Composite material screen for reducing composite edge ink leakage and manufacturing method thereof

Abstract

A composite material screen that reduces ink leakage from composite edges and a method for making the same include: a screen frame; a composite screen including a scraper surface and a printing surface, wherein the composite screen includes: a first material screen fixed to the screen frame, the first material screen including a predetermined bonding area; a second material screen bonded to the first material screen via a film layer, the first and second material screens forming a composite edge at their junction, the second material screen including a graphic area pattern; and a leak-proof layer bonded to the printing surface of the composite screen and to the predetermined bonding area, thereby covering the composite edge through the leak-proof layer, the leak-proof layer including a pattern corresponding to the graphic area pattern at a position corresponding to the graphic area pattern. The present invention prevents slurry / printing ink from overflowing from the junction of the two material screens during screen printing.

Description

Technical Field

[0001] The present invention relates to a composite material screen and a manufacturing method thereof, in particular to a composite material screen which is formed by two meshes of different materials or different specifications and can reduce composite edge ink leakage and a manufacturing method thereof. Background Art

[0002] In the prior art, the structure of a solar cell typically includes finger-shaped electrodes (finger lines) and bus-shaped electrodes (bus bars). Most solar cell designs use very fine "finger-shaped electrodes" to transfer photoelectrons collected in the active area to larger "bus-shaped electrodes," which are then transferred to the component's circuit system. To increase the efficiency of solar cells, the finger-shaped electrodes must be designed to be thin and tall, resulting in a better aspect ratio in the solar cell structure and high energy conversion efficiency. In the prior art, the finger-shaped electrodes are perpendicular to the bus-shaped electrodes and are distributed equidistantly on the silicon chip (wafer). As meshing technology improves, the finger-shaped electrodes are becoming increasingly thinner.

[0003] In the prior art, finger-shaped electrodes are typically produced through screen printing. To further reduce the cost of printing screens, a composite screen is formed by weaving together a lower-cost first mesh and a higher-cost second mesh. A polymer material or photosensitive emulsion is then coated onto the second mesh to form a patterned area. However, when a scraper is used to apply slurry to the composite screen with this structure, due to the reduced area of ​​the second mesh, the scraper begins pressing down from the first mesh and applies pressure through the interface with the second mesh. This makes it easy for slurry to overflow from the interface between the first and second meshes. This is especially true when the size of the higher-cost second mesh in the screen is smaller and the closer the interface is to the patterned area, the greater the amount of ink overflowing from the interface.

[0004] In order to solve the above problem, in the prior art, a gap filler is filled at the junction of the first material mesh and the second material mesh to prevent ink leakage. However, since the gap filler is combined with the polymer material or photosensitive emulsion on the second material mesh on one side and the film layer material of the composite first and second material meshes on the other side, it is difficult to combine due to the different material properties of the two sides. When the composite material mesh is printed, the mesh will be stretched, resulting in cracks between the gap filler and the photosensitive emulsion layer or at the junction of the film layer on the other side of the gap filler, and the slurry will still overflow from the junction.

[0005] For the above reasons, how to provide a new screen structure so that the slurry / printing ink does not overflow from the junction of the two materials during screen printing remains an issue to be solved. Summary of the Invention

[0006] To achieve the aforementioned objectives, the present invention provides a composite material screen that reduces ink leakage from a composite edge, comprising: a screen frame; a composite screen, comprising a scraper surface and a printing surface, and the composite screen comprising: a first material screen, fixed to the screen frame, and the first material screen comprising a predetermined bonding area; and a second material screen, combined with the first material screen through a film layer, wherein the first material screen and the second material screen are combined to form a composite edge, and the second material screen comprises a graphic area pattern; and a leak-proof layer, combined on the printing surface of the composite screen and combined to the predetermined bonding area, so as to cover the composite edge through the leak-proof layer, and the leak-proof layer comprises a pattern corresponding to the graphic area pattern at a position corresponding to the graphic area pattern.

[0007] Preferably, the first material web further includes the film layer on the printing surface, and the film layer on the first material web is not in contact with the predetermined bonding area.

[0008] Preferably, the distance between the composite edge and the pattern in the graphic area is less than 3 cm.

[0009] Preferably, the width of the predetermined bonding area is 0.5 cm to 2 cm.

[0010] Preferably, the material of the film layer is polyethylene, hot melt adhesive, polyimide, photosensitive emulsion or other polymer materials, and the material of the leak-proof layer is polyimide, photosensitive emulsion or other polymer materials. When the material of the film layer is the same as that of the leak-proof layer, the leak-proof layer is an extension of the film layer.

[0011] Preferably, the anti-leakage layer is made of polyimide, photosensitive emulsion or other polymer materials, the anti-leakage layer is combined with the printing surface of the composite net, and the graphic area pattern is formed on the second material net through the anti-leakage layer.

[0012] On the other hand, the present invention also provides a method for producing a composite material screen that reduces ink leakage from a composite edge, comprising the following steps: reserving a predetermined bonding area on a first material net; combining the first material net with a second material net through a film layer to form a composite net, wherein the composite net includes a scraper surface and a printing surface, and a composite edge is formed where the first material net and the second material net are combined; stretching and fixing the composite net to a screen frame by a tension force; bonding a leak-proof layer to the printing surface of the composite net, and bonding the leak-proof layer to the predetermined bonding area so that the leak-proof layer covers the composite edge; and forming a graphic area pattern on the second material net through a development process.

[0013] Furthermore, the step of combining the first material web and the second material web through the film layer to form the composite web includes: combining the film layer on the printing surface of the first material web, and arranging the film layer on the first material web to be non-contact with the predetermined combining area.

[0014] Preferably, in the step of forming the graphic area pattern on the second material web through the development process, the distance between the composite edge and the graphic area pattern is set to be less than 3 cm.

[0015] Preferably, the width of the predetermined bonding area is 0.5 cm to 2 cm.

[0016] Preferably, the leak-proof layer is made of polyimide, photosensitive emulsion or other polymer materials. After the leak-proof layer is bonded to the printing surface of the composite mesh, the graphic area pattern is formed on the leak-proof layer and the second material mesh through the development process.

[0017] Preferably, the development process is a laser development process. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] A person skilled in the art will have a better understanding of the various aspects of the present invention and its specific features and advantages after reading the following detailed description with reference to the accompanying drawings, which include:

[0019] Figure 1 A schematic diagram of the structure of a composite material screen for reducing composite edge ink leakage according to an embodiment of the present invention;

[0020] Figure 2 for Figure 1 Schematic diagram of the AA cross-section structure in;

[0021] Figure 3 A schematic diagram of an implementation of a composite material screen for reducing composite edge ink leakage according to an embodiment of the present invention;

[0022] Figure 4 A schematic cross-sectional view of a composite material screen for reducing composite edge ink leakage according to another embodiment of the present invention;

[0023] Figure 5 A flowchart of a method for manufacturing a composite material screen with reduced composite edge ink leakage according to an embodiment of the present invention;

[0024] Figure 6 The flowchart is a method for manufacturing a composite material screen with reduced composite edge ink leakage according to another embodiment of the present invention.

[0025] Description of reference numerals:

[0026] 1-composite material screen, 10-screen frame, 20-composite screen, 201-first material screen, 203-second material screen, 2031-film layer, 2033-composite edge, 2035-graphic area pattern, 30-leakage-proof layer, A1-predetermined bonding area, D1-width, D2-distance, S1-scraper surface, S2-printing surface, M1-first composite material layer, M2-second composite material layer, M3-third composite material layer, 40-object to be printed, 401-pattern. DETAILED DESCRIPTION

[0027] The following describes the embodiments of the present invention in more detail with reference to the drawings and component symbols, so that people skilled in the art can implement the invention accordingly after reading this specification.

[0028] Figure 1 is a schematic diagram illustrating the structure of a composite material screen for reducing composite edge ink leakage according to an embodiment of the present invention; Figure 2 A schematic diagram to illustrate Figure 1 Please refer to the AA cross-section structure in Figure 1 and Figure 2 In one embodiment of the present invention, a composite material screen 1 is provided for reducing composite edge ink leakage. The composite material screen 1 includes a screen frame 10, a composite mesh 20, and an anti-leakage layer 30. The composite mesh 20 includes a scraper surface S1 and a printing surface S2.

[0029] On the other hand, the composite web 20 further includes a first web 201 and a second web 203. The first web 201 is fixed to the web frame 10 and includes a predetermined bonding area A1. The second web 203 is bonded to the first web 201 via a film layer 2031, which covers both the first and second webs 201 and 203. The bond between the first and second webs 201 and 203 forms a composite edge 2033. The second web 203 includes a graphic area pattern 2035. The anti-leakage layer 30 is bonded to the printing surface S2 of the composite web 20 and to the predetermined bonding area A1, covering the composite edge 2033 through the anti-leakage layer 30. A pattern (not shown) corresponding to the graphic area pattern 2035 is included on the anti-leakage layer 30 at a location corresponding to the graphic area pattern 2035. Among them, the first material net 201 can be terylene, the second material net 203 can be a wire mesh, and the leakage-proof layer 30 will be directly combined with the predetermined bonding area A1 that does not include the film layer 2031, so the bonding strength between the leakage-proof layer 30 and the first material net 201 will not be insufficient due to material problems.

[0030] Depend on Figure 1 and Figure 2As shown in the schematic diagram, the composite material screen 1 includes a first composite material layer M1, a second composite material layer M2, and a third composite material layer M3. The first composite material layer M1 comprises a film layer 2033, a first material mesh 201, a second material mesh 203, and a leak-proof layer 30; the second composite material layer M2 comprises a film layer 2033, a first material mesh 201, and a leak-proof layer 30; and the third composite material layer M3 comprises the first material mesh 201 and the leak-proof layer 30. The composite edge 2033 formed at the junction of the first material mesh 201 and the second material mesh 203 represents the first composite material layer M1. The leak-proof layer 30 simultaneously covers the portions of the first composite material layer M1, the second composite material layer M2, and the third composite material layer M3 located on the printing surface S2.

[0031] Furthermore, in one embodiment of the present invention, the width D1 of the predetermined bonding area A1 is within a range of 0.5 cm to 2 cm, and the distance D2 between the composite edge 2033 and the graphic area pattern 2035 is less than 3 cm. This small distance makes the composite material screen 1 of the present invention more suitable for printing screens with a higher-cost second material screen 203. Furthermore, it should be understood that while the drawings of one embodiment of the present invention illustrate two layers of film 2031 covering and bonding the first material screen 201 and the second material screen 203, in other embodiments of the present invention, only one layer of film 2031 may be used to cover and bond the first material screen 201 and the second material screen 203, or three layers of film 2031 may be used to cover and bond the first material screen 201 and the second material screen 203.

[0032] Figure 3 This is a schematic diagram for explaining an embodiment of the present invention to reduce composite edge ink leakage composite material screen implementation. Figure 1 and Figure 3 When the composite screen of the present invention is in use, the scraper scrapes the slurry from the scraper surface S1 into the second material web 203. The slurry then passes through the graphic area pattern 2035 of the second material web 203 and the pattern corresponding to the graphic area pattern 2035 on the leak-proof layer 30. The slurry is then printed onto the object 40 according to the pattern of the graphic area pattern 2035 to form a pattern 401. In the screen structure of the present invention, because the leak-proof layer 30 covers the composite edge 2033, when the scraper scrapes the slurry from the scraper surface S1 into the second material web 203, the slurry does not overflow from the composite edge 2033, that is, it does not overflow from the junction of the first material web 201 and the second material web 203, thereby causing the production line to stop.

[0033] Figure 4 This is a schematic diagram illustrating the cross-sectional structure of a composite material screen for reducing composite edge ink leakage according to another embodiment of the present invention. Figure 4In another embodiment of the present invention, the first material web 201 further includes a film layer 2031 on the printing surface S2, and the film layer 2031 on the first material web 201 does not contact the predetermined bonding area A1. Providing the film layer 2031 on the first material web 201 further protects the first material web 201 and allows the film layer 2031 to be applied to the printing surface S2 of the first material web 201 in a single step, leaving the predetermined bonding area A1 free of the film layer 2031. This simplifies the manufacturing process.

[0034] On the other hand, in one embodiment of the present invention, the material of the film layer 2031 can be polyethylene, hot melt adhesive, polyimide, photosensitive emulsion, or other polymer materials, and the material of the leakage-proof layer 30 can be polyimide, photosensitive emulsion, or other polymer materials. When the film layer 2031 and the leakage-proof layer 30 are made of the same material, the film layer 2031 and the leakage-proof layer 30 can be considered as one body, that is, the leakage-proof layer 30 can be considered as an extension of the film layer 2031.

[0035] It is worth noting that in other embodiments of the present invention, when the leak-proof layer 30 is made of polyimide, photosensitive emulsion, or other polymer materials, the leak-proof layer 30 is bonded to the printed surface S2 of the composite web 20, and the graphic area pattern 2035 is formed on the second web 203 through the leak-proof layer 30. Specifically, when the leak-proof layer 30 is in the form of a thin polymer film, it can be directly bonded to the printed surface S2 of the composite web 20, for example, by laminating. In this case, because the actual thickness of the leak-proof layer 30 and the second web 203 is very thin, the leak-proof layer 30 bonded to the composite web 20 will be embedded in the second web 203, meaning that the leak-proof layer 30 and the second web 203 can be considered integral. Therefore, after the leak-proof layer 30 is developed, the graphic area pattern 2035 can be formed directly on the leak-proof layer 30 and the second web 203. In other words, the graphic area pattern 2035 is formed on the second web 203 through the leak-proof layer 30.

[0036] Figure 5 This is a flow chart for explaining a method for making a composite material screen with reduced composite edge ink leakage according to an embodiment of the present invention. Figure 5A method for manufacturing a composite material mesh that reduces ink leakage from composite edges according to an embodiment of the present invention includes steps S10-S50. Step S10 comprises reserving a predetermined bonding area on a first material mesh, wherein the width of the predetermined bonding area can be any value within a range of 0.5 cm to 2 cm. Step S20 comprises combining the first material mesh with a second material mesh via a film layer to form a composite mesh, wherein the composite mesh includes a scraper surface and a printing surface, and the bonding area between the first material mesh and the second material mesh forms a composite edge. Step S30 comprises stretching and securing the composite mesh to a screen frame using a tensile force. Step S40 comprises combining a leak-proof layer onto the printing surface of the composite mesh and the leak-proof layer to the predetermined bonding area, thereby covering the composite edge with the leak-proof layer. Step S50 comprises forming a graphic area pattern on the second material mesh via a development process.

[0037] In addition, in step S50, the distance between the composite edge and the pattern of the graphic area can be set to be less than 3 cm, so as to be applicable to various high-cost second material meshes.

[0038] Furthermore, in step S20, the film layer, the first material web, and the second material web can be laminated together through a lamination process to form the composite web. In step S30, the composite web can be stretched and secured to the web frame using a top frame method. In step S40, the leak-proof layer can be bonded to the printed surface of the composite web through a heat lamination process, or the leak-proof layer in the form of a film can be directly laminated to the printed surface of the composite web. In step S50, the development process is a laser development process.

[0039] Figure 6 This is a flow chart for explaining another embodiment of the present invention, a method for making a composite material screen that reduces composite edge ink leakage. Figure 6 In another embodiment of the present invention, step S20 may further include step S101, which comprises bonding the film layer to the printing surface of the first material web, and disposing the film layer on the first material web so that it does not contact the predetermined bonding area. This further protects the first material web with the film layer, and allows the film layer to be bonded to the printing surface of the composite web in one step during the manufacturing process, with the predetermined bonding area being free of the film layer.

[0040] On the other hand, in one embodiment of the manufacturing method of the present invention, the material of the film layer can be polyethylene, hot melt adhesive, polyimide, photosensitive emulsion, or other polymer materials, and the material of the leak-proof layer can be polyimide, photosensitive emulsion, or other polymer materials. When the film layer and the leak-proof layer are made of the same material, the film layer and the leak-proof layer can be considered as one, that is, the leak-proof layer can be considered an extension of the film layer.

[0041] It is worth mentioning that in other embodiments of the manufacturing method of the present invention, the material of the leak-proof layer can be polyimide, photosensitive emulsion, or other polymer materials. After the leak-proof layer is bonded to the printing surface of the composite mesh, the graphic area pattern is formed on the leak-proof layer and the second material mesh through the development process. In other words, when the leak-proof layer is in the form of a thin film of polymer material, the leak-proof layer can be directly bonded to the printing surface of the composite mesh. In this case, because the actual thickness of the leak-proof layer and the second material mesh is very thin, the leak-proof layer bonded to the composite mesh will be embedded in the second material mesh. Therefore, after the leak-proof layer is subjected to the development process, the graphic area pattern can be directly formed on the leak-proof layer and the second material mesh. In other words, the graphic area pattern is formed on the second material mesh through the leak-proof layer, and the leak-proof layer can be regarded as an extension of the graphic area pattern.

[0042] In summary, the present invention successfully provides a composite screen and its manufacturing method that reduces ink leakage from the composite edge. In the structure of the composite screen of the present invention, an integrally formed leak-proof layer covers the junction between the first and second material meshes, namely the composite edge, thereby preventing slurry from overflowing from the junction. Furthermore, the present invention adjusts the width of the predetermined junction area and the distance between the composite edge and the graphic area on the second material mesh, making the composite screen of the present invention suitable for use with high-cost second material meshes.

[0043] The above description is only used to explain the preferred embodiments of the present invention and is not intended to limit the present invention in any form. Therefore, any modifications or changes made to the present invention under the same inventive spirit should still be included in the scope of protection intended by the present invention.

Claims

1. A composite material screen that reduces composite edge ink leakage, characterized in that: include: a mesh frame; A composite web comprising a scraper surface and a printing surface, and the composite web comprises: a first material net fixed on the net frame, wherein the first material net includes a predetermined bonding area; and a second material mesh, bonded to the first material mesh via a film layer, wherein a composite edge is formed where the first material mesh and the second material mesh are bonded, and the second material mesh includes a graphic area pattern; and a leakproof layer bonded to the printed surface of the composite web and bonded to the predetermined bonding area, so that the leakproof layer covers the composite edge, and the leakproof layer includes a pattern corresponding to the pattern in the graphic area at a position corresponding to the pattern in the graphic area; Wherein, the first material net further includes the film layer on the printing surface, and the film layer on the first material net is not in contact with the predetermined combining area.

2. The composite material screen for reducing composite edge ink leakage according to claim 1, characterized in that: The distance between the composite edge and the pattern in the graphic area is less than 3 cm.

3. The composite material screen for reducing composite edge ink leakage according to claim 1, characterized in that: The width of the predetermined bonding area is 0.5 cm to 2 cm.

4. The composite material screen for reducing composite edge ink leakage according to claim 1, characterized in that: The material of the film layer is polyethylene, polyimide or other polymer materials, and the material of the leak-proof layer is polyimide or other polymer materials. When the material of the film layer is the same as that of the leak-proof layer, the leak-proof layer is an extension of the film layer.

5. The composite material screen for reducing composite edge ink leakage according to claim 1, characterized in that: The material of the leak-proof layer is polyimide or other polymer materials, and the graphic area pattern is formed on the second material net through the leak-proof layer.

6. A method for producing a composite material screen to reduce composite edge ink leakage, characterized in that: The following steps are involved: Reserving a predetermined bonding area on a first material web; Combining the first material web and the second material web through a film layer to form a composite web, wherein the composite web includes a scraper surface and a printing surface, and a composite edge is formed where the first material web and the second material web are combined; stretching and fixing the composite mesh onto a mesh frame by applying a tensile force; bonding a leak-proof layer to the printed surface of the composite web, and bonding the leak-proof layer to the predetermined bonding area so as to cover the composite edge with the leak-proof layer; and forming a graphic area pattern on the second material web through the anti-leakage layer by a development process; The step of combining the first material web and the second material web through a film layer to form a composite web includes: combining the film layer on the printing surface of the first material web, and setting the film layer on the first material web to be non-contact with the predetermined combining area.

7. The method for manufacturing a composite material screen with reduced composite edge ink leakage according to claim 6, characterized in that: In the step of forming a graphic area pattern on the second material web through a development process, the distance between the composite edge and the graphic area pattern is set to be less than 3 cm.

8. The method for manufacturing a composite material screen with reduced composite edge ink leakage according to claim 6, characterized in that: The width of the predetermined bonding area is 0.5 cm to 2 cm.

9. The method for manufacturing a composite material screen with reduced composite edge ink leakage according to claim 6, characterized in that: The material of the leak-proof layer is polyimide or other polymer materials. After the leak-proof layer is combined with the printing surface of the composite net, the graphic area pattern is formed on the leak-proof layer and the second material net through the development process.

10. The method for manufacturing a composite material screen with reduced composite edge ink leakage according to claim 9, characterized in that: The development process is a laser development process.

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