Lexmark International, Inc.

International Business Machines Corporation

Robert Arnold Christiansen

Gary Raymond Williams

Curtis Ray Droege

Lawrence Russell Steward

Fred Young Brandon

Martin Victor DiGirolamo

Michelle Kathryn Morris

Mark Meredith Trayner

Frank M Rose, Jr

James R Smith

Kenneth D Woosley

Joel A DiGirolamo

A print head having an ink reservoir therein is made by forming, in a one-shot plastic injection molding step, a rigid monolithic frame including high melt temperature material having an opening therein extending from a first side to a second side, and first and second bonding surfaces surrounding the opening and facing the first and second sides, respectively. First and second thin flexible films are adhesively secured to the first and second bonding surfaces, respectively. The adhesive material may be a hot melt adhesive or dry adhesive films pre-formed to the shape of the bonding surfaces. By securing the flexible films to the bonding surfaces adhesively, rather than by heat staking, it is not necessary to form the frame of different materials during two separate molding steps.

Print head cartridge made with jointless one-piece frame consisting of a single material throughout

A print head having an ink reservoir therein is made by forming, in a one-shot plastic injection molding step, a rigid monolithic frame comprising high melt temperature material having an opening therein extending from a first side to a second side, and first and second bonding surfaces surrounding the opening and facing the first and second sides, respectively. First and second thin flexible films are adhesively secured to the first and second bonding surfaces, respectively. The adhesive material may be a hot melt adhesive or dry adhesive films pre-formed to the shape of the bonding surfaces. By securing the flexible films to the bonding surfaces adhesively, rather than by heat staking, it is not necessary to form the frame of different materials during two separate molding steps.

Print head cartridge and method of making a print head cartridge by one-shot injection molding

An extended wear developer sleeve coating formulation that provides optimum print quality for a toner cartridge that prints 30,000 pages. The coating formulation contains an unique coupling agent which acts to chemically bond the graphite material and the phenolic resin components of the formulation together, even at high graphite loads, to increase the cohesive strength of the coating and improve its wear resistance.

Extended wear developer sleeve with coupling agent

A copper supporting sheet (5) has holes (9) for connecting semiconductor chips (3) to surface mount components (27). A laminate of polyimide (7) has holes (13) corresponding to the supporting layer holes (9) with copper 15 covering those holes (13). In addition to crossing those holes (13), the copper 15 forms conventional circuit patterns. The side having circuit patterns is populated by surface mount techniques with components (27). The opposite side has silicon chips (3) attached to the copper sheet (5) adjacent to holes (9). Wires (17) are ultrasonically bonded to the chips (3) and extended to the inside of the holes (13) in the polyimide layer (7), where they are ultrasonically bonded to copper (15). Crossover connection of the circuit patterns (17a) are achieved using the same technique. The circuit board is densely populated and cost-effective, with good heat dissipation characteristics.

Circuit board with self-supporting connection between sides

Flexible flat ribbon cables with a polyester binder silver particle conductive ink deposited on a heat bondable substrate are bonded to each other or to rigid circuit boards by applying ultrasonic energy to the cables. The conductors are bonded to form connections and are prevented from being deformed laterally to bridge to adjacent conductors due to preferential substrate bonding between adjacent conductors. Both apparatus for and the method of preferential substrate bonding is disclosed.

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Salvisa, KY, United States of America

Robert Arnold Christiansen