Filter for ink jet printhead

Abstract: An ink jet printhead includes a chip layer (16) having a via (30) for receiving ink, and having at least one actuator (18). A barrier layer (28) is disposed adjacent the chip layer, and forms at least one throat (22) which has a width and a cross-sectional area. The barrier layer also forms at least one bubble chamber (20), with each throat adapted to receive ink from the via and provide it to the respective bubble chamber. A nozzle layer (14) is disposed adjacent the barrier layer, opposite the chip layer, and forms at least one nozzle for ejecting ink from the respective bubble chamber when the ink is energized by the associated actuator. At least one post (24) is disposed proximate the throat, and extends part way between the chip layer and the nozzle layer. The post forms one or more gates through which the ink must pass from the via to the at least one throat.

Description: This invention relates to the field of ink jet print heads. More particularly the invention relates to the field of integrated ink filtration for ink jet print heads. As the several technologies which are combined to produce ink jet printheads have advanced, printheads capable of printing with increasingly finer resolution have been developed. As a part of this development, the geometries of the printhead have been reduced. As a result, problems that were previously insignificant have become serious detractions in printhead reliability. For example, when printheads had larger geometries, debris in the ink was able to more easily pass through the different parts of the ink jet printhead, eventually passing out of the printhead through the nozzle without creating a problem. Now, however, several of the parts within a printhead are too narrow to allow the debris to pass, and so become clogged. The clogging may result in a nozzle which can no longer receive ink, thus impacting the print quality of the printhead. Filters of various different configurations have been used to attempt to catch the debris before it encounters a part within the printhead that is too narrow for the debris to pass. Unfortunately, such filters typically either add expensive additional processing steps to the manufacture of the printhead, or produce more resistance to the flow of ink than is necessary to perform the function of filtering, thus creating other problems with the use of the filter. What is needed, therefore, is a filter for an ink jet printhead that is easy and inexpensive to integrate with the manufacture of the printhead, and which does not unduly inhibit the flow of ink through the printhead. EP-A-314486 discloses an ink jet printhead comprising: a chip layer forming a via for receiving ink and having an actuator for energising the ink; a barrier layer disposed adjacent to and overlying the chip layer, forming a throat having a width and a cross-sectional area, and a bubble chamber, the throat being adapted to receive the ink from the via and provide it to the bubble chamber; a nozzle layer disposed adjacent to and overlying the barrier layer, opposite the chip layer, forming a nozzle for ejecting the ink from the bubble chamber when the ink is energised by the actuator; and at least one barrier comprising a post, pillar or dam disposed proximate the throat, between the said via and the throat, said barrier extending part way between the chip layer and the nozzle layer and defining a width or height of at least one gate through which the ink must pass from the via to the throat. EP-A-627318 discloses a similar device but in which the said barrier extends all of the way between the chip layer and the nozzle layer. The present invention is characterised in that said width or height of the said gate is equal to or greater than the width of the said throat. Preferably, when a plurality of gates and a plurality of throats are provided, the summed cross-sectional area of all of the gates is equal to or greater than the summed cross-sectional area of all of the throats. The or each barrier may extend from the chip layer toward, but not as far as, the nozzle layer, or from the nozzle layer toward, but not as far as, the chip layer. In one embodiment the said barrier comprises posts extending from the chip layer toward, but not as far as, the nozzle layer, and pillars extending from the nozzle layer toward, but not as far as, the chip layer, the said pillars being interdigitated with the said posts. In another embodiment the said barrier forms a dam disposed proximate the throat, extending part way between the chip layer and the nozzle layer. The dam terminates at a free edge and forms the gate (between the free edge and an opposing layer) through which the ink must pass from the via to the throat. In all embodiments, the gate or gates allow the ink to pass from the via and eventually through the nozzle, but inhibits debris from passing into the throat, which is typically narrower than the bubble chamber, and clogging the throat. Some embodiments of the invention will now be described by way of example and with reference to the accompanying drawings, in which:- Fig. 1 is a top plan view of a portion of an ink jet printhead; Fig. 2A is a cross-sectional view of a first embodiment of a bubble chamber; Fig. 2B is a cross-sectional view of a second embodiment of a bubble chamber; Fig. 3 is a top plan view of an ink jet printhead showing posts; Fig. 4 is a top plan view of an ink jet printhead showing interdigitated posts and pillars, and a dam; Fig. 5A is a cross-sectional view of a first embodiment of posts; Fig. 5B is a cross-sectional view of a second embodiment of posts; Fig. 5C is a cross-sectional view of a first embodiment of a dam; Fig. 5D is a cross-sectional view of a second embodiment of a dam; Fig. 5E is a cross-sectional view of a third embodiment of a dam; and Fig. 5F is a cross-sectional view of interdigitated posts and pillars. Referring now to the figures, which it should be noted are not to scale, there is depicted in Fig. 1 a top plan view of a portion of an ink jet printhead 10. In this view, nozzle layer 14 is on top, and chip layer 16 is visible through the nozzle 12 that is formed in nozzle layer 14. Also visible through nozzle 12 is actuator 18, which in different embodiments may be, for example, a thermal heater or a piezoelectric element. The actuator 18 is within bubble chamber 20, which is depicted in phantom lines, which is formed in the barrier layer between the nozzle layer 14 and the chip layer 16. Also formed in the barrier layer is a throat 22, which connects to bubble chamber 20. During operation of the printhead 10, ink is brought through throat 22 and into bubble chamber 20, where it is energized with actuator 18, such as being rapidly heated with a heater. The expansion of the ink when it is energized expels a portion of the ink from bubble chamber 20 through nozzle 12 and out of the printhead 10 onto a substrate. Printhead 10 typically has many of the throat 22, bubble chamber 20, actuator 18, nozzle 12 combinations, rather than just the one that is depicted in Fig. 1. Fig. 2A is a cross-sectional view of a first embodiment of the bubble chamber 20, which allows a barrier layer 28 to be seen between the nozzle layer 14 and the chip layer 16. There is depicted in Fig. 2B a cross-sectional view of a second embodiment of the bubble chamber 20, in which the nozzle layer 14 and the barrier layer 28 are integrally formed from a single piece of common material, such as a plastic. This combined nozzle layer 14 - barrier layer 28 may be formed by a process such as laser ablation. Referring again to Fig. 1, there are also depicted posts 24, which form gates 26. The posts 24 are also depicted in phantom, as they are also formed of material between the chip layer 16 and the nozzle layer 14. The posts 24 serve as filter elements to filter the ink before it flows into throat 22, so that any debris that may be in the ink is not trapped in throat 22, which might cause it to clog. Fig. 3 is a top plan view of a greater portion of printhead 10, showing several bubble chambers 20 connected by throats 22 to an ink plenum 32. While only six such bubble chambers 20 are depicted in Fig. 3, it will be appreciated that typical printheads 10 will have many more such bubble chambers 20. The nozzle layer 14, depicted in Figs. 1 and 2, has not been depicted in Fig. 3. In the chip layer 16 there is formed a via 30, through which the ink flows into the plenum 32, and then into the throats 22 and bubble chambers 20. An arrangement of posts 24a can be seen in this view. As depicted in Fig. 3, the posts 24a form gates 26a, where the width of the gates 26a is equal to the width of the throats 22. Also as depicted in Fig. 3, the total cross-sectional area of the gates 26a is greater than the sum of the cross-sectional areas of the throats 22. In this example the posts 24a are rectangular in shape. Also, the posts 24a are set back somewhat from the edge of the via 30 through which ink is received. There is also depicted in Fig. 3 a series of posts 24b. The posts 24b also form gates 26b, through which the ink flows to get from the via 30 to the throats 22. In this example the posts 24b are depicted as circular in shape. However, it will be appreciated that even though posts 24a are depicted as rectangular, and posts 24b are depicted as circular, the posts 24 may be of any shape. The posts 24b are not set back from the edge of the via 30, as are the posts 24a, but are instead set right at the edge of the via 30. Also, the gates 26b formed by the posts 24b have a width that is greater than the width of the throats 22. Traditional technology teaches that the space between filter elements, such as gates 26, must be narrower than the narrowest element of the printhead 10, which is typically the throat 22. However, it has been found that by forming gates 26 that are equal to or wider than the width of the throats 22, that any debris which may be in the ink is still effectually stopped or repelled by the posts 24. In addition, because the gates 26 may thus be wider than previously believed, the ink is allowed to pass through the filter elements with less resistance, thereby causing fewer problems associated with ink transport within the printhead 10. The posts 24 are preferably disposed proximate the throats 22, but at the edge of the via 30, such as are posts 24b, rather than being set back from the edge of the via 30, such as posts 24a. By so doing, any debris stopped by the posts 24 may tend to remain in the via 30, and not stay trapped against the posts 24, and blocking a gate 26. In Fig. 4 there is depicted a dam 34 which forms the filter element of this embodiment. Dam 34, as depicted in Fig. 4, extends from one end of the ink plenum 32 to the other. However, in alternate embodiments, dam 34 may form a gate 26 at one or both ends of the plenum 32, which gate 26 may be as wide or wider than the width of the throats 22, as explained above. Dam 34 also forms another gate 26 which is not visible in Fig. 4, but which will be explained in greater detail hereafter. Also depicted in Fig. 4 are posts 24 which are interdigitated with pillars 36. The distinction between posts 24 and pillars 36 will be described in greater detail hereafter. As depicted, the posts 24 have a rectangular shape and the pillars 36 have a circular shape. However, as mentioned above, the shape of both the posts 24 and the pillars 36 may be of any shape which is convenient to form during the manufacturing process. Again, the gates 26 formed between the posts 24 and pillars 36 may be as wide or wider than the throats 22. Fig. 5A depicts a cross-sectional view of printhead 10, showing additional important aspects of the posts 24. As can be seen, the posts 24 in this embodiment do not extend completely from the chip layer 16 to the nozzle layer 14, but instead extend for only a portion of the thickness of the barrier layer 28. In this embodiment the posts 24 extend from adjacent the chip layer 16. The gates 26 that are formed by the posts 24 are equal in width to the throat 22. In the embodiment of Fig. 5B the posts 24 extend from adjacent the nozzle layer 14 toward, but not to, the chip layer 16. Also in this embodiment the gates 26 which are formed by the posts 24 have a width that is greater than throats 22. Fig. 5C is a cross-sectional view of a first embodiment of the dam 34. In this embodiment the dam 34 extends from adjacent the chip layer 16 toward, but not to, the nozzle layer 14. The dam 34 forms a gate 26 between the top of the dam 34 and the nozzle layer 14. The gate 26 as depicted in this embodiment is equal in height (the distance from the dam 34 to nozzle layer 14) to the width of the throats 22, which is the horizontal dimension of throat 22 as shown in Fig. 5C. A second embodiment of the dam 34 is depicted in Fig. 5D. In this embodiment the dam 34 is split into two portions. One of the portions extends from adjacent the chip layer 16 toward, but not to, the nozzle layer 14, and the other portion extends from adjacent the nozzle layer 14 toward, but not to, the chip layer 16. As depicted in Fig. 5C, the gates 26 formed are equal in height to the width of the throats 22. In variations of this embodiment the dam 34 may be broken into more than two portions, with the portions interdigitated, or staggered, as to which layer, 14 or 16, they extend from, as described in more detail below. In Fig. 5E there is depicted a third embodiment of the dam 34, in which the dam 34 extends from adjacent the nozzle layer 14 toward, but not to, the chip layer 16. In this embodiment the gate 26 that is formed between the bottom of the dam 34 and chip layer 16 is greater in height than the width of the throats 22. The height of gate 26 as shown in Fig. 5E is the distance from the dam 34 to the chip layer 16, and as before, the width of throat 22 is the horizontal dimension as shown in Fig. 5E. In Fig. 5F there is depicted yet another embodiment of the filter elements, which are formed by posts 24 and pillars 36. While posts 24 may extend from either the chip layer 16 or the nozzle layer 14, as described above, when filter elements extend from both the chip layer 16 and the nozzle layer 14, one set is called posts 24 and the other set is called pillars 36. In this embodiment, the posts 24 and the pillars 36 are interdigitated with a spacing of one post 24 between two adjacent pillars 36. However, it will be appreciated that other methods of interdigitation, such as two posts 24 between two adjacent pillars 36, may be used with equal application. In this embodiment, the gates 26 which are formed between the posts 24 and the pillars 36 have a width that is equal to the width of the throats 22. As before, the width of the gates 26 may also be greater than the width of the throats 22. While posts 24 or dam 34 may extend from adjacent either the chip layer 16 or the nozzle layer 14, in the preferred embodiment they extend from adjacent the chip layer 16. When such is the case, the posts 24 or dam 34 may then be formed from the material of the barrier layer 28, at the same time as the throats 22 and bubble chambers 20 are formed, and using the same methods. Thus, minimal, and preferably negligible, additional effort or cost need be expended to form the posts 24 or dam 34. When posts 24, dam 34, or pillars 36 extend from adjacent the nozzle layer 14, then the posts 24, dam 34, or pillars 36 are preferably formed from something other than barrier layer 28, though they may be formed of material that is the same as that which is used to form barrier layer 28. In the embodiment such as is depicted in Fig. 2B, the posts 24, or pillars 36 as the case may be, which extend from the barrier layer 28, and barrier layer 28 and nozzle layer 14 may all be integrally formed of a single piece of material. It is also preferable in all embodiments that the total cross-sectional area of the gates 26 be equal to or greater than the summed cross-sectional areas of the throats 22. When this is the case, debris that is caught by the filter elements and blocks gates 26 will not unduly inhibit the flow of ink through the throats 22 which is required for proper operation of the printhead 10. While a point may come, if there is an excessive amount of debris in the ink, when the flow of ink is inhibited to such an extent that proper operation of the printhead 10 is inhibited, having more cross-sectional area in the gates 26 than in the throats 22 will increase the amount of debris that can be caught by the filter elements before such an event occurs.

Claims: An ink jet printhead comprising: a chip layer (16) forming a via (30) for receiving ink and having an actuator (18) for energising the ink; a barrier layer (28) disposed adjacent to and overlying the chip layer, forming a throat (22) having a width and a cross-sectional area, and a bubble chamber (20), the throat being adapted to receive the ink from the via and provide it to the bubble chamber; a nozzle layer (14) disposed adjacent to and overlying the barrier layer, opposite the chip layer, forming a nozzle (12) for ejecting the ink from the bubble chamber when the ink is energised by the actuator; and at least one barrier comprising a post (24), pillar (36) or dam (34) disposed proximate the throat, between the said via and the throat, said barrier extending part way between the chip layer and the nozzle layer and defining a width or height of at least one gate (26) through which the ink must pass from the via to the throat; characterised in that said width or height of the said gate is equal to or greater than the width of the said throat. A printhead as claimed in claim 1, including a plurality of said gates (26) and a plurality of said throats (22) and wherein the summed cross-sectional area of all of the said gates is equal to the summed cross-sectional area of all of the said throats. A printhead as claimed in claim 1, including a plurality of said gates (26) and a plurality of said throats (22) and wherein the summed cross-sectional area of all of the said gates is greater than the summed cross-sectional area of all of the said throats. A printhead as claimed in any of claims 1 to 3, wherein the or each said barrier (24;34;36) extends from the chip layer (16) toward, but not as far as, the nozzle layer (14). A printhead as claimed in any of claims 1 to 3, wherein the or each said barrier (24;34;36) extends from the nozzle layer (14) toward, but not as far as, the chip layer (16). A printhead as claimed in any of claims 1 to 3, wherein the said barrier comprises posts (24) extending from the chip layer (16) toward, but not as far as, the nozzle layer (14), and pillars (36) extending from the nozzle layer toward, but not as far as, the chip layer, the said pillars being interdigitated with the said posts.

Inventors: KAUFMAN MICAH ABRAHAM, KELTY JANINE MARIE, POWERS JAMES HAROLD, RAULINAITIS MICHAEL, STEWARD LAWRENCE RUSSELL, KAUFMAN, MICAH ABRAHAM, KELTY, JANINE MARIE, POWERS, JAMES HAROLD, RAULINAITIS, MICHAEL, STEWARD, LAWRENCE RUSSELL
Applicants: LEXMARK INT INC, LEXMARK INTERNATIONAL, INC.
Application year: 1997
Main classification: B41J2
IPC codes: B41J2