Substantially planar ejection actuators and methods relating thereto

1. A micro-fluid ejection head for a micro-fluid ejection device, the head comprising a fluid ejection actuator disposed on a substrate, and a nozzle member having nozzles adjacent to the substrate for expelling droplets of fluid from one or more nozzles in the nozzle member upon activation of the ejection actuator, wherein the fluid ejection actuator comprises a substantially planer ejection actuator provided by a conductive layer adjacent to the substrate configured to have an anode segment spaced apart from a cathode segment, a thermal barrier segment between the anode segment and cathode segment, wherein the anode segment, cathode segment, and the thermal barrier segment provide a substantially planar surface; and a resistive layer adjacent to the substantially planar surface.

2. The ejection head of claim 1 , wherein the conductive layer comprises a conductive film selected from the group consisting of aluminum, gold, copper, tantalum, and aluminum/copper films.

3. The ejection head of claim 1 , wherein the thermal barrier segment comprises a material selected from the group consisting of spin on glass, silicon oxide, BPSG and aerogel materials.

4. The ejection head of claim 1 , further comprising one or more protective layers adjacent to the resistive layer.

5. The ejection head of claim 1 , wherein the ejection head comprises a thermal inkjet print head.

6. The ejection head of claim 1 , wherein the thermal barrier segment comprises an aerogel material.

7. The ejection head of claim 6 , further comprising a cap over the aerogel material, the cap comprising a material selected from the group consisting of spin on glass, silicon nitride, silicon oxide and BPSG.

8. A substantially planar resistive fluid ejection actuator, comprising a conductive layer adjacent to a substrate, the conductive layer configured to have an anode segment spaced apart from a cathode segment, a thermal barrier segment disposed between the anode segment and cathode segment, wherein the anode segment, cathode segment and the thermal barrier segment define a substantially planar surface and a resistive layer adjacent to the substantially planar surface.

9. The actuator of claim 8 , wherein the conductive layer comprises a film selected from the group consisting of aluminum, tantalum, copper, gold, and aluminum/copper films.

10. The actuator of claim 8 , wherein the thermal barrier segment comprises a material selected from the group consisting of silicon oxide, spin on glass, and aerogel materials.

11. The actuator of claim 8 , further comprising one or more protective layers adjacent to the resistive layer.

12. A method for manufacturing a resistive fluid ejection actuator, comprising:

configuring a conductive layer adjacent to a support substrate to have an anode segment spaced apart from a cathode segment with a well therebetween,

applying a thermal barrier layer within the well and over the anode segment and cathode segment;

removing at least a portion of the thermal barrier layer to expose the anode segment and cathode segment and to define a thermal barrier segment within the well, wherein the anode segment, cathode segment, and the thermal barrier segment provide a substantially planar surface; and

applying a resistive layer adjacent to the planar surface to provide a fluid ejection actuator.

13. A method of claim 12 , wherein configuring a conductive layer comprises configuring a conductive layer comprising a conductive film selected from the group consisting of aluminum, gold, copper, tantalum, and aluminum/copper films.

14. A method of claim 12 , further comprising applying one or more protective layers adjacent to the resistive layer.

15. The method of claim 12 , wherein applying a resistive layer adjacent to the planar surface provides a substantially planar fluid ejection actuator.