Low energy, long life micro-fluid ejection device

(canceled)

The micro-fluid ejection head of claim 21, wherein the resistive layer has a thickness ranging from about 300 to about 1000 Angstroms.

(canceled)

The micro-fluid ejection head of claim 21, wherein the protective layer has a thickness ranging from about 900 to about 5500 Angstroms.

The micro-fluid ejection head of claim 21, wherein the resistive layer comprises a tantalum-aluminum alloy and the protective layer comprises a material selected from the group consisting of diamond like carbon, silicon doped diamond like carbon, silicon nitride, silicon carbide, titanium, tantalum, and an oxidized metal layer.

The micro-fluid ejection head of claim 21, wherein the polymeric layer comprises a cross-linked epoxy material.

The micro-fluid ejection head of claim 21, wherein the polymeric layer overlaps opposing edges of the thermal ejection actuators in an amount ranging from about 1 to about 4 microns.

(canceled)

The micro-fluid ejection head of claim 21, wherein the actuators are elongate actuators having a length to width ratio ranging from about 1.5:1 to about 5:1.

(canceled)

The method of claim 25, wherein the flow feature layer comprises a polymeric thick film layer.

(canceled)

The method of claim 24, wherein the polymeric layer comprises a planarization layer having a thickness ranging from about 1 to about 6 microns.

The method of claim 24, wherein the polymeric layer is deposited so that the polymeric layer overlaps opposing edge portions of the thermal ejection actuators.

(canceled)

A micro-fluid ejection head made by the method of claim 24.

A micro-fluid ejection head having improved thermal ejection actuator life, comprising:

• a plurality of thermal ejection actuators disposed on a substrate, each of the thermal ejection actuators including a resistive layer and a protective layer for protecting a surface of the resistive layer;
• and
• a polymeric layer having a degradation temperature of less than about 400° C. overlapping a portion of the thermal ejection actuators so that the polymeric layer overlaps less than about five microns of the thermal ejection actuators adjacent at least one edge thereof.

A method for extending a life of thermal ejection actuators for a micro-fluid ejection head comprising:

• providing a plurality of thermal ejection actuators on a substrate, wherein the actuators comprise a resistive layer and a protective layer overlying the resistive layer;
• and
• depositing a polymeric layer having a degradation temperature of less than about 400° C. in overlapping relationship with at least a portion of the thermal ejection actuators, wherein the polymeric layer overlaps less than about five microns of the actuators adjacent at least one edge thereof.