The present disclosure relates to a liquid ejection head and a method for manufacturing the liquid ejection head
In some liquid ejection heads used in inkjet print apparatuses or the like, a protective film containing a metal oxide is provided at a portion of a silicon substrate (such as an inner surface of a through hole serving as a liquid flow path) in contact with a liquid in order to suppress dissolution (corrosion) of the silicon substrate by the liquid such as ink. However, before forming the protective film on the silicon substrate, a residue (organic residue) such as a resist used for forming a through hole may reattach to the silicon substrate and cause organic contamination, and if a surface condition of the silicon substrate changes, an adhesion of the formed protective film may be lowered. As a result, a peeling phenomenon such as swelling or floating occurs in the protective film, and the silicon substrate may be dissolved starting from this point. On the other hand, Japanese Patent Application Laid-Open No. 2018-103382 discloses a method in which the protective film formed on a rear surface of the substrate is removed by etching, and then a new protective film is formed on the removed portion. According to this method, the organic residue adhering to the rear surface of the substrate is also removed together with the protective film, and the rear surface of the substrate is cleaned, whereby the adhesion between the substrate and the protective film can be enhanced.
However, in the method disclosed in Japanese Patent Application Laid-Open No. 2018-103382, since the protective film is etched after a port of a liquid flow path opening on the rear surface of the substrate is closed with the dry film resist, the protective film around the opening, covered with the resist cannot be removed. Therefore, organic contamination remains in this region, and a peeling phenomenon of the protective film may occur, which may prevent sufficient bonding strength with a member bonded to the rear surface of the substrate.
It is therefore an aspect of the present disclosure to provide a highly reliable liquid ejection head and a method for manufacturing the same by suppressing the dissolution of the substrate and sufficiently ensuring the bonding strength between the substrate and a member to be bonded to the substrate.
A liquid ejection head according to the present disclosure comprises: a substrate made of silicon and having a first surface and a second surface opposite to the first surface; an ejection port forming member bonded to the first surface of the substrate and formed with an ejection port for ejecting a liquid; and a bonded member configured to be bonded to the second surface of the substrate, wherein a through flow path is formed in the substrate, which is configured to pass through the substrate and to supply the liquid to the ejection port, and a first protective film made of a metal oxide is formed on an inner surface of the through flow path. In one aspect of the present disclosure, a second protective film made of a silicon compound is formed on all of the second surface of the substrate. In other aspect of the present disclosure, the first protective film has an end surface on the same plane as the second surface of the substrate.
A method according to the present disclosure, for manufacturing a liquid ejection head which comprises: a substrate made of silicon and having a first surface and a second surface opposite to the first surface; an ejection port forming member bonded to the first surface of the substrate and formed with an ejection port for ejecting a liquid; and a bonded member configured to be bonded to the second surface of the substrate, wherein a through flow path is formed in the substrate, which is configured to pass through the substrate and to supply the liquid to the ejection port, and a first protective film made of a metal oxide is formed on an inner surface of the through flow path, the method comprising the steps of: forming the first protective film on at least the second surface of the substrate; thinning the substrate from a side of the second surface after forming the first protective film, and removing the first protective film formed on the second surface to expose all of the second surface; and forming a second protective film made of a silicon compound on all of the exposed second surface.
Further features of the present disclosure will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Embodiments of the present disclosure will now be described with reference to the drawings.
The liquid ejection head 10 ejects a liquid such as ink to print an image on a print medium, and has a print element substrate 15 having a substrate 3 and an ejection port forming member 8. The print element substrate 15 is bonded to a support member 20 with a resin adhesive 21.
The substrate 3 made of silicon has a front surface (hereinafter also referred to as “substrate front surface”) 3a and a rear surface (hereinafter also referred to as “substrate rear surface”) 3b on the opposite side thereof, and the ejection port forming member 8 made of a photosensitive epoxy resin is bonded to the substrate front surface 3a. A plurality of ejection ports 9 for ejecting liquid and a pressure chamber 11 communicating with the plurality of ejection ports 9 are formed in the ejection port forming member 8. The substrate 3 is formed with a plurality of individual flow paths (through flow paths) 4 for passing through the substrate 3, communicating with the pressure chamber 11, and supplying liquid to the ejection port 9. On the substrate front surface 3a, an energy generating element (heater) 1 for generating energy used for ejecting liquid is provided at a position facing the ejection port 9. The liquid in the pressure chamber 11 can be foamed and ejected from the ejection port 9 by the energy generated by the energy generating element 1. An interlayer insulating film 2 including a driving circuit made of a semiconductor element for driving the energy generating element 1 and a wire layer is also formed on the substrate front surface 3a by a multilayer wiring technique using photolithography. The support member 20 is formed with a common flow path 22 which passes through the support member 20 and communicates with the plurality of individual flow paths 4.
A first protective film 5 made of metal oxide for suppressing the dissolution of the substrate 3 by a liquid such as ink is formed on the inner surface of the individual flow path 4. The dissolution of silicon often occurs when an alkaline ink is used as the liquid. Therefore, as a specific material of the first protective film 5, it is preferable that the first protective film 5 has high corrosion resistance to an alkali solution, for example, an oxide of Ti, Zr, Hf, V, Nb, or Ta is presented, and TiO (titanium oxide) is particularly preferable. The first protective film 5 is not provided up to the substrate rear surface 3b, but has an end surface 5a on the same plane as the substrate rear surface 3b, and the end surface 5a is a surface formed by polishing in a manufacturing process of the liquid ejection head 10 described later.
A second protective film 7 made of a silicon compound for suppressing the dissolution of the substrate 3 by a liquid such as ink is formed on the substrate rear surface 3b of the substrate. The second protective film 7 is formed to the inside of the individual flow path 4 so as to cover the end surface 5a of the first protective film 5 on the substrate rear surface 3b side. Thus, as described above, it is possible to suppress the deterioration of the reliability of the first protective film 5 due to the progress of corrosion from the end surface 5a on the side of the substrate rear surface 3b, which is the polishing surface. Since the second protective film 7 is formed on the bonding surface (substrate rear surface 3b) of the substrate 3 bonded with the support member 20, it is preferable that the second protective film 7 has excellent adhesion to the substrate 3, and in addition, it is preferable that the second protective film 7 itself has liquid resistance such as ink resistance. For this reason, as a specific material of the second protective film 7, it is preferable to use a silicon compound containing carbon such as SiC, SiOC, SiCN, SiOCN, and the like, and particularly the use of SiC (silicon carbide) is preferable.
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According to the present embodiment, even if the substrate rear surface 3b is contaminated with organic residues before the first protective film 5 is formed, the organic residues can be removed from the substrate rear surface 3b together with the first protective film 5 by thinning the substrate 3 from the substrate rear surface 3b side after the first protective film 5 is formed. By forming the second protective film 7 on the entire surface of the substrate rear surface 3b thus cleaned, the adhesion between the substrate 3 and the second protective film 7 can be enhanced. Further, since the support member 20 is bonded to the entire surface of the substrate rear surface 3b through the second protective film 7 formed with good adhesion, the bonding strength between the substrate 3 and the support member 20 can also be secured. It should be noted that, due to the thinning (polishing) of the substrate 3, there is a concern that corrosion progresses from the end surface 5a exposed on the substrate rear surface 3b, thereby reducing the reliability of the first protective film 5, but there is no such concern because the end surface 5a of the first protective film 5 is covered by the second protective film 7. That is, since the inner surface of the individual flow path 4 is covered with the first protective film 5, and the substrate rear surface 3b and the end surface 5a of the first protective film 5 on the side of the substrate rear surface 3b are covered with the second protective film 7, the dissolution of the substrate 3 by the liquid such as ink can be suppressed.
The present embodiment differs from the first embodiment in that the flow path substrate 30 is incorporated between the print element substrate 15 and the support member 20 (accordingly, the shape of the common flow path 22 is changed). The flow path substrate 30 is formed with a connection flow path 23 that communicates with the common flow path 22 and the plurality of individual flow paths 4 and smooths the flow of the liquid from the common flow path 22 to the plurality of individual flow paths 4. The flow path substrate 30 is made of silicon, and as a method of forming the connection flow path 23, for example, anisotropic etching by wet etching can be used. A third protective film 17 made of a silicon compound for suppressing the dissolution of the flow path substrate 30 by the liquid such as ink is formed on both the front and rear surfaces of the flow path substrate 30 (the surface facing the substrate 3 and the surface on the opposite side thereof) and the inner surface of the connection flow path 23. As a specific material of the third protective film 17, like the second protective film 7, it is preferable to use, for example, a silicon compound containing carbon such as SiC, SiOC, SiCN, or SiOCN, and it is particularly preferable to use SiC. As the method for forming the third protective film 17, a general film forming method such as a CVD method or a sputtering method can be used, but a plasma CVD method is preferably used in consideration of the coverage property.
As described above, in the present embodiment, the bonded member to be bonded to the substrate rear surface 3b is different from that in the first embodiment, but the obtained effect is the same as that in the first embodiment. Although the flow path substrate 30 is bonded to the print element substrate 15 by the resin adhesive 31 and to the support member 20 by the resin adhesive 21, plasma activation bonding using an oxide film may be used for at least any of the bonding.
The present embodiment differs from the first embodiment in that the flow path structure formed on the substrate 3 is changed (accordingly, the shape of the common flow path 22 is changed). In other words, the substrate 3 is formed with through flow paths 4 and 24 comprising a plurality of individual flow paths 4 opening to the substrate front surface 3a and a common flow path 24 opening to the substrate rear surface 3b and communicating with the plurality of individual flow paths 4. Therefore, in the present embodiment, the manufacturing method of the liquid ejection head 10 is different from that in the first embodiment as described below, and the area of the bonding surface (the substrate rear surface 3b) of the substrate 3 bonding with the support member 20 is smaller than that in the first embodiment, but the obtained effect is the same as that in the first embodiment.
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The present disclosure will now be described in more detail with reference to specific examples.
In the present example, the liquid ejection head 10 shown in
When a storage immersion test in which the liquid ejection head 10 thus prepared was immersed in the ink for a certain period of time was performed, peeling or dissolution of the substrate 3 was not confirmed.
The liquid ejection head 10 shown in
When a storage immersion test in which the liquid ejection head 10 thus prepared was immersed in the ink for a certain period of time was performed, peeling or dissolution of the substrate 3 was not confirmed.
In the present example, the liquid ejection head 10 shown in
When a storage immersion test in which the liquid ejection head 10 thus prepared was immersed in the ink for a certain period of time was performed, peeling or dissolution of the substrate 3 was not confirmed.
According to the present disclosure, it is possible to provide a highly reliable liquid ejection head and its manufacturing method by suppressing the dissolution of a substrate and sufficiently securing the bonding strength between the substrate and a member bonded to the substrate.
While the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2021-125351, filed Jul. 30, 2021, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2021-125351 | Jul 2021 | JP | national |