Patent Document

BACKGROUND 
       [0001]    1. Technical Field 
         [0002]    The present disclosure relates to a method for manufacturing a fluid ejection device and to a fluid ejection device. In particular, the present disclosure regards a process for manufacturing a head for fluid emission based upon piezoelectric technology, and to a head for fluid emission based on piezoelectric technology. 
         [0003]    2. Description of the Related Art 
         [0004]    Multiple types of fluid ejection devices are known in the prior art, in particular inkjet heads for printing applications (known as printheads). Heads of this sort, with appropriate modifications, may moreover be used for emission of fluids other than ink, for example, for applications in the biological or biomedical fields, for local application of biological material (e.g., DNA) during manufacture of sensors for biological analyses. 
         [0005]    Known manufacturing methods envisage coupling via gluing or bonding of a large number of pre-machined wafers; said method is costly and typically requires high precision, and the resulting device has a large thickness. 
       BRIEF SUMMARY 
       [0006]    One or more embodiments of the present disclosure provide a method for manufacturing a fluid ejection device and a corresponding fluid ejection device. 
         [0007]    For example, one embodiment is directed to a method for manufacturing a fluid ejection device. The method includes forming a first recess in a first semiconductor by removing selective portions of the first semiconductor body. The first semiconductor body includes a membrane layer and a piezoelectric actuator located over the membrane. The selective portions are removed until the membrane layer is reached. The method further includes forming an intermediate through hole through the membrane by removing a selective portion of the membrane layer and providing a second semiconductor body having a first surface and a second surface. The method further includes forming a second recess in a third semiconductor body. The method further includes forming an outlet through hole in the third semiconductor body by removing selective portions of the third semiconductor body outside of said second recess. The outlet through hole forms a fluid ejection nozzle of the fluid ejection device. The first and third semiconductor bodies coupled together. This coupling includes housing the piezoelectric actuator in the first recess and the intermediate through hole, the first recess, and the outlet through hole are fluidically coupled to each other. The method also includes coupling together the first semiconductor body and the second semiconductor body. This coupling includes forming a chamber inside the fluid ejection device with a first surface of the second semiconductor body facing the first recess. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0008]    For a better understanding of the present disclosure, preferred embodiments thereof are now described purely by way of non-limiting example with reference to the attached drawings, wherein: 
           [0009]      FIG. 1  shows a fluid ejection device according to one embodiment that does not form part of the present disclosure; 
           [0010]      FIGS. 2-23  show steps of manufacture of a fluid ejection device according to one embodiment of the present disclosure; and 
           [0011]      FIGS. 24-26  show the fluid ejection device machined according to the steps of  FIGS. 2-23  during respective operating steps. 
       
    
    
     DETAILED DESCRIPTION 
       [0012]    Fluid ejection devices based upon piezoelectric technology can be produced by bonding or gluing together a plurality of wafers machined previously using micromachining technologies typically used for manufacturing MEMS (microelectromechanical systems) devices. In particular,  FIG. 1  shows a liquid-ejection device  1  that does not form part of the present disclosure. With reference to  FIG. 1 , a first wafer  2  is machined so as to form thereon one or more piezoelectric actuators  3 , designed to be controlled for generating a deflection of a membrane  7 , which extends partially suspended over one or more chambers  10  that are designed to define respective reservoirs for containing fluid  6  to be expelled during use. A second wafer  4  is machined so as to form one or more chambers  5  for containing the piezoelectric actuators  3  such as to insulate, in use, the piezoelectric actuators  3  from the fluid  6  to be expelled; a third wafer  8  is machined to form one or more inlet holes  9  of the fluid  6 , in fluid connection with the chambers  10 ; and a fourth wafer  12  is machined to form holes  13  for expelling the fluid  6  (outlet holes). Then, the aforementioned wafers  2 ,  4 ,  8  and  12  are assembled together by means of bonding regions and/or gluing regions and/or adhesive regions. Said regions are designated as a whole in  FIG. 1  by the reference number  15 . 
         [0013]    Following upon steps of bonding/gluing, the fluid ejection device  1  of  FIG. 1  is obtained. 
         [0014]    The manufacturing process described with reference to  FIG. 1  involves machining of at least four wafers made of semiconductor material in separate steps, and steps of assembly of said wafers to obtain the finished fluid ejection device. This leads to high manufacturing costs and a greater complexity of machining and integration on account of the large number of wafers that are to be machined. Furthermore, the steps of assembly of the wafers typically require a high precision, and any possible misalignment between the wafers during assembly may entail both structural weaknesses and a non-optimal operation of the finished device. 
         [0015]    With reference to  FIGS. 2-23 , there now follows a description of a process for manufacturing a fluid ejection device  50  (illustrated in  FIG. 24  at the end of the manufacturing steps), according to one embodiment of the present disclosure that overcomes one or more of the drawbacks described with reference to the steps for manufacture of the device of  FIG. 1 . 
         [0016]    In particular,  FIGS. 2-5  describe steps for micromachining a top wafer including one or more cavities for housing piezoelectric actuators and one or more fluid ejection holes or nozzles (or outlet nozzles).  FIGS. 6-13  describe steps for micromachining an intermediate wafer that houses the piezoelectric actuators. Finally,  FIG. 16  describes steps for micromachining a bottom wafer that houses fluid-access channels or inlet channels. 
         [0017]      FIGS. 14A-15  and  17 - 23  describe steps for coupling together the aforementioned wafers, and further manufacturing steps for completing formation of the fluid ejection device according to the present disclosure. 
         [0018]    Hence, according to the present disclosure, the steps of manufacture of the fluid ejection device  50  envisage machining and assembly of a small number of wafers (in particular, three wafers). 
         [0019]    With reference to  FIG. 2 , a wafer  100 , including a substrate  101 , is provided, for example having a thickness of between approximately 400 and 1000 μm, in particular approximately 725 μm. The substrate  101  is, according to one embodiment of the present disclosure, made of semiconductor material, such as silicon. The substrate  101  has a first surface  101   a  and a second surface  101   b , opposite to one another in a direction Z. On the first surface  101   a , a first interface layer  103 , made of silicon oxide (in particular, SiO 2 ) is formed by thermal oxidation. The first interface layer  103  has, for example, a thickness of between approximately 0.7 and 2 μm, in particular approximately 1 μm. 
         [0020]    On top of the first interface layer  103  an intermediate layer  105  of epitaxially grown polysilicon is formed, having a thickness, for example, of between approximately 15 and 50 μm, in particular approximately 25 μm. In particular, the intermediate layer  105  is grown epitaxially until it reaches a thickness greater than the desired thickness (for example, approximately 3 μm more), and then is subjected to a step of CMP (chemical mechanical polishing) for reducing the thickness thereof and obtaining an exposed top surface with low roughness. 
         [0021]    The intermediate layer  105  may be made of a material other than polysilicon, for example silicon or some other material, provided that it can be removed selectively with respect to the material of which the first interface layer  103  is made. 
         [0022]    Formed on top of the intermediate layer  105  is a second interface layer  107 , similar to the first interface layer  103  (e.g., made of silicon oxide SiO 2 , with a thickness, for example, of between 0.7 and 2 μm, in particular approximately 1 μm). 
         [0023]    Formed on top of the second interface layer  107  is a structural layer  109 , for example of polysilicon. The structural layer  109  has a thickness, for example, of between approximately 80 and 150 μm, in particular 105 μm. The structural layer  109  is, for example, grown epitaxially on top of the second intermediate layer  107  until it reaches a thickness greater than the desired thickness (for example, approximately 3 μm more), and is then subjected to a step of CMP for reducing the thickness thereof and obtaining an exposed top surface with low roughness. 
         [0024]    With reference to  FIG. 3A , the substrate  101  could be reduced in thickness by means of the grinding technique until it reaches a thickness, for example, of between 400 and 600 μm, for example 600 μm. This is followed by a step of forming a mask on top of the wafer  100 , above the structural layer  109 . For this purpose, a mask layer is formed, e.g., of TEOS (tetraethyl orthosilicate) oxide deposited with the PECVD technique, having a thickness of approximately 2.5 μm, on top of the structural layer  109 . The mask layer is defined lithographically so as to form an edge-mask region  111  and a nozzle-mask region  112 . The edge-mask region  111  is designed to delimit a portion of the wafer  100  that, in subsequent steps, will contain a layer of glue or adhesive layer from a portion of the wafer  100  that, in subsequent steps, will operate as chamber for containing a piezoelectric actuator. The nozzle-mask region  112  is designed to delimit a surface portion  109 ′ of the wafer  100  in which part of the liquid-ejection channel is to be formed. In particular, the surface portion  109 ′ has, in top view, a substantially rectangular shape, with chamfered corners. 
         [0025]      FIG. 3B  is a schematic top view of the wafer  100 , where the edge-mask region  111  and the nozzle-mask region  112  are visible. The cross-sectional view of  FIG. 3A  is taken along the line of section III-III of  FIG. 3B . 
         [0026]    With reference to  FIG. 4 , a photoresist mask  115  is formed on the wafer  100  designed to coat the surface of the wafer  100  except for the surface portion  109 ′. By means of a dry-etching step (indicated by the arrows  116 ), the region of the structural layer  109  that extends into an area corresponding to the surface portion  109 ′ not protected by the mask  115  is partially or completely removed. According to the embodiment illustrated in  FIG. 4 , the structural layer  109  is removed completely until the second intermediate layer  107 , which operates as etch-stop layer, is reached. 
         [0027]    There is thus formed a channel  118  that extends throughout the thickness of the structural layer  109 . 
         [0028]    Alternatively (in a way not shown in the figure), it is possible to partially remove the structural layer  109 , up to a depth of, for example, 80 μm, and complete the etching step subsequently, during the step of  FIG. 5 . 
         [0029]    As shown in  FIG. 5 , the mask  115  is removed, and then a further etching step is performed, identified in the figure by the arrows  123 , in order to remove portions of the structural layer  109  not protected by the edge-mask regions  111  and nozzle-mask regions  112 . In one embodiment, the etch is of a dry type, and the etching chemistry is chosen in such a way as to remove selectively the material of which the structural layer  109  is made but not the material of which the second intermediate layer  107  is made. 
         [0030]    Thus formed in the structural layer  109  is a pad recess  120  and a piezoelectric-housing recess  122 , which are separated from one another by the edge-mask regions  111  and by the structural-layer portion  109  lying underneath the latter. The depth, in the structural layer  109 , of the pad recess  120  and of the piezoelectric-housing recess  122  is comprised, for example between 20 and 50 μm, for example 25 μm. During this etching step, it is possible to complete etching of the channel  118  in the case where the step of  FIG. 4  has not enabled the second intermediate layer  107  to be reached. Instead, since the etching chemistry for removal of the structural layer  109  is chosen in such a way as to remove selectively the structural layer  109  but not the intermediate layer  107 , etching of the channel  118  does not proceed any further in depth in the wafer  100 . 
         [0031]    With reference to  FIGS. 6-13 , there are now described steps of machining of a wafer  200  that houses one or more actuator elements (e.g., piezoelectric elements), designed to be operated, in use, for expelling fluid from the fluid ejection device according to the present disclosure. 
         [0032]    With reference to  FIG. 6 , the wafer  200  is provided, including a substrate  201 , for example having a thickness of between approximately 400 and 1000 μm, in particular approximately 725 μm. The substrate  201  is, according to one embodiment of the present disclosure, made of semiconductor material, such as silicon. The substrate  201  has a first surface  201   a  and a second surface  201   b , opposite to one another in the direction Z. On the first surface  201   a , a membrane layer  202  is formed, for example of silicon oxide, having a thickness, for example, of between approximately 1 and 4 μm, in particular 2.5 μm. This is followed by formation of a stack including a piezoelectric element and electrodes for actuation of the piezoelectric element. For this purpose, deposited on the wafer  200 , above the membrane layer  202 , is a first layer of conductive material  204 , for example titanium (Ti) or platinum (Pt), having a thickness, for example, of between approximately 20 and 100 nm; then, on top of the first layer of conductive material  204 , a layer of piezoelectric material  206 , for example PZT (Pb, Zr, TiO 3 ), having a thickness, for example, of between 1.5 and 2.5 μm, in particular 2 μm, is deposited; then, deposited on top of the layer of piezoelectric material  206  is a second layer of conductive material  208 , for example ruthenium, having a thickness, for example of between approximately 20 and 100 nm. 
         [0033]    As shown in  FIG. 7 , formed on top of the second layer of conductive material  208  is a mask  211 , designed to cover the second layer of conductive material  208  in an area corresponding to portions of the latter that will form, subsequently, a top electrode for actuation of the piezoresistive element. An etching step enables removal of portions of the second layer of conductive material  208  not protected by the mask  211 . Using the same mask  211 , but different etching chemistry, etching of the wafer  200  is continued to remove exposed portions of the layer of piezoelectric material  206  so as to form a piezoelectric element  226 . Etching is interrupted at the first layer of conductive material  204 , and ( FIG. 8 ) the mask  211  is removed. Etching of the second layer of conductive material  208  is carried out, for example, by means of wet etching, and etching of the piezoelectric layer  206  by means of dry or wet etching. 
         [0034]    As shown in  FIG. 9 , the second layer of conductive material  208  is defined so as to conclude formation of the top electrode. For this purpose, a mask  213  (for example, a photoresist mask) is formed on top of part of the second layer of conductive material  208  in such a way as to remove selective portions thereof that extend at the outer edge of the piezoelectric element  226 , but not portions of the second layer of conductive material  208  that extend at the centre of the piezoelectric element  226 . 
         [0035]    The portion of the piezoelectric element  226  exposed following upon the etching step of  FIG. 9  forms, in top view, a frame that surrounds the top electrode  228  completely or partially and has a width P1, for example, measured in the direction X, of between 4 and 8 μm. There is thus formed a top electrode  228 , designed to be biased, in use, for activating the piezoelectric element  226  (as illustrated more clearly in what follows). 
         [0036]    As shown in  FIG. 10 , a mask  215  (for example, a photoresist mask) is formed, which is designed to protect the top electrode  228  and the piezoelectric element  226  and extends laterally with respect to the piezoelectric element  228  for a distance P2, measured in the direction X starting from the edge of the piezoelectric element  228 , of, for example, between 2 and 8 μm. This is followed by an etching step to remove portions of the first layer of conductive material  204  not protected by the mask  215 . A bottom electrode  224  is thus formed for actuating the piezoelectric element in use. 
         [0037]    As shown in  FIG. 11 , the mask  215  is removed from the wafer  200 , and a step of deposition of a passivation layer  218  is carried out on the wafer  200 . The passivation layer is, for example, silicon oxide SiO 2  deposited with the PECVD technique, and has a thickness, for example, of between approximately 15 and 495 nm, for example approximately 300 nm. 
         [0038]    By means of a subsequent lithography and etching step, the passivation layer  218  is selectively removed in a central portion of the top electrode  228 , whereas it remains in at an edge portion of the top electrode  228 , of the piezoelectric element  226 , of the bottom electrode  224 , and of exposed portions of the membrane layer  202 . 
         [0039]    According to what has been described so far, the passivation layer  218  does not cover the top electrode  228  completely, which can hence be contacted electrically by means of a conductive path. Instead, the bottom electrode  224  may not be accessible electrically, being completely protected by the overlying piezoelectric element  226  and by the passivation layer  218 . Then, simultaneously, a step is performed of selective removal of a portion of the passivation layer  218  in an area corresponding to the bottom electrode  224 , and in particular in an area corresponding to the portion of the bottom electrode  224  that extends, in the plane XY, beyond the outer edge of the piezoelectric element  226 . In this way, a region  224 ′ of the bottom electrode  224  is exposed and can thus be contacted electrically by means of a conductive path of its own. The openings to form the electrical contacts with the top electrode  228  and the bottom electrode  224  can be made during one and the same lithography and etching step (in particular, using one and the same mask). 
         [0040]    The step of forming a first conductive path  221  and a second conductive path  223  is illustrated in  FIG. 12 . For this purpose, a step of deposition of conductive material, such as for example a metal, in particular titanium or gold, is carried out until a layer is formed having a thickness, for example, of between approximately 20 and 500 nm, for example approximately 400 nm. By means of photolithography steps, the layer of conductive material thus deposited is selectively etched to form the first conductive path  221 , which extends over the wafer  200  in electrical contact with the top electrode  228 , and the second conductive path  223 , which extends over the wafer  200  in electrical contact with the bottom electrode  224  through the region  224 ′ formed previously. The first and second conductive paths  221 ,  223  extend over the wafer  200  until regions where it is desired to form conductive pads  227  are reached, which are designed to operate as electrical access points for biasing, in use, the top electrode  228  and the bottom electrode  224  so as to activate the piezoelectric element  226  in a way in itself known. 
         [0041]    As shown in  FIG. 13 , the passivation layer  218  and the membrane layer  202  are selectively etched in a region which extends alongside the stack formed by the bottom electrode  224 , the piezoelectric element  226 , and the top electrode  228 , to form a trench  225  that exposes a surface portion of the substrate  201 . The trench  225  has a quadrangular or circular shape, in any case with a maximum diameter such as to be completely contained, in top view when aligned along Z, by the channel  118  illustrated in  FIG. 4 . In particular, according to one embodiment, the trench  225  has, in top view, a shape that is the same as the shape chosen, once again in top view, for the channel  118 . In any case, irrespective of the shape chosen for the trench  225 , in subsequent manufacturing steps the trench  225  will be set aligned, in the direction Z, with the channel  118  so that the channel  118  and the trench  225  will be in fluid connection with one another (this step is illustrated in greater detail in  FIGS. 14A and 14B ). Furthermore, the piezoelectric-housing recess  122 , formed in the wafer  100 , is designed to house the piezoelectric element  226  and the top electrode  228  and the bottom electrode  224 . The piezoelectric-housing recess  122  surrounds the piezoelectric element  226  completely and insulates it fluidically from the external environment and above all from the channel  118 , which extends outside the piezoelectric-housing recess  122 . In this way, when in use the fluid ejection device interacts with the fluid to be ejected, the piezoelectric element is not in contact with said fluid. 
         [0042]    The process steps described with reference to  FIGS. 2-5  (machining of the wafer  100 ) and  6 - 13  (machining of the wafer  200 ) can be carried out indifferently either in parallel or sequentially. 
         [0043]    In any case, with reference to  FIG. 14A , the wafer  100  (in the machining step of  FIG. 5 ) and the wafer  200  (in the machining step of  FIG. 13 ) are coupled together in such a way that the channel  118  and the trench  225  will be substantially aligned with one another in the direction Z, and in fluid connection with one another.  FIG. 14B  shows the wafer  100  and the wafer  200  at the end of the coupling step of  FIG. 14A . 
         [0044]    With reference to the wafer  100 , the portions of the structural layer  109  that extend to a height, along Z, greater than the recesses  120  and  122  are the portions of the structural layer  109  protected by the edge-mask region  111  and by the nozzle-mask region  112 . During the coupling step of  FIGS. 14A and 14B , it is the edge-mask regions  111  and nozzle-mask regions  112  that provide part of the coupling interface between the wafers  100  and  200 . To guarantee a good adhesion between the wafers  100  and  200 , a bonding polymer  230  is applied on the wafer  100  in the edge-mask regions  111  and nozzle-mask regions  112 ; after the step of alignment and coupling between the wafers  100  and  200 , a step of thermal treatment (which may vary in time and in temperature according to the bonding polymer  230  used) enables completion of adhesion between the wafers  100  and  200 . 
         [0045]    With reference to  FIG. 15 , the substrate  201  of the wafer  200  is subjected to a grinding step to reduce the thickness thereof to a value of approximately 70 μm. By means of successive lithography and etching steps, the remaining portion of the substrate  201  is selectively etched until the membrane layer  202  is reached so as to open a chamber  232  in an area corresponding to the piezoelectric element  226  (in other words, the chamber  232  is aligned, in the direction Z, to the piezoelectric element  226 ). The chamber  232  moreover extends also towards the channel  118  and the trench  225  formed previously, which are thus fluidically accessible from outside. Portions  201 ′ of the substrate  201  that extend, in top view, laterally with respect to the piezoelectric element  226 , to the channel  118 , and to the trench  225  are preserved. 
         [0046]    With reference to  FIG. 16 , the steps of machining of a wafer  300  are now described. The steps of  FIG. 16  can be carried out simultaneously with any of the steps described with reference to  FIGS. 2-15 , either prior thereto or afterwards, indifferently. 
         [0047]    With reference to  FIG. 16 , the wafer  300  including a substrate  301 , made, for example, of semiconductor material, in particular silicon, is provided having a top face  301   a  and a bottom face  301   b , opposite to one another in the direction Z. On the top face  301   a  an intermediate layer  302  is formed, made, for example, of silicon oxide SiO 2 . Then, on top of the intermediate layer  302 , a structural layer  304  is formed, made, for example, of semiconductor material, in particular silicon or polycrystalline silicon. The structural layer  304  has a thickness, for example, of between approximately 30 and 70 μm, for example approximately 50 μm. The structural layer  304  is selectively etched (by means of lithography and etching steps, in themselves known), to form a trench  306  that extends throughout the thickness of the structural layer  304  until the intermediate layer  302  is reached. The intermediate layer  302  functions, in this case, as etch-stop layer. The trench  306  has, in top view, a circular shape with a diameter of approximately 20 μm. However, other shapes and dimensions may be chosen, as desired. In subsequent manufacturing steps, the trench  306  forms an inlet channel for the fluid to be ejected. 
         [0048]    With reference to  FIG. 17 , the wafer  300  is coupled to the wafer  200  in such a way that the trench  306  is in fluid connection with the chamber  232 . The coupling step is carried out, as described with reference to  FIGS. 14A and 14B , using a bonding polymer  236 , laid on the surface of the portions  201 ′ of the substrate  201  of the wafer  200 . Following upon alignment and physical coupling between the wafers  200  and  300 , a step of thermal treatment of the bonding polymer  236  (in a way in itself known, according to the bonding polymer used) enables bonding of the wafers  200  and  300  together by means of the bonding polymer  236 . 
         [0049]    With reference to  FIG. 18 , a grinding step is carried out on the underside  301   b  of the substrate  301  of the wafer  300  to reduce the thickness of the substrate  301 . The grinding step proceeds until a desired thickness of the substrate  301  is obtained, such approximately 150 μm. A subsequent step of chemical polishing of the exposed surface of the substrate  301  enables removal of possible imperfections deriving from the previous grinding step. 
         [0050]    A masked-etching step is carried out so as to open a channel  312  throughout the thickness of the substrate  301  in an area corresponding to the trench  306 , exposing a surface portion of the intermediate layer  302 . The channel  312  is, in particular, aligned along Z with the trench  306 . A further selective-etching step enables removal of the portion of the intermediate layer  302  exposed through the channel  312 , setting the channel  312  in fluid communication with the trench  306  and thus forming a channel  316  for access to the chamber  232 . 
         [0051]    Subsequent manufacturing steps envisage the formation of the fluid ejection nozzle. Said nozzle is formed by machining the wafer  100  so as to set the chamber  232  in fluid communication with the outside world through the channel  118 . 
         [0052]    For this purpose ( FIG. 19 ), to facilitate subsequent manufacturing steps, the wafer  300  is coupled, by means of a thermal-release biadhesive tape  410 , with a fourth wafer  400  having the sole function of favoring handling of the device that is being produced. In subsequent steps, the fourth wafer  400  will be removed. The fourth wafer  400  is, for example, made of silicon and has a thickness of approximately 500 μm. The thermal-release biadhesive tape  410  is, for example, laid on the wafer  400  by lamination. 
         [0053]    With reference to  FIG. 20 , the substrate  101  of the wafer  100  is completely removed by means of a grinding step and a subsequent step of chemical etching to remove possible residue of the substrate  101  not removed by the grinding step. The chemical etching presents moreover the advantage of being more precise than grinding, and chemical etching can be chosen in such a way as to be selective in regard to the material to be removed, with etch stopping at the intermediate layer  103 . 
         [0054]    It is hence advisable in this step to provide alignment markers  103 ′ on the exposed intermediate layer  103 . Said markers  103 ′ have the function of identifying with high precision, in subsequent machining steps, the spatial arrangement of the channel  118  where the fluid ejection nozzle is to be formed. 
         [0055]    With reference to  FIG. 21 , steps of deposition of a resist mask  502 , lithography of the resist layer  502 , and etching of the underlying intermediate layer  103  are carried out. A new etch using the same resist mask  502  enables removal of selective portions of the structural layer  105  exposed through the resist mask  502  so as to form a trench  501  that extends throughout the thickness of the structural layer  105  in an area corresponding to the channel  118  and aligned, in the direction Z, with the channel  118 . 
         [0056]    The etch is interrupted at the intermediate layer  107 . A subsequent etching step ( FIG. 22 ) enables removal of the portion of the intermediate layer  107  exposed through the trench  501 . The resist mask is removed, and the intermediate layer  103  is etched up to complete removal thereof. In this way, a fluid ejection nozzle  510  is formed. In particular, the nozzle  510  has, in top view, a circular shape and a diameter chosen as desired, according to the application of the fluid ejection device and the amount of fluid that is to be ejected. Even more in particular, the nozzle  510  has, in perspective view, a cylindrical or frustoconical shape. The axis of the cylinder or truncated cone is aligned, along Z, with the axis of the channel  118 . 
         [0057]    With reference to  FIG. 23 , production of the liquid-ejection device  50  is completed by removing the fourth wafer  400  and the thermal-release biadhesive tape  410 , and by opening a window  515  through the wafer  100  to make the conductive pads  227  accessible from outside. 
         [0058]    Removal of the fourth wafer  400  and the thermal-release biadhesive tape  410  moreover renders the inlet channel  316  fluidically accessible from outside. 
         [0059]    Furthermore, it is possible to form electrical connections  520 , for example by means of conductive wires, in the area of the pads  227 . By appropriately biasing the pads  227  through the electrical connections  520 , the piezoelectric element  226  is actuated in use. 
         [0060]      FIGS. 24-26  show the liquid-ejection device  50  in operating steps during use. 
         [0061]    In a first step ( FIG. 24 ), the chamber  232  is filled with a fluid  52  that is to be ejected. Said step of charging of the fluid  52  is carried out through the inlet channel  316  (see arrow  530 ). 
         [0062]    As shown in  FIG. 25 , the piezoelectric element  226  is controlled through the top electrode  228  and the bottom electrode  224  (which are biased through the electrical connections  520 ) in such a way as to generate a deflection of the membrane layer  202  towards the inside of the chamber  232  (arrow D1). Said deflection causes a movement of the fluid  52  through the channel  118  towards the nozzle  510  and generates controlled expulsion of a drop  55  of fluid  52  towards the outside of the fluid ejection device  50 . 
         [0063]    As shown in  FIG. 26 , the piezoelectric element  226  is controlled through the top electrode  228  and the bottom electrode  224  (which are biased through the electrical connections  520 ) in such a way as to generate a deflection of the membrane layer  202  in a direction opposite to that of  FIG. 25  (arrow D2) so as to increase the volume of the chamber  232  by recalling further fluid  52  towards the chamber  232  through the inlet channel  316 . The chamber  232  is hence recharged with fluid  52 . 
         [0064]    The piezoelectric element may then again be actuated, as illustrated in  FIG. 25 , for expulsion of a further drop of fluid. The steps of  FIGS. 25 and 26  are repeated throughout the printing process. 
         [0065]    Actuation of the piezoelectric element by biasing the top electrode  228  and bottom electrode  224  is in itself known and not described in detail herein. 
         [0066]    From an examination of the characteristics of the disclosure provided according to the present disclosure, the advantages that it affords are evident. 
         [0067]    In particular, the steps of manufacture of the liquid-ejection device according to the present disclosure utilize coupling of just three wafers, reducing the risks of misalignment in so far as just two steps of coupling between wafers (i.e., the step of  FIG. 14A  and the step of  FIG. 17 ) are performed, and the manufacturing costs are reduced. 
         [0068]    Finally, it is clear that modifications and variations may be made to what has been described and illustrated herein, without thereby departing from the sphere of protection of the present disclosure. 
         [0069]    For instance, the steps described with reference to  FIG. 2  are not necessary in the case where a pre-machined wafer of a SOI (Silicon-On-Insulator) type is purchased. However, it should be noted that this latter solution has a cost higher than the one associated with the steps of  FIG. 2 . Likewise, also the wafers  200  and  300  may be of the SOI type. 
         [0070]    The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Technology Category: b