A precision screen-printed card and its manufacturing process

Abstract

This invention belongs to the field of card production technology, and particularly relates to a precision screen-printed card and its manufacturing process. A precision screen-printed card includes: a card substrate, the surface of which is provided with a precision screen-printed graphic layer. The precision screen-printed graphic layer is formed by screen printing with high-viscosity raised-letter ink through a high-mesh precision screen. The line width of the precision screen-printed graphic layer is 0.05mm-0.08mm, and the precision screen-printed graphic layer has a perceptible three-dimensional raised structure. This achieves stable reproduction of fine lines, is suitable for various card substrates and other processes, making the cards more exquisite and reducing production costs.

Description

Technical Field

[0001] This invention belongs to the field of card production technology, and in particular relates to a precision screen-printed card and its manufacturing process. Background Technology

[0002] As collectible and entertainment products, the intricate graphic design on the surface of trading cards is crucial to enhancing product quality and user experience. This is especially true for minute details like individual hairs and fabric textures, which demand extremely high precision in printing processes and strong three-dimensional representation. Currently, many intricate lines in trading card UI designs are created using cold foil stamping. However, cold foil stamping is limited by the material transfer method, resulting in a limited thickness of the graphic layer. Under conditions of fine lines, it cannot create a stable and perceptible three-dimensional depth, failing to meet players' needs for tactile feedback and visual depth. Furthermore, traditional techniques also have significant limitations in reproducing high-precision lines.

[0003] Existing precision screen printing technology is mainly used in the field of electronic devices. The technical goal of this field is to focus on the functional stability and continuity of circuits. There are no design requirements for the three-dimensional tactile feel and decorative expression of graphics and text. Its supporting process parameters and ink system are all set around the electronic functional requirements, which cannot be directly adapted to the decorative printing requirements of card surfaces, making it difficult to achieve the three-dimensional and clear reproduction of fine graphics and text on cards.

[0004] To address the aforementioned issues, this invention innovatively applies precision screen printing technology to the field of card surface decoration. Through the coordinated design of screen parameters and ink systems, it achieves stable transfer of fine lines on the card and a distinct raised tactile feel, effectively solving the technical defects of existing card manufacturing processes. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned technical problems by providing a precision screen-printed card and its manufacturing process, which achieves stable reproduction of fine lines, is applicable to various card substrates and other processes, and makes the cards more exquisite while reducing production costs.

[0006] In view of this, the present invention provides a precision screen-printed card, comprising: a card substrate, wherein the surface of the card substrate is provided with a precision screen-printed graphic layer, the precision screen-printed graphic layer is formed by screen printing with high viscosity raised lettering ink through a high mesh count precision screen, the line width of the precision screen-printed graphic layer is 0.05mm-0.08mm, and the precision screen-printed graphic layer has a perceptible three-dimensional raised structure.

[0007] This technical solution achieves stable reproduction of fine lines, is applicable to various card substrates and other processes, making the cards more exquisite and reducing production costs.

[0008] Furthermore, the manufacturing process of precision screen-printed cards includes the following steps: S1: Screen parameter design and preparation. A high mesh count precision screen with a mesh count of not less than 420 is selected. Photosensitive emulsion is coated on the precision screen. The ink blocking layer is formed by exposure and development to obtain a precision screen with clear ink passage openings. S2: Ink preparation and mixing. High viscosity embossing ink is selected. High viscosity embossing ink can be quickly set after screen removal, without leveling or edge shrinkage. S3: Precision screen printing operation: The precision screen prepared in step S1 is installed on the screen printing machine, high viscosity embossed ink is placed on the screen, and the ink is transferred to the surface of the card substrate through the ink passage opening by the squeegee operation to form a precision screen printed graphic layer. Post-printing processing: The screen-printed cards are dried and set before the post-printing process begins.

[0009] In this technical solution, the mesh count is not less than 420. The synergistic design of high-mesh precision screen printing and high-viscosity embossed ink achieves stable reproduction of fine lines on cards, with printable lines as fine as 0.05mm. This effectively solves the problem of traditional processes failing to accurately reproduce fine elements such as hair strands and fabric textures, significantly improving the graphic precision of cards. The selected high-viscosity embossed ink sets quickly after screen removal, without leveling or edge shrinkage. This not only ensures the edge clarity of fine lines but also forms a perceptible three-dimensional raised graphic layer, overcoming the shortcomings of existing cold foil stamping processes in terms of flatness and insufficient three-dimensional tactile feel. It simultaneously meets users' dual needs for visual depth and tactile feedback on cards. This process is applicable to various card substrates such as paper, plastic, and multi-layer composites. The graphic layer after screen printing is compatible with various post-printing processes such as lamination, hot stamping, and color printing, exhibiting excellent substrate versatility and process scalability. It can adapt to the production of different types and design requirements of cards, reducing the process modification costs for enterprises. This provides the card printing industry with a new high-precision, high-three-dimensional surface decoration process, filling a technological gap in the industry.

[0010] Furthermore, the mesh count of the precision wire mesh described in S1 is 420-500 mesh.

[0011] Furthermore, the sizing pressure of the sizing operation described in S3 is 0.1MPa-0.3MPa, and the sizing speed is 5cm / s-15cm / s.

[0012] Furthermore, the drying and shaping process in S4 is ultraviolet drying, with a drying time of 3 seconds.

[0013] Furthermore, the screen printing machine includes a base, on which are provided: A placement table for holding cards; A column, on which a horizontal frame slides vertically, and a fixing frame is fixedly installed on the horizontal frame, and the fixing frame fixes the wire mesh through a clamping structure; A scraper, which can move up and down to approach or move away from the screen under the drive of a cylinder, is used to laterally squeeze ink through the mesh onto the card surface; The ink return blade is located on the side of the doctor blade. The ink return blade can move up and down to approach or move away from the screen under the drive of a cylinder. The ink return blade is used to scrape back the ink after printing. A fine-tuning structure is provided for fine-tuning the position of the squeegee as it moves laterally across the screen surface to squeeze the ink through.

[0014] In this technical solution, when the squeegee moves laterally across the screen surface to press the ink through, if the ink is thick, the squeegee can move slightly backward to prevent damage to the screen.

[0015] Furthermore, the fine-tuning structure includes: A first tool holder, wherein a receiving groove is provided on the first tool holder, the width of the receiving groove being greater than the thickness of the scraper, a first connecting hole is provided on the first tool holder, and a second connecting hole matching the first connecting hole is provided on the scraper. A connecting bolt, which passes through a first connecting hole and a second connecting hole and is threadedly connected to a lock nut; Springs are installed between the two sides of the scraper and the wall of the receiving groove. The springs always have a tendency to push the scraper towards the middle of the receiving groove.

[0016] In this technical solution, when the resistance encountered by the squeegee when it moves laterally across the screen surface and squeezes the ink through is greater than the supporting force of the spring, the spring will deform, causing the squeegee to move slightly, thereby protecting the screen from damage.

[0017] Furthermore, the ink return blade is also provided with a scraping structure, which is used to scrape off the ink residue on the ink return blade.

[0018] In this technical solution, after the ink is scraped back by the ink scraper after printing, some ink residue will remain on the ink scraper. If it is not treated, problems such as caking will occur, resulting in waste. The scraping structure can scrape off the residual ink on the ink scraper in time and return it to the screen for reuse, which can reduce ink waste.

[0019] Furthermore, the scraping structure includes: A scraping cylinder, which is connected to a return ink blade; A scraper plate is connected to the output end of a scraper cylinder and is arranged parallel to the surface of the ink return blade.

[0020] Furthermore, the clamping structure includes: A clamping groove, wherein the width of the clamping groove is greater than the thickness of the wire mesh frame; The fastening bolt is threaded to the fixing bracket and extends into the clamping groove. The end of the fastening bolt that extends into the clamping groove is connected to an extension piece.

[0021] In this technical solution, the wire mesh frames on both sides of the wire mesh extend into the clamping groove, and the fastening bolts are tightened so that the extension piece is in close contact with the upper surface of the wire mesh frame, and the lower surface of the wire mesh frame is in close contact with the wall of the clamping groove, so that the wire mesh is clamped.

[0022] The beneficial effects of this invention are: 1. Achieves stable reproduction of fine lines, suitable for various card substrates and other processes, making cards more exquisite and reducing production costs.

[0023] 2. The mesh count should be no less than 420. The synergistic design of high-mesh precision screen printing and high-viscosity embossed ink achieves stable reproduction of fine lines on cards, with printable lines as fine as 0.05mm. This effectively solves the problem of traditional processes failing to accurately reproduce fine elements such as hair strands and fabric textures, significantly improving the graphic precision of cards. The selected high-viscosity embossed ink sets quickly after screen removal, without leveling or edge shrinkage. This not only ensures the edge clarity of fine lines but also forms a perceptible three-dimensional raised graphic layer, overcoming the shortcomings of existing cold foil stamping processes in terms of flatness and insufficient three-dimensional tactile feel. It simultaneously meets users' dual needs for visual depth and tactile feedback on cards. This process is applicable to various card substrates such as paper, plastic, and multi-layer composites. The graphic layer after screen printing is compatible with various post-printing processes such as lamination, hot stamping, and color printing, exhibiting excellent substrate versatility and process scalability. It can adapt to the production of different types and design requirements of cards, reducing the process modification costs for enterprises. This provides the card printing industry with a new high-precision, high-three-dimensional surface decoration process, filling a technological gap in the industry.

[0024] 3. When the squeegee moves horizontally across the screen surface to press the ink through, if the ink is thick, the squeegee can be moved slightly backward to prevent damage to the screen. Attached Figure Description

[0025] Figure 1 It is a 3D diagram of a screen printing machine; Figure 2 This is a partial schematic diagram of a screen printing machine; Figure 3 yes Figure 2 A magnified view of a section at point A in the middle; Figure 4 yes Figure 3 Enlarged view of a section at point B; Figure 5 This is an exploded view of the fine-tuned structure.

[0026] The markings in the diagram are as follows: 1. Base; 2. Placement platform; 3. Column; 4. Horizontal frame; 5. Fixing frame; 6. Clamping structure; 7. Scraper; 8. Ink return blade; 9. Fine adjustment structure; 10. First blade holder; 11. Receiving groove; 12. First connecting hole; 13. Connecting bolt; 14. Locking nut; 15. Spring; 16. Scraping cylinder; 17. Scraping plate; 18. Clamping groove; 19. Fastening bolt; 20. Extension piece; 21. Second connecting hole. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.

[0028] In the description of this application, it should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. For ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following drawings denote similar items; therefore, once an item is defined in one drawing, it need not be further discussed in subsequent drawings.

[0029] It should be noted that the terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and not to describe a specific order or sequence. It should be understood that such use of data can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and are not limited in number; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0030] It should be noted that in the description of this application, the directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this application. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0031] It should be noted that, in this application, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, it should be noted that the scope of the methods and apparatuses in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. Additionally, features described with reference to certain examples may be combined in other examples.

[0032] Example 1 A precision screen-printed card includes a card substrate with a precision screen-printed graphic layer on its surface. The graphic layer is formed by screen printing high-viscosity raised-letter ink using a high-mesh precision screen. The line width of the graphic layer is 0.05mm-0.08mm, and the graphic layer has a perceptible three-dimensional raised structure. This allows for stable reproduction of fine lines, is suitable for various card substrates and other processes, resulting in more exquisite cards with lower production costs.

[0033] Example 2 The manufacturing process of precision screen-printed cards includes the following steps: S1: Screen parameter design and preparation. A high mesh count precision screen with a mesh count of not less than 420 is selected. Photosensitive emulsion is coated on the precision screen. The ink blocking layer is formed by exposure and development to obtain a precision screen with clear ink passage openings. S2: Ink preparation and mixing. High viscosity embossing ink is selected. High viscosity embossing ink can be quickly set after screen removal, without leveling or edge shrinkage. S3: Precision screen printing operation: The precision screen prepared in step S1 is installed on the screen printing machine, high viscosity embossed ink is placed on the screen, and the ink is transferred to the surface of the card substrate through the ink passage opening by the squeegee operation to form a precision screen printed graphic layer. Post-printing processing: The screen-printed cards are dried and set before the post-printing process begins.

[0034] The number of meshes should be no less than 420. The synergistic design of high-mesh precision screen printing and high-viscosity embossed ink achieves stable reproduction of fine lines on cards, with printable lines as fine as 0.05mm. This effectively solves the problem of traditional processes failing to accurately reproduce fine elements such as hair strands and fabric textures, significantly improving the graphic precision of cards. The selected high-viscosity embossed ink sets quickly after screen removal, without leveling or edge shrinkage. This not only ensures the edge clarity of fine lines but also forms a perceptible three-dimensional raised graphic layer, overcoming the shortcomings of existing cold foil stamping processes in terms of flatness and insufficient three-dimensional tactile feel. It simultaneously meets users' dual needs for visual depth and tactile feedback on cards. This process is applicable to various card substrates such as paper, plastic, and multi-layer composites. The graphic layer after screen printing is compatible with various post-printing processes such as lamination, hot stamping, and color printing, exhibiting excellent substrate versatility and process scalability. It can adapt to the production of different types and design requirements of cards, reducing the process modification costs for enterprises. This provides the card printing industry with a new high-precision, high-three-dimensional surface decoration process, filling a technological gap in the industry.

[0035] The mesh size of the precision screen described in S1 is 420-500 mesh. The squeegee pressure in the squeegee operation described in S3 is 0.1MPa-0.3MPa, and the squeegee speed is 5cm / s-15cm / s. The drying and setting treatment in S4 is ultraviolet drying, and the drying time is 3 seconds.

[0036] Example 3 like Figures 1-5 As shown, the screen printing machine includes a base 1, on which the following are provided: Placement table 2, which is used to place cards; A column 3, on which a horizontal frame 4 slides vertically, and a fixing frame 5 is fixedly installed on the horizontal frame 4. The fixing frame 5 fixes the wire mesh through a clamping structure 6. The scraper 7 can move up and down under the drive of a cylinder to approach or move away from the screen. The scraper 7 is used to move laterally across the screen surface to squeeze ink through the mesh to the card surface. The ink return blade 8 is located on the side of the doctor blade 7. The ink return blade 8 can move up and down to approach or move away from the screen under the drive of a cylinder. The ink return blade 8 is used to scrape back the ink after printing. The fine-tuning structure 9 is used to fine-tune the position of the doctor blade 7 when it moves laterally across the screen surface to squeeze the ink through.

[0037] When the squeegee 7 moves laterally across the screen surface to press the ink through, if the ink is thick, the squeegee 7 can move slightly backward to prevent damage to the screen.

[0038] The fine-tuning structure 9 includes: A first tool holder 10 is provided with a receiving groove 11, the width of which is greater than the thickness of the scraper 7. A first connecting hole 12 is provided on the first tool holder 10, and a second connecting hole 21 matching the first connecting hole 12 is provided on the scraper 7. A connecting bolt 13 passes through a first connecting hole 12 and a second connecting hole 21 and is threadedly connected to a lock nut 14. Spring 15 is provided between the two sides of the scraper 7 and the wall of the receiving groove 11. Spring 15 always has the tendency to push the scraper 7 towards the middle of the receiving groove 11.

[0039] When the resistance encountered by the squeegee 7 as it moves laterally across the screen surface and squeezes the ink through is greater than the supporting force of the spring 15, the spring 15 will deform, causing the squeegee 7 to move slightly, thereby protecting the screen from damage.

[0040] The ink return blade 8 is also equipped with a scraping structure, which is used to scrape off the residual ink on the ink return blade 8. After printing, ink will remain on the ink return blade 8 after it has been scraped back. If this is not dealt with, problems such as caking will occur, resulting in waste. The scraping structure can promptly scrape off the residual ink on the ink return blade 8 and return it to the screen for reuse, thereby reducing ink waste.

[0041] The scraping structure includes: Scraping cylinder 16, which is connected to ink return blade 8; The scraping plate 17 is connected to the output end of the scraping cylinder 16 and is arranged parallel to the surface of the ink return blade 8.

[0042] The clamping structure 6 includes: Clamping groove 18, the width of which is greater than the thickness of the wire mesh frame; Fastening bolt 19 is threadedly connected to the fixing bracket 5 and extends into the clamping groove 18. The end of the fastening bolt 19 extending into the clamping groove 18 is connected to an extension piece 20.

[0043] The wire mesh frames on both sides extend into the clamping groove 18. Tighten the fastening bolts 19 so that the extension piece 20 is in close contact with the upper surface of the wire mesh frame and the lower surface of the wire mesh frame is in close contact with the wall of the clamping groove 18, thus clamping the wire mesh.

[0044] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.

Claims

1. A precision screen-printed card, comprising: The card substrate includes a precision screen-printed graphic layer on its surface. The precision screen-printed graphic layer is formed by screen printing high-viscosity raised lettering ink through a high-mesh precision screen. The line width of the precision screen-printed graphic layer is 0.05mm-0.08mm, and the precision screen-printed graphic layer has a perceptible three-dimensional raised structure.

2. A manufacturing process applicable to the precision screen-printed card as described in claim 1, characterized in that, Includes the following steps: S1: Screen parameter design and preparation. A high mesh count precision screen with a mesh count of not less than 420 is selected. Photosensitive emulsion is coated on the precision screen. The ink blocking layer is formed by exposure and development to obtain a precision screen with clear ink passage openings. S2: Ink preparation and mixing. High viscosity embossing ink is selected. High viscosity embossing ink can be quickly set after screen removal, without leveling or edge shrinkage. S3: Precision screen printing operation: The precision screen prepared in step S1 is installed on the screen printing machine, high viscosity embossed ink is placed on the screen, and the ink is transferred to the surface of the card substrate through the ink passage opening by the squeegee operation to form a precision screen printed graphic layer. Post-printing processing: The screen-printed cards are dried and set before the post-printing process begins.

3. The manufacturing process of a precision screen-printed card according to claim 2, characterized in that, The precision wire mesh described in S1 has a mesh count of 420-500 mesh.

4. The manufacturing process of a precision screen-printed card according to claim 2, characterized in that, The squeegee pressure for the squeegee operation described in S3 is 0.1MPa-0.3MPa, and the squeegee speed is 5cm / s-15cm / s.

5. The manufacturing process of a precision screen-printed card according to claim 2, characterized in that, The drying and shaping process in S4 is ultraviolet drying, and the drying time is 3 seconds.

6. The manufacturing process of a precision screen-printed card according to claim 2, characterized in that, The screen printing machine includes a base (1), on which are provided: Placement table (2), the placement table (2) is used to place cards; A column (3) is vertically slidable on the column (3), and a fixing frame (5) is fixedly installed on the horizontal frame (4). The fixing frame (5) fixes the wire mesh through a clamping structure (6). The scraper (7) can move up and down under the drive of a cylinder to approach or move away from the screen. The scraper (7) is used to laterally move on the screen surface to squeeze ink through the mesh to the card surface. The ink return knife (8) is located on the side of the doctor blade (7). The ink return knife (8) can move up and down under the drive of a cylinder to approach or move away from the screen. The ink return knife (8) is used to scrape the ink back after printing. The fine-tuning structure (9) is used to fine-tune the position of the doctor blade (7) when the doctor blade (7) moves laterally across the screen surface to squeeze the ink through.

7. The manufacturing process of a precision screen-printed card according to claim 6, characterized in that, The fine-tuning structure (9) includes: The first tool holder (10) has a receiving groove (11) on it. The width of the receiving groove (11) is greater than the thickness of the scraper (7). The first tool holder (10) has a first connecting hole (12) on it. The scraper (7) has a second connecting hole (21) that matches the first connecting hole (12). A connecting bolt (13) passes through a first connecting hole (12) and a second connecting hole (21) and is threadedly connected to a lock nut (14); Spring (15) is provided between the two sides of the scraper (7) and the groove wall of the receiving groove (11). The spring (15) always has the tendency to push the scraper (7) towards the middle of the receiving groove (11).

8. The manufacturing process of a precision screen-printed card according to claim 6, characterized in that, The ink return blade (8) is also provided with a scraping structure, which is used to scrape off the ink residue on the ink return blade (8).

9. The manufacturing process of a precision screen-printed card according to claim 8, characterized in that, The scraping structure includes: Scraping cylinder (16), which is connected to ink return blade (8); The scraper (17) is connected to the output end of the scraper cylinder (16) and is arranged parallel to the surface of the ink return knife (8).

10. The manufacturing process of a precision screen-printed card according to claim 6, characterized in that, The clamping structure (6) includes: Clamping groove (18), the width of which is greater than the thickness of the wire mesh frame; Fastening bolt (19) is threaded to the fixing bracket (5) and extends into the clamping groove (18). The end of the fastening bolt (19) extending into the clamping groove (18) is connected to an extension piece (20).

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