Process for making a micro-fluid ejection head structure

1. A method of making a micro-fluid ejection head structure comprising:

dry-spraying a device surface of a substrate with a photoresist material to provide a spray-coated layer on the surface of the substrate, the spray-coated layer having a thickness ranging from about 0.5 to about 20 microns;

imaging and developing flow features in the spray-coated layer; and

applying a nozzle plate layer to the spray-coated layer, the nozzle plate layer having a thickness ranging from about 5 to about 40 microns and containing nozzle holes therein.

2. The method of claim 1 wherein the dry-spraying comprises spray coating a photoresist material in a highly volatile carrier fluid onto the device surface of the substrate whereby the carrier fluid substantially evaporates so that the photoresist material is applied to the substrate in solid rather than liquid form.

3. The method of claim 2 wherein the dry-spraying comprises spray coating two or more spray-coated layers onto the device surface of the substrate.

4. The method of claim 1 wherein the nozzle plate layer comprises a dry film photoresist layer that is applied to the spray-coated layer using an adhesive.

5. The method of claim 1 wherein the nozzle plate layer comprises a dry film photoresist that is laminated to the spray-coated layer using thermal compression bonding or roll lamination.

6. The method of claim 5 further comprising an act of forming nozzle holes in the nozzle plate layer by patterning and developing the nozzle plate layer.

7. The method of claim 1 further comprising an act of forming nozzle holes in the nozzle plate layer by dry etching the nozzle plate layer.

8. The method of claim 1 wherein the spray-coated layer comprises a negative photoresist layer.

9. The method of claim 1 wherein the nozzle plate layer comprises a negative photoresist layer.

10. The method of claim 1 wherein the spray-coated layer comprises a composition selected from the group consisting essentially of epoxy, acrylate, polyimide, novolac, diazonaphthaquinone, cyclized rubber, and chemically amplified photoresists.

11. The method of claim 1 wherein the nozzle plate layer comprises a composition selected from the group consisting essentially of epoxy, acrylate, polyimide, novolac, diazonaphthaquinone, cyclized rubber, and chemically amplified photoresists.

12. The method of claim 1 wherein the micro-fluid ejection device head structure comprises an inikjet printhead.

13. A method of making a micro-fluid ejection head structure comprising:

dry-spraying a device surface of a substrate with a layer of photoresist material to provide a spray-coated layer on the surface of the substrate, the spray-coated layer having a thickness ranging from about 0.5 to about 20 microns;

imaging fluid chambers and fluid supply channels in the spray-coated layer;

applying a polymeric material to the spray-coated layer, the polymeric material having a thickness ranging from about 5 to about 40 microns;

forming nozzle holes in the polymeric material; and developing the fluid chambers and fluid supply channels imaged in the spray-coated layer.

14. The method of claim 13 wherein the dry-spraying act comprises spray coating a photoresist material in a highly volatile carrier fluid onto the device surface of the substrate whereby the carrier fluid substantially evaporates so that the photoresist material is applied to the substrate in solid rather than liquid form.

15. The method of claim 13 wherein the dry-spraying act comprises spray coating two or more spray-coated layers onto the device surface of the substrate.

16. The method of claim 13 wherein the polymeric material comprises a dry film photoresist layer and wherein the dry film photoresist layer is laminated to the spray-coated layer.

17. The method of claim 16 wherein the act of forming nozzle holes in the dry film photoresist layer comprises patterning and developing the dry film photoresist.

18. The method of claim 16 wherein the act of forming nozzle holes in the dry film photoresist layer comprises dry etching the dry film photoresist layer.

19. The method of claim 13 wherein the polymeric material comprises a dry film photoresist layer and wherein the dry film photoresist layer is laminated to the spray-coated layer using thermal compression bonding or roll lamination.

20. The method of claim 19 wherein the act of forming nozzle holes in the dry film photoresist layer comprises dry etching the dry film photoresist layer.

21. The method of claim 13 wherein the polymeric material comprises a negative photoresist layer.

22. The method of claim 13 wherein the spray-coated layer comprises a composition selected from the group consisting essentially of epoxy, acrylate, polyimide, novolac, diazonaphthaquinone, cyclized rubber, and chemically amplified photoresists.

23. The method of claim 13 wherein the polymeric material comprises a composition selected from the group consisting essentially of epoxy, acrylate, polyimide, novolac, diazonaphthaquinone, cyclized rubber, and chemically amplified photoresists.

24. The method of claim 13 wherein the micro-fluid ejection device head structure comprises an inikjet printhead.

25. A method of making a micro-fluid ejection head structure comprising:

dry-spraying a device surface of a substrate with a polymeric material to provide a spray-coated layer on the surface of the substrate, the spray-coated layer having a thickness ranging from about 0.5 to about 20 microns;

forming flow features in the spray-coated layer; and

applying a nozzle plate layer to the spray-coated layer, the nozzle plate layer having a thickness ranging from about 5 to about 40 microns and containing nozzle holes therein.

26. The method of claim 25 , wherein the forming flow features act comprises imaging and developing flow features in the spray-coated layer, wherein the polymeric material comprises a photoresist material.