Patent ID: 7306744
Filing Date: 2007-12-11
Classification: B41J

Abstract:
1. A method of manufacturing a nozzle plate, the nozzle plate having a concave portion on one major surface thereof, the nozzle plate having the other major surface to which a cavity plate is adapted to be bonded so that plurality of independent cavities for receiving liquid are formed in cooperation with the nozzle plate, and a plurality of nozzle openings through each of which the liquid is adapted to be ejected in the form of droplet, the plurality of nozzle openings being formed so as to be substantially parallel along a thickness direction of the nozzle plate and opening at the concave portion, the method comprising the steps of: preparing a processing substrate formed of silicon as a main material, the processing substrate having two major surfaces; preparing a supporting substrate for supporting the processing substrate thereon, the supporting substrate having two major surfaces; bonding one of the two major surfaces of the processing substrate to one of the two major surfaces of the supporting substrate via a bonding layer including a resin layer constituted from a resin as a main material; forming a concave portion on the other major surface of the processing substrate by subjecting the processing substrate to an etching process so as to form a thin wall portion, the plurality of nozzle openings being to be formed in the thin wall portion, wherein the thus formed concave portion will be used as the concave portion of the nozzle plate; forming the plurality of nozzle openings in the concave portion of the processing substrate by subjecting the other major surface of the processing substrate to an etching process, wherein the resin layer functions as a stop layer for the etching process; and releasing the processing substrate from the supporting substrate and the bonding layer to obtain the nozzle plate; wherein the concave portion forming step and the nozzle opening forming step are carried out in a state that the processing substrate is being supported by the supporting substrate; wherein the nozzle opening forming step includes, prior to the etching process, the step of forming a mask on the other major surface of the processing substrate while the processing substrate is supported by the supporting substrate; and wherein the nozzle opening forming step further includes the steps of: