Patent Publication Number: US-2023150198-A1

Title: Molded panels

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional Patent Application of U.S. National Stage Application under 35 U.S.C. 371 of application Ser. No. 16/495,472, filed on Sep. 19, 2019, which claims priority to PCT International Application No. PCT/US2017/030374, filed on May 1, 2017, the entireties of which are incorporated by reference herein. 
    
    
     BACKGROUND 
     Microfabrication and micromachining processes may refer to processes in which micrometer scale or smaller devices and structures may be formed. For example, microelectromechanical systems corresponds to various microstructures which may be implemented in sensors or other devices. As another example, microfluidic devices, such as inkjet printheads, may correspond to devices of a micrometer or smaller scale that convey, dispense, and/or process small amounts (e.g., microliters) of fluid substances. 
    
    
     
       DRAWINGS 
         FIG.  1    is a flowchart that illustrates some operations of an example process. 
         FIG.  2    is a flow diagram of an example process. 
         FIG.  3    is a flowchart that illustrates some operations of an example process. 
         FIGS.  4 A-B  are flow diagrams of an example process. 
         FIG.  5    is a block diagram that illustrates some example components of example devices formed by example processes. 
     
    
    
     Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements. The figures are not necessarily to scale, and the size of some parts may be exaggerated to more clearly illustrate the example shown. 
     DESCRIPTION 
     Examples of devices may comprise fluid ejection devices, fluidic sensors, lab-on-a-chip (LOC) devices, integrated fluidic processing devices, microelectromechanical systems, and/or other such microfabricated devices. In such examples, a fluidic die (such as a fluid ejection die) may be molded into a panel, where the molded panel may have a fluid slot formed through the panel. The molded panel may be formed with a mold chase into which a mold material may be input. Example mold materials that may be used in examples described herein may comprise an epoxy mold compound, such as CEL400ZHF40WG from Hitachi Chemical, Inc., and/or other such materials. The mold chase may have a fluid slot feature that may align with fluid feed holes of the fluidic die such that a fluid slot may be formed in the molded panel that corresponds to the fluid slot feature of the mold chase. Furthermore, a release liner may be positioned on an interior surface of the mold chase, such that mold material input to the mold chase may contact the release liner during formation of the molded panel with the mold chase. Example release liners may be formed from various materials, such as polyvinyl fluoride films (PTFE) and other similar materials. 
     In some examples, prior to forming the molded panel, a removable protective layer may be distributed over the fluid feed holes of the fluidic die. In such examples, the protective layer may cover and seal the fluid feed holes such that mold material may not enter the fluid feed holes during formation of the molded panel. Example protective layers may be formed from various materials, such as a plastic-based material (e.g., thermoplastic), a metal based material, an alloy, an acrylic-based material, HT10.10 from Brewer Science, Inc., thermal decomposable polymers from Novomer, Inc., and/or other such materials. In some examples, a height of the protective layer distributed on the fluid ejection die may be within a range of approximately 1 micrometers to approximately 20 micrometers. In some examples, a height of the protective layer distributed on the fluid ejection die may be within a range of approximately 5 micrometers to approximately 10 micrometers. The term “approximately” when used with regard to a value may correspond to a range of ±10%. In some examples, the removable protective layer may be deformable, such that engagement thereof by a portion of the fluid slot feature of the mold chase (and a release liner positioned thereon) may cause deformation of the protective layer. Accordingly, engagement of the protective layer with a portion of the fluid slot feature may further form a seal between the fluid slot feature (and release liner thereon) and the protective layer on the fluidic die such that mold material may not collect therebetween during formation of the molded panel. 
     In some examples, a fluidic die may be a fluid ejection die, and the fluid ejection die may be molded into a molded panel such that the fluid ejection die and molded panel collectively may be referred to as a fluid ejection device. In these examples, the molded panel may have a fluid slot formed as described above, where the fluid slot is fluidly connected to fluid feed holes of the fluid ejection die. In these examples, fluid may be conveyed through such fluid slot to the fluid feed holes of the fluid ejection die. In some examples, a fluid ejection die may be a printhead, and a fluid ejection device may comprise at least one printhead at least partially embedded in a molded panel having a fluid slot formed therethrough in the manner described herein. 
     In some examples corresponding to printheads, fluid ejection dies may be generally arranged end-to-end along a width of the molded panel such that a printing device implementing the fluid ejection device may perform a page-wide printing process. In other example fluid ejection devices, a single fluid ejection die may be molded into the molded panel. In some examples, fluid ejection dies may be referred to as slivers. In addition, the fluid ejection dies may be formed with silicon or a silicon-based material. Various features, such as nozzles, may be formed from various materials used in silicon device based fabrication, such as silicon dioxide, silicon nitride, metals, epoxy, polyimide, other carbon-based materials, etc. As described herein, a sliver may correspond to a fluid ejection die having: a thickness of approximately 650 μm or less; exterior dimensions of approximately 30 mm or less; and/or a length to width ratio of approximately 3 to 1 or larger. 
     Furthermore, some fluid ejection devices, as described herein, may be implemented in printing devices, such as two-dimensional printers and/or three-dimensional printers (3D). In some examples, a fluid ejection device may be implemented into a printing device and may be utilized to print content onto a media, such as paper, a layer of powder-based build material, reactive devices (such as lab-on-a-chip devices), etc. Example fluid ejection devices include ink-based ejection devices, digital titration devices, 3D printing devices, pharmaceutical dispensing devices, lab-on-chip devices, fluidic diagnostic circuits, and/or other such devices in which amounts of fluids may be dispensed/ejected. In some examples, a printing device in which a fluid ejection device may be implemented may print content by deposition of consumable fluids in a layer-wise additive manufacturing process. Generally, consumable fluids and/or consumable materials may include all materials and/or compounds used, including, for example, ink, toner, fluids or powders, or other raw material for printing. Generally, printing material, as described herein may comprise consumable fluids as well as other consumable materials. Printing material may comprise ink, toner, fluids, powders, colorants, varnishes, finishes, gloss enhancers, binders, and/or other such materials that may be utilized in a printing process. 
     Turning now to the figures, and particularly, to  FIG.  1   , this figure illustrates some operations of an example process  10 . In this example, at least one fluid ejection die may be arranged on a carrier (block  12 ). A molded panel may be formed with a mold chase having a fluid slot feature and a release liner positioned on an interior surface of the mold chase (block  14 ). In such examples, the fluid slot feature of the mold chase may be aligned with fluid feed holes of the fluid ejection die. The molded panel may include the at least one fluid ejection die embedded therein such that a top surface of the fluid ejection die may be approximately planar with a top surface of the molded panel. The molded panel may be released from the mold chase and the release liner. Upon release from the mold chase and release liner, the molded panel may have a fluid slot formed therethrough that corresponds to the fluid slot feature of the mold chase. In such examples, the fluid slot of the molded panel may be fluidly connected to fluid feed holes of the fluid ejection die. 
       FIG.  2    provides a flow diagram that illustrates some operations of an example process  50 . In this example, a fluid ejection die  52  may be arranged on a carrier  54  (block  56 ). In some examples, the carrier  54  may have a temporary adhesive surface such that a top surface  58  of the fluid ejection die  52  may contact and temporarily adhere to the carrier  54 . As shown, the fluid ejection die  52  comprises nozzles  60  having nozzle orifices  62  formed in a top surface of the fluid ejection die  52  through which fluid drops may be ejected. On a bottom surface  64 , the fluid ejection die  52  includes fluid feed holes  66  formed therethrough and fluidly connected to the nozzles  60  such that fluid may be conveyed from the fluid feed holes to the nozzles for ejection as fluid drops. In addition, the fluid ejection die  52  may comprise at least one electrical contact point  68  through which electrical connections to the fluid ejection die  52  may be facilitated. 
     At block  80 , a molded panel  82  may be formed with a mold chase  84  having a release liner  86  disposed on an interior surface of the mold chase  84  such that the release liner  86  contacts the mold material of the molded panel  82 . Furthermore, as shown at block  80 , the mold chase  84  includes a fluid slot feature  88  that aligns with the fluid feed holes  66  of the fluid ejection die  52  that is molded into the molded panel  82 . As shown in this example, the fluid slot feature of the mold chase  84  and the portion of the release liner  86  disposed thereon may contact the bottom surface  64  of the fluid ejection die during formation of the molded panel  82  and cover the fluid feed holes  66 . 
     At block  100 , the molded panel  82  including the fluid ejection die  52  molded (and at least partially embedded) therein may be released from the mold chase  84  and release liner  86  such that a fluid slot  102  may be formed through the molded panel  82 . As shown, the fluid slot  102  may be fluidly connected to the fluid feed holes  66  of the fluid ejection die  52 . In block  110 , the carrier  54  may be released from the molded panel  82  and fluid ejection die. As may be appreciated, a fluid ejection device may be formed by the example process  50  provided in  FIG.  2   . 
     Turning now to  FIG.  3   , this figure provides a flowchart  150  that illustrates an example sequence of operations that may be performed by an example process. In this example, fluid ejection dies may be arranged on a carrier (block  152 ). In such examples, the carrier may temporality couple with a top surface of the fluid ejection dies in which nozzle orifices may be formed. On a bottom surface of the fluid ejection dies, in which fluid feed holes may be formed, a protective layer may be distributed thereon (block  154 ), where the protective layer may cover and seal the fluid feed holes. 
     The carrier including the fluid ejection dies may be positioned proximate a mold chase such that a molded panel may be formed with the mold chase and mold material. In such examples, the mold chase may have a fluid slot feature that may facilitate formation of at least one fluid slot for each fluid ejection die to be molded into the molded panel. Furthermore, as described previously, a release liner may be coupled to an interior surface of the mold chase, such that mold material to be formed into the molded panel may contact the release liner. The protective layer distributed on the bottom surface of each fluid ejection die may be engaged by a portion of the release liner that covers the fluid slot feature of the mold chase corresponding to the fluid ejection die (block  156 ). By engaging the protective layer of each fluid ejection die with the fluid slot feature corresponding to the fluid ejection die, the protective layer may deform and thereby form a seal over the fluid feed holes. 
     The molded panel may be formed with the mold chase and release liner (block  158 ). In some examples, the molded panel may be formed by transfer molding with the mold chase and release liner. As discussed, the molded panel may include the fluid ejection dies embedded therein such that a top surface of the fluid ejection dies (in which the nozzle orifices may be formed) may be approximately planar with a top surface of the molded panel. The molded panel may be released from the mold chase and release liner. Upon release of the molded panel, a fluid slot may be present in the molded panel that corresponds to the fluid slot feature of the mold chase. Accordingly, the protective layer disposed on the bottom surface of each fluid ejection die may be exposed in each fluid slot. The protective layer may be removed from the bottom surface of each fluid ejection die (block  162 ) such that the fluid feed holes of each fluid ejection die are fluidly connected to the corresponding fluid feed slot formed through the molded panel. In these examples, the protective layer engaged with the release liner disposed on the fluid slot feature may form a seal such that mold material used in the molded panel formation process may be prevented from entering the fluid feed holes of the fluid ejection dies. 
     The molded panel that includes the fluid ejection dies molded therein may be released from the carrier (block  164 ), and the molded panel may be singulated (block  166 ). In such examples in which a plurality of fluid ejection dies may be molded into the molded panel, the molded panel and fluid ejection dies thereof may be singulated into fluid ejection devices having one fluid ejection die each or fluid ejection devices having a plurality of fluid ejection dies. Singulating the devices may comprise dicing the molded panel, cutting the molded panel, and/or other such known singulation processes. 
       FIGS.  4 A-B  provide flow diagrams that illustrate some operations of an example process  200 . In  FIG.  4 A , at block  202 , a fluid ejection die  204  may be arranged on a carrier  206 . As shown, the fluid ejection die  204  may have a first surface  208  (i.e., a top surface) in which nozzle orifices  210  may be formed. The first surface  208  may be placed and removably coupled with the carrier  206 . Each nozzle orifice may correspond to and be fluidly connected to a fluid chamber  212  (which may also be referred to as an ejection chamber). While not shown, each fluid chamber  212  may include at least one fluid actuator that may be actuated to cause displacement of fluid in the fluid chamber  212 , which, in turn, may cause ejection of a fluid drop via the nozzle orifice  210 . On a second surface  214  of the fluid ejection die (i.e., a bottom surface), the fluid feed holes  216  may be formed. Furthermore, the fluid ejection die may comprise electrical contacts  218 . 
     At block  230 , a protective layer  232  is distributed on a portion of the second surface  214  of the fluid ejection die  204  such that the protective layer covers the fluid feed holes  216  of the fluid ejection die  204 . At block  250 , the fluid ejection die and carrier are positioned such that molding of a molded panel may be performed with a mold chase  252  having a release liner  254  disposed on an interior surface thereof. As described in previous examples, the mold chase  252  may have a fluid slot feature  256  that may correspond to a fluid slot to be formed in a molded panel formed therewith. The fluid slot feature  256  may align with the fluid feed holes  216  of the fluid ejection die  204 . In this example, the protective layer  232  disposed on the second surface  214  of the fluid ejection die  204  may be engaged by the release liner  254  portion covering the fluid slot feature  256  such that the protective layer may deform and form a seal between the release liner  254  portion and the second surface  214  of the fluid ejection die  204  such that mold material may be prevented from entering the fluid feed holes  216  during formation of the molded panel with the mold material. 
     At block  270 , mold material is formed into a molded panel  272  with the mold chase  252  and release liner  254 . As shown, the protective layer  232  is positioned between the release liner  254  portion covering the fluid slot feature and portion of the second surface  214  of the fluid ejection die  204  in which the fluid feed holes  216  are formed. In  FIG.  4 B , at block  300 , the molded panel  272 , which includes the fluid ejection die  204  molded therein, is released from the mold chase  252  and release liner  254 . A fluid slot  302  is formed through a portion of the molded panel  272 , where the fluid slot  302  corresponds to the fluid slot feature  256  of the mold chase  252 . As shown, the fluid slot  302  exposes the protective layer  232  that covers the fluid feed holes  216 . In block  310 , the protective layer  232  has been removed such that the fluid slot  302  is fluidly connected to the fluid feed holes. In some examples, removing the protective layer may comprise wet dipping in protective layer material remover. For example, if the protective layer material is HT10.10, the molded panel may be wet dipped in WaferBond remover from Brewer Science, Inc. At block  320 , the carrier  206  is detached from the molded panel  272  and fluid ejection die  204  molded in the molded panel  272 . 
       FIG.  5    is a top view of an example fluid ejection device  300 . In this example, the fluid ejection device  300  comprises a molded panel  302  and a plurality of fluid ejection dies  304   a - c  molded in the molded panel  302 . As shown, the fluid ejection dies  304   a - c  are generally arranged end-to-end along a width of the molded panel  302 . In this example, a respective fluid slot  306   a - c  is illustrated in dashed line for each row of fluid ejection dies  304   a - c . In such examples, the molded panel  302  including the fluid ejection dies  304   a - c  may be formed in a manner described herein. Furthermore, in some examples, the molded panel  302  may be singulated into fluid ejection devices that comprise a respective row of fluid ejection dies  304   a - c  along singulation lines  308   a - b . In other examples, all the fluid ejection dies may be implemented in a single fluid ejection device  300  in which each row of fluid ejection dies  308   a - c  is to eject a different fluid. In some examples, the fluid ejection device  300  may be implemented in a page-wide, fixed printhead, printing device. 
     While the example of fluid ejection device  100  is illustrated with three sets of fluid ejection dies  104   a - c , other examples may comprise various arrangements of fluid ejection dies based on the fluid ejection systems and processes into which the examples may be implemented. 
     Accordingly, examples provided herein may provide devices including a molded panel having fluid ejection dies molded therein. In addition, the molded panel be formed with a mold chase and a release liner disposed on an interior surface of the mold chase. Furthermore, the mold chase may have a fluid slot feature that forms a fluid slot in a molded panel formed thereby. 
     The preceding description has been presented to illustrate and describe examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the description. Therefore, the foregoing examples provided in the figures and described herein should not be construed as limiting of the scope of the disclosure, which is defined in the Claims.