The present disclosure relates to fluid ejection devices.
Fluid ejection devices are often used for ink-jet heads for printing applications. Printheads of this sort, with appropriate modifications, can likewise be used for ejecting fluids other than ink, for example, for applications in the biological or biomedical field, for local application of biological material (e.g., DNA) in the manufacture of sensors for biological analyses, for the decoration of fabrics or ceramics, and in applications of 3D printing and additive production.
Manufacturing methods for fluid ejection devices often envisage coupling via gluing or bonding of a large number of pre-machined components; typically, the various components are manufactured separately and assembled in a final production step. A printhead is typically formed by a large number of fluid ejection devices (of the order of hundreds or thousands), each of which includes a nozzle, a chamber for containing the fluid coupled to the nozzle, and an actuator coupled to the chamber, for causing outlet of the fluid through the respective nozzle. It is desirable for each of the fluid ejection devices belonging to a printhead to be as identical as possible to the other fluid ejection devices belonging to the same printhead, to guarantee uniformity of performance, above all in terms of volume of the fluid ejected and ejection rates.
The method of assembly of the aforementioned pre-machined components proves costly and involves high precision; the resulting device moreover presents a large thickness.
For instance, U.S. Patent Application Publication No. 2017/182778 discloses a method for manufacturing a fluid ejection device that envisages coupling of three wafers at least in part pre-machined. The method described envisages coupling steps (e.g., using bonding techniques) that involves a high degree of accuracy in order to obtain a good alignment between the wafers and between the functional elements obtained therein. Moreover, formation of the actuation membrane of the ejection device (to which the piezoelectric actuator is coupled) envisages an etching step via which the area of the suspended portion of the membrane is defined. It is evident that devices manufactured at different times and/or with different machinery may be subject to undesired variations of the size of the aforesaid suspended area, with the risk of jeopardizing reproducibility of the ejection device.
Various embodiments of the present disclosure provide a method for manufacturing a fluid ejection device, and a fluid ejection device, that overcome the drawbacks of the prior art. The fluid ejection device is based upon piezoelectric technology, and includes two wafers of semiconductor material machined and coupled together.
According to one embodiment, the fluid ejection device is fabricated by forming a first wafer and a second wafer. A piezoelectric actuator is formed on a first side of the first wafer, and an outlet channel is formed in the first wafer and lateral to the piezoelectric actuator. A recess and at least one inlet channel fluidically coupled to the recess are formed in the second wafer. The first wafer and the second wafer are coupled together such that the piezoelectric actuator faces and is in the recess, and the recess forms a reservoir configured to hold fluid. A nozzle plate is coupled to a second side, opposite to the first side, of the first wafer. An ejection nozzle, at least partially aligned with the outlet channel, is formed through the nozzle plate such that the ejection nozzle is fluidically coupled to the recess through the outlet channel.
For a better understanding of the present disclosure, various embodiments thereof are now described, purely by way of non-limiting example, with reference to the attached drawings, wherein:
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A second wafer 4 is machined so as to define the volume of the chamber 10 and so as to form one or more inlet holes 9 for the fluid 6, in fluidic connection with the chambers 10.
As will be discussed in further detail below, each of the first wafer 2 and the second wafer 4 is a multilayer structure including various sub layers.
In the embodiment illustrated, the second wafer 4 includes a substrate 4a of semiconductor material, and a structural layer 4b of semiconductor material coupled to the substrate 4a. The inlet holes 9 are formed through the substrate 4a, in particular throughout the thickness of the substrate 4a, whereas the structural layer 4b is shaped so as to define the size and shape of the chamber 10.
One or more expulsion holes (nozzles) 13 for the fluid 6 are formed in a nozzle plate 8 separate from the first and the second wafers 2, 4, in particular a dry layer (dry-film) coupled to the first wafer 2 at one side of the latter opposite to the side directly facing the second wafer 4. The nozzle 13 is at least partially aligned, in the direction Z, to the outlet channel 33, and, via the latter, is in fluidic connection with the chamber 10.
In one embodiment, the nozzle plate 8 is not a further wafer of semiconductor material, but a layer chosen from the following: a permanent epoxy-based dry-film photoresist, such as TMMF, or a dry-film based upon benzocyclobutene (BCB), or a dry-film of polydimethylsiloxane (PDMS).
In general, the nozzle plate 8 is chosen from a material such as to promote chemical stability to acid or alkaline solutions, organic solvents and other compounds that could be present in the fluid 6 to be ejected. The present applicant has found that TMMF is adapted to various microfluidic applications.
In one embodiment, the nozzle plate 8 has a thickness, measured along Z, of between 5 μm and 100 μm, for example 50 μm.
The first and the second wafers 2, 4 are coupled together by means of interface soldering regions, and/or bonding regions, and/or gluing regions, and/or adhesive regions, for example, of polymeric material, generically designated by the references 35, 37 (see also
Extending between the nozzle plate 8 and the first wafer 2, in particular between the nozzle plate 8 and the membrane 7, is a cavity 23 having a shape and dimensions such as to enable deflection of the membrane 7 towards the nozzle plate 8.
The piezoelectric actuator 3 comprises a piezoelectric region 16 arranged between a top electrode 18 and a bottom electrode 19, adapted to supply an electrical signal to the piezoelectric region 16 for generating, in use, a deflection of the piezoelectric region 16, which, consequently, causes a deflection of the membrane 7. Metal paths extend from the top electrode 18 and from the bottom electrode 19 towards an electrical contact region, provided with contact pads adapted to be biased during use, to activate the actuator 3.
Since the piezoelectric actuator 3 faces the chamber 10, one or more insulation and protection layers cover the piezoelectric actuator 3. In the embodiment illustrated, the insulation and protection layers comprise: a first passivation layer 21a (made, for example, of undoped silica glass (USG), or SiO2, or SiN, or some other dielectric material), which extends over the piezoelectric region 16 and over the top electrode 18 and bottom electrode 19, to cover the region 16 completely; a second passivation layer 21b (made, for example, of silicon nitride), which extends over the first passivation layer 21a to completely cover the latter; and a protection layer 21c, which extends over the second passivation layer 21b to completely cover the latter.
The protection layer 21c is, for example, a dry-epoxy layer (epoxy-based dry-film), of commercially available type, such as TMMR or BCB. The protection layer 21c has the function of protecting the piezoelectric actuator and the underlying passivation layers 21a, 21b from potentially corrosive agents present in the fluid 6 that, in use, is present in the chamber 10.
In one embodiment, the first passivation layer 21a has a thickness ranging between 0.1 μm and 0.5 μm and has the function of intermetal insulating dielectric. In one embodiment, the second passivation layer 21b has a thickness ranging between 2 μm and 10 μm and has the function of passivation. In one embodiment, the protection layer 21c has a thickness ranging between 2 μm and 10 μm and has the function of chemical barrier against the fluid to be ejected.
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An insulation layer 25,
Formation of the piezoelectric actuator 3 includes a step of formation, on the insulation layer 25, of the bottom electrode 19 (which is formed, for example, by a layer of TiO2 having a thickness of between 5 nm and 50 nm on which a layer of Pt having a thickness ranging between 30 nm and 300 nm is deposited). This is then followed by deposition of a piezoelectric layer on the bottom electrode 19, via deposition of a layer of PZT (Pb, Zr, TiO3), having a thickness ranging between 0.5 μm and 3.0 μm, more typically 1 μm or 2 μm (that will form, after subsequent definition steps, the piezoelectric region 16). Next, deposited on the piezoelectric layer is a second layer of conductive material, for example Pt or Ir or IrO2 or TiW or Ru, having a thickness ranging between 30 nm and 300 nm, to form the top electrode 18.
The electrode and piezoelectric layers are subjected to lithographic and etching steps so as to pattern them according to a desired pattern, thus forming the bottom electrode 19, the piezoelectric region 16, and the top electrode 18.
One or more insulation and protection layers are then deposited on the bottom electrode 19, on the piezoelectric region 16, and on the top electrode 18. The insulation and protection layers include dielectric materials used for electrical insulation/passivation of the electrodes, for example, layers of USG, SiO2, or SiN, or Al2O3, either single or stacked, having a thickness ranging between 10 nm and 1000 nm.
As described previously, the embodiment illustrated includes sequential formation of a USG layer 21a, a SiN layer 21b and a dry-epoxy layer 21c, such as TMMR.
In one embodiment, the passivation layers are etched and selectively removed for creating trenches for access to the bottom electrode 19 and to the top electrode 18. This is followed by a step of deposition of conductive material within the trenches thus created, and a subsequent patterning step enables formation of conductive paths for selectively accessing the top electrode 18 and the bottom electrode 19 so as to electrically bias them during use. It is moreover possible to form further passivation layers to protect the conductive paths. Conductive pads are likewise formed alongside the piezoelectric actuator, electrically coupled to the conductive paths.
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With reference to the second wafer 4, the steps for manufacturing it envisage,
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Machining steps are then carried out at the back side 31b of the substrate 31 of the first wafer 2. In particular,
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Finally, a step of coupling the nozzle plate 8 to the mask layer 17 is carried out, by, for example, laminating a film of TMMF, which seals the cavity 23. In a step prior or subsequent to coupling of the nozzle plate 8 to the mask layer 17, the nozzle 13 is obtained by making a through-hole through the nozzle plate 8 in a region thereof such that, when coupled to the mask layer 17, it is vertically aligned (in the direction Z) with the outlet channel 33. A further step of selective etching of the portion of the mask layer 17 exposed through the nozzle 13 makes it possible to set the nozzle 13 in fluidic connection with the outlet channel 33.
Alternatively to what has been described above, it is likewise possible, using a mask obtained for this purpose, to etch the portion of the mask layer 17 at the channel 33 prior to the step of coupling the nozzle plate 8 to the mask layer 17.
The ejection device 1 of
In a first step,
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The printhead 100 may be used not only for ink-jet printing, but also for applications such as high-precision deposition of liquid solutions containing, for example, organic material, or generally in the field of deposition techniques of an inkjet-printing type, for selective deposition of materials in the liquid phase.
The printhead 100 further comprises a reservoir 101, arranged underneath the ejection devices 1, adapted to contain in an internal housing 102 of its own the fluid 6 (for example ink).
Further interfaces (e.g., a manifold) between the reservoir 101 and the ejection devices 1 may be present for fluidically coupling the reservoir 101 to the one or more inlet holes 9 of each ejection device 1.
The printhead 100 may be incorporated in any type of printer.
The printer 200 of
From an examination of the characteristics of the various embodiments of the present disclosure, the advantages that the various embodiments afford are evident.
For example, it may be noted that the steps for manufacturing the fluid ejection device according to the present disclosure entail coupling of just two wafers, thus reducing the risks of misalignment, limiting the manufacturing costs, and rendering the final device structurally more solid.
In fact, an error committed during the steps of gluing of a number of wafers is difficult to recover, and there may be noted an effect of error accumulation in the formation of a stack of wafers, which rapidly leads to a final device does not function properly. Moreover, it may be noted that mechanical bonding, normally used for coupling wafers, enables a precision of alignment of some micrometers to be achieved, typically more than 5 μm; instead, machining steps that envisage photolithographic steps enable a level of precision of below 0.5 μm to be achieved and are consequently advantageous.
Finally, it is clear that modifications and variations may be made to what has been described and illustrated herein, without thereby departing from the scope of the present disclosure.
The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
Number | Date | Country | Kind |
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102019000005794 | Apr 2019 | IT | national |
Number | Date | Country | |
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Parent | 16848549 | Apr 2020 | US |
Child | 17572374 | US |