Patent ID: 6200491
Filing Date: 2001-03-13
Classification: B41J

Abstract:
A method of forming a microlens array for use in an acoustic ink print head, the method comprising the steps of:forming a mold substrate having a plurality of pedestals on an upper surface of the mold substrate;depositing predetermined amounts of a photoresist material on the upper surface of the pedestals, wherein the predetermined amount of photoresist material deposited on the pedestals is substantially the same for each pedestal;melting the photoresist material by a predetermined temperature until semi-spherical photoresist mounds are formed from the deposited photoresist material;etching the mold substrate in accordance with a pattern of the semi-spherical mounds, whereby the geometry of the semi-spherical mounds is transferred into the mold substrate, forming a microlens array mold stamper;heating an acoustic ink print head substrate to a temperature which softens the acoustic ink print head substrate to a degree whereby molding of the acoustic ink print head substrate can be achieved;pressing the microlens array mold stamper into a top surface of the heated acoustic ink print head substrate to thereby form an array of concave indentations corresponding to the semi-spherical mounds of the microlens array mold stamper; andseparating the microlens array mold stamper from the upper surface of the acoustic ink print head substrate, whereby a microlens array is formed in the upper surface of the acoustic ink print head substrate.