Patent Application
20050012772
In some fluid ejection devices, such as printheads, a drop ejecting element is formed on a front side of a substrate and fluid is routed to an ejection chamber of the drop ejecting element through an opening or slot in the substrate. Often, the substrate is a silicon wafer and the slot is formed in the wafer by chemical etching. Methods of forming the slot through the substrate include etching into the substrate from both the front side and the backside so as to form a front side opening and a backside opening in the substrate.
Unfortunately, since a portion of the slot is formed by etching into the substrate from the front side and a portion of the slot is formed by etching into the substrate from the backside, misalignment between the backside opening and the front side opening of the slot may occur. Such misalignment may result, for example, in undercutting of one or more layers formed on the front side of the substrate.
For these and other reasons, there is a need for the present invention.
One aspect of the present invention provides a method of forming an opening through a substrate having a first side and a second side opposite the first side. The method includes forming spaced stops in the first side of the substrate, partially forming a first portion of the opening in the substrate from the second side by a first process, further forming the first portion of the opening in the substrate from the second side by a second process, including forming the first portion of the opening to the spaced stops, and forming a second portion of the opening in the substrate from the first side, including forming the second portion of the opening between the spaced stops.
In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
Ink supply assembly 14, as one embodiment of a fluid supply assembly, supplies ink to printhead assembly 12 and includes a reservoir 15 for storing ink. As such, in one embodiment, ink flows from reservoir 15 to inkjet printhead assembly 12. In this embodiment, ink supply assembly 14 and inkjet printhead assembly 12 can form either a one-way ink delivery system or a recirculating ink delivery system. In a one-way ink delivery system, substantially all of the ink supplied to inkjet printhead assembly 12 is consumed during printing. In a recirculating ink delivery system, however, only a portion of the ink supplied to printhead assembly 12 is consumed during printing. As such, a portion of the ink not consumed during printing is returned to ink supply assembly 14.
In one embodiment, inkjet printhead assembly 12 and ink supply assembly 14 are housed together in an inkjet or fluidjet cartridge or pen. In another embodiment, ink supply assembly 14 is separate from inkjet printhead assembly 12 and supplies ink to inkjet printhead assembly 12 through an interface connection, such as a supply tube (not shown). In either embodiment, reservoir 15 of ink supply assembly 14 may be removed, replaced, and/or refilled. In one embodiment, where inkjet printhead assembly 12 and ink supply assembly 14 are housed together in an inkjet cartridge, reservoir 15 includes a local reservoir located within the cartridge and/or a larger reservoir located separately from the cartridge. As such, the separate, larger reservoir serves to refill the local reservoir. Accordingly, the separate, larger reservoir and/or the local reservoir may be removed, replaced, and/or refilled.
Mounting assembly 16 positions inkjet printhead assembly 12 relative to media transport assembly 18 and media transport assembly 18 positions print medium 19 relative to inkjet printhead assembly 12. Thus, a print zone 17 is defined adjacent to nozzles 13 in an area between inkjet printhead assembly 12 and print medium 19. In one embodiment, inkjet printhead assembly 12 is a scanning type printhead assembly. As such, mounting assembly 16 includes a carriage for moving inkjet printhead assembly 12 relative to media transport assembly 18 to scan print medium 19. In another embodiment, inkjet printhead assembly 12 is a non-scanning type printhead assembly. As such, mounting assembly 16 fixes inkjet printhead assembly 12 at a prescribed position relative to media transport assembly 18. Thus, media transport assembly 18 positions print medium 19 relative to inkjet printhead assembly 12.
Electronic controller 20 communicates with inkjet printhead assembly 12, mounting assembly 16, and media transport assembly 18. Electronic controller 20 receives data 21 from a host system, such as a computer, and includes memory for temporarily storing data 21. Typically, data 21 is sent to ink-jet printing system 10 along an electronic, infrared, optical or other information transfer path. Data 21 represents, for example, a document and/or file to be printed. As such, data 21 forms a print job for inkjet printing system 10 and includes one or more print job commands and/or command parameters.
In one embodiment, electronic controller 20 provides control of ink-jet printhead assembly 12 including timing control for ejection of ink drops from nozzles 13. As such, electronic controller 20 defines a pattern of ejected ink drops which form characters, symbols, and/or other graphics or images on print medium 19. Timing control and, therefore, the pattern of ejected ink drops, is determined by the print job commands and/or command parameters. In one embodiment, logic and drive circuitry forming a portion of electronic controller 20 is located on inkjet printhead assembly 12. In another embodiment, logic and drive circuitry is located off inkjet printhead assembly 12.
In one embodiment, each drop ejecting element 30 includes a thin-film structure 32, an orifice layer 34, and a firing resistor 38. Thin-film structure 32 has a fluid (or ink) feed channel 33 formed therein which communicates with fluid feed slot 44 of substrate 40. Orifice layer 34 has a front face 35 and a nozzle opening 36 formed in front face 35. Orifice layer 34 also has a nozzle chamber 37 formed therein which communicates with nozzle opening 36 and fluid feed channel 33 of thin-film structure 32. Firing resistor 38 is positioned within nozzle chamber 37 and includes leads 39 which electrically couple firing resistor 38 to a drive signal and ground.
In one embodiment, during operation, fluid flows from fluid feed slot 44 to nozzle chamber 37 via fluid feed channel 33. Nozzle opening 36 is operatively associated with firing resistor 38 such that droplets of fluid are ejected from nozzle chamber 37 through nozzle opening 36 (e.g., normal to the plane of firing resistor 38) and toward a medium upon energization of firing resistor 38.
Example embodiments of inkjet printhead assembly 12 include a thermal printhead, a piezoelectric printhead, a flex-tensional printhead, or any other type of fluid ejection device known in the art. In one embodiment, inkjet printhead assembly 12 is a fully integrated thermal inkjet printhead. As such, substrate 40 is formed, for example, of silicon, glass, or a stable polymer, and thin-film structure 32 is formed by one or more passivation or insulation layers of silicon dioxide, silicon carbide, silicon nitride, tantalum, poly-silicon glass, or other suitable material. Thin-film structure 32 also includes a conductive layer which defines firing resistor 38 and leads 39. The conductive layer is formed, for example, by aluminum, gold, tantalum, tantalum-aluminum, or other metal or metal alloy.
In one embodiment, drop ejecting elements 130 include a thin-film structure 132, an orifice layer 134, and firing resistors 138. Thin-film structure 132 has fluid (or ink) feed channels 133 formed therein which communicate with fluid feed slot 144 of substrate 140. Orifice layer 134 has a front face 135 and nozzle openings 136 formed in front face 135. Orifice layer 134 also has nozzle chambers 137 formed therein which communicate with respective nozzle openings 136 and respective fluid feed channels 133 of thin-film structure 132.
In one embodiment, during operation, fluid flows from fluid feed slot 144 to nozzle chambers 137 via respective fluid feed channels 133. Nozzle openings 136 are operatively associated with respective firing resistors 138 such that droplets of fluid are ejected from nozzle chambers 137 through nozzle openings 136 and toward a medium upon energization of firing resistors 138 positioned within respective nozzle chambers 137.
As illustrated in the embodiment of
In one embodiment, fluid feed slot 144 includes a first portion 145 and a second portion 146. First portion 145 is formed in and communicates with second side 142 of substrate 140 and second portion 146 is formed in and communicates with first side 141 of substrate 140. First portion 145 and second portion 146 communicate with each other so as to form fluid feed slot 144 through substrate 140. Fluid feed slot 144, including first portion 145 and second portion 146, is formed in substrate 140 according to an embodiment of the present invention. In one embodiment, fluid feed slot 144, including first portion 145 and second portion 146, is formed in substrate 140 by chemical etching, as described below.
In one embodiment, substrate 140 includes spaced stops 148. Stops 148 extend into substrate 140 from first side 141 and, in one embodiment, are oriented substantially perpendicular to first side 141. Stops 148 control etching of substrate 140 and, therefore, formation of first portion 145 and second portion 146 of fluid feed slot 144. As such, stops 148 are formed of a material which is resistant to etchant used for etching substrate 140, as described below. Thus, stops 148 constitute etch stops of substrate 140.
Stops 148 define and control formation of fluid feed slot 144 in substrate 140. More specifically, stops 148 limit fluid feed slot 144 and define a maximum dimension of second portion 146 and a minimum dimension of first portion 145 of fluid feed slot 144. In addition, stops 148 establish a location of second portion 146 at first side 141 and accommodate misalignment between first portion 145 and second portion 146, as described below. Furthermore, stops 148 provide for self-alignment between first portion 145 and second portion 146 of fluid feed slot 144.
In one embodiment, substrate 160 represents substrate 140 of ink-jet printhead assembly 112 and opening 150 represents fluid feed slot 144 formed in substrate 140. As such, drop ejecting elements 130 of inkjet printhead assembly 112 are formed on first side 162 of substrate 160. Thus, first side 162 forms a front side of substrate 160 and second side 164 forms a backside of substrate 160 such that fluid flows through opening 150 and, therefore, substrate 160 from the backside to the front side. Accordingly, opening 150 provides a fluidic channel for the communication of ink with drop ejecting elements 130 through substrate 160.
In one embodiment, opening 150 is formed in substrate 160 after drop ejecting elements 130 are formed on substrate 160. More specifically, opening 150 is formed in substrate 160 after thin-film structure 132, firing resistors 138, and orifice layer 134 are formed on first side 162 of substrate 160. In one embodiment, processing of substrate 160 for forming opening 150 is started after thin-film structure 132 and firing resistors 138 of drop ejecting elements 130 are formed on first side 162 of substrate 160.
As illustrated in the embodiments of
In one embodiment, as illustrated in the embodiment of
In one embodiment, masking layer 180 is formed by deposition and patterned by photolithography and etching to define exposed portions of first side 162 of substrate 160. More specifically, masking layer 180 is patterned to outline where slots 166 (
Also, as illustrated in the embodiment of
Next, as illustrated in the embodiment of
During the deep RIE, an exposed section is alternatively etched with a reactive etching gas and coated until a slot is formed. In one exemplary embodiment, the reactive etching gas creates a fluorine radical that chemically and/or physically etches the substrate. In this exemplary embodiment, a polymer coating that is selective to the etchant used is deposited on inside surfaces of the forming slot, including the sidewalls and bottom. The coating is created by using carbon-fluorine gas that deposits (CF2)n, a low surface energy fluorinated hydrocarbon, on these surfaces. In this embodiment, the polymer substantially prevents etching of the sidewalls during the subsequent etch(es). The gases for the etchant alternate with the gases for forming the coating on the inside of the slots.
As illustrated in the embodiment of
Next, as illustrated in the embodiment of
In one embodiment, etch stops 170 and layer 172 are formed by disposing a material in slots 166 and on first side 162. The material is resistant to the etchant selected for use in etching opening 150 through substrate 160, as described below. In one embodiment, etch stops 170 and layer 172 are formed of a conformal material which is spun-deposited on first side 162. In one embodiment, the material includes an epoxy and, more specifically, a photoimageable epoxy. An example of such a material includes SU8.
As illustrated in the embodiment of
In one embodiment, as illustrated in the embodiment of
Also, as illustrated in the embodiment of
In one embodiment, etch stops 170 are spaced at a first dimension D1 in a first direction (i.e., a horizontal direction with reference to the Figures) and masking layer 184 is patterned to define opening 185 with a second dimension D2 in the first direction. In some embodiments, second dimension D2 is equal to or less than first dimension D1. In addition, second dimension D2 is typically positioned within first dimension D1.
As illustrated in the embodiment of
In some embodiments, first portion 152 of opening 150 is partially formed using an anisotropic etch process which initially forms first portion 152 with substantially parallel sides. In one embodiment, the etch process is a dry etch, such as a plasma based fluorine (SF6) etch. In a particular embodiment, the dry etch is a reactive ion etch (RIE) and, more specifically, a deep RIE (DRIE), as described above. It is, however, within the scope of the present invention for first portion 152 of opening 150 to be partially formed using other fabrication techniques such as laser machining.
When initially etching first portion 152 of opening 150 into substrate 160 from second side 164, masking layer 184 defines where substrate 160 is etched. As such, first portion 152 of opening 150 is initially formed with second dimension D2 in the first direction. In one embodiment, initial etching of first portion 152 is stopped before reaching first side 162 of substrate 160 and, more specifically, before reaching etch stops 170 in substrate 160. In another embodiment, initial etching of first portion 152 is continued between etch stops 170 to the side of layer 172 at first side 162 of substrate 160.
As illustrated in the embodiment of
As illustrated in the embodiment of
Typically, first portion 152 is further formed and second portion 154 is formed using an anisotropic chemical etch process. More specifically, the chemical etch process is a wet etch process and uses a wet anisotropic etchant such as tetra-methyl ammonium hydroxide (TMAH), potassium hydroxide (KOH), or other alkaline etchant. As such, a geometry of opening 150 through substrate 160 is defined by crystalline planes of the silicon substrate. For example, first portion 152 of opening 150 follows crystalline planes 168 of substrate 160 and second portion 154 of opening 150 follows crystalline planes 169 of substrate 160.
In one embodiment, substrate 160 has a <100> Si crystal orientation and the wet anisotropic etches of first portion 152 and second portion 154 follow <111> Si planes of substrate 160. As such, crystalline planes 168 and 169 include <111> Si planes of substrate 160. Thus, sides of first portion 152 of opening 150 and sides of second portion 154 of opening 150 are oriented at angles of approximately 54 degrees to second side 164 and first side 162, respectively.
As illustrated in the embodiment of
As described above, etch stops 170 are formed of a material resistant to the wet anisotropic etchant used to further form first portion 152 and form second portion 154 of opening 150. As such, etch stops 170 define a maximum dimension of second portion 154 and a minimum dimension of first portion 152, as described below. In addition, etch stops 170 establish a location of second portion 154 at first side 162 and accommodate misalignment between first portion 152 formed from second side 164 and second portion 154 formed from first side 162.
More specifically, when etching into substrate 160 from first side 162, etch stops 170 limit etching of substrate 160 to areas between etch stops 170 and prevent etching laterally of etch stops 170. As such, undercutting or etching into substrate 160 under the edges of layer 172 and, more specifically, thin-film structure 132 is avoided when etching into substrate 160 from first side 162. Thus, etch stops 170 define substantially vertical sidewalls of second portion 154 of opening 150 and control a width of opening 150 at first side 162. Etch stops 170, therefore, control where opening 150 communicates with first side 162.
Furthermore, when etching into substrate 160 from second side 164, etch stops 170 cause further etching of first portion 152 to self-terminate. More specifically, when further etching of first portion 152 reaches etch stops 170, etching of first portion 152 continues to follow the crystalline orientation or crystalline planes of substrate 160. For example, in one embodiment, as described above, etching of first portion 152 follows <111> Si planes of substrate 160. As such, when etching of first portion 152 reaches one or more etch stops 170, etching continues along <111> Si planes of substrate 160.
A depth at which etch stops 170 extend into substrate 160 from first side 162, however, is selected such that etching of first portion 152 toward first side 162 and beyond etch stops 170 self-terminates before reaching first side 162. As such, etch stops 170 provide for self-alignment between first portion 152 as formed from second side 164 and second portion 154 as formed from first side 162. More specifically, etch stops 170 accommodate misalignment between first portion 152 and second portion 154 by confining second portion 154 between spaced etch stops 170 and causing first portion 152 to self-terminate at etch stops 170. In addition, a dimension of second portion 154 of opening 150 is self-limiting and self-aligned by etch stops 170.
While the above description refers to the inclusion of substrate 160 having opening 150 formed therein in an inkjet printhead assembly, as one embodiment of a fluid ejection assembly of a fluid ejection system, it is understood that substrate 160 having opening 150 formed therein may be incorporated into other fluid ejection systems including non-printing applications or systems as well as other applications having fluidic channels through a substrate, such as medical devices. Accordingly, the present invention is not limited to printheads, but is applicable to any slotted substrates. In addition, while the above description refers to routing fluid or ink through opening 150 of substrate 160, it is understood that any flowable material, including a liquid such as water, ink, blood, photoresist, or organic light-emitting materials or flowable particles of a solid such as talcum powder or a powdered drug, may be fed or routed through opening 150 of substrate 160.
Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations calculated to achieve the same purposes may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. Those with skill in the chemical, mechanical, electromechanical, electrical, and computer arts will readily appreciate that the present invention may be implemented in a very wide variety of embodiments. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
