KR20100113600A - Double laser drilling of a printhead integrated circuit attachment film - Google Patents

Abstract

A method for producing a perforated polymer film. The method comprises the steps of: (a) masking the polymer film with a first mask in which a first laser transmission zone is formed; (b) laser ablation of the first opening through the polymer film using the first mask; (c) masking the film with a second mask in which a second laser transmission zone is formed, wherein each second zone is aligned with the corresponding first opening and has a larger circumferential dimension than the corresponding first opening. Having it; (d) reaming the first opening by laser ablation of the polymer film using a second mask, such that the reamed first opening forms a second opening in the film.

Description

DOUBLE LASER DRILLING OF A PRINTHEAD INTEGRATED CIRCUIT ATTACHMENT FILM}

The present invention relates to a printer, and more particularly to an inkjet printer.

Applicants have developed a variety of printers employing pagewidth printheads instead of traditional reciprocating printhead designs. Pagewidth design increases printing speed because the printhead does not traverse back and forth across the page to line the image. The pagewidth printhead simply deposits ink on the medium as the medium passes at high speed. These printheads enable full color 1600dpi printing at speeds near 60 pages per minute, which is not previously possible with conventional inkjet printers.

Printing at this speed consumes ink rapidly, which causes problems in supplying sufficient ink to the printhead. In addition to the higher flow rate, dispensing ink along the entire length of the pagewidth printhead is more complicated than supplying ink to a relatively small reciprocating printhead.

Another problem with the ink supply system is to avoid any particles reaching the nozzles. This is because particles are likely to block or damage the nozzles, affecting print quality. Therefore, it is desirable to remove as far as possible any particle debris that may accompany the ink flowing through the ink supply system in the manufacturing process of each component of the ink supply system.

In a first aspect, the present invention

(a) masking the polymer film with a first mask in which one or more first laser transmission zones are formed;

(b) laser-ablation one or more first apertures through the polymer film using the first mask;

(c) masking the film with a second mask in which at least one second laser transmission zone is formed, wherein each second zone is aligned with a corresponding first opening and has a perimeter greater than the corresponding first opening. Having a perimeter dimension;

(d) reaming the one or more first openings by laser ablation of the polymer film using the second mask, such that the reamed first openings form one or more second openings in the film. Provided is a method of making an apertured polymeric film, comprising the steps of:

Optionally, the perforated polymer film is an adhesive polymer film for attaching one or more printhead integrated circuits to an ink manifold, wherein the one or more second openings are one or more ink supply holes. To form.

Optionally, said adhesive polymer film comprises a central polymer film sandwiched between adhesive layers.

Optionally, said central polymer film is a polyimide film and said adhesive layer is an epoxy layer.

Optionally, the film is installed in a film package, the film package including the adhesive polymer film and a pair of removable protective liners, each liner protecting each adhesive layer.

Optionally, the laser ablation step ends at one of the protective liners.

Optionally, the laser ablation step is drilled through one of the central polymer film, the adhesive layers and the protective liners.

Optionally, the method further comprises (d) replacing at least one of said protective liners with a replacement liner.

Optionally, each first opening has a circumference that is about 5-30 microns smaller than the predetermined circumference of the corresponding second opening.

Optionally, each first opening has a circumference less than about 10 microns smaller than the predetermined circumference of the corresponding second opening.

Optionally, each second opening has a predetermined length dimension up to about 50 microns and a predetermined width dimension up to about 500 microns.

Optionally, the first opening is aligned with a carbonaceous deposit and the second opening is substantially free of the carbonaceous soot deposit.

In another aspect, as a film for attaching one or more printhead integrated circuits to an ink supply manifold, a film obtained or obtainable by the above method is provided.

In a second aspect, the invention provides a method for attaching one or more printhead integrated circuits onto an ink supply manifold,

(i) providing an adhesive film having a plurality of ink supply holes formed therein,

(ii) bonding the film to the ink supply manifold;

(iii) bonding the one or more printhead integrated circuits to the film,

In the step (i) the film,

(a) providing an adhesive protective film,

(b) masking the film with a first mask having a plurality of first laser transmission zones formed therein;

(c) laser ablation of the plurality of first holes through the polymer film using a first mask,

(d) masking the film with a second mask in which a plurality of second laser penetration zones are formed, each second zone being aligned with a corresponding first aperture and having a circumference greater than the corresponding first aperture Having dimensions;

(e) reaming the first hole by laser ablation of the polymer film using the second mask, such that each reamed first hole forms an ink supply hole through the film, A method of attaching one or more printhead integrated circuits to an ink supply manifold is provided.

Optionally, the ink supply manifold is an LCP molding.

Optionally, a plurality of said printhead integrated circuits are attached to said ink supply manifold so as to provide a pagewidth printhead butt to end.

Optionally, the ink supply hole is positioned to supply ink to ink supply channels formed on the rear side of the one or more printhead integrated circuits.

Optionally, the bonding step is carried out by thermal curing and / or thermal compression.

Optionally, the ink supply aperture is substantially free of carbon soot deposits.

In another aspect, a printhead assembly comprising at least one printhead integrated circuit bonded to an adhesive film having a plurality of ink supply holes formed thereon and attached to an ink supply manifold, the printhead assembly being obtained or obtained by the above method. A printhead assembly is provided.

Best Mode for Carrying Out the Invention Embodiments of the present invention will be described below only with reference to the accompanying drawings.

1 is a front and side perspective view of a printer embodying the present invention.
2 is a front view of the printer of FIG. 1 in an open position;
Figure 3 is a view of the printhead cartridge removed from the printer of Figure 2;
4 is a view of a state in which the outer housing is removed from the printer of FIG.
5 is a view of a state in which the printhead cartridge is installed with the outer housing removed from the printer of FIG.
6 is a schematic representation of a fluidic system of a printer.
7 is a top and front perspective view of the printhead cartridge.
8 is a top and front perspective view of the printhead cartridge in the protective cover.
9 is a top and front perspective view of a printhead cartridge created from a protective cover.
10 is a bottom and front perspective view of the printhead cartridge.
11 is a bottom and rear perspective view of the printhead cartridge.
12 (a) -12 (f) are front views of all sides of a printhead cartridge.
13 is an exploded perspective view of the printhead cartridge.
14 is a cross sectional view through an ink inlet coupling of a printhead cartridge.
15 is an exploded perspective view of the ink inlet and the filter assembly.
16 is a cross-sectional view of the cartridge valve associated with the printer valve.
17 is a perspective view of an LCP molding and a flex PCB.
18 is an enlarged view of a portion A shown in FIG. 17;
19 is an exploded bottom perspective view of the LCP / Flex PCB / Printhead IC assembly.
20 is an exploded top perspective view of an LCP / flex PCB / printhead IC assembly.
Figure 21 is an enlarged view of the underside of the LCP / Flex PCB / Printhead IC assembly.
Figure 22 is an enlarged view of Figure 21 with the printhead IC and flex PCB removed.
Figure 23 is an enlarged view of Figure 22 with the printhead IC attachment film removed.
FIG. 24 is an enlarged view of FIG. 23 with LCP channel molding removed. FIG.
Fig. 25 shows a printhead IC having a back channel and a nozzle superimposed on an ink supply passage.
FIG. 26 is an enlarged horizontal perspective view of an LCP / Flex PCB / Printhead IC assembly. FIG.
27 is a plan view of an LCP channel molding.
28 (a) and 28 (b) are schematic cross-sectional views of LCP channel molding priming without weirs.
29 (a), 29 (b) and 29 (c) are schematic cross-sectional views of LCP channel molding priming with weirs.
30 is an enlarged horizontal perspective view of an LCP molding with the position of contact force and reaction force.
Fig. 31 shows a reel of the IC attachment film.
32 shows a portion of an IC attachment film between liners.
33 (a) -33 (c) are partial cross-sectional views illustrating various stages of traditional laser drilling of an attachment film.
34 (a) -34 (c) are partial cross-sectional views illustrating various stages of dual laser drilling of an attachment film in accordance with the present invention.

summary( OVERVIEW )

1 shows a printer 2 embodying the present invention. The main body 4 of the printer supports the media feed tray 14 at the rear and the pivoting face 6 at the front. 1 shows the enclosed pivoting surface 6 such that the display screen is in its vertical viewing position. Control buttons 10 extend from the sides of the screen 8 to facilitate operator input while viewing the screen. For printing, a single sheet is withdrawn from media stack 12 in transfer tray 14 and passed through a printhead (hidden in the printer). The printed sheet 16 is ejected through the printed media outlet slot 18.

FIG. 2 shows a state in which the turning face 6 is opened to show the inside of the printer 2. Opening the front of the printer reveals the printhead cartridge 96 installed therein. The printhead cartridge 96 is a cartridge engagement cam that is pushed down to ensure that the ink coupling (described later) is fully engaged and that the printhead IC (described later) is correctly positioned adjacent the paper feed path. secured in place by a cartridge engagement cam 20. The cam 20 is manually operated by a release lever 24. The pivoting surface 6 will not be closed, so the printer will not operate until the release lever 24 is pushed down and fully engaged with the cam. When the turning surface 6 is closed, the printer contacts 22 engage with the cartridge contacts 14.

3 shows the printer 2 with the pivoting surface 6 and printhead cartridge 96 removed. When the turning surface 6 is tilted forward, the user pulls the cartridge release lever 24 until the cam 20 is disengaged. This may allow the handle 26 of the cartridge 96 to be gripped and pulled upwards. The upstream and downstream ink couplings 112A and 112B are released from the printer conduit 142. This is described in more detail below. The process is reversed to install a new cartridge. New cartridges are shipped and sold in unprimed conditions. Thus, to prepare a printer for printing, an active fluid system (described below) uses a downstream pump to prepare ink in cartridges and printheads.

In Fig. 4, the outer case of the printer 2 has been removed to reveal its inside. Large ink tank 60 is a separate reservoir for all four different inks. The ink tank 60 is a replacement cartridge itself that is coupled to the printer upstream of the shut off valve 66 (see FIG. 6). There is also a sump 92 for drawing ink from the cartridge 96 by the pump 62. The printer fluid system will be described in detail with reference to FIG. 6. In brief, ink from the tank 60 flows through the upstream ink lines 84 to the shutoff valves 66 and the printer conduits 142. As shown in Fig. 5, when the cartridge 96 is installed, the pump 62 (driven by the motor 196) draws ink into the LCP molding 64 to printhead IC 68 (Fig. 6). 7-20) are primed by capillary action. Excess ink drawn by the pump 62 is transferred to the reservoir 92 accommodated with the ink tank 60.

The overall connector force between cartridge contacts 104 and printer contacts 22 is relatively large because a number of contacts are used. In the illustrated embodiment, the total contact force is 45N (Newton). This load is sufficient to stretch and deform the cartridge. 30, the internal structure of the chassis molding 100 is shown. The compressive load of the printer contacts on the cartridge contacts 104 is indicated by arrows. The reaction force at the bearing surface 28 is likewise indicated by an arrow. In order to maintain the structural integrity of the cartridge 96, the chassis molding 100 has a structural member 30 extending in the plane of the connector force. In order for the reaction force to act in the plane of the connector force, the chassis also has contact ribs 32 supported on the support surface 28. This allows the load on the structural member 30 to be fully compressed to maximize the rigidity of the cartridge while minimizing any stretch.

Print engine pipeline ( PRINT ENGINE PIPELINE )

The print engine pipeline refers to the printer's processing of print data that is received from an external source and output for printing. The print engine pipeline is described in detail in USSN 11/014769 (RRC001YS), filed December 20, 2004, the contents of which are incorporated herein by reference.

Fluid system FLUIDIC SYSTEM )

Traditional printers have relied on structures and components in printheads, cartridges and ink lines to avoid fluidity problems. Some common fluidity problems are deprimed or dried nozzles, outgassing bubble artifacts, and color mixing from cross contamination. To avoid these problems, optimizing the design of printer components is a passive approach to fluid control. Typically, the only active component used to modify these is the nozzle actuator itself. However, this is often inadequate and consumes a large amount of ink when attempting to correct the problem. This problem is exacerbated in the pagewidth printhead because of the length and complexity of the ink conduits supplying the printhead IC.

The applicant has addressed this problem by developing an active fluid system for the printer. Several such systems are described in detail in USSN 11/677049 (Applicant's Document SBF006US), the contents of which are incorporated herein by reference. 6 illustrates one of a single pump implementation of an active fluid system that may be suitable for use with the printhead described herein.

The fluidic architecture shown in FIG. 6 is a single ink line for only one color. The color printer may have a separate line (and a separate ink tank 60) for each ink color. As shown in Fig. 6, this structure has a single pump 62 downstream of the LCP molding 64 and a shutoff valve 66 upstream of the LCP molding. The LCP molding supports the printhead IC 68 through an adhesive IC attachment film 174 (see FIG. 25). The shutoff valve 66 isolates the ink in the ink tank 60 from the printhead IC 66 whenever the printhead is powered down. This ensures that no color mixing in the printhead IC 68 reaches the ink tank 60 during the period of inactivity. This problem is explained in more detail in the cross-referenced specification USSN 11/677049 (Applicant's document number SBF006US).

Ink tank 60 has a venting bubble point pressure regulator 72 for maintaining a relatively constant hydrostatic pressure in the ink at the nozzles. Bubble point pressure regulators in ink reservoirs are described comprehensively in co-pending USSN 11/640355 (Applicant's Document No. RMC007US), incorporated herein by reference. However, for the purpose of this description, the regulator 72 is submerged in the ink of the ink tank 60 and the bubble outlet 74 is discharged to the atmosphere through a sealed conduit 76 extending to the air inlet 78. Are represented as As the printhead IC 68 consumes ink, the pressure in the ink tank 60 drops until the pressure difference at the bubble outlet 74 sucks air into the tank. This air forms bubbles in the ink that rises to the headspace of the tank. This pressure difference is the bubble point pressure and will depend on the diameter (or minimum dimension) of the bubble outlet 74 and also the Laplace pressure of the ink meniscus at the outlet lying at the inlet of the air.

Bubble point regulators use the bubble point pressure required to create bubbles at submerged bubble outlets 74 to maintain a substantially constant hydrostatic pressure at the outlet (the convex meniscus of the air Slight fluctuations as they form and float into the headspace within the ink tank). If the hydrostatic pressure at the outlet is at the bubble point, the hydrostatic pressure profile in the ink tank may be known regardless of how much more ink is consumed from the tank. The pressure at the ink surface in the tank will decrease towards the bubble point pressure as the ink level drops to the outlet. Of course, as long as the outlet 74 is exposed, the headspace is exposed to the atmosphere and negative pressure is lost. The ink tank must be refilled or replaced (if cartridge) before the ink level reaches the bubble outlet 74. The ink tank 60 may be a fixed reservoir that may be refilled, a replaceable cartridge, or a refillable cartridge (described in RRC001US incorporated by reference). In order to protect from particulate fouling, the outlet 80 of the ink tank 60 has a coarse filter 82. The system also uses a fine filter in coupling to the frithead cartridge. Since the filter has a finite life, it is particularly convenient for the user to replace the old filter by simply replacing the ink cartridge or printhead cartridge. If the filter is a separate consumable item, regular replacement depends on the diligence of the user.

When bubble outlet 74 is at bubble point pressure and shutoff valve 66 is open, the hydrostatic pressure at the nozzles is constant and less than atmospheric. However, if the shutoff valve 66 is closed for a period of time, degassing bubbles may be formed in the printhead IC 68 or LCP molding that changes the pressure at the nozzles. Likewise, the expansion and contraction of bubbles from the temperature fluctuations during the day can change the pressure in the ink line 84 downstream of the shutoff valve 66. Similarly, the pressure in the ink tank can be changed during periods of inactivity due to dissolved gases coming out of solution.

The downstream ink line 86 from the LCP 64 to the pump 62 may include an ink sensor 88 connected to the electronic controller 90 for the pump. The sensor 88 detects the presence of ink in the downstream ink line 86. Alternatively, the system may be free of sensor 88 and pump 62 may be configured to run for a suitable period of time for several different operations. This may adversely affect the running cost due to the increase of ink waste.

The pump 62 is supplied to the reservoir 92 (when pumped in the forward direction). The reservoir 92 is physically located within the printer to be raised below the printhead IC 68. This allows a column of ink in the downstream ink line 86 to be 'hanged' out of the LCP 64 during the standby period, thereby allowing a negative fluid static in the printhead IC 68. Pressure is generated. Negative pressure at the nozzles points the ink meniscus inwards to suppress color mixing. Of course, the peristatic pump 62 needs to be stopped in the open state such that there is fluid communication between the LCP 64 and the ink outlet in the reservoir 92.

The pressure difference between the ink lines of different colors can occur during inactive periods. Moreover, paper dust or other particles on the nozzle plate can carry ink from one nozzle to another. Driven by a slight pressure difference between each ink line, color mixing can occur even while the printer is inactive. The shutoff valve 66 isolates the ink tank 60 from the nozzle of the printhead IC 68 to prevent color mixing from leading to the ink tank 60. Once the ink in the tank is contaminated with different colors, it is irreversible and must be replaced.

The capper 94 not only prevents dehydration of the printhead IC 68, but also seals the nozzles during the waiting period to protect the nozzle plate from paper first and other particles. Maintenance station. Caber 94 is also configured to wipe the nozzle plate to remove dried ink and other contaminants. Dehydration of the printhead IC 68 occurs when the ink solvent, typically water, evaporates to increase ink viscosity. If the ink viscosity is too high, the ink ejection actuators cannot eject ink drops. If capper sealing is weakened, dehydrated nozzles may be problematic when restarting the printer after a power down or standby period.

The above problems are not uncommon during the operating life of the fritter and can be effectively corrected with the relatively simple flow structure shown in FIG. The problems can also cause the user to prime the printer initially, deprime the printer before moving the printer, or restore the printer to a known print ready state using a simple troubleshooting protocol. . Some examples of these solutions are described in detail in the above referenced USSN 11/677049 (Applicant's Document No. SBF006US).

Printhead  cartridge( PRINTHEAD CARTRIDGE )

The printhead cartridge 96 is shown in Figures 7-16 (a). 7 illustrates a state in which the cartridge 96 is assembled and completed. Most of the cartridge is wrapped in a cartridge chassis 100 and chassis lid 102. A window of the chassis 100 exposes cartridge contacts 104 that receive data from a print engine controller in the printer.

8 and 9 show the cartridge 96 locked to the protective cover 98. The protective cover 98 prevents damage upon contact of the electrical contacts 104 with the printhead IC 68 (see FIG. 10). The user can grip the top of the cartridge 96 to remove the protective cover 98 immediately before printer installation.

FIG. 10 shows the lower side and the 'back' of the printhead cartridge 96 (with respect to the paper feed direction). The printhead contacts 104 are wrapped in a series of wire bonds 110 at one side of the printhead IC 68, wrapping a curved support surface (described below in the description of LCP molding). Conductive pads on the circuit board 108. On the other side of the printhead IC 68 is a paper shield 106 to prevent direct contact with the media substrate.

11 shows the lower side and 'front' of the printhead cartridge 96. The front side of the cartridge has two ink couplings 112A and 112B at either end. Each ink coupling has four cartridge valves 114. When the cartridge is installed in the printer, the ink couplings 112A and 112B are combined with a complementary ink supply interface (described in more detail below). The ink supply interface has a printer conduit 142 that engages the cartridge valve 114 and opens the valve. One of the ink couplings 112A is an upstream ink coupling and the other is a downstream ink coupling 112B. The upstream coupling 112A establishes fluid communication between the printhead IC 68 and the ink supply 60 (see FIG. 6) and the downstream coupling 112B is connected to the reservoir 92 (see FIG. 6). Connected.

Various forms of the printhead cartridge 96 are shown in FIG. 12. The top view of the cartridge 96 shows the position of the sectional drawing shown in FIG. 14, FIG. 15, and FIG.

13 is an exploded perspective view of the cartridge 96. The LCP molding 64 is attached downstream of the cartridge chassis 100. Next, the flex PCB 108 is attached downstream of the LCP molding 64 and wrapped around one side to expose the printhead contacts 104. Inlet manifold and filter 116 and outlet manifold 118 are attached to the top of chassis 100. The inlet manifold and filter 116 are connected to the LCP inlet 122 via elastomeric connectors 120. Likewise, LCP outlet 124 is connected to outlet manifold 118 through another set of elastomeric connectors 120. The chassis lid 102 covers the inlet and outlet manifolds in the chassis 100 at the top and a removable protective cover 98 snaps onto the bottom to protect the contacts 104 and the printhead IC. Fixed (see FIG. 11).

Inlet and filter manifolds INLET AND FILTER MANIFOLD )

FIG. 14 is an enlarged cross-sectional view taken along line 14-14 of FIG. 12. 14 shows the fluid path through one of the cartridge valves 114 of the upstream coupling 112A to the LCP molding 64. The cartridge valve 114 has an elastomeric sleeve 126 biased upon sealing engagement with the fixed valve member 128. The cartridge valve 114 is separated from the fixed valve member 128 to compress the elastomer sleeve 126 to flow ink along the top of the inlet and filter manifold 116 to the roof channel 138. Opened by printer conduit 142 (see FIG. 16). Loop channel 138 leads to an upstream filter chamber 132 with one wall formed by filter membrane 130. Ink passes through the filter membrane 130 into the downstream filter chamber 134 and out of the LCP inlet 122. As it is filtered, ink flows along the LCP main channel 136 and is sent to a printhead IC (not shown).

Specific features and advantages of the inlet and filter manifold 116 will now be described with reference to FIG. 15. The exploded perspective view of FIG. 15 best illustrates the compact design of the inlet and filter manifold 116. There are several forms of design that contribute to the compact form. First, the cartridge valves are closed to each other at intervals. This is achieved by deviating from the traditional form of self sealing ink valves. Previous designs used elastomeric members that were biased in sealing engagement with the fastening members. However, the elastomeric member was either in the form of a diaphragm in the case where the ink flowed through the diaphragm or the solid shape in which the ink flowed to the periphery.

In cartridge coupling, it is quite convenient for the cartridge valve to open automatically upon installation. This means that one valve is most easily and inexpensively provided by a coupling having an elastomeric member joined by a rigid member on the other valve. If the elastomeric member is in the form of a diaphragm, the elastomeric member retains itself against the central rigid member, usually under tension. This provides an effective seal and requires a relatively low tolerance. However, this also requires that the elastomeric member have a wide range of peripheral mounting. The width of the elastomer will conflict between the desired coupling force, the integrity of the seal and the physical properties of the elastomer used.

As best shown in FIG. 16, the cartridge valve 114 of the present invention uses an elastomeric sleeve 126 that seals the fixed valve member 128 under residual compression. The valve 114 opens when the cartridge is installed in the printer and the conduit end 148 of the printer valve 142 further compresses the sleeve 126. A collar 146 is opened from the fixed valve member 128 to connect the LCP 64 to the printer fluid system via the upstream and downstream ink couplings 112A and 112B (see FIG. 6). . The side wall of the sleeve is configured to protrude outward as inward collapse can cause flow obstruction. As shown in FIG. 16, the sleeve 126 has a relatively fragile line around its mid-section that facilitates and guides the buckling process. This reduces the force required to couple the cartridge to the printer and ensures that the sleeve is buckled outward.

The coupling is configured for 'no-drip' disengagement of the cartridge from the printer. When the cartridge is pulled upward from the printer, the elastomeric sleeve 126 pushes the collar 146 to seal the fixed valve member 128. Once the sleeve 126 seals the valve member 128 (by sealing the side of the cartridge of the coupling), the sealing collar 146 is lifted with the cartridge. This opens the collar 146 from the end of the conduit 148. When the seal ruptures, the ink meniscus is formed across the gap between the color and the end of the conduit 148. The shape of the end of the fixed valve member 128 allows the ink meniscus to move toward the center of its bottom instead of printing at a certain point. At the center of the round bottom of the fixed valve member 128, the ink meniscus proceeds to separate itself from the substantially horizontal bottom. In order to achieve the lowest possible energy state, the surface tension advances the separation of the meniscus from the fixed valve member 128. The bias for minimizing the meniscus surface area is strong, so the separation operation is completed with very little ink remaining in the cartridge valve 114, if any. Any remaining ink is not enough to cause the ink to drip off and stain before disposing of the cartridge.

When a new cartridge is installed in the printer, the air in conduit 150 will be entrained by the ink flow 152 and sucked by the cartridge. In this respect, the inlet manifold and filter assembly have a high bubble tolerance. Returning to FIG. 15 again, ink flows through the top of the fixed valve member 128 to the loop channel 138. When the loop channel is at the highest point of the inlet manifold 116, the loop channel can capture bubbles. However, the bubbles still flow towards the filter inlet 158. In this case, the filter assembly itself is resistant to bubbles.

Bubbles upstream of the filter member 130 may affect the flow rate. That is, the bubbles effectively reduce the wetted surface area of the contaminated side of the filter member 130. The filter membrane has a long rectangular shape, so that even if a significant number of bubbles are drawn to the contaminating side of the filter, the wet surface area remains large enough to filter the ink at the required flow rate. This is very important for the high speed operation provided by the present invention.

Although the upstream filter chamber 132 cannot cross the filter membrane 130, bubbles due to degassing may create bubbles in the downstream filter chamber 134. The filter outlet 156 is located at the bottom of the downstream filter chamber 134 and diagonally opposite the inlet 158 in the upstream chamber 132 to minimize the bubble effect in either chamber on the flow rate.

Filters 130 for each color are stacked vertically and closely and side by side. The partition wall 162 partially defines the upstream filter chamber 132 on one side and partially defines the downstream chamber 134 of color adjacent to the other side. If the filter chambers are very thin (in the case of a compact design), the filter membrane 130 may push against the opposite wall of the downstream filter chamber 134. This effectively reduces the surface area of the filter membrane 130. Therefore, it is not beneficial to maximize the flow rate. To prevent this, the opposing wall of the downstream chamber 134 has a series of spacer ribs 160 to separate the membrane 130 from the wall.

Positioning filter inlets and outlets at diagonally opposite corners helps to purify the system of air during the initial priming of the system.

To reduce the risk of particle contamination of the printhead, the filter membrane 130 is welded downstream of the first partition wall before the next partition wall 162 is welded to the first partition wall. As such, any small pieces of filter membrane 130 that are separated during the welding process will be on the 'contaminated' side of filter 130.

LCP  molding/ Flex PCB Of Printhead  IC LCP MOLDING Of FLEX PCB Of PRINTHEAD IC )

LCP molding 64, flex PCB 108 and printhead IC 68 assembly are shown in FIGS. 17-33. 17 is a perspective view of the LCP molding 64 downstream with the flex PCB and printhead IC 68 attached. The LCP molding 64 is secured to the cartridge chassis 100 through countersunk holes 166 and 168. Hole 168 is an oblong hole for adjusting any mismatch of coefficients of thermal expansion (CTE) without bending the LCP. The printhead ICs 68 are arranged end to end in a line along the longitudinal size of the LCP molding 64. The flex PCB 108 is wire bonded to the printhead IC 68 at one edge. Flex PCB 108 is also secured to the LCP molding at the cartridge contact 104 edge as well as at the printhead IC. Fixing the flex PCB at both edges allows the flex PCB to be held very closely to the curved support surface 170 (see FIG. 19). This ensures that the flex PCB is not bent at a denser radius than a certain minimum, thereby reducing the risk of splitting conductive tracks through the flex PCB.

FIG. 18 is an enlarged view of a portion A shown in FIG. 17. FIG. 18 illustrates a line of wire bonding contacts 164 along the line of the printhead IC 68 and the side of the flex PCB 108.

19 is an exploded perspective view of the LCP / Flex / Printhead IC assembly showing the underside of each component. 20 is another exploded perspective view illustrating the upper side of the components. LCP molding 64 has an LCP channel molding 176 sealed underneath. The printhead IC 68 is attached to the underside of the channel molding 176 by an adhesive IC attachment film 174. On top of the LCP channel molding 176 is the LCP main channel 184. These are open to the ink inlet 122 and the ink outlet 124 of the LCP molding 64. At the bottom of the LCP main channel 184 is a series of ink supply passages 182 leading to the printhead IC 68. The adhesive IC attachment film 174 has a series of laser drilling supply holes 186 such that the attachment side of each printhead IC 68 is in fluid communication with the ink supply passage 182. Features of the adhesive IC attaching film will be described below in detail with reference to FIGS. 31 to 33.

LCP molding 64 has recesses 178 for receiving electronic components 180 in a drive circuit on flex PCB 108. For optimal electrical efficiency and operation, the cartridge contacts 104 on the PCB 108 should be close to the printhead IC 68. However, to maintain the paper path adjacent to the printhead in a straight line instead of in a curved or angled shape, the cartridge contacts 104 need to be on the side of the cartridge 96. The conductive path in the flex PCB is known as a trace. Since the flex PCB must be bent around a corner, the trace can crack and break the connections. To counter this, the trace can be branched before bending and then rejoined after bending. If one branch of the branched part cracks, the other branch holds the connection. Unfortunately, splitting the traces into two and then joining them together again can cause electro-magnetic interference problems that cause noise in the circuit.

Making the traces wide is not an effective solution because the wide traces do not resist cracking significantly more. As long as the trace begins to crack, the crack will progress relatively quickly and easily across the entire width. Adjusting the bending radius deeply is more effective in minimizing trace cracks, thereby minimizing the number of traces across the bends of the flex PCB.

Page-width printheads have additional complexity because of the large array of nozzles that must be ejected in a relatively short time. Spraying many nozzles immediately puts a large current load on the system. This can create high levels of inductance through circuits that can result in a harmful voltage dip in operation. To avoid this, the flex PCB has a series of capacitors that discharge during the nozzle firing sequence to reduce the current load on the rest of the circuit. Since there is a need to maintain a straight paper path past the printhead IC, the capacitor is traditionally attached to the flex PCB close to the contacts on the side of the cartridge. Unfortunately, the capacitor forms additional traces that jeopardize the cracking of the bend of the flex PCB.

This is undertaken by mounting a capacitor 180 (see FIG. 20) adjacent to the printhead IC 68 to reduce the possibility of trace breakage. The paper path is linear by recessing capacitors and other components towards the LCP molding 64. The paper shield mounted on the 'front' of the cartridge 96 (relative to the conveying direction) and the relatively flat surface of the flex PCB downstream of the printhead IC 68 may cause paper jams. Minimize risk.

Isolation of the contacts from the remaining components of the flex PCB minimizes the number of traces extending through the bends. This provides considerable reliability because the likelihood of cracking is reduced. Placing circuit components next to the printhead IC means that the cartridge needs to be slightly wider, which is not beneficial for compact designs. However, the advantage provided by this form is that it overcomes any shortcomings of a slightly wider cartridge. First, the contacts can be larger because there are no traces from components running between and around the contacts. By larger contacts, the connection can be made more reliable and better to cope with manufacturing inaccuracies between cartridge contacts and printer side contacts. Since the mating contacts are up to the user to correctly insert the cartridge, the above is particularly important in this case.

Secondly, the edges of the flex PCB wire-bonded to the printhead IC side are not under residual stress and attempt to break away from the bending radius. The flex can be secured to the support structure in capacitors and other components so wire bonding to the printhead IC is less likely to form during manufacture and less cracking since it is not used to secure the flex.

Third, the capacitors are much closer to the nozzles of the printhead IC, so that electromagnetic interference by the discharge capacitor is minimized.

FIG. 21 is an enlarged view of the lower side of the printhead cartridge 96 showing the flex PCB 108 and the printhead IC 68. The wire bonding contacts 164 of the flex PCB 108 run in parallel with the contact pads of the printhead IC 68 on the underside of the adhesive IC attachment film 174. FIG. 22 shows FIG. 21 with the printhead IC 68 and flex PCB removed to reveal the supply holes 186. The holes are arranged in four longitudinal rows. Each row delivers one specific color of ink, and each row is aligned with a single channel on the back of each printhead IC.

FIG. 23 shows the lower side of the LCP channel molding 176 with the adhesive IC attachment film 174 removed. This exposes the ink supply passages 182 connected to the LCP main channel 184 (see FIG. 20) formed on the other side of the channel molding 176. It will be appreciated that the supply passages 182 partially form when the adhesive IC attachment film 174 is in place. In addition, it will be appreciated that the attachment film must be positioned correctly, since the individual supply passage 182 must be aligned with the laser perforated supply holes 186 through the film 174.

24 shows the lower side of the LCP molding with the LCP channel molding removed. This exposes an array of blind cavities 200 containing air when the cartridge is primed with ink to dampen any pressure pulses. This will be described in detail below.

Printhead IC  Adhesive film PRINTHEAD IC ATTACH FILM )

laser ablation  film( Laser Ablated Film )

 31 to 33, the adhesive IC attaching film will be described in detail. The film 174 is laser drilled and wound onto a reel 198 for convenient incorporation into the printhead cartridge 96. For handleability and storage, the film 174 has two protective liners (typically PET liners) on either side. One is an existing liner 188B that is already attached to the film prior to laser drilling. The other is a replacement liner 192 that replaces the existing liner 188A after a drilling operation.

A portion of the laser drilled film 174 shown in FIG. 32 is depicted by removing a portion of the existing liner 188B to expose the feed aperture 186. The replacement liner 192 on the other side of the film replaces the existing liner 188A after the feed hole 186 is laser drilled.

33 (a) -33 (c) show in detail how the film 174 is produced by laser ablation. Figure 33 (a) shows in detail the laminate structure of the film before laser drilling. Central web 190 is typically a polyimide film and provides strength for the laminate. Web 190 is interposed between adhesive layers 194A and 194B, which are typically epoxy layers. Each adhesive layer 194A and 194B is covered with a respective liner 188A and 188B. Central web 190 typically has a thickness of 20-100 microns (usually about 50 microns). Each adhesive layer 194A and 194B typically has a thickness of 10-50 microns (usually about 25 microns).

Returning to FIG. 33 (b), laser drilling is performed from the side of the film formed by the liner 188A. Hole 186 is drilled through first liner 188A, epoxy layers 194A, 194B and central web 190. Hole 186 terminates somewhere in liner 188B, so that liner 188B may be thicker than liner 188A (eg, liner 188A may be 10-20 microns thick and Liner 188B may be 30-100 microns thick)

Next, the foraminous liner 188A on the laser entry side is removed and replaced with a replacement liner 192, thereby providing the film 174 shown in FIG. 33 (c). Next, a strip of film 174 is wound on reel 198 (see FIG. 31) for storage and handleability prior to attachment. When the printhead cartridge is assembled, a suitable length is drawn from the reel 198 so that the liners are removed so that the holes 186 mate with the correct ink supply passageway 182 (see FIG. 25) to form the LCP channel molding 176. It is attached to the lower side of the.

Laser drilling is a standard method for forming holes in polymer films. However, a problem with laser drilling is that carbon soot 197 is deposited at and around the drilling site (see FIGS. 33 (b) and 33 (c)). Soot around the protective liner is easily handled because it is usually replaced after laser drilling. However, soot 197 deposited in and around the actual feed hole 186 is potentially problematic. Soot may be removed when the film is compressed between the LCP channel molding 176 and the printhead IC 68 during bonding. Any soot 197 removed represents a means by which particles enter the ink supply system and potentially block the nozzles in the printhead IC 68. Moreover, soot is surprisingly hard and can be removed by conventional sonication and / or IPA cleaning techniques.

From the analysis of the laser drilled film 174, soot 197 is generally present at the laser-entry side of the film 174 (ie, epoxy layer 194A and central web 190). Applicants have generally observed that the film is not on the laser-exit side (ie, epoxy layer 194B) of the film.

Dual path laser At ablation  Film by Double - Pass Laser Ablated Film )

It may be desirable to provide a method of making the IC attachment film 174 that does not suffer from the above-described problems associated with carbon soot deposits.

Applicant has surprisingly found that most of the soot deposits are removed, including soot deposits 197 on the laser inlet side of the dual path laser ablation of the ink supply apertures 186. The starting point for dual path laser ablation is the film shown in FIG. 33 (a).

Laser drilling (ie, more generally laser ablation) in the present invention typically uses an excimer laser having a pulse frequency in the range of 200 Hz to 400 Hz. The spot size of the laser is usually relatively large compared to the size of the ink supply hole, which means that several ink holes are ablated simultaneously. Since the laser spot size is relatively large, each laser drilling step is performed by masking the film using a mask in which a plurality of laser transmission (or laser transparent) zones are formed.

In the first step, the first hole 185 is laser drilled from the side of the film formed by the liner 188A. This hole 185 is drilled through the liner 188A, the epoxy layers 194A and 194B and the central web 190. Hole 185 terminates somewhere in liner 188A. The hole 185 by the first laser drilling, formed using the first mask, has a smaller dimension than the intended ink supply hole 186. Typically, each length and width dimension of the first hole 185 is about 10 microns less than the length and width dimensions of the intended ink supply hole 186. It can be seen from FIG. 34A that the first hole 185 has a soot 197 deposited in the first liner 188A, the first epoxy layer 194A and the central web 190.

In the second step, the first hole 185 is reamed by further laser drilling using a second mask to provide an ink supply hole 186 having a desired dimension. This reaming process produces very little soot, so that the final ink supply hole 186 has clean sidewalls as shown in Fig. 34 (b).

Finally, referring to FIG. 34 (c), the first liner 188A is wound with a reel by being replaced with a replacement liner 92 so that the film package to be used later to attach the printhead IC 68 to the LCP channel molding 176. Is provided. The second liner 188B may also be replaced at this stage if desired.

Comparing the films shown in FIGS. 33 (c) and 34 (c), it will be appreciated that the dual laser ablation method provides a film 174 with ink supply holes 186 that is much cleaner than simple laser ablation. . Therefore, the film is well suited for attaching the printhead IC 68 to the LCP channel molding 176 and does not contaminate the ink with unwanted soot deposits.

Printhead IC At the end  For improved ink supply ( ENHANCED INK SUPPLY

TO PRINTHEAD IC ENDS )

FIG. 25 shows the printhead IC 68 superimposed on the ink supply hole 186 through the adhesive IC attachment film 174 and also superimposed on the ink supply passage 182 under the LCP channel molding 176. will be. Adjacent printhead ICs 68 are positioned end to end at the bottom of the LCP channel molding 176 via the attachment film 174. At the junction between adjacent printhead ICs 68, one of the ICs 68 is a 'drop triangle' of nozzles in a row that is laterally displaced from the corresponding row of the remaining nozzle array 220. ) Part. This allows the edges of printing from one printhead IC to be adjacent to printing from an adjacent printhead IC. By displacing the drop triangle 206 of the nozzles, the spacing (in a direction perpendicular to the media transport) between adjacent nozzles is related to whether the nozzles are on the same IC or on either side of the junction on different ICs. Without change. This requires accurate relative positioning of adjacent printhead ICs 68, and a fiducial mark 204 is used to accomplish this. This process can be a waste of time, but it can avoid creating artifacts in the printed image.

Unfortunately, some of the nozzles at the end of the printhead IC 68 may run out of ink for most of the nozzles in the remaining array 220. For example, the nozzles 222 may be supplied with ink from two ink supply holes. The ink supply hole 224 is the closest. However, in the case of obstruction and particularly large demand from the nozzles to the left side of the hole 224, the supply hole 226 is closest to the nozzles at 222, so that ink deprivation may occur due to ink starvation. There is little possibility.

In contrast, if there is no 'extra' ink supply hole 201 placed at the junction between adjacent printhead ICs 68, then the nozzles 214 at the end of the printhead IC 68 are merely ink supply holes 216. And fluid communication with the. Having an additional ink supply hole 210 means that the nozzles are not too far from the ink supply hole, which is at risk of ink shortage.

Ink supply holes 208 and 210 are provided from a common ink supply passage 21. The ink supply passage 212 has a capacity to supply both holes since the supply hole 208 has nozzles only on its left side and the supply hole 210 has nozzles only on its right side. Therefore, the total flow rate through the supply passage 21 is approximately equal to the supply passage supplying only one hole.

FIG. 25 shows the number of channels (color) of the ink supply—discrepancy between the four and five channels of the printhead IC 68. The third and fourth channels 218 on the back of the printhead IC 68 are supplied from the same ink supply hole 186. This feed hole is slightly enlarged to cross the two channels 218.

This is because the printhead IC 68 is manufactured for use in various printer and printhead types. This printer has five color channels-CMYK and IR (infrared)-but this design and other printers can be only four channel printers, while other printers can only be three channels (CC, MM and Y). have. In this regard, a single color channel can be supplied to two of the printhead IC channels. A print engine controller (PEC) microprocessor can easily adjust it to the print data sent to the printhead IC. Moreover, supplying the same color to the two nozzle rows of the IC provides a degree of nozzle redundancy that can be used for dead nozzle compensation.

Pressure pulse ( PRESSURE PULSES )

 A sharp spike in ink pressure occurs when the ink flowing to the printhead stops abruptly. This can happen at the end of a print job or page. The assignee's high speed pagewidth printheads require a high flow rate of supply ink during operation. Therefore, most of the ink in the ink line for the nozzles moves at a relatively large and recognizable rate.

If the print job simply ends abruptly at the end of the printed page, it requires that a relatively large amount of ink flowing relatively quickly stops immediately. However, sudden stop of the ink momentum causes shock waves in the ink lines. The LCP molding 64 (see FIG. 19) is particularly hard and provides little flexibility as the column of ink in the ink line is stopped. Without any compliance in the ink line, the shock wave can exceed the Laplace pressure (the pressure provided by the surface tension of the ink at the nozzle opening to retain the ink in the nozzle chambers) and the printhead IC 68 Can rush to the front of the. If the nozzles are flooded, ink cannot be ejected and artifacts appear at printing.

Resonant pulses of the ink appear when the nozzle firing rate coincides with the resonant frequency of the ink line. Again, because of the rigid structure that defines the ink line, many nozzles for one color and for spraying at the same time can cause standing waves or resonance pulses in the ink line. This can lead to nozzle flooding or, conversely, nozzle deprime due to a sudden pressure drop after spikes when the Laplace pressure is exceeded.

To undertake this, LCP molding 64 incorporates a pulse damper to remove pressure spikes from the ink line. This damper may be an enclosed volume of gas that can be compressed by the ink. Alternatively, the damper may be a compliant section of the ink line that can elastically bend and absorb pressure pulses.

In order to minimize design complexity and maintain compact form, the present invention uses a compressible volume of gas to dampen pressure pulses. Damping the pressure pulse using gas compression can be accomplished with a small amount of gas. This maintains a compact design while preventing any nozzle flooding from transient spikes in ink pressure.

As shown in Figs. 24 and 26, the pulse damper is not a single volume of gas for compression by the pulse of ink. Rather than a damper, it is an array of cavities 200 distributed along the length of the LCP molding 64. Pressure pulses traveling through long printheads, such as pagewidth printheads, can be attenuated at any point in the ink flow line. However, the pulse will cause nozzle flooding as it passes through the nozzles in the printhead integrated circuit, regardless of whether they are later lost in the damper. By incorporating multiple pulse dampers directly into the ink supply conduit immediately following the nozzle array, any pressure spikes are attenuated at sites that do not cause harmful flooding.

As can be seen in FIG. 26, the air damping cavity 200 can generate any pressure pulses in the LCP main channel 184 of the LCP channel molding 176. It acts directly on and quickly disappears.

The priming of the cartridge will now be described with particular reference to the LCP channel molding 176 shown in FIG. LCP channel molding 176 is primed with ink by suction applied to main channel outlet 232 from the pump of the fluid system (see FIG. 6). The main channel 184 is filled with ink, and then the ink supply passage 182 and the printhead IC 68 self-prime by capillary action.

Main channel 184 is relatively long and thin. Moreover, the air cavity 200 must remain unprimed when trying to dampen pressure pulses in the ink. This may be problematic during the priming process, which may easily fill the cavity 200 by capillary action, or the main channel 184 may not be fully primed due to trapped air. To ensure complete priming of the LCP channel molding 176, main channel 184 has weirs 228 at the downstrean end before outlet 232. In order to prevent the air cavity of the LCP molding 64 from priming, the air cavity has an opening with an upstream edge shaped to face the ink meniscus as it moves over the wall of the cavity.

The form of such a cartridge will be described with reference to Figs. 28 (a), 28 (b) and 29 (a). These figures schematically illustrate the priming process. 28 (a) and 28 (b) illustrate problems that may occur when there is no dam in the main channel, while FIGS. 29 (a) to 29 (c) illustrate the function of the weir 228. .

28 (a) and 28 (b) are schematic cross-sectional views through one of the main channels 184 of the LCP channel molding 176 and a line of air cavities 200 in the loop of that channel. . Ink 238 is drawn through inlet 230 and flows along the bottom of main channel 184. It is important to note that the advancing meniscus has a steep contact angle with the bottom of the channel 184. This gives a slightly rounded shape to the leading portion of the ink flow 238. When the ink reaches the end of the channel 184, the ink level rises and the rounded front contacts the top of the channel before the rest of the ink flow. As shown in FIG. 28 (b), the channel 184 is not fully primed and air is captured immediately. These air pockets remain and interfere with the operation of the printhead. The ink attenuation characteristics are changed so that air can become an ink obstruction.

In FIGS. 29A-29C, channel 184 has a weir 228 downstream. As shown in Fig. 29A, the ink flow 238 is held behind the weir 228 and rises toward the top of the channel. Weir 228 has a sharp edge on top that acts as a meniscus anchor point. The advancing meniscus is anchored to anchor 240 so that ink does not simply flow over weir 228 as soon as the ink level is above the upper edge.

As shown in Fig. 29 (b), the bulging meniscus causes the ink to rise until the ink is filled in the channel 184 to the top. By sealing the cavity 200 with separate air pockets, the swollen meniscus at the weir 228 is broken from the pointed upper edge 240 to fill the ink outlet 232 and the end of the channel 184 (FIG. 29 (c)). The pointed edge 240 is positioned precisely so that the ink meniscus swells until the ink fills up to the top of the channel 184, but does not cause the ink to swell too much so as to contact a portion of the end air cavity 242. Once the meniscus touches and secures inside the end air cavity 242, the meniscus may be primed with ink. Thus, the height of the weir and its position below the cavity are closely controlled. The curved downstream surface of the weir 228 ensures that there is no other fixation point that allows the ink meniscus to fill the gap for the cavity 242.

Another mechanism that the LCP uses to prevent priming of the cavity 200 is the shape of the upstream and downstream edges of the cavity opening. As shown in Figures 28 (a), 28 (b) and 29 (a)-29 (c), all upstream edges have a curved transition face 234 while the downstream edge 236 is pointed. The ink meniscus advancing along the loop of the channel 184 can be fixed to the pointed upstream edge and then moved inward into the cavity by capillary action. The front side, in particular the curved front side 234 at the upstream edge, eliminates the strong fixation point at which the sharp edge is provided.

Similarly, the applicant's study found that the pointed downstream edge 236 would facilitate depriming if some ink was inadvertently filled into the cavity 200. If the printer is hit, impacted or tilted, or if the fluid system has to reverse flow for some reason, the cavity 200 may be fully or partially primed. When the ink flows back in its normal direction, the pointed downstream edge 236 helps to draw the meniscus back to its natural fixation point (ie, pointed corner). As such, movement management of the ink meniscus through the LCP channel molding 176 is a mechanism for accurately priming the cartridge.

The invention has been described only by way of example herein. Those skilled in the art will recognize many variations and modifications without departing from the spirit and scope of the broad inventive concept. Accordingly, the embodiments shown and described in the accompanying drawings are to be considered as illustrative and not restrictive.

Claims (20)

As a method of manufacturing an apertured polymeric film,
(a) masking the polymer film with a first mask in which one or more first laser transmission zones are formed;
(b) laser-ablation one or more first apertures through the polymer film using the first mask;
(c) masking the film with a second mask in which at least one second laser transmission zone is formed, wherein each second zone is aligned with a corresponding first opening and has a perimeter greater than the corresponding first opening. Having a perimeter dimension;
(d) reaming the one or more first openings by laser ablation of the polymer film using the second mask, such that the reamed first openings form one or more second openings in the film. Method for producing a perforated polymer film, characterized in that it comprises a step. The method of claim 1,
The perforated polymer film is an adhesive polymer film for attaching one or more printhead integrated circuits to an ink manifold, wherein the one or more second openings form one or more ink supply holes. Method for producing a polymer film. The method of claim 2,
Wherein said adhesive polymer film comprises a central polymer film interposed between adhesive layers. The method of claim 3,
Wherein said central polymer film is a polyimide film and said adhesive layer is an epoxy layer. The method of claim 3,
The film is installed in a film package, the film package including the adhesive polymer film and a pair of removable protective liners, each liner protecting each adhesive layer Method for producing a perforated polymer film. The method of claim 5,
Said laser ablation step is terminated in one of said protective liners. The method of claim 6,
And said laser ablation step is drilled through one of said central polymer film, said adhesive layers and said protective liners. The method of claim 5,
(d) replacing at least one of the protective liners with a replacement liner. The method of claim 1,
Wherein each first opening has a circumferential dimension that is about 5-30 microns smaller than the predetermined circumferential dimension of the corresponding second opening. The method of claim 1,
Wherein each first opening has a circumferential dimension that is about 10 microns smaller than the predetermined circumferential dimension of the corresponding second opening. The method of claim 1,
Wherein each second opening has a predetermined length dimension up to about 50 microns and a predetermined width dimension up to about 500 microns. The method of claim 1,
Wherein said first opening is aligned with a carbonaceous deposit and said second opening is substantially free of said carbonaceous soot deposit. A film for attaching one or more printhead integrated circuits to an ink supply manifold, wherein the film is obtained or obtainable by the method according to claim 2. A method for attaching one or more printhead integrated circuits onto an ink supply manifold,
(i) providing an adhesive film having a plurality of ink supply holes formed therein,
(ii) bonding the film to the ink supply manifold;
(iii) bonding the one or more printhead integrated circuits to the film,
In the step (i) the film,
(a) providing an adhesive protective film,
(b) masking the film with a first mask having a plurality of first laser transmission zones formed therein;
(c) laser ablation of the plurality of first holes through the polymer film using a first mask,
(d) masking the film with a second mask in which a plurality of second laser penetration zones are formed, each second zone being aligned with a corresponding first aperture and having a circumference greater than the corresponding first aperture Having dimensions;
(e) reaming the first hole by laser ablation of the polymer film using the second mask, such that each reamed first hole forms an ink supply hole through the film. A method of attaching one or more printhead integrated circuits to an ink supply manifold. The method of claim 14,
And the ink supply manifold is an LCP molding. The method of claim 14,
And a plurality of the printhead integrated circuits are attached to the ink supply manifold so as to provide a pagewidth print head end to end. The method of claim 14,
And the ink supply hole is positioned to supply ink to ink supply channels formed on a rear side of the one or more print head integrated circuits. The method of claim 14,
And the bonding step is performed by thermal curing and / or thermal compression. The method of claim 14,
And the ink supply aperture is substantially free of carbon soot deposits. A printhead assembly comprising at least one printhead integrated circuit bonded to an adhesive film having a plurality of ink supply holes formed thereon and attached to an ink supply manifold, wherein the printhead assembly is obtained by the method according to claim 14. A printhead assembly that can be lost or obtained.

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