second, then the ink channels 211-214 must have a cross- sectional area of 16 mm2 each. - Any particles carried in the ink that are less than 60 microns in diameter will be carried into the
nozzle channel 114. Any of these particles which are greater than 20 microns in diameter cannot be ejected from thenozzle 110. Even if pre-filtered ink is supplied to the user, there is a possibility of particle contamination when the ink is re- filled. Therefore, the ink must be effectively filtered to eliminate any particles between 20 and 60 microns. - With regard to power supply, the peak current consumption of the full width
colour ZBJ head 200 is about several amperes. This must be supplied to the entire length of thechip 100 with insignificant voltage drop. Also, the ZBJ head has more than 35 signal connections, the exact number depending upon the chosen circuit design, and accordingly insignificant voltage drop is also required. - Mechanical support to the
ZBJ chip 100 can be provided by theink channel extrusion 210 in the manner shown in Fig. 5. Theink channel 210 extrusion has three functions: to provide the ink paths and keep the four colours separate; to provide mechanical support for theZBJ chip 110; and to assist in dissipating the waste heat to theink 106. - For these reasons it is preferable that the
ink channel extrusion 210 be extruded from aluminium, and anodised to provide electrical insulation from thebusbars extrusion 210 need only be maintained to approximately ≦ 50 microns, as theextrusion 210 is not in contact with thenozzles 110. The edges of thechannel extrusion 210 should be sealed against theZBJ chip 100 to prevent air from entering thehead assembly 200. This can be achieved with the same epoxy as that used to glue theassembly 200. - One way of supplying the necessary power to the
chip 110 is by power connections which run the full length of thechip 110. These can be connected using tape automated bonding (TAB) to thebusbars head assembly 200. The signal connections to theZBJ chip 100 can be formed using the same TAB tapes as are used to supply power to theZBJ chip 100. Furthermore, as seen in Fig. 5, the busbars 201,202 can be configured as heat sink elements surrounding theextrusion 210. - The A4 full width continuous
tone ZBJ head 200 has a high current consumption of several amperes when operating. The distribution of this current to and across thechip 100 is not possible using standard integrated circuit construction. However, the geometry of theZBJ chip 100 leads to a simple solution. The entire edge of thechip 100 can be used to supply power, with connections being made to a wide aluminium trace along both of the long edges of thechip 100. Power can be supplied by thebusbars chip 100 connected to the chip by tape automated bonding (TAB), compressible solder bumps, spring leaf connection to gold plated traces, a large number of wire bonds, or other connection technology. - The full length full colour head can have a power dissipation of up to 500 watts when all nozzles are printing, depending on the nozzle efficiency. Before a final design of a ZBJ head can be derived, the following should be taken into account, as all these factors affect heat generation and dissipation.
- (1) The number of nozzles: The number of
nozzles 110 directly effects the power dissipation, but is also linked to print speed, image quality and continuous tone issues. - (2) Heater energy: The heater energy is typically 200 nJ per drop. Any reduction in heater energy allows the power dissipation to be reduced without affecting print speed.
- (3) Supply Voltage: A low supply voltage is desirable, however, a reduction in voltage increases the current consumption and the size of on-chip driver transistors. Power dissipation will not be greatly affected by the supply voltage if the nozzle energy is maintained constant. In the preferred embodiment a supply voltage of +24V is used for the heater drivers and +5V for logic electronics.
- (4) Nozzle Duty Cycle: Increases in the nozzle duty cycle directly increases the power consumption but also increases the print speed.
- (5) Print Speed: Print speed is related to the number of
nozzles 110, the number of drops per pixel, the pixel size and the nozzle duty cycle. A reduction in print speed can reduce power requirements, but typically will not affect the total energy per page. - (6) Permissible Chip Temperature: The chip temperature must be maintained well below the boiling point of the ink 106 (generally about 100°C).
- (7) Ink Channel Geometry: This will affect the amount of heat dissipation available through the
ink 106. - (8) Cooling Method: Convection cooling is adequate for scanning heads, but full length heads require additional methods such as heat sinks, forced air cooling or heat pipes. Liquid cooling is a possible solution to the problem of high power density in the head strip. As liquid ink is already in contact with the head, a recirculating pumped ink system with a heat exchanger can be used if heat dissipation problems cannot be solved by easier methods.
- (9) Ink Thermal Conductivity: The thermal conductivity of the
ink 106 becomes relevant if the ink is to provide a significant power dissipation conduit. - (10) Ink Channel Thermal Conductivity: The thermal conductivity of the
ink channel extrusion 210 is also relevant. - (11) Heat Sink Design: Heat sink size and design can be readily changed to provide optimum heat dissipation. The heat sink can be made quite large with little expense and little adverse effect at the system level.
- (12) High Temperatures: The operating temperature of the ZBJ heater elements may be in excess of 300°C. It is important that the active elements (drive transistors and logic) of the
ZBJ chip 100 do not experience this temperature extreme. This can be achieved by locating the drive transistors as far from the heater elements as possible. The active elements can be located at the edges of thechip 100, leaving only the heaters and the aluminium connecting lines in the high temperature region. Also, obtaining an adequate heat transfer is a serious potential problem. The heater should exceed 300°C yet the overall chip temperature must be kept well below the boiling point (100°C) of theink 106. While heat transfer from the heat sink (51,52) to ambient should not be a problem, transferring heat from thechip 100 to the heat sink (51,52) efficiently is important. - For full colour full length ZBJ heads to be applicable to large markets, such as colour photocopies and printers selling for less than about US$5,000, the manufacturing cost of the head should be as low as possible. In general, a target assumed for each head is about US$100 or less in volume with a mature process.
- The
ZBJ head 200 is essentially a single piece construction and the head cost will consist almost entirely of theZBJ chip 100 itself. TheZBJ chip 100 cost is determined by processing cost per wafer, number of heads per wafer, and yield. Assuming that the processing costs per wafer is about $800, and the number of heads per wafer is 25, the pre-yield cost per head is $32. - To achieve a head cost of $100, the mature-process yield must be about 30%. However, the chip area for the full colour full length ZBJ heads 200 is of the order of 8.8 cm2. Those skilled in the art would initially believe that such a large size would imply a yield close to zero. However, there are several factors which make the expectant yield not as low as first impressions. These factors are:
- (1) Most of the
chip 100 consists of heaters, nozzle tips, and connecting lines, which should not be sensitive to point dislocations in the silicon wafer; - (2) The majority of the
chip 100 has a three micron or greater feature size, and will be relatively insensitive to very small particles; - (3) The
chips 100 are not subject to semiconductor processing steps in areas likely to be affected by wafer-etch rounding, resist-edge beading, or process shadowing (i.e. there are no active circuit elements near the nozzles). - The fault tolerance redundancy of the ZBJ head is preferably provided to improve the yield. This can allow a large number of defects to exist on the chip without affecting the operation of any of the nozzles. Furthermore, it is not necessary to incorporate 100% redundancy, but it is necessary to reduce the non-redundant region of the ZBJ head to a size consistent with an adequate yield. Even with fault tolerance, there are several factors which can act to reduce yields below reasonable levels. Some of these factors are:
- (1) Process variations whereby large area variations in process parameters such as etch depth and sheet resistance beyond acceptable limits will result in no yield from affected wafers. Generally, tolerances on these parameters are matched to the ZBJ head requirements during production engineering;
- (2) Mechanical damages: if the mechanical strength of any ZBJ head design is adequate to withstand processing stresses, the ZBJ design can be altered to provide adequate strength. However, this alteration is normally at the expense of the chip area, and therefore yield;
- (3) Wafer taper: the
ZBJ chip 100 is unusually sensitive to wafer taper due to the back-etching of thenozzles 110. Wafers should be polished to reduce taper to less than 5 microns before processing; - (4) Slip: as the
chips 100 extend the entire length of the wafer, major slip defects can reduce yield to zero. A special furnace design and processing can be provided to accommodate the long rectangular wafers; - (5) Etch depth: this must be consistent to within 5% over the entire wafer to ensure that the barrel plasma etch does not etch the heater. If this tolerance is unable to be achieved, the particular ZBJ design should be altered to be less sensitive to etch variations.
- As indicated earlier, fault tolerance is included in the
ZBJ chip 100 so as to improve yield as well as to improve head life. The provision of fault tolerance is considered essential so as to achieve low manufacturing costs of the ZBJ chips 100. Furthermore, whilst the fault tolerance concept described herein is specifically applied to theZBJ chip 100, the same concept can be used for other types of BJ heads if a configuration with two heaters per nozzle is created. - The disadvantage of fault tolerance is that chip complexity is doubled. However, due to the topography of the
nozzles 110, there is only a slight (about 10%) increase in chip area. The yield decrease this causes is dwarfed by the yield increase provided by fault tolerance. - The ZBJ system described herein implements fault tolerance by providing two heater elements for each
nozzle 110. As thenozzles 110 are circular and on the surface of thechip 100, eachheater 120 is provided with two heater elements on opposite sides of thenozzle 110 and preferably having identical geometries. The heater elements are termed a main heater and a redundant heater. Accordingly, the ink drop fired from thenozzle tip 111 by either heater is essentially the same. - Control of the redundant heater for fault tolerance is provided by sensing the voltage at the drive transistor to the main heater drive. This node makes a high-to-low transition every time the
nozzle 110 is fired. Three faults are detected by the behaviour of this node: - 1. Open heater: if the heater is open circuit, the node will be stuck low;
- 2. Open drive transistor: if this occurs, the node will be stuck high; and
- 3. Shorted drive transistor: if the transistor is short, the heater will overheat, go open circuit and the node will be stuck low.
- Because the
ZBJ chip 100 is very long and thin, and has many holes etched through it, the mechanical strength of thechip 100 is insufficient to allow high yield dicing in the conventional manner. - A simple solution using a diced back etch is illustrated in Fig. 33 where
channels 147 are etched in the back surface of thewafer 149, most of the way through thewafer 149. Thewafer 149 is then scored 145 on the front surface. Thechannels 147 can be etched using the same processes that are used to etch theink channels 101 andnozzle vias 110. The spacing ofvias 146 along thedice line 145 can be adjusted to give the optimum trade-off between strength for handling and ease of dicing. To prevent the ZBJ chips 100 from accidentally separating during the remaining processing steps, tags 148 (Fig. 34) can be left along the edges of thewafers 149. Thesetags 148 must be diced off before the ZBJ chips 100 are separated. If thetags 148 are, say, 5 mm wide, then the wafer length for 220 mm heads must be 230 mm. Thewafers 149 can also be supported by thesetags 148 during the various chemical processing steps to prevent processing "shadows" from affecting the regions of theZBJ chip 100. - The full width
colour ZBJ chip 110 has dimensions of approximately 220 mm × 4 mm, yet requires very fine line widths, such as 3 microns for the one nozzle per pixel design, and 2 microns for the four nozzle per pixel design. To maintain focus and resolution when imaging the resist patterns is difficult, but is within the limits of current technology. - Either full wafer projection printing or an optical stepper can be used. In both cases, the projection equipment requires modification to the stage to allow for 220 mm travel in the long axis.
- In a 1:1 projection printing system, a scanning projection printer is modified to match the mask transport mechanism to permit very long masks. Defects caused by particles on the mask are projected at a 1:1 ratio and are in focus, so cleaner conditions are required to achieve the same defect level. A 1:1 projection printer also requires a mask of an image area of 220 mm × 104 mm. This requires modification to the mask fabrication process. The manufacturing of 2 micron resolution masks of this size is viable for high volume production, but the masks are very expensive in small volumes. For these reasons, a stepper configuration should also be considered.
- The use of 5:1 reduction stepper reduces some of the problems associated with a scanning projection printer, particularly those associated with the production of very large masks, and the particle contamination of the mask. However, some new problems are introduced. Firstly, a different imaging area of 10 mm × 8 mm is used. Then the full size wafer can be imaged in 22 × 13 steps. This provides a total of 286 steps which generally takes about 250 seconds to print. As there are approximately 10 imaging steps required for the manufacture of the
ZBJ chip 100, total exposure time per wafer can be about 2,500 seconds which substantially reduces the production rate of such devices. Also, the use of the wafer stepper introduces the following two problems which effect the ZBJ chip design: - 1. The
ZBJ chip 100 is longer than the step size in one axis; and - 2. The mask cannot readily be changed during exposure of the wafer, therefore one mask must be used for the entire head.
- The first of these problems can be countered by using a repeating design, and ensuring that alignment at the perimeters of that repeating block is not critical. As the
wafer 149 is only diced in one direction, the repeating block does not have to be rectangular, but can avoid critical features such as nozzles. The left hand and right hand edges of the mask pattern can be quite irregular, provided they match each other. - Also, each signal line must terminate at the bonding pads 207,223 (Fig. 35), which are typically arranged at the side edges of the
chip 100. This normally requires that the side edges of thechip 100 be imaged with a different pattern than that of the centre of theZBJ chip 100. This can be achieved by blading the mask to obscure the bonding pads and associated circuitry on all but the first exposure of the chip. - Fig. 35 shows a basic floor plan or chip layout of a stepper mask for a full width continuous tone
colour ZBJ chip 100, including complete redundancy for full fault tolerance. The magnified portion of the drawing illustrates anirregular mask boundary 258. - The ZBJ chips 100 can be processed in a manner very similar to standard semiconductor processing. There are however, some extra processing steps required. These are: accurate wafer thickness control, deposition of a HfB2 heater element; etching of the nozzle tip; back etching of the ink channels; and back etching of the nozzle barrels.
- A 2 micron NMOS process with two level metal is assumed as this is the basis of the four nozzle per pixel design. CMOS or bipolar processes can also be used.
- Wafer preparation for scanning BJ heads is similar to that for standard semiconductor devices, except that the back surface must also be accurately ground and polished, and wafer thickness maintained at better than 5 microns. This is because both sides of the wafer are photolithographically processed, and etch depth from the reverse side is critical.
- Full width fixed ZBJ chips require different wafer preparation than do those used in scanning heads, as the ZBJ chip must be at least 210 mm long in order to be able to print an A4 page, and at least 297 mm long for a A3 pages. This is much wider than the typical silicon crystalline cylinder. Wafers can be sliced longitudinally from the cylinder to accommodate the long chips required.
- When the wafer has been ground and polished the resultant wafer should generally be about 600 microns thick. The resultant wafer is a rectangular shape approximately 230 mm × 104 mm × 600 microns thick. On this wafer, approximately 25 full colour heads can be processed. Such a wafer will appear similar to that of Fig. 34. A 230 mm long 6 inch cylinder can be used to produce up to 2,600 full width, full colour heads before yield losses.
- Due to the one piece construction of the
ZBJ print chip 100, and the use of a stepper for exposure, wafer flatness requirements are no more severe than those of the transistor fabrication processes. The wafer can be gettered using back-side phosphorous diffusion, but back-side damage can result. - Wafer processing of the
ZBJ chip 100 uses a combination of special processes required for heater deposition and nozzle formations, and standard processes used for drive electronics fabrication. As the size of theZBJ chip 100 is largely determined by thenozzles 110 and not by the drive transistors, there is little size advantage in using a very fine process. The process disclosed here is based on a 2 micron self-aligned polysilicon gate NMOS process, but other processes such as CMOS or bipolar can be used. The process size disclosed here is the largest size compatible with the interconnect density required to thenozzles 113 of the high density four colour ZBJ head. This also requires two levels of metal. Two levels of metal can be required for simpler heads, as high current tracks run across the chip, and very long clock tracks run along the chip. - The wafer processing steps required for the formation of the
ZBJ nozzles 110 are intermingled with the steps required for the drive transistors. As the process used for the drive transistors can be standard as known to those skilled in the art, there is no requirement to specify such steps in this specification. - The wafer processing of the
ZBJ chip 100 is illustrated in Figs. 36 to 45 which show the cross section for a single nozzle. Figs. 36 to 45 also illustrate the corresponding and simultaneous construction of transistors arranged outboard of the nozzle arrays. - Firstly, with reference to Fig. 36, a 0.5
micron layer 132 of thermal SiO2 is grown on the P-type dopedsubstrate 130. This is patterned with the driver circuit requirements as well as with thethermal shunt vias 400. - With reference now to Fig. 37, a thin gate oxide is thermally grown on the
substrate 130. This will also affect the electrical connections of thethermal shunt 140 to thesubstrate 130, but will have an insignificant effect on thermal conduction. Polysilicon is deposited to form thegates 403 and interconnects of the transistors. The drain and source of the transistors are N-type doped using thepolysilicon gate 403 as a mask. This will also dope thethermal shunt connection 403 to thesubstrate 130. A 0.05 micron layer of HfB2 is deposited to form theheater 120. A 0.5 micron layer of aluminium is deposited over thesubstrate 130 to form the first level ofmetal 134. A resist is patterned with the sum of the heater and thefirst level metal 134, and wet etched with a phosphoric acid-nitrate etchant. The HfB2 layer is reactive ion etched using the aluminium as a mask. The etch is performed with a halogenic gas such as CCl4 (carbon tetrachloride), as described in US Patent No. 4,889,587. The wafer is then at the stage illustrated in Fig. 37. The mask shows the groundcommon track 405 and the V+common track 405. - A resist is then patterned with a pattern which exposes the
heater element 120, and wet etched with a phosphoric acid-nitric etchant. The wafer then corresponds to that illustrated in Fig. 38, also showing aheater connection electrode 407, andHfB 2 408 under aluminium. - If the above steps are followed, there will result a 500 Angstroms layer of HfB2 under all of the first level of
metal 134. This includes the connections to the sources and the drains of all the FET's as well as Schottky diodes, in the control circuitry. If necessary, another masking and RIE etching can be used before the deposition of aluminium to remove HfB2 from unwanted areas. - Fig. 39 illustrates the provision of the
interlevel oxide 136. This is a layer of CVD SiO2 or PECVD SiO2, approximately 1 micron thick. The thickness of this layer can be determined by the thermal lag required between theheater 120 and thethermal shunt 140. Fig. 39 shows the cross-section of the wafer after this step in which 410 is a thermal shunt via, 411 represents the nozzle cavity, 412 a via for connection to the transistor and 413 the heater connection vias. - Referring now to Fig. 40, the
second level metal 138 is formed as a layer of 0.5 micron aluminium which forms both thethermal shunt 140 and the second level ofinterconnects 144 to theheaters 120,heater connection 416 andconnection 415 for the drive circuitry. Two levels of metal are unlikely to be necessary for ZBJ heads with one nozzle per pixel, but are likely to be required for high speed colour heads with four nozzles per pixel. The thickness and material of this layer can be changed to suit the thermal requirements of the heater chamber depending on the specific application. - Referring now to Fig. 41, a
CVD glass overcoat 142 is applied, approximately 4 microns thick. A low temperature CVD process, such as PECVD, can be used. This layer is very thick and provides mechanical strength for thenozzle tip 417, as well as environmental protection. A 17 micron diameter hole is RIE etched through the 4 micron glass overcoat with an SiO2 etching species. This forms the top of thenozzle tip 417 and completes the configuration illustrated in Fig. 41. - The hole (417) formed by a RIE of SiO2 is extended at least 30 microns into the silicon by further RIE, using a silicon etching gas. In this case, the SiO2 overcoat is used as the RIE mask. As RIE is relatively unselective, a substantial amount of the SiO2 overcoat will be sacrificed. For example, if the etch rate is 5:1 (Si:SiO2), then the CVD glass overcoat is deposited to a depth of 10 microns so that 4 microns remains after etching the silicon. This hole (417) can be etched as deeply as possible to minimise accuracy requirements in the depth of back etching of the nozzle barrel (113). Reactive ion etching is used to obtain near vertical side walls, to ensure that the ink flows to the end of the nozzle by surface tension.
- The wafer is back-etched to a thickness of approximately 200 microns. The actual thickness is not critical, but the variation in thickness is, however. The wafer must be etched such that the thickness variation is less than ± 2 microns over the wafer. If this is not achieved, it is difficult to subsequently ensure that the process of back etching the nozzles does not over-etch and destroy the heaters.
- The next step for a four colour head is to RIE
etch ink channels 101 in the reverse side of the surface of thechip 100 in the manner illustrated in Figs. 6 to 9. These channels 101 (Fig. 5) are approximately 600 microns wide × 100 microns deep. Thesechannels 101 are not essential to the operation of theZBJ chip 100, but have two advantages. Namely, thechannels 101 reduce the ink flow rate through the filter from approximately 8 mm per second to 2 mm per second. This flow rate reduction can alternatively be achieved by locating the filter differently in theZBJ head 200. Also, the channels reduce the depth that thenozzles 110 need to be etched from 190 microns to 90 microns. As the nozzle barrels 113 are 40 microns in diameter, this has a major effect on the ratio of length to diameter of thebarrels 113. - The ink channel back-etching process can also be used to thin the wafer along the dice lines in the manner earlier described with reference to Fig. 33.
- The etch depth of the next step, nozzle barrel back-
etching 419, is critical to ensure that thenozzle barrel 113 properly joins with the nozzle tip 417 (111) to form the thermal chamber. A solution to this problem is to incorporate end point detection using optical spectroscopy. A chemical etch stop signal can be created by filling thenozzle tips 417 previously etched from the front surface of the substrate with a detectable chemical signature, and monitoring the exhaust gases with an emission spectroscope. The nozzle barrels 113 are formed with an anisotropic reactive ion etch of silicon.Holes 40 microns in diameter (later widened to 60 microns with an isotropic plasma etch), are etched 70 microns into the silicon from the reverse side of the wafer. These holes are at the bottom of the previously etched ink channels, which are 100 microns deep. As the wafer is thinned to 200 microns, these holes etch to within 30 microns of the front surface of the silicon. - When the
end point 421 detection signal from the spectroscope begins, the etch can be stopped, even if some of the nozzles have not joined up to the tips. This is because the next step (10 micron isotropic etching of all exposed silicon) joins up any that are within about 12 microns. Fig. 42 shows the ZBJ chip at the end of this step. - Etch depth uniformity over the entire wafer surface is critical. The tolerance depends largely on the depth of each etch achievable with the 18 micron hole etched from the front of the chip. Given that the front etched hole is etched 30 ± 2 microns, wafer thickness is 200 ± 2 microns, ink channel back etch depth is 100 ± 4 microns, overall isotropic etch of silicon is 10 ± 1 microns, maximum joining distance is 12 microns, and the minimum between the nozzle barrel and the heater is 10 microns, cumulative tolerances mean that the nozzle barrel etch must be 70 ± 4 microns. All of these tolerances can be loosened if the front etch can be deeper than 30 microns. The accuracy of alignment of the back-etching process to the front surface processes need only be to within ± 10 microns, as alignment of the barrel and tip is not critical.
- The cumulative effect of these tolerances is illustrated in Fig. 43. The
cross-hatched area 424 seen in Fig. 43 shows the region of uncertainty in the final nozzle geometry, and the single-hatchedarea 423 shows the safety margin for the nozzle barrel to nozzle tip join using these tolerances. This safety margin is required because the reactive ion etches will not leave perfectly flat bottomed holes. The uncertainty of the wafer thickness (200 ± 2 microns) and the channel etch (100 ± 4 microns) are combined into one thickness figure of 100 ± 6 microns as the channels are too large to be shown in this figure. - Other minor problems exist with this step, including: the resist must be very thick to be maintained for 70 microns of RIE; the etch is deep and narrow, giving problems with removal of spent etchant; shadowing of the projection pattern by the walls of the ink channels must be avoided; and adequate resist coverage of the stepped surface must be achieved. This is not critical as etching of the ink channel walls can be tolerated.
- However, the actual shape and dimensions of the rearside of the
nozzles 110 is not critical. This provides considerable scope for other solutions. All that is required is that the minimum mechanical strength is maintained, and that a shape conducive to ink capillary action is achieved. Some possible alternatives are: - Multi-stage RIE with progressively
narrower barrels 113 can be used. This avoids the problems of an accumulation of spent etchant and thick resists, but involves more processing steps; - Etching of wide holes which encompass
several nozzles 110, with the nozzles clustered in groups to provide maximum spacing between these holes, and therefore conserving mechanical strength. This is illustrated in Fig. 46. - The entire ZBJ wafer is then subjected to a 10 ± 1 micron isotropic plasma etch of all exposed silicon. This has two purposes. Firstly, this forms the
thermal chamber 115 by undercutting 425 thethermal silicon dioxide 132 in the region of theheater 120. This is also to ensure that the nozzle barrels 113 join with thenozzle tips 111 resulting from a widening 426 of thebarrels 113. As the wafer is etched from both sides, anynon-joining barrels 113 andtips 111 that are within 18 microns (twice (10 - 1) microns) should join up. Non-joining barrels and tips within approximately 12 microns will behave essentially similarly to joined barrels and tips. This reduces the accuracy requirements of the barrel back-etch 419. - The etch must be highly selective towards silicon, and have a negligible etch rate with thermal silicon dioxide, otherwise the
heater insulation layer 132 will be destroyed. This results in the configuration illustrated in Fig. 44. - The 4
micron glass overcoat 142 must now be etched to expose the bonding pads. This is not performed before the nozzle tip silicon etch because poor selectivity can cause the 30 micron RIE silicon etch to etch through the aluminium layer 139. TheZBJ chip 100 can then be passivated with a 0.5micron layer 144 of tantalum or other suitable material. It can be difficult to achieve a highly conformal coating, but irregularities in the passivation thickness will not substantially affect the performance of theZBJ chip 100. - The
ZBJ chip 100 has no electrical output, and therefore true functional testing can only be achieved by loading the device with ink into printing and printing patterns which exercise eachindividual nozzle 110. This cannot be performed at multi-probe time. An effective method of functional testing thechips 100 at multi-probe time is to test the power consumption in the V+ to ground path as eachheater 120 is turned on in sequence. Each time aheater 120 is fired, a current pulse should occur. As this is a separate circuit with negligible quiescent current, these pulses are readily detected. The entire pattern of operational heaters and redundant circuits can be determined in approximately 1 second with inexpensive equipment. Therefore, the entire wafer can be multi-probed in under one minute. The pattern of functional and non-functional heaters can be read into a computer and be used for compiling process statistics and detecting local quality control problems. - Scribing is along the top surface of the etched dice channels 147 (see Fig. 33). The
end tabs 148 for handling must be diced off before the ZBJ chips 100 can be separated. Thechips 100 can be glued in place in thehead assemblies 200 and connected using tape automated bonding, with one tape along each edge of the chip. Alternatively, standard wire bonding can be used, as long as enough wires are bonded to meet the high current requirements of thechip 100. Fig. 45 illustrates the cross-section of the completed device. - Fig. 47 is a plan view of typical components used in a ZBJ chip of the structure shown in Fig. 14. Figs. 48 to 78 are vertical cross-sections through the centre line of Fig. 47 at various manufacturing stages.
- Fig. 48: The manufacturing process commences with a standard silicon wafer of P-type doping with a resistivity of approximately 25 ohm cm.
- Fig. 49: A layer of
silicon nitride 501 approximately 0.15 microns thick is grown on thewafer 500. This is a standard NMOS process . - Fig. 50: A
first mask 501 is used to pattern thesilicon nitride 501 to prepare for boron implantation. - Fig. 51: The
wafer 500 is implanted with afield 503 of boron to eliminate the formation of spurious transistors. - Fig. 52: A
thermal oxide layer 504 approximately 0.8 microns thick is grown on the boron implantedfield 503. - Fig. 53: The remaining
silicon nitride 501 is removed. - Fig. 54: This is a standard NMOS process which implants arsenic to form
regions 505 for deletion mode transistors. This step involves the spin deposition of a resist, exposure of the resist to the second mask, development of the resist, arsenic implantation, and resist removal. - Fig. 55: A 0.1
micron gate oxide 506 is thermally grown. This is part of a standard NMOS process and increases the field oxide thickness to 0.9 microns. - Fig. 56: A 1 micron layer of
polysilicon 507 is deposited over theentire wafer 500 using chemical vapour deposition. - Fig. 57: The
polysilicon 507 is patterned using athird mask 508. Thewafer 500 is spin coated with resist. The resist is exposed using the third mask and is developed. Thepolysilicon 507 is then etched using an anisotropic ion enhanced etching to reduce undercutting. - Fig. 58: The
gate oxide 506 is etched where exposed by the polysilicon etch of the third mask. This results inetch diffusion windows 509 being formed and will also thin thefield oxide 504 leaving a thickness of 0.8 microns. - Fig. 59:
N+ diffusion regions 510 approximately 1 micron deep are formed in thediffusion windows 509. - Fig. 60: A 1 micron layer of
glass 511 is deposited using chemical vapour deposition. - Fig. 61: The
CVD glass 511 is etched where contacts are required to thepolysilicon 507, thediffusions 510 and in the heater region. Contactregions 512 are formed. This process differs from the standard NMOS process in that the depth of etch is controlled so that there is an appropriate amount ofthermal SiO 2 504 remaining under the heaters. - Fig. 62: A 0.05
micron layer 513 of HfB2 is deposited over thewafer 500. This is not a standard NMOS process. - Fig. 63: A HfB2 layer 513 is etched using ion enhanced etching with CCl4 as the etchant. This exposes the
heaters 514. This step requires spin coating of resist, exposure to a fifth level mask, development of resist, ion enhanced etching, and resist stripping. - Fig. 64: A 1 micron
first metal level 515 of aluminium is evaporated over thewafer 500. - Fig. 65: The
first metal level 515 is etched using a sixth level mask. This step requires spin coating of resist, exposure to the sixth mask, development of resist, plasma etching, and resist stripping. The etch must be strongly selective over HfB2, as the HfB2 layer is only 0.05 microns and will be exposed when themetal 515 is etched. - Fig. 66: A 1
micron layer 516 of glass is deposited using chemical vapour deposition. - Fig. 67: Pattern contacts for the seventh level mask are made using a standard contact etch for 2 micron NMOS with double level metal. This step requires spin coating of resist, exposure to the seventh mask, development of resist, ion enhanced etching, and resist stripping.
- Fig. 68: A 1 micron second
level metal layer 517 of aluminium is evaporated over thewafer 500. Thismetal layer 517 provides the second level of contacts. This is required because a high wiring density is required to theheaters 514, which must be metal for low resistance. This layer also provides the thermal diffuser or thermal shunt as described in the earlier embodiments. - Fig. 69: The
second level metal 517 is etched using an eighth mask. This step requires spin coating of resist, exposure to the eighth mask, development of the resist, plasma etching, and resist stripping. This is a normal NMOS step. The isolated metal disk above theheaters 514 is the thermal diffuser used to distribute waste heat to avoid hot-spots. - Fig. 70: A
thick layer 518 of glass is deposited over thewafer 500. Thelayer 518 must be thick enough to provide adequate mechanical strength to resist the shock of imploding bubbles. Also, enough glass must be deposited to diffuse the heat over a wide enough area so that the ink does not boil when in contact with it. 4 micron thickness is considered adequate, but can be easily varied if desired. - Fig. 71: This step requires etching using a ninth level mask of a
cylindrical barrel 519 into theovercoat 518, through thethermal oxide layer 504 down to the implantedfield 503. Both CVD glass and thermal quartz are etched. This step requires spin coating of resist, exposure to a ninth level mask, development of resist, and anisotropic ion enhanced etching, and resist stripping. - Fig. 72: The
thermal chamber 520 is formed by an isotropic plasma etch of silicon, highly selective over SiO2. This is essential, as otherwise the protective layer of SiO2 separating theheater 514 from the passivation will be etched. The previously etchedbarrel 519 acts as the mask for this step. In this case, an isotropic etch of 17 microns is used. Care must be taken not to fully etch the thermal SiO2 layer 504. - Fig. 73:
Nozzle channels 521 are etched from the reverse side of thewafer 500 by an anisotropic ion enhanced etching. Thechannels 521 are about 60 microns in diameter, and about 500 microns deep. The depth of thechannels 521 is such that the distance between the top of the channel and the bottom of thethermal chamber 520 is the required nozzle length. The etching place through a layer of resist 522. - Fig. 74: The nozzle via is etched from the front side of the
wafer 500 using a highly anisotropic ion enhanced etching. This etch is from the bottom of the thethermal chamber 520 to the top of the back etchednozzle channels 521, and is about 20 microns in length, and 20 microns in diameter. The nozzle barrels 523 are formed therefrom. - Fig. 75: A 0.5
micron passivation layer 524 of tantalum is conformably coated over theentire wafer 500. - Fig. 76: In this step, windows are opened for the
bonding pads 525. This requires a resist coating, exposure to a twelfth level mask, resist development, etching of thetantalum passivation layer 524, ion enhance etching of theovercoat 518, and resist stripping. As 2 microns of aluminium is available in the pad regions, it is easy to avoid etching through the pads formed by thesecond level metal 517. - Fig. 77: After probing of the
wafer 500, the ZBJ chip is mounted into a frame or support extrusion as earlier described and glued into place.Wires 526 are bonded to the pads formed by thesecond level metal 525 at the ends of the chip. Power rails are bonded along the two long edges of the chip. Connections are then potted in epoxy resin. - Fig. 78: This shows a forward ejection type ZBJ nozzle filled with
ink 527. In this case, the droplet is ejected downwards when the nozzle fires. This type of head requires priming of ink using positive pressure, as it will not be filled by capillary action. A similar head construction can be used for reverse firing nozzles by filling the head heat chip from the other side. - Whilst the foregoing represents a fabrication process for a general, preferred nozzle structure, similar steps, although with some differences, can be used for the specific nozzle structures illustrated in Figs. 13 to 18. Each of the following processes is a 2 micron NMOS with two level metal process as this is the simplest process which can be used to produce high resolution, high performance colour ZBJ devices. Also, the consistency between the processes permits an easier comparison therebetween.
- A summary of the process steps required to provide the structure shown in Fig. 13 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride;
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) grow 0.8 micron field oxide;
- 6) implant depletion
arsenic using mask 2; - 7) grow 0.1 micron gate oxide;
- 8) deposit polysilicon (1 micron);
- 9) pattern
polysilicon using mask 3; - 10) etch diffusion windows;
- 11) diffuse n+ regions;
- 12)
deposit 1 micron CVD glass; - 13) pattern
contacts using mask 4; - 14) deposit 0.05 micron hafnium boride heater;
- 15) etch
heater using mask 5; - 16) deposit first metal (1 micron);
- 17) pattern metal using mask 6;
- 18)
deposit 1 micron CVD glass; - 19) pattern contacts using mask 7;
- 20) deposit second metal (including thermal shunt), 1 micron aluminium;
- 21) pattern
metal using mask 8; - 22) deposit 10 microns CVD glass;
- 23) etch nozzle through CVD glass using mask 9;
- 24) etch thermal chamber using isotropic etch;
- 25) back-etch barrels through the
wafer using mask 10; - 26) join thermal chambers to barrels using an anisotropic, unmasked etch;
- 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 11; - 29) wafer probe;
- 30) mount into head assembly;
- 31) bond wires;
- 32) pot in epoxy;
- 33) fill with ink. Head will fill by capillarity.
- A summary of the process steps required to provide the structure shown in Fig. 14 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) grow 0.8 micron field oxide;
- 6) implant depletion
arsenic using mask 2; - 7) grow 0.1 micron gate oxide;
- 8) deposit polysilicon (1 micron);
- 9) pattern
polysilicon using mask 3; - 10) etch diffusion windows;
- 11) diffuse n+ regions;
- 12)
deposit 1 micron CVD glass; - 13) pattern
contacts using mask 4; - 14) deposit 0.05 micron HfB2 heater;
- 15) etch
heater using mask 5; - 16) deposit first metal (1 micron);
- 17) pattern metal using mask 6;
- 18)
deposit 1 micron CVD glass; - 19) pattern contacts using mask 7;
- 20) deposit second metal (including thermal diffuser), 1 micron aluminium;
- 21) pattern
metal using mask 8; - 22)
deposit 3 microns CVD glass; - 23) etch entrance to thermal chamber through CVD glass using mask 9;
- 24) etch thermal chamber using isotropic plasma etch;
- 25) etch holes 520 microns deep, 80 microns wide from the back side of the wafer, using
mask 10; - 26) join thermal chambers to barrels using an anisotropic RIE using thermal chamber entrance as a mask;
- 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 11; - 29) wafer probe;
- 30) bond wires;
- 31) pot in epoxy
- 32) mount into head assembly;
- 33) fill head assembly with ink;
- 34) prime head with positive ink pressure above the bubble pressure of the nozzle.
- A summary of the process steps required to provide the structure shown in Fig. 15 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride;
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) etch a circular trench around the nozzle position. 22 microns diameter, 2 microns deep, 1 micron wide using
mask 2; - 6) grow 0.4 micron field oxide (this also grows on the trench walls);
- 7) deposit 0.05 micron HfB2 heater;
- 8) etch
heater using mask 3; - 9) implant
arsenic using mask 4; - 10) grow 0.1 micron gate oxide;
- 11) deposit polysilicon (1 micron);
- 12) pattern
polysilicon using mask 5; - 13) etch diffusion windows;
- 14) diffuse n+ regions;
- 15)
deposit 1 micron CVD glass; - 16) pattern contacts using mask 6;
- 17) deposit first metal (1 micron);
- 18) pattern metal using mask 7;
- 19)
deposit 1 micron CVD glass; - 20) pattern
contacts using mask 8; - 21) deposit second metal, 1 micron aluminium;
- 22) pattern metal using mask 9;
- 23) deposit 20 microns CVD glass, forming the nozzle layer;
- 24) anisotropically etch thermal chamber and nozzle using mask 10 (undersized diameter of less than 18 microns);
- 25) etch holes 520 microns deep, 80 microns wide from the back side of the wafer, using
mask 11. Join to nozzles. - 26) use a silicon specific isotropic "wash" etch to enlarge the thermal chamber to the edge of to the heater trench;
- 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 12; - 29) wafer probe;
- 30) bond wires;
- 31) pot in epoxy;
- 32) mount into head assembly;
- 33) fill head assembly with ink.
- A summary of the process steps required to provide the structure shown in Fig. 16 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride;
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) etch a circular trench around the nozzle position. 22 microns diameter, 2 microns deep, 1 micron wide using
mask 2; - 6) grow 0.4 micron field oxide (this also grows on the trench walls);
- 7) deposit 0.05 micron HfB2 heater;
- 8) etch
heater using mask 3; - 9) implant
arsenic using mask 4; - 10) grow 0.1 micron gate oxide;
- 11) deposit polysilicon (1 micron);
- 12) pattern
polysilicon using mask 5; - 13) etch diffusion windows;
- 14) diffuse n+ regions;
- 15)
deposit 1 micron CVD glass; - 16) pattern contacts using mask 6;
- 17) deposit first metal (1 micron);
- 18) pattern metal using mask 7;
- 19)
deposit 1 micron CVD glass; - 20) pattern
contacts using mask 8; - 21) deposit second metal (including thermal diffuser), 1 micron aluminium;
- 22) pattern metal using mask 9;
- 23)
deposit 3 microns CVD glass; - 24) anisotropically etch thermal chamber and nozzle using mask 10 (undersized diameter of less than 18 microns to avoid etching heaters);
- 25) etch holes 520 microns deep, 80 microns wide from the back side of the wafer, using
mask 11. Join to nozzles. - 26) use a silicon specific isotropic "wash" etch to enlarge the thermal chamber to the edge of to the heater trench;
- 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 12; - 29) wafer probe;
- 30) bond wires;
- 31) pot in epoxy;
- 32) mount into head assembly;
- 33) fill head assembly with ink.
- A summary of the process steps required to provide the structure shown in Fig. 17 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride;
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) grow 0.7 micron field oxide;
- 6) implant
arsenic using mask 2; - 7) grown 0.1 micron gate oxide;
- 8) deposit polysilicon (1 micron);
- 9) pattern
polysilicon using mask 3; - 10) etch diffusion windows;
- 11) diffuse n+ regions;
- 12) etch a 2 micron deep circular depression slightly wider than the nozzle
diameter using mask 4; - 13)
deposit 1 micron CVD glass; - 14) pattern
contacts using mask 5; - 15) deposit 0.05 micron HfB2 heater;
- 16) etch heater anisotropically (in the vertical direction only) using mask 6;
- 17) deposit first metal (1 micron);
- 18) pattern metal using mask 7;
- 19)
deposit 1 micron CVD glass. This provides inter- level dielectric, as well as covering the heater. - 20) pattern
contacts using mask 8; - 21) deposit second metal (including thermal diffuser), 1 micron aluminium;
- 22) pattern metal using mask 9;
- 23) deposit 20 microns CVD glass;
- 24) anisotropically etch nozzle into CVD
glass using mask 10; - 25) etch the silicon thermal chamber anisotropically using an ion assisted plasma etch specific for silicon, using CVD glass nozzle as a mask;
- 26) etch holes 520 microns deep, 80 microns wide from the back side of the wafer, using
mask 11. Join to thermal chambers; - 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 12; - 29) wafer probe;
- 30) bond wires;
- 31) pot in epoxy;
- 32) mount into head assembly;
- 33) fill head assembly with ink.
- A summary of the process steps required to provide the structure shown in Fig. 18 is as follows:
- 1) starting wafer: p type, 600 microns thick;
- 2) grow 0.15 microns silicon nitride;
- 3) pattern
nitride using mask 1; - 4) implant field;
- 5) grow 0.7 micron field oxide;
- 6) implant
arsenic using mask 2; - 7) grown 0.1 micron gate oxide;
- 8) deposit polysilicon (1 micron);
- 9) pattern
polysilicon using mask 3; - 10) etch diffusion windows;
- 11) diffuse n+ regions;
- 12) etch a 2 micron deep circular depression slightly wider than the nozzle
diameter using mask 4; - 13)
deposit 1 micron CVD glass; - 14) pattern
contacts using mask 5; - 15) deposit 0.05 micron HfB2 heater;
- 16) etch heater anisotropically (in the vertical direction only) using mask 6;
- 17) deposit first metal (1 micron);
- 18) pattern metal using mask 7;
- 19)
deposit 1 micron CVD glass. This provides inter- level dielectric, as well as covering the heater. - 20) pattern
contacts using mask 8; - 21) deposit second metal (including thermal diffuser), 1 micron aluminium;
- 22) pattern metal using mask 9;
- 23)
deposit 3 microns CVD glass; - 24) anisotropically etch thermal chamber into CVD
glass using mask 10; - 25) etch silicon nozzle anisotropically using an ion assisted plasma etch specific for silicon, using CVD glass hole as a mask;
- 26) etch holes 520 microns deep, 80 microns wide from the back side of the wafer, using
mask 11. Join to nozzles; - 27) deposit 0.5 micron tantalum passivation;
- 28) open
pads using mask 12; - 29) wafer probe;
- 30) bond wires;
- 31) pot in epoxy;
- 32) mount into head assembly;
- 33) fill head assembly with ink.
- The
ZBJ printhead 200 incorporating theZBJ chip 100 is useful in a variety of printing applications either printing across the page in the traditional manner, as a scanning print head, or as a stationary full width print head.TABLE 1 Application -Feature 1.Scanning Contone colour ZBJ Head 2.Scanning Grey Tone ZBJ Head 3.Photo Size Contone Color ZBJ Head 4.Full Width A4 Contone Color ZBJ Head Chip Size (mm) 10 × 4 10 × 1.5 100 × 2 220 × 4 No. of Nozzles 2048 512 5120 51200 No. of Pixels 128 128 1280 3200 Nozzles Per Pixel Per Color 4 4 1 4 No. of colours 4 1 4 4 Print Speed 3 mins (A4) 3 mins (A4) 8 sec (photo) 3.7 sec (A4) Tone FULL GREY SCALE Resolution (pixel/inch) 400 400 400 400 Application /Feature 5.Full Width A4 Bilevel ZBJ Head 6.High Speed A3 Contone colour ZBJ Head 7.Medium Speed A3 Contone colour ZBJ Head Chip Size (mm) 220 × 2 310 × 4 310 × 2 No. of Nozzles 12800 71680 17920 No. of Pixels 12800 4480 4480 Nozzles Per Pixel Per Color 1 4 1 No. of colours 1 4 4 Print Speed 3.7 sec (A4) 5.3 sec (A3) 21 sec (A3) Tone FULL GREY SCALE Resolution (pixel per inch) 1600 400 400
Claims (11)
- A method of fabricating a bubblejet print device (100) using semiconductor fabrication techniques, said method comprising the steps ofproviding a substrate member (130) having a heater means (120), electrodes (407, 408) electrically connected to said heater means (120), and an overcoat (142) for protecting said heater means (120),forming a first hole (111, 417) into said substrate member (130) adjacent to said heater means (120) from one side on which said overcoat (142) is provided,forming a second hole (113, 419) into said substrate member (130) from the other side, said second hole (113, 419) being communicated with said first hole (111, 417), thereby forming a passageway (110) through said substrate member (130).
- A method according to claim 1, further comprising the step of forming a heat dissipation passage (400, 410).
- A method according to claim 1, wherein a plurality of said passageways (110) is two-dimensionally formed in said substrate member (130).
- A method according to claim 1, wherein a plurality of said heater means (120) is formed on said substrate member (130) and a plurality of said passageways (110) is formed in correspondency with said plurality of said heater means (120).
- A method according to claim 3 or 4, further comprising the step of forming an ink channel (101) communicating with said plurality of said passageways (110).
- A method according to claim 1, further comprising the step of forming a drive circuit on said substrate member (130) and a surface portion thereof.
- A method according to claim 6, wherein said drive circuit has a transistor (164, 193).
- A method according to claim 6, wherein each step of said step of providing said substrate member (130) having said heater means (120) and said electrodes (407, 408) electrically connected to said heater means (120), and said step of forming said drive circuit comprises a plurality of substeps at least a part of which are common to both of said steps.
- A method according to claim 1, wherein said substrate member (130) consists of a silicon substrate.
- A method according to claim 1, further comprising the step of removing at least a part of that portion of said substrate member (130), on which said heater means (120) is formed.
- A method according to claim 1, wherein said substrate member (130) is etched along intended dice or score lines (147) to facilitate dicing of said substrate member (130) into individual print devices.
Applications Claiming Priority (36)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPK437491 | 1991-01-30 | ||
AU4374/91 | 1991-01-30 | ||
AU4740/91 | 1991-02-22 | ||
AU4733/91 | 1991-02-22 | ||
AUPK473791 | 1991-02-22 | ||
AUPK473891 | 1991-02-22 | ||
AUPK473591 | 1991-02-22 | ||
AUPK474591 | 1991-02-22 | ||
AU4743/91 | 1991-02-22 | ||
AUPK473191 | 1991-02-22 | ||
AUPK474291 | 1991-02-22 | ||
AUPK473391 | 1991-02-22 | ||
AU4746/91 | 1991-02-22 | ||
AUPK473291 | 1991-02-22 | ||
AU4745/91 | 1991-02-22 | ||
AU4738/91 | 1991-02-22 | ||
AU4739/91 | 1991-02-22 | ||
AUPK474691 | 1991-02-22 | ||
AUPK474191 | 1991-02-22 | ||
AU4737/91 | 1991-02-22 | ||
AU4736/91 | 1991-02-22 | ||
AU4735/91 | 1991-02-22 | ||
AUPK473491 | 1991-02-22 | ||
AUPK473691 | 1991-02-22 | ||
AUPK473991 | 1991-02-22 | ||
AUPK474391 | 1991-02-22 | ||
AU4741/91 | 1991-02-22 | ||
AUPK474491 | 1991-02-22 | ||
AUPK474091 | 1991-02-22 | ||
AU4731/91 | 1991-02-22 | ||
AU4732/91 | 1991-02-22 | ||
AU4742/91 | 1991-02-22 | ||
AU4734/91 | 1991-02-22 | ||
AU4744/91 | 1991-02-22 | ||
AU89998/91A AU657931B2 (en) | 1991-01-30 | 1991-12-23 | An integrally formed bubblejet print device |
AU89998/91 | 1991-12-23 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0498292A2 EP0498292A2 (en) | 1992-08-12 |
EP0498292A3 EP0498292A3 (en) | 1993-02-24 |
EP0498292B1 true EP0498292B1 (en) | 1996-11-27 |
Family
ID=27586060
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP92101475A Expired - Lifetime EP0498292B1 (en) | 1991-01-30 | 1992-01-29 | Integrally formed bubblejet print device |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0498292B1 (en) |
AT (1) | ATE145589T1 (en) |
AU (1) | AU657931B2 (en) |
DE (1) | DE69215397T2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SG109973A1 (en) * | 1997-07-15 | 2005-04-28 | Silverbrook Res Pty Ltd | Fluid supply mechanism for multiple fluids to multiple spaced orifices |
Families Citing this family (39)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5905517A (en) * | 1995-04-12 | 1999-05-18 | Eastman Kodak Company | Heater structure and fabrication process for monolithic print heads |
US5815179A (en) * | 1995-04-12 | 1998-09-29 | Eastman Kodak Company | Block fault tolerance in integrated printing heads |
EP0765222A1 (en) * | 1995-04-12 | 1997-04-02 | Eastman Kodak Company | A portable printer using a concurrent drop selection and drop separation printing system |
AUPN232695A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Nozzle duplication for fault tolerance in integrated printing heads |
US6045710A (en) * | 1995-04-12 | 2000-04-04 | Silverbrook; Kia | Self-aligned construction and manufacturing process for monolithic print heads |
AUPN233395A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | A high speed digital fabric printer |
AUPN232595A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Block fault tolerance in integrated printing heads |
AUPN229595A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Integrated drive circuitry in lift print heads |
EP0772525A1 (en) * | 1995-04-12 | 1997-05-14 | Eastman Kodak Company | Constructions and manufacturing processes for thermally activated print heads |
AUPN234995A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | A self-aligned manufacturing process for monolithic lift print heads |
US6012799A (en) * | 1995-04-12 | 2000-01-11 | Eastman Kodak Company | Multicolor, drop on demand, liquid ink printer with monolithic print head |
US5801739A (en) * | 1995-04-12 | 1998-09-01 | Eastman Kodak Company | High speed digital fabric printer |
EP0765226A1 (en) * | 1995-04-12 | 1997-04-02 | Eastman Kodak Company | Color video printer and a photo-cd system with integrated printer |
AUPN230695A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | A manufacturing process for monolithic lift print heads using anistropic wet etching |
US5838339A (en) * | 1995-04-12 | 1998-11-17 | Eastman Kodak Company | Data distribution in monolithic print heads |
AUPN231895A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Data distribution in monolithic lift print heads |
AUPN230495A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Integrated four color lift print heads |
WO1996032809A1 (en) * | 1995-04-12 | 1996-10-17 | Eastman Kodak Company | A color photocopier using a drop on demand ink jet printing system |
AUPN229295A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | A notebook computer with integrated lift color printing system |
US5825385A (en) * | 1995-04-12 | 1998-10-20 | Eastman Kodak Company | Constructions and manufacturing processes for thermally activated print heads |
US5984446A (en) * | 1995-04-12 | 1999-11-16 | Eastman Kodak Company | Color office printer with a high capacity digital page image store |
US5859652A (en) * | 1995-04-12 | 1999-01-12 | Eastman Kodak Company | Color video printer and a photo CD system with integrated printer |
AUPN234695A0 (en) * | 1995-04-12 | 1995-05-04 | Eastman Kodak Company | Heater structure for monolithic lift print heads |
US5850241A (en) * | 1995-04-12 | 1998-12-15 | Eastman Kodak Company | Monolithic print head structure and a manufacturing process therefor using anisotropic wet etching |
AUPN522295A0 (en) * | 1995-09-06 | 1995-09-28 | Eastman Kodak Company | Cmos process compatible fabrication of lift print heads |
EP0771656A3 (en) * | 1995-10-30 | 1997-11-05 | Eastman Kodak Company | Nozzle dispersion for reduced electrostatic interaction between simultaneously printed droplets |
AUPN623895A0 (en) * | 1995-10-30 | 1995-11-23 | Eastman Kodak Company | A manufacturing process for lift print heads with nozzle rim heaters |
US6193347B1 (en) | 1997-02-06 | 2001-02-27 | Hewlett-Packard Company | Hybrid multi-drop/multi-pass printing system |
US6259463B1 (en) | 1997-10-30 | 2001-07-10 | Hewlett-Packard Company | Multi-drop merge on media printing system |
US6193345B1 (en) | 1997-10-30 | 2001-02-27 | Hewlett-Packard Company | Apparatus for generating high frequency ink ejection and ink chamber refill |
US6234613B1 (en) * | 1997-10-30 | 2001-05-22 | Hewlett-Packard Company | Apparatus for generating small volume, high velocity ink droplets in an inkjet printer |
US6820966B1 (en) | 1998-10-24 | 2004-11-23 | Xaar Technology Limited | Droplet deposition apparatus |
WO2000024584A1 (en) * | 1998-10-24 | 2000-05-04 | Xaar Technology Limited | Droplet deposition apparatus |
CN1565845A (en) | 1999-06-30 | 2005-01-19 | 西尔弗布鲁克研究股份有限公司 | Printhead support structure and assembly |
DE60043240D1 (en) * | 2000-06-30 | 2009-12-10 | Silverbrook Res Pty Ltd | INK SUPPLY UNIT FOR A PRINTER |
US6676250B1 (en) | 2000-06-30 | 2004-01-13 | Silverbrook Research Pty Ltd | Ink supply assembly for a print engine |
JP5159069B2 (en) * | 2006-08-29 | 2013-03-06 | キヤノン株式会社 | Liquid ejection method |
CN107782767B (en) * | 2016-08-26 | 2022-01-07 | 深迪半导体(绍兴)有限公司 | Heating plate of gas sensor and processing method |
CN114633003A (en) * | 2022-03-25 | 2022-06-17 | 中国人民解放军陆军装甲兵学院 | Welding method and device for medium-thickness aluminum alloy plate |
Family Cites Families (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE3331488A1 (en) * | 1982-09-01 | 1984-03-01 | Konishiroku Photo Industry Co., Ltd., Tokyo | HEAD PIECE FOR A PAINT SPRAY PRINTING DEVICE |
JPS608076A (en) * | 1983-06-28 | 1985-01-16 | Seiko Instr & Electronics Ltd | Ink jet recorder |
JPS6018359A (en) * | 1983-07-12 | 1985-01-30 | Hitachi Ltd | Thermal recording apparatus |
JPS61106270A (en) * | 1984-10-30 | 1986-05-24 | Fuji Xerox Co Ltd | Thermal head |
US4812859A (en) * | 1987-09-17 | 1989-03-14 | Hewlett-Packard Company | Multi-chamber ink jet recording head for color use |
US4847630A (en) * | 1987-12-17 | 1989-07-11 | Hewlett-Packard Company | Integrated thermal ink jet printhead and method of manufacture |
JPH01186700A (en) * | 1988-01-14 | 1989-07-26 | Matsushita Electric Ind Co Ltd | Printed wiring board structure |
JP2614265B2 (en) * | 1988-04-12 | 1997-05-28 | 株式会社リコー | Liquid jet recording head |
GB8810241D0 (en) * | 1988-04-29 | 1988-06-02 | Am Int | Drop-on-demand printhead |
DE68914897T2 (en) * | 1988-07-26 | 1994-08-25 | Canon Kk | Liquid jet recording head and recording apparatus provided with this head. |
JPH02204044A (en) * | 1989-02-03 | 1990-08-14 | Canon Inc | Ink jet head |
-
1991
- 1991-12-23 AU AU89998/91A patent/AU657931B2/en not_active Ceased
-
1992
- 1992-01-29 DE DE69215397T patent/DE69215397T2/en not_active Expired - Lifetime
- 1992-01-29 EP EP92101475A patent/EP0498292B1/en not_active Expired - Lifetime
- 1992-01-29 AT AT92101475T patent/ATE145589T1/en active
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN, vol. 9, no. 121 (M-382)(1844), 25th May 1985; & JP-A-60 8076 (SEIKO DENSHI KOGYO K.K.) 16.01.1985 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
SG109973A1 (en) * | 1997-07-15 | 2005-04-28 | Silverbrook Res Pty Ltd | Fluid supply mechanism for multiple fluids to multiple spaced orifices |
Also Published As
Publication number | Publication date |
---|---|
AU657931B2 (en) | 1995-03-30 |
DE69215397T2 (en) | 1997-06-05 |
AU8999891A (en) | 1992-08-06 |
ATE145589T1 (en) | 1996-12-15 |
EP0498292A3 (en) | 1993-02-24 |
EP0498292A2 (en) | 1992-08-12 |
DE69215397D1 (en) | 1997-01-09 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP0498292B1 (en) | Integrally formed bubblejet print device | |
US5841452A (en) | Method of fabricating bubblejet print devices using semiconductor fabrication techniques | |
US6019457A (en) | Ink jet print device and print head or print apparatus using the same | |
US5815173A (en) | Nozzle structures for bubblejet print devices | |
JP3222593B2 (en) | Inkjet recording head and monolithic integrated circuit for inkjet recording head | |
JPH05338178A (en) | Ink jet print device | |
JP4685174B2 (en) | Ink jet print head having ink flow control structure | |
EP0154515B1 (en) | Bubble jet printing device | |
EP0498293B1 (en) | Bubblejet image reproducing apparatus | |
CN1307053C (en) | Inkjet printhead having thermal bend actuator heating element electrically isolated from nozzle chamber ink | |
EP0498291B1 (en) | Nozzle structures for bubblejet print devices | |
EP0434946A2 (en) | Ink jet printhead having ionic passivation of electrical circuitry | |
US6364466B1 (en) | Particle tolerant ink-feed channel structure for fully integrated inkjet printhead | |
US6517735B2 (en) | Ink feed trench etch technique for a fully integrated thermal inkjet printhead | |
US4835553A (en) | Thermal ink jet printhead with increased drop generation rate | |
JP2839964B2 (en) | Printhead substrate and printhead manufacturing method | |
JP3046640B2 (en) | Method of manufacturing substrate for recording head and method of manufacturing recording head | |
JP2846501B2 (en) | Printhead substrate and printhead manufacturing method | |
JP3046641B2 (en) | Method of manufacturing substrate for ink jet recording head and method of manufacturing ink jet recording head | |
JP3173811B2 (en) | Substrate for inkjet recording head and method for manufacturing inkjet recording head | |
JP3241060B2 (en) | Substrate for inkjet recording head, inkjet recording head, and inkjet recording apparatus | |
JPH0911468A (en) | Substrate for ink-jet recording head, ink-jet recording head, ink-jet recording device and information processing system | |
JPH08276597A (en) | Plate-shaped substrate for recording head, recording head using plate-shaped substrate and liquid jet recording apparatus loaded with recording head | |
JPH11179914A (en) | Substrate for ink jet recording head | |
JPH0596731A (en) | Base board for recording head and fabrication of recording head |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
17P | Request for examination filed |
Effective date: 19920129 |
|
AK | Designated contracting states |
Kind code of ref document: A2 Designated state(s): AT BE CH DE DK ES FR GB GR IT LI LU NL PT SE |
|
PUAL | Search report despatched |
Free format text: ORIGINAL CODE: 0009013 |
|
AK | Designated contracting states |
Kind code of ref document: A3 Designated state(s): AT BE CH DE DK ES FR GB GR IT LI LU NL PT SE |
|
17Q | First examination report despatched |
Effective date: 19940809 |
|
GRAH | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOS IGRA |
|
GRAH | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOS IGRA |
|
GRAA | (expected) grant |
Free format text: ORIGINAL CODE: 0009210 |
|
AK | Designated contracting states |
Kind code of ref document: B1 Designated state(s): AT BE CH DE DK ES FR GB GR IT LI LU NL PT SE |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: ES Free format text: THE PATENT HAS BEEN ANNULLED BY A DECISION OF A NATIONAL AUTHORITY Effective date: 19961127 Ref country code: NL Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 19961127 Ref country code: AT Effective date: 19961127 Ref country code: GR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 19961127 Ref country code: BE Effective date: 19961127 Ref country code: CH Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 19961127 Ref country code: LI Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 19961127 Ref country code: DK Effective date: 19961127 |
|
REF | Corresponds to: |
Ref document number: 145589 Country of ref document: AT Date of ref document: 19961215 Kind code of ref document: T |
|
REF | Corresponds to: |
Ref document number: 69215397 Country of ref document: DE Date of ref document: 19970109 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: LU Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 19970131 |
|
ET | Fr: translation filed | ||
ITF | It: translation for a ep patent filed |
Owner name: PROROGA CONCESSA IN DATA: 28.04.97;SOCIETA' ITALIA |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: SE Effective date: 19970227 Ref country code: PT Effective date: 19970227 |
|
NLV1 | Nl: lapsed or annulled due to failure to fulfill the requirements of art. 29p and 29m of the patents act | ||
REG | Reference to a national code |
Ref country code: CH Ref legal event code: PL |
|
PLBE | No opposition filed within time limit |
Free format text: ORIGINAL CODE: 0009261 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT |
|
26N | No opposition filed | ||
REG | Reference to a national code |
Ref country code: GB Ref legal event code: 732E |
|
REG | Reference to a national code |
Ref country code: FR Ref legal event code: TP |
|
REG | Reference to a national code |
Ref country code: GB Ref legal event code: IF02 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: IT Payment date: 20100120 Year of fee payment: 19 Ref country code: FR Payment date: 20100210 Year of fee payment: 19 |
|
PGFP | Annual fee paid to national office [announced via postgrant information from national office to epo] |
Ref country code: GB Payment date: 20100126 Year of fee payment: 19 Ref country code: DE Payment date: 20100131 Year of fee payment: 19 |
|
GBPC | Gb: european patent ceased through non-payment of renewal fee |
Effective date: 20110129 |
|
REG | Reference to a national code |
Ref country code: FR Ref legal event code: ST Effective date: 20110930 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: FR Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20110131 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GB Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20110129 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: IT Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20110129 |
|
REG | Reference to a national code |
Ref country code: DE Ref legal event code: R119 Ref document number: 69215397 Country of ref document: DE Effective date: 20110802 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: DE Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20110802 |