Thermal Head Cover Member Design for Connection Stability
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Solution Overview
Problem
Existing thermal heads face the possibility of connection member separation from the substrate or external substrate, which affects their reliability and performance.
Innovation Solution
A thermal head design that includes a substrate with a heat generating portion, a driving IC, a connection member with a second electrode, and a second cover member with a thinner portion that overlies a first cover member, reducing the likelihood of separation by distributing external forces and creating a reaction against them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a connection member is disposed on the substrate to provide electrical connection, then electrical connectivity is achieved, but the connection member may separate from the substrate
Solution Approach 1:
The second cover member extends in the longitudinal direction beyond the lateral extent of the connection member, creating an overlying portion that provides reinforcement from an additional spatial dimension. This dimensional extension allows the cover member to bridge and stabilize the connection member without adding complexity to the electrical connection path.
Solution Approach 2:
The second cover member is divided into a first portion with the same thickness as the first cover member and a second portion that is thinner, allowing different regions to serve different functions: the first portion provides structural support and alignment, while the second portion reduces weight and material usage while maintaining coverage.
2Ease of manufacture
If the second cover member has uniform thickness, then manufacturing is simplified, but it cannot provide optimized structural support and weight distribution
Solution Approach 1:
The second cover member features non-uniform thickness with a first portion matching the thickness of the first cover member for structural support, and a thinner second portion for weight reduction. This local variation in thickness allows each region to be optimized for its specific function while maintaining overall manufacturing feasibility.
3Area of stationary object
If the second cover member extends fully beyond the first cover member, then coverage is maximized, but weight and material usage increase
Solution Approach 1:
The second cover member implements variable thickness where the first portion extends fully to provide maximum coverage and structural support, while the second portion is thinner to reduce material usage and weight. This localized thickness variation achieves optimal balance between coverage area and material efficiency.
Data Source
AI summary
A thermal head includes: a substrate; a heat generating portion disposed on the substrate; a first electrode electrically connected to the heat generating portion; a driving IC which controls actuation of the heat generating portion; a first cover member which covers the driving IC; a connection member which is disposed on the substrate and has a connecting section electrically connected to a second electrode; and a second cover member which covers the connecting section and extends toward the first cover member. The second cover member includes a first portion and a second portion which is thinner than the first portion. The first portion is disposed next to the connection member. The second portion lies farther away from the connection member than the first portion, and includes an overlying part which overlies the first cover member.