Now, an embodiment of the present invention will be described hereinafter with reference to the accompanying drawings.
The support member 200 has an ink supply port 210 formed thereon as one of a plurality of liquid supply ports passing through the support member 200. Each ink supply port 210 is formed in a long rectangle in the longitudinal direction of the support member 200. That is, the ink supply port 210 is an elongated, rectangular opening, as seen from an upper surface of the support member 200.
On a front surface of the support member 200 having the recording element substrate 400 as the liquid discharge substrate to be mounted, an electrode pad 220 is disposed on the further outside of both tip end portions of the ink supply port 210. Further, on a back surface of the support member 220, i.e. a surface opposing to the front surface on which the electrode pad 220 is disposed, a backside electrode terminal (not shown) is formed. This backside electrode terminal is electrically connected to the electrode pad 220 on the front surface of the support member 200 through an electrical wiring pattern wired inside the support member 200.
Moreover, on the front surface of the support member 200, a plurality of radiation pads 211 is disposed along and near a long side of the ink supply port 210.
On the front surface of the support member 200, the first sealing resin 510 is coated on a portion between each of the both tip end portions of the ink supply port 210 and the electrode pad 220 situated on the outside of each tip end portion, and a portion between the radiation pad 211 and the ink supply port 210. Moreover, the first sealing resin 510 is coated in “U-shape” so as to surround each of the both tip end portions of the ink supply port 210 (see
Then, here, because it is desirable to maintain a coated shape without change as far as possible, it is preferable to use resin having characteristics of high viscosity/high thixotropy. In the present embodiment, the resin having viscosity which was not smaller than 100 Pa·s and not greater than 200 Pa·s was used. The thixotropic index thereof was not smaller than 1.8 and not greater than 2.2. This imparted the projecting shape in U-shape described above to the first sealing resin 510 on the surface of the support member 200.
On the recording element substrate 400, the ink supply port 405, i.e. a through hole for supplying liquid from a back surface to a front surface of the substrate is formed. This ink supply port 405 has a shape similar to that of the ink supply port 210 as a liquid supply port of the support member 200 and communicates with the ink supply port 210.
On the front surface of the recording element substrate 400, a plurality of electrothermal conversion elements (not shown), each an energy generating unit for generating energy for discharging ink which is liquid, is disposed side-by-side with the ink supply port 405 between. Further, a channel forming member 415 is joined to the front surface of the recording element substrate 400, which forms a liquid chamber surrounding each of the plurality of electrothermal conversion elements, an ink discharge port 410 communicating with each liquid chamber and serving as a liquid discharge port, and an ink feeding tube (liquid tube) for feeding ink from the ink supply port 405 to each liquid chamber. A plurality of the ink discharge ports 410 is disposed in line in the longitudinal direction of the recording element substrate 400.
Further, on the back surface of the recording element substrate 400, an electrode (bump) 420 to be connected to the electrode pad 220 on the front surface of the support member 200, and a radiation bump 421 to be connected to the radiation pad 211 on the front surface of the support member 200 are provided.
The recording element substrate 400 is mounted on the support member 200 by joining the electrode pad 220 of the support member 200 and the electrode (bump) 420 of the recording element substrate 400 using ultrasonic bonding etc. At this time, the shape of the first sealing resin 510 is crushed due to mounting of the recording element substrate 400 to be slightly reduced in height compared to the projecting shape initially coated to form. However, as described above, the first sealing resin 510 may scarcely spread over a coated area owing to the usage of material having a high thixotropic index (thixotropy). Therefore, the height of the first sealing resin 510 does not become lower than a height of a gap G between the recording element substrate 400 and the support member 200 on the first sealing resin 510. Here, even after the recording element substrate 400 is mounted on the support member 200, the first sealing resin 510 hermetically seals the gap G between the recording element substrate 400 and the support member 200, and still maintains the shape thereof in a manner that communication between the ink supply port 210 and the ink supply port 405 is not blocked. Therefore, the first sealing resin 510 can serve as a bank which prevents the ink from flowing from the ink supply port 210 to reach the electrode pad 220 and the electrode (bump) 420.
In addition, as required, at this time, a heating process (curing) may be carried out to cure the first sealing resin 510, then, applying the following processes described below.
The second sealing resin 520 is coated on the entire circumference of a side surface of the recording element substrate 400. At this time, the second sealing resin 520 used is preferably resin which has low viscosity/low thixotropy and good fluidity as much as possible. In the present embodiment, the resin having viscosity which was not smaller than 10 Pa·s and not greater than 70 Pa·s was used. The thixotropic index thereof was not smaller than 0.9 and not greater than 1.1, but it may be smaller than this. Accordingly, the second sealing resin 520 may get through the gap G between the support member 200 and the liquid discharge substrate 400 into the inside thereof due to the capillary phenomenon.
Subsequently, a heating process (curing) is performed to cure the second sealing resin 520.
The second sealing resin 520 completely got through the gap G between the recording element substrate 400 and the support member 200 due to the capillary phenomenon, and therefore, this gap G was completely hermetically sealed. In a portion except the both tip end portions in the discharge port rows of the recording element substrate 400, a meniscus film 511 of the second sealing resin 520 is formed on an edge side of the ink supply port 405 of the recording element substrate 400 and an edge side of the ink supply port 210 of the support member 200. This meniscus film 511 of the second sealing resin 520 does not cause a trouble such as blocking of an opening of the ink supply port 210 or the ink supply port 405.
Also, relating to the both tip end portions in the discharge port rows of the recording element substrate 400, the first sealing resin 510 functions as a bank, preventing the second sealing resin 520 from flowing into from the direction of the electrode (bump) 420 of the recording element substrate 400 to be excessively supplied.
Further, the second sealing resin 520 flows into a cavity portion between the inside of the U-shaped projecting portion of the first sealing resin 510 and the both tip end portions of the discharge port rows of the recording element substrate 400 (the gap G between the recording element substrate 400 and the support member 200) due to the capillary phenomenon. At this time, the second sealing resin 520 gets into from the longitudinal direction of the recording element substrate 400 and finally enters the inside of the U-shaped projecting portion of the first sealing resin 510. Here, the second sealing resin 520 forms the meniscus film 511 on the edge side of the ink supply port 210 or the ink supply port 405 and does not flow to spill at each ink supply port. Further, gas such as air remaining in the gap G between the recording element substrate 400 and the support member 200 is pushed out by the second sealing resin 520 to be exhausted through the liquid supply port 210 of the support member 200. Accordingly, an air passage, blowhole (cavity), pinhole or the like does not be produced, enabling more complete sealing thereby.
Now, the embodiment described above will be described hereinafter in more detail.
The first sealing resin 510 is coated in U-shape to surround the both tip end portions of the liquid supply port 210 of the support member 200, and the recording element substrate 400 is mounted over the first sealing resin 510. This mounting of the recording element substrate 400 causes the first sealing resin 510 coated on the support member 200 to surround, in U-shape, also the both tip end portions of the discharge port rows in the recording element substrate 400. Because it is desirable to maintain the projecting shape initially formed by coating the first sealing resin 510 without change as far as possible, it is suitable to use resin having characteristics of high viscosity/high thixotropy.
The second sealing resin 520 is coated on the circumference of the side surface of the recording element substrate 400 mounted on the support member 200, and completely gets into the gap G between the recording element substrate 400 and the support member 200 due to the capillary phenomenon to cure. Accordingly, the second sealing resin 520 completely covers the electrode (bump) 420 for electrical connection and the radiation bump 421, providing complete, hermetical sealing of the gap G between the recording element substrate 400 and the support member 200. At this time, in a portion except the vicinity of the both tip end portions of the recording element substrate 400, the meniscus film 511 is formed on the edge side of the ink supply port 405 in the recording element substrate 400 and the edge side of the ink supply port 210 in the support member 200. Therefore, a trouble is not caused that the second sealing resin 520 blocks an opening of the ink supply port 210 or the ink supply port 405. Further, also in the vicinity of the both tip end portions of the recording element substrate 400, a trouble is not caused that the first sealing resin 510 or the second sealing resin 520 blocks an opening of the ink supply port 210 or the ink supply port 405. This is because the projecting shape of the first sealing resin 510 controls movement/supply of the second sealing resin in the vicinity of the both tip end portions of the recording element substrate 400 not to cause the trouble described above.
Now, the case without the usage of the first sealing resin 510 will be described with reference to
In order that the second sealing resin 520 completely hermetically seals the gap G between the support member 200 and the recording element substrate 400 using the capillary phenomenon, it is suitable to use resin having low viscosity/low thixotropy and good fluidity. However, this may also cause a harmful effect as described below.
In the portion except the vicinity of the both tip end portions of the recording element substrate 400, the second sealing resin 520 flows into only in the d1 direction (direction intersecting with the longitudinal direction of the opening of the ink supply port 210 or the ink supply port 405). However, in the vicinity of the both tip end portions of the recording element substrate 400, the second sealing resin 520 flows into not only in the d1 direction, i.e. the direction from the right to left side or from the left to right side of
Even if the amount supplied is excessive only to a slight degree, discharge failure occurs in several to several dozen ink discharge ports 410 successive from the ink discharge port 410 at the both tip end portions of the recording element substrate 400 as the starting point.
On the contrary, if the amount of the second sealing resin 520 supplied is reduced, it becomes considerably difficult to completely hermetically seal the gap G between the recording element substrate 400 including the electrode (bump) 420 and the support member 200. As a result, it is more likely to provide insufficient sealing, and the quality may drop in stability. Therefore, it is necessary to supply an extra amount, to some extent, of the second sealing resin 520.
Then, in the present embodiment, before a process for mounting the recording element substrate 400, the first sealing resin 510 is coated in the vicinity of the both tip end portions of the ink supply port 210 in the support member 200. The first sealing resin 510 coated in this way serves as a bank against the second sealing resin 520, and thereby the movement/supply of the second sealing resin 520 flowing into in the d2 direction is controlled. Therefore, the gap G between the recording element substrate 400 including the electrode (bump) 420 and the support member 200 can be completely hermetically sealed, and concurrently, discharge failure of the ink discharge port 410 in the recording element substrate 400 can be prevented.
Next, a coated shape/area of the first sealing resin 510 will be described.
In the present embodiment, a sealing process flow is divided into two processes, and first, the first sealing resin 510 is coated on the support member 200, and subsequently the recording element substrate 400 is mounted to join the electrode (bump) 420 for electrical connection and the radiation bump 421. Next, from the entire circumference of the outer peripheral part of the side surface of the recording element substrate 400, the second sealing resin 520 is coated and filled into the gap G between the support member 200 and the recording element substrate 400 (see
In the ink jet head of the present embodiment, assuming that the sealing process is performed once, it is required to coat the entire circumference and the peripheral part of the ink supply port 210 of the support member 200 with the first sealing resin 510, before the recording element substrate 400 is mounted on the support member 200. Alternatively, after the recording element substrate 400 is mounted on the support member 200 of the recording element substrate 400, it is required to coat the entire circumference of the outer peripheral part of the side surface of the recording element substrate 400 with the second sealing resin 520.
In the latter case, after joining the radiation bump 421 and the radiation pad 211, the second sealing resin 520 is coated, and therefore, a joint surface of the radiation bump 421 and the radiation pad 211 has no other substances therebetween, providing the best heat radiation rate. However, it is necessary to use, as the second sealing resin 520, resin having low viscosity/low thixotropy and good fluidity. Therefore, the second sealing resin 520 flows into the both tip end portions of the ink supply port 210 in the support member 200 not only in the d1 direction, i.e. from two directions, but also in the d2 direction. Then, an amount of the second sealing resin 520 supplied becomes more excessive than required, and therefore the meniscus film 511 is not formed, and as a result, discharge failure is more likely to occur in several to several dozen ink discharge ports 410 successive from the ink discharge port 410 at the both tip end portions of the recording element substrate 400 as the starting point.
On the contrary, in the former case, before mounting the recording element substrate 400 on the support member 200, the first sealing resin 510 can be coated on the peripheral part of the ink supply port 210 not so as to block it. Therefore, discharge failure of the ink discharge port 410 is less likely to occur, even when the recording element substrate 400 is mounted. Further, even if the second sealing resin 520 is coated from the outer peripheral part of the side surface of the recording element substrate 400 after mounting the recording element substrate 400, the first sealing resin 510 previously coated may serve as a bank for each of the entire circumferences of the ink supply port 210 and the ink supply port 405. Therefore, discharge failure of the ink discharge port 410 does not occur due to blocking of the ink supply port 210 or the ink supply port 405 by the second sealing resin 520.
However, in this case, the first sealing resin 510 forming the bank for each of the entire circumferences of the ink supply port 210 and the ink supply port 405 eliminates an exit hole for gas such as air present between the recording element substrate 400 and the support member 200. Accordingly, a trouble such as an air passage, blowhole, pinhole or the like may be produced thereby. Further, because for the first sealing resin 510, it is desirable to maintain the shape initially formed by coating it without change as far as possible, as described above, the resin having characteristics of high viscosity/high thixotropy is used. As a result, the first sealing resin 510 has very insufficient fluidity/emission rate. Accordingly, the first sealing resin 510 may not be completely exhausted, and it is likely to remain on the surface where the radiation bump 421 is in contact with the radiation pad 211. As a result, thermal conductivity from the recording element substrate 400 to the support member 200 is decreased, resulting in poor heat dissipation. This may increase a possibility of causing a trouble of the ink jet head due to an abnormal rise in temperature during image formation when the ink jet head is mounted on the ink jet recording apparatus.
As described above, in order to prevent discharge failure of the ink discharge port 410, it is necessary to coat the first sealing resin 510 on an appropriate portion. Also, in order to secure sufficient heat dissipation, it is important that the first sealing resin 510 be not left behind as far as possible on the joint surface between radiation bump 420 and the radiation pad 211. Then, for the reasons described above, the first sealing resin 510 is coated in the portion between the outside of the both tip end portions of the ink supply port 210 of the support member 200 and the radiation pad 211 disposed in the vicinity of the both tip end portions so as to surround each of the both tip end portions of the ink supply port 210. Coating the first sealing resin 510 in this way can control decrease in heat conductivity to the minimum. Further, discharge failure also can be prevented which is caused due to the second sealing resin 520 coated after mounting the recording element substrate 400 on the support member 200, in several to several dozen ink discharge ports 410 successive from the ink discharge port 410 corresponding to the both tip end portions of the discharge port rows as the starting point.
For forming a most efficient shape of the first sealing resin 510, it is suitable to form a continuous bank against the second sealing resin 520 flowing into in the d1 direction (two directions) and the d2 direction by the first sealing resin 510 correspondingly to each of the directions.
In the present embodiment, the coated shape of the first sealing resin 510 is a projecting “U-shape”, and this allows for formation of a continuous bank in an unbroken line in the perpendicular directions to the d1 and d2 directions, respectively. Then, also, the U-shape substantially includes, for example, a C-shape, V-shape or the like which may be expected to have the effect as described above.
Further, the first sealing resin 510 is crushed due to mounting of the recording element substrate 400 to be slightly widened (extended), and so the first sealing resin 510 is not coated continuously in three sides according to the U-shape, and then it can be coated in three short straight lines (alternatively, several dots thereof are coated on a particular portion) in the perpendicular directions to the d1 and d2 directions, respectively, to form each bank, providing the same advantageous result.
In addition, the present embodiment as described above includes the electrothermal conversion element for generating heat energy to discharge ink, and, needless to say, the present invention is also applicable to a liquid discharge head in which the ink is discharged by other methods, such as using a vibrating element.
As described above, the ink jet head manufactured by mounting the recording element substrate 400 on the support member 200 is joined to a plastic housing having a contact portion for electrical connection with the ink jet recording apparatus, and a part for mounting an ink tank. The head cartridge, in this way, is finished (see
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2006-148146, filed May 29, 2006, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2006-148146 | May 2006 | JP | national |