A thread tying process for the production of a knotless screen

Abstract

This invention relates to the field of screen printing, and more particularly to a wire-clamping process for producing knotless screen printing plates. The technical solution includes the following steps: Step 1: Straightening, using a top-frame machine and an electronic imager to level the mesh; Step 2: Wire pulling, using a laser cutter to pull the upper and lower wires of the screen printing plate prepared in Step 1; Step 3: Pressing, pressing the screen printing plate after wire pulling in Step 2 according to the standard operating procedure (SOP) and allowing it to stand; Step 4: Scanning, placing the pressed and settled screen printing plate on a 3D scanner, and starting the scanning with the first pulled wire as the starting point; Step 5: PI laser engraving, importing the drawing from Step 5 into a PI machine, setting parameters for PI laser engraving, and obtaining the finished screen printing plate. This invention reduces screen printing plate deformation by pulling the upper and lower wires, and simultaneously uses a wire-clamping synthesis process to create knots on both sides of the fine grid lines of the battery graphic, resulting in better printed line shapes.

Description

Technical Field

[0001] This invention relates to the field of printing screen manufacturing, and more particularly to a wire clamping process for producing knotless screen printing plates. Background Technology

[0002] With the maturity of PI plate-making technology in the screen printing industry, existing screen printing technology has been widely used in various battery fields. Because the printing channel of the knotless screen printing plate does not have the interlacing of warp and weft nodes, the printed battery cells are significantly better than those of conventional screen printing plates in terms of grid line aspect ratio and grid line cross-section. In addition, the knotless screen printing plate can provide better precision and ink transfer during the printing process, eliminating the printing defects caused by traditional grid nodes. The phenomena of grid breakage and false printing are significantly reduced, which helps to improve the overall printing quality of battery cells.

[0003] However, due to the varying grid spacing of the battery cell pattern and the deformation during screen making, it is impossible to fit the fine grid lines of the battery pattern into the warp spacing of the mesh when making a knotless screen. Therefore, it is often necessary to perform wire pulling on the screen, removing the warp threads according to the battery drawing to create a channel of a certain width. This can easily lead to mesh breakage during the manufacturing process. Furthermore, poor quality wire pulling requires rework and a second high-temperature pressing process, which can cause changes in the size of the pulled pattern, resulting in a mismatch with the original pattern and further scrapping of the mesh. In addition, the laser cutting method used in the existing wire pulling process can damage the steel wire, leaving steel wire residue. Moreover, the screen is prone to displacement during cutting, making it more susceptible to bursting and cracking during the manufacturing or printing process. Summary of the Invention

[0004] In order to overcome the problems and disadvantages mentioned in the background art, the present invention provides a wire clamping process for the production of knotless screen printing plates.

[0005] The technical solution adopted by this invention to solve its technical problem is: a wire-clamping process for the production of knotless screen printing plates, specifically including the following steps:

[0006] Step 1: Straightening. The mesh is leveled using a top frame machine and an electronic imager to adjust the straightness for subsequent scanning of the meshless screen.

[0007] Step 2: Wire drawing. Using a laser cutting machine, set the wire drawing spacing and number of wires for the knotless mesh, and perform wire drawing on the knotless mesh prepared in Step 1.

[0008] Step 3: Pressing and heating. The mesh-free screen that has been drawn out in Step 2 above is pressed and heated according to the SOP process and then left to stand.

[0009] Step 4: Scanning. Place the heat-pressed and settled mesh-free stencil on a 3D scanner, set the parameters, and start scanning with the first drawn filament as the starting point of the scan image.

[0010] Step 5: Line stitching. Using computer drawing, each grid line of the original un-grid screen is completely placed within the grid lines of the scanned image from Step 4 above, thus completing the line stitching and obtaining the drawing paper.

[0011] Step Six: PI Laser Printing. Import the drawing from Step Five above into the PI machine and start setting parameters for PI laser printing to obtain the finished screenless stencil.

[0012] Furthermore, in step two, the number of filaments drawn in the knotless mesh is set to 2-3 depending on the purpose, and the total number of filaments drawn from the upper and lower lines is controlled to 4-6, so as to reduce the deformation and damage to the knotless mesh caused by filament drawing.

[0013] Furthermore, in step two, the meshless screen is set with a wire spacing of 305-420 mesh, depending on the intended use.

[0014] Furthermore, after the pressing in step three is completed, the resting time is 8-10 hours to reduce the change in graphic size of the non-woven screen due to pressing.

[0015] Furthermore, in step four, positioning points are added at the four corners of the meshless screen during the scanning process for precise positioning in the subsequent wire bonding process.

[0016] Furthermore, the method for stitching and synthesizing in step five is as follows: using the scanned image from step four as the bottom layer, the grid lines of the bottom scanned image are irregularly curved. Based on the four added positioning points, the scanned image of the screenless original image is accurately positioned on its upper layer, that is, the battery pattern on the screenless original image is placed on the bottom scanned image in the direction of the meridian. Through computer algorithms, each grid line on the screen original image is placed into its grid line according to the curvature of the bottom scanned image, thus obtaining the stitched composite image and completing the drawing.

[0017] Furthermore, in step six, according to the PI machine display screen, any grid line is selected and previewed to check whether the fine grid lines of the entire battery pattern are within the grid of the non-grid screen, ensuring the quality of the wire bonding synthesis.

[0018] Compared with the prior art, the present invention has the following advantages: The present invention uses a laser cutting machine to draw the upper and lower meshes of the knotless screen, which is different from the existing drawing technology that draws each mesh individually. The total number of drawn meshes is over a hundred, avoiding laser energy splashing, deformation of the knotless screen, and steel wire residue on the mesh surface. At the same time, it avoids the problems of low efficiency and quality issues caused by the long drawing process of the existing technology, which can easily lead to displacement of the knotless screen during the drawing process.

[0019] This invention uses computer-generated graphics to completely place the fine grid lines of each battery pattern in the scanned image of the knotless screen printing plate. This eliminates the need to pull each strand of mesh on the screen, allowing the fine grid lines of the battery pattern to be placed into the warp spacing of the mesh. This greatly reduces the cost of producing knotless screen printing plates, avoids the occurrence of plate bursting and cracking, and also reduces the problem of quality degradation due to wire pulling, requiring rework and secondary high-temperature pressing.

[0020] The knotless screen printing plate obtained by the present invention through the wire clamping process has a closer distance between the grid lines and the knots on both sides, and the slope of the grid line edges is increased. The mesh is also supported. During subsequent printing, the squeegee is closer to the knots during its movement, which results in higher and better lines printed, reducing the problem of incomplete printing. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0022] Figure 1 A schematic diagram of the structure after cutting the wire mesh of a knotless mesh using existing technology;

[0023] Figure 2 This is a schematic diagram of the mesh structure after the wire-locking process described in this invention;

[0024] Figure 3 This is a scanned image of the knotless screen printing plate using the wire-clamping process described in this invention;

[0025] Figure 4 This is a scanned image of the original image used in the fabrication of the meshless screen printing plate described in this invention;

[0026] Figure 5 This is a composite scan of the wire-locked screen and the original image of the wire-locked screen using the wire-locking process described in this invention.

[0027] Figure 6 This is a scanned image of a meshless screen printing plate that has been inspected by a PI machine according to the present invention;

[0028] Figure 7 A schematic diagram of the knotless mesh structure of the existing wire drawing process;

[0029] Figure 8 This is a schematic diagram of the knotless screen structure of the wire-clamping process described in this invention. Detailed Implementation

[0030] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0031] Example 1

[0032] A wire-clamping process for producing knotless screen printing plates, such as Figures 1-6 As shown, firstly, the knotless mesh to be made is manually placed in the top frame machine. The electronic imager within the machine levels the straightness of the mesh, maintaining tension and effectively reducing waste caused by unstable tension, thus improving the yield rate. Then, the finished knotless mesh is manually placed on the positioning holes of the laser cutting machine. The number of threads to be drawn is set to 2, and the thread spacing is 310-360 mesh. After setting, the laser cutting machine is started to draw threads from the top and bottom two threads of the knotless mesh, for a total of 4 threads. Unlike existing wire-drawing techniques that draw each individual mesh strand, this method draws only a hundred strands in total, avoiding issues such as laser energy splashing, deformation of the knotless mesh, and steel wire residue on the mesh surface. It also avoids the problems of long drawing times, easy displacement of the knotless mesh during the drawing process, resulting in low efficiency and quality issues. Furthermore, laser cutting can lead to a lower slope at the grid edges, causing the scraper to travel further from the mesh knots, resulting in poor line shape and potential for subsequent false printing.

[0033] After the laser cutting lines are completed, the knotless screen is heat-pressed using a heat press machine according to the standard operating procedure (SOP). Then, the heat-pressed knotless screen is placed in a clean, cool, dry, and well-ventilated environment to allow it to stand. Direct sunlight and high humidity should be avoided during this process to prevent dimensional deformation due to environmental factors. It is important to note that the resting time should be controlled at 8-9 hours. Too short a resting time will cause unstable tension in the knotless screen, affecting subsequent printing results. Too long a resting time will cause the screen to absorb dust and impurities from the air, leaving residue inside the mesh and hindering smooth passage during subsequent printing.

[0034] Subsequently, the knotless screen, after being left to stand, is placed on a 3D scanner. The first filament extracted during the aforementioned filament-drawing process is used as the starting point for scanning. Simultaneously, the filament-drawing along the upper and lower lines allows for the determination of the scanning spacing and image size, ensuring the accuracy of the scanned image. It is important to note that a positioning point is added at each of the four corners of the knotless screen during the scanning process. Figure 3 As shown, this is used for precise positioning in the subsequent wire bonding process;

[0035] After scanning is complete, you will obtain the scanned image and the original screen print, such as... Figure 3-4 As shown, the drawing process begins using a computer. Each fine grid line of the battery pattern in the original, un-grid-printed image is completely placed within the grid lines of the scanned image, thus completing the drawing. Figure 5 As shown, the wire composite image is obtained. In this way, the fine grid lines of the battery pattern can be placed into the warp spacing of the mesh without having to pull out every single mesh on the screen. This greatly reduces the cost of making a knotless screen. At the same time, because the number of steel wires cut by laser is small, the deformation of the screen is small, avoiding the phenomenon of screen bursting and cracking. It also reduces the problem of quality degradation due to wire pulling and the need for rework, which would require secondary high-temperature pressing.

[0036] Furthermore, the above-mentioned method for synthesizing the wire-clamping pattern is as follows: First, the scanned image is used as the bottom layer. It should be noted that due to the heat pressing and laser cutting, the grid lines of the scanned image are irregularly curved. Based on the positioning point added above, the original image without mesh is accurately positioned on the top layer of the scanned image. That is, the battery graphic on the original image without mesh is placed on the bottom scanned image in the direction of the meridian. Through computer algorithms, each grid line on the original image without mesh is placed into its grid line according to the curvature of the bottom scanned image. In this way, the composite image with the wire-clamping pattern is obtained, and the drawing is completed.

[0037] Subsequently, the wire-cut composite pattern is manually imported into the PI machine. It's important to note that during import, the screen should be checked to ensure that all the fine grid lines of the battery graphic are within the screen grid. One grid line can be selected for preview to ensure the quality of the wire-cut composite and avoid quality degradation caused by direct laser printing. Once confirmed, PI laser printing can begin, resulting in a knot-free screen. This completes the knot-free screen production process using the wire-cut technique. The wire-cut process avoids damage to the mesh caused by laser cutting, resulting in a more resilient screen, increasing its printing lifespan, and reducing the problem of grid breakage.

[0038] Example 2

[0039] A wire-clamping process for producing knotless screen printing plates, such as Figures 7-8 As shown, the knotless mesh to be made is first placed manually in the top frame machine. The electronic imager inside is used to level the straightness of the mesh and maintain its tension. Then, the knotless mesh is placed manually on the positioning hole of the laser cutting machine. The number of wires to be drawn is set to 3, and the wire spacing is 360-410 mesh. After the settings are completed, the laser cutting machine is started to draw the top and bottom meshes of the knotless mesh, with a total of 6 wires drawn. This avoids the long drawing time of the existing wire drawing process, which can easily cause the knotless mesh to shift during the drawing process, resulting in low efficiency and quality problems.

[0040] After the laser cutting lines are completed, the knotless screen is heat-pressed using a heat press machine according to the standard operating procedure (SOP). Then, the heat-pressed knotless screen is placed in a clean, cool, dry, and well-ventilated environment to allow it to stand. Direct sunlight and high humidity should be avoided during this process to prevent dimensional deformation due to environmental factors. It is important to note that the resting time should be controlled at 9-10 hours. Too short a resting time will cause unstable tension in the knotless screen, affecting subsequent printing results. Too long a resting time will cause the screen to absorb dust and impurities from the air, leaving residue inside the mesh and hindering smooth passage during subsequent printing.

[0041] Subsequently, the knotless screen is manually placed on a 3D scanner. The first wire drawn during the wire-drawing process is used as the starting point for scanning. After scanning, the scanned image and the original screen image are obtained. The computer then begins drawing, placing each fine grid line of the battery pattern in the grid line of the scanned image. This completes the drawing and produces a composite image. This method eliminates the need to draw every single wire on the screen, allowing the fine grid lines of the battery pattern to be placed into the warp spacing of the mesh. This significantly reduces the cost of producing the knotless screen. Furthermore, because the number of steel wires cut by laser is small, the screen deformation is minimal, avoiding issues such as screen bursting and cracking. It also reduces the need for rework due to wire drawing, which would require secondary high-temperature pressing.

[0042] Subsequently, the wire-splitting composite drawing is manually imported into the PI machine. A single grid line is randomly selected and previewed to ensure the quality of the wire-splitting composite, avoiding quality degradation caused by direct laser drawing. Once confirmed to be correct, PI laser drawing can begin, resulting in a knotless screen printing plate, thus completing the knotless screen printing process for wire-splitting. Figures 7-8 As shown, the resulting knotless screen printing plate with the wire-clamping process is closer to the knots on both sides in terms of grid line distance, which increases the slope of the grid line edge and supports the mesh. During subsequent printing, the squeegee is closer to the knots during its movement, resulting in higher and better-shaped printed lines and reducing the problem of incomplete printing.

[0043] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0044] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A wire-clamping process for producing knotless screen printing plates, characterized by the following steps: Step 1: Straightening. The mesh is leveled using a top frame machine and an electronic imager to adjust its straightness for subsequent screen scanning. Step 2: Wire drawing. Using a laser cutting machine, set the wire drawing spacing and number of wires for the knotless mesh, and perform wire drawing on the knotless mesh prepared in Step 1. Step 3: Pressing. Press the knotless mesh obtained from the wire drawing process in Step 2 according to the SOP process and let it stand. Step 4: Scanning. Place the heat-pressed and settled mesh-free stencil on a 3D scanner, set the parameters, and start scanning with the first drawn filament as the starting point of the scan image. Step 5: Line stitching. Using computer drawing, each grid line of the original un-grid screen is completely placed within the grid lines of the scanned image from Step 4 above, thus completing the line stitching and obtaining the drawing paper. Step Six: PI Laser. Import the drawing from Step Five into the PI machine, and check through the PI machine display screen whether the fine grid lines of the entire battery graphic are within the screen grid. After confirming that there are no errors, start setting parameters to perform PI laser drawing, so as to obtain a screen-finished product without grid knots. After the pressing in step three is completed, the resting time is 8-10 hours.

2. The wire clamping process for producing a knotless screen printing plate according to claim 1, characterized in that: The number of wires drawn in the non-woven mesh in step two is set to 2-3 depending on the purpose.

3. A wire clamping process for producing a knotless screen printing plate according to any one of claims 1-2, characterized in that: The meshless screen in step two is set with a wire drawing spacing of 305-420 meshes depending on the application.

4. The wire clamping process for producing a knotless screen printing plate according to claim 1, characterized in that: In step four, several positioning points are added to the four corners of the screen during the scanning process to create a screen without any mesh knots.

5. The wire clamping process for producing a knotless screen printing plate according to claim 4, characterized in that: The method for wire-locking synthesis in step five is as follows: using the scanned image from step four as the bottom layer, the grid lines of the bottom scanned image are irregularly curved. Based on the four added positioning points, the scanned image of the original screenless screen is accurately positioned on its upper layer, that is, the battery pattern on the original screenless screen is placed on the bottom scanned image in the direction of the meridian. Through computer algorithms, each grid line on the original screenless screen is placed into its grid line according to the curvature of the bottom scanned image, thus obtaining the synthesized image with wire-locking completed, and the drawing is completed.

6. The wire clamping process for producing a knotless screen printing plate according to claim 1, characterized in that; In step six, according to the PI machine display screen, arbitrarily select a grid line and check through preview whether the fine grid lines of the entire battery pattern are all within the grid of the non-grid screen.

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