Process method for improving single-machine productivity in cover plate screen printing process

Abstract

The invention relates to the technical field of cover plate manufacturing, in particular to a process method for improving single-machine productivity in a cover plate screen printing process, which comprises the following steps: S1, film manufacturing; s2, a silk-screen tool is manufactured; s3, manufacturing a screen printing plate; s4, equipment debugging; and S5, product debugging and manufacturing. Screen printing of a plurality of substrates is completed at the same time through single-time printing operation, the production time of a unit product and the equipment occupation cost are reduced, the debugging frequency in the production process is reduced through the optimized film compensation design and the high-stability screen printing plate, the equipment can be in a continuous and stable production state for a longer time, and the overall production efficiency is further improved; physical deformation in the printing process is precisely punched, the problems of fuzzy lines, thickening and the like caused by ink diffusion are effectively solved, the positioning flatness and consistency of each substrate are ensured, the potential difference problem during multi-substrate printing is solved, and the high consistency of products in batches is ensured.

Description

Technical Field

[0001] This invention relates to the field of cover plate manufacturing technology, and in particular to a process method for improving single-machine productivity during cover plate screen printing. Background Technology

[0002] Cover glass, as a key exterior and protective component of consumer electronics products such as smartphones, tablets, and wearable devices, often features brand logos, decorative patterns, and functional textures on its surface through screen printing. Screen printing is widely used in this field due to its adaptability, low cost, and excellent ink thickness performance. However, with increasingly fierce market competition and accelerated product upgrades, manufacturers face immense pressure to continuously improve production efficiency and reduce unit costs. Against this backdrop, increasing the single-machine capacity of screen printing equipment has become a crucial issue.

[0003] Traditional cover plate screen printing processes suffer from numerous bottlenecks that restrict both production capacity and quality. Firstly, in terms of production efficiency, the mainstream method generally employs single-station, single-piece printing, meaning only one cover plate can be printed per printing cycle. This model directly limits the maximum theoretical capacity of the equipment to the single reciprocating motion cycle of the squeegee, leaving very little room for improvement. To meet the ever-increasing production demands, companies can only increase the number of machines and production lines. This not only leads to a significant increase in factory space, equipment investment, and energy costs, but also adds complexity to production management and maintenance.

[0004] Secondly, traditional processes face significant challenges in terms of printing accuracy and consistency. During screen printing, the ink naturally spreads and diffuses after printing, resulting in printed lines that are wider than the film design size. This is particularly noticeable in fine textures or small logos, easily causing blurred fonts, broken lines, or adhesion, leading to a decrease in product yield. Existing solutions often rely on empirical compensation during the design phase, but lack precise and quantifiable standards, resulting in inconsistent compensation effects and significant variations between different machines and batches.

[0005] Furthermore, attempting to improve single-print output using step-and-repeat fixtures with multiple substrates in parallel setups presents new technical challenges. Firstly, traditional fixtures (typically made of aluminum or ordinary plastic) lack sufficient machining precision, resulting in significant tolerances (usually ≥±0.1mm) for the depth, parallelism, and consistency of the substrate positioning grooves. This prevents multiple substrate surfaces from maintaining a precise plane. During printing, squeegee pressure causes the screen to contact the higher substrates first, while poor contact with the lower substrates leads to inconsistent printed pattern thickness or even partial missing areas on substrates at different locations within the same fixture. This drastically deteriorates registration accuracy and may actually decrease yield.

[0006] Furthermore, the lifespan and stability of the screen are also key factors affecting production capacity. During continuous high-speed printing, the screen is subjected to constant friction and stretching, resulting in plastic deformation and tension decay. Traditional processes do not have strict requirements for screen tension control (typically 22±2N), and the tension is uneven at the four corners. This not only accelerates screen deformation, causing the printed image to gradually elongate and become distorted with each use, requiring frequent shutdowns for adjustments or even screen replacements, but uneven tension can also cause problems such as poor screen removal and screen clogging, severely disrupting continuous production processes and reducing the overall utilization rate of the equipment.

[0007] Finally, the entire production process relies heavily on manual experience for setup and debugging. From tooling installation and screen alignment to setting printing parameters (such as screen distance, squeegee pressure, and speed), operators need to repeatedly test print and make adjustments. Each product or tooling change requires a significant downtime for setup and debugging, further compressing effective production time and making it unsuitable for the trend of flexible production with multiple varieties and small batches.

[0008] In summary, existing cover plate screen printing processes face a series of interconnected technical challenges in their pursuit of high efficiency, high precision, and high stability. These challenges include low single-unit production efficiency, a lack of quantitative standards for precision compensation, poor consistency across multiple printing sheets, short screen lifespan, and long setup times. Therefore, the industry urgently needs a systematic process approach that can fundamentally and collaboratively address these issues, thereby achieving a significant leap in single-machine production capacity while ensuring and even improving printing quality. Summary of the Invention

[0009] To overcome the shortcomings of existing technologies, this invention provides a process method for improving single-machine productivity during cover plate screen printing. It enables the simultaneous screen printing of multiple substrates in a single printing operation, reducing production time and equipment occupancy costs per unit product. Optimized film compensation design and a highly stable screen reduce the frequency of adjustments during production, allowing the equipment to maintain continuous and stable production for longer periods, further improving overall production efficiency. It precisely offsets physical deformation during printing, effectively solving problems such as blurred and thickened lines caused by ink diffusion, ensuring the positioning flatness and consistency of each substrate, resolving the positional difference problem during multi-substrate printing, and guaranteeing high consistency of products within a batch.

[0010] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a process method for improving single-machine productivity in cover plate screen printing, comprising the following steps: S1, Film Production; S2, Silk screen printing tooling production; S3, screen printing; S4. Equipment debugging; S5. Product debugging and manufacturing.

[0011] Furthermore, the film production method is as follows:

[0012] S11, Graphic Design;

[0013] S12, Screen stretching compensation;

[0014] S13, Output film.

[0015] Furthermore, the method for manufacturing the screen printing fixture is as follows:

[0016] S21. Material selection;

[0017] S22, Groove machining.

[0018] Furthermore, the screen printing method is as follows:

[0019] S31. Frame selection;

[0020] S32. Determine the netting parameters;

[0021] S33, Film Transfer.

[0022] Furthermore, the equipment debugging method is as follows:

[0023] S41. Tooling and screen installation;

[0024] S42, Screen distance setting.

[0025] Furthermore, the product debugging and manufacturing method is as follows:

[0026] S51, Trial Printing and Testing;

[0027] S52, parameter fine-tuning;

[0028] S53, mass production.

[0029] Furthermore, the film production involves creating a film based on the product graphic, and reserving space for ink extension during the film design stage. The film production also includes compensation for screen stretching tolerances.

[0030] Furthermore, the screen printing fixture is manufactured as follows: a screen printing fixture capable of supporting multiple substrates to be screen printed is manufactured, and the screen printing fixture has slots for accommodating the substrates.

[0031] Furthermore, the screen printing process involves creating a screen with predetermined dimensions and tension parameters.

[0032] Furthermore, the equipment debugging involves installing the screen printing fixture and screen onto the screen printing equipment and setting the screen distance.

[0033] Compared with the prior art, the beneficial effects that this invention can achieve are:

[0034] 1. It enables the screen printing of multiple substrates in a single printing operation, reducing the production time and equipment occupancy cost per unit product. The optimized film compensation design and high-stability screen reduce the frequency of debugging during the production process, enabling the equipment to remain in a continuous and stable production state for a longer period of time, further improving the overall production efficiency.

[0035] 2. It precisely counteracts the physical deformation during the printing process, effectively solving problems such as blurred and thickened lines caused by ink diffusion, ensuring the positioning flatness and consistency of each substrate, solving the positional difference problem when printing multiple substrates, and guaranteeing the high consistency of products within a batch. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of a process method for improving single-machine productivity in cover plate screen printing according to the present invention;

[0037] Figure 2 This is a schematic diagram of the film production for a process method to improve single-machine productivity in cover plate screen printing according to the present invention;

[0038] Figure 3 This is a schematic diagram of the screen printing tooling used in a process method for improving single-machine productivity during cover plate screen printing according to the present invention.

[0039] Figure 4 This is a schematic diagram of the screen printing process for improving single-machine productivity in cover plate screen printing according to the present invention.

[0040] Figure 5 This is a schematic diagram of equipment debugging for a process method to improve single-machine productivity in cover plate screen printing according to the present invention;

[0041] Figure 6 This is a schematic diagram illustrating the product debugging and manufacturing process of a method for improving single-machine productivity during cover plate screen printing according to the present invention. Detailed Implementation

[0042] To make the technical means, creative features, and achieved objectives and effects of this invention easier to understand, the invention is further described below with reference to specific embodiments. However, the following embodiments are merely preferred embodiments of this invention and not all of them. Other embodiments obtained by those skilled in the art based on the embodiments described herein without creative effort are all within the protection scope of this invention. Unless otherwise specified, the experimental methods in the following embodiments are conventional methods, and the materials and reagents used in the following embodiments are commercially available unless otherwise specified.

[0043] Example:

[0044] Example: Combination Figure 1 — Figure 6 As shown, this invention provides a process method for increasing single-machine productivity during cover plate screen printing, including... Step 1. Film Preparation: Step 11, Graphic Design: Use graphic design software (such as AutoCAD or CorelDRAW) to draw the final product design and perform dimensional compensation: X-axis direction: All pattern lines are reduced inward by 0.05mm on one side (to compensate for the lateral extension of the ink). Y-axis direction: All pattern lines are indented by 0.025mm on one side (to compensate for the longitudinal extension of the ink). Step 12, Screen Stretch Compensation: Along the screen printing initiation direction (positive X-axis direction), the spacing between adjacent product graphics increases in a gradient of 0.025mm / piece (e.g., if the spacing between the 1st and 2nd pieces is 2.0mm, then the spacing between the 2nd and 3rd pieces is 2.025mm, and so on), to offset the cumulative stretching deformation during screen printing.

[0052] Step 13, Output film:

[0053] The compensated image is output to a high-precision film (resolution ≥ 5080 dpi), and the film size matches the screen size (700mm × 800mm).

[0054] Step 2. Fabrication of screen-printed fixtures:

[0055] Step 21, Material Selection:

[0056] Hard birch laminate (10-12mm thick) with a moisture content ≤8% is selected to ensure thermal stability.

[0057] Step 22, Slot machining:

[0058] Slot dimensions: Designed according to the shape of the substrate, the depth is calculated using the formula: Slot depth = substrate thickness - 0.1mm (e.g., if the substrate thickness is 0.7mm, then the slot depth is 0.6mm).

[0059] Processing method: Use a laser cutting machine (power ≥200W) to cut grooves, ensuring that the verticality of the groove wall is ≤0.02mm and the groove depth tolerance is ±0.05mm.

[0060] Slot layout: The single tooling is designed with 4 slots (or 6 / 8 slots), and the slot spacing error is ≤0.05mm, enabling multiple substrates to be printed simultaneously in a single screen printing operation.

[0061] Step 3. Screen printing:

[0062] Step 31, Frame Selection:

[0063] It uses an aluminum alloy mesh frame (700mm×800mm), with a frame width of 40mm and a wall thickness of 2mm.

[0064] Step 32, Netting Parameters:

[0065] Fabric type: Polyester fabric (350 mesh, 30μm wire diameter).

[0066] Tension control: After stretching the net, let it stand for 24 hours, then use a tension meter to measure the center and four corners of the net.

[0067] Overall tension: 24±1N.

[0068] Tension difference at four corners: ≤1N (if not up to standard, the net must be re-stretched).

[0069] Step 33, Film Transfer:

[0070] The film pattern is transferred to the screen using photosensitive emulsion (12μm thick) with an exposure energy of 80-100mJ / cm².

[0071] Step 4. Equipment debugging;

[0072] Step 41, Tooling and Screen Mount Installation:

[0073] Fix the screen printing fixture on the screen printing machine platform, load the screen into the screen fixture, and adjust the fixture so that the center of the screen coincides with the center of the fixture (error ≤ 0.1mm).

[0074] Step 42, Screen Distance Setting:

[0075] Set the screen distance (gap between the bottom surface of the screen fabric and the surface of the substrate) using the fine-tuning knob:

[0076] Recommended value: 1-3mm (1mm for thin ink, 3mm for thick ink).

[0077] Parallelism calibration: The gap difference between the four corners of the tooling is ≤0.05mm when measured with a feeler gauge.

[0078] Step 5. Product debugging and manufacturing:

[0079] Step 51, Trial Printing and Debugging:

[0080] Place the substrate into the fixture slot (ensure there is no shaking).

[0081] Scraper parameters: hardness 70 Shore A, angle 60°, pressure 0.3MPa, speed 0.8m / s.

[0082] Print 3-5 test plates, and test the following:

[0083] Graphic dimensions: The actual printed dimensions in the X / Y directions were verified using a 2D measuring instrument to ensure that the deviation from the design value was ≤ ±0.03mm (verification of film compensation effect).

[0084] Registration accuracy: Pattern position deviation between multi-slot substrates ≤ 0.05mm (tooling accuracy verification).

[0085] Step 52, Parameter Fine-tuning:

[0086] If the graphic dimensions are out of tolerance: adjust the squeegee pressure (±0.05MPa) or printing speed (±0.2m / s).

[0087] If there is a misregistration: recalibrate the screen parallelism or the tooling positioning pins.

[0088] Step 53: Mass Production

[0089] Continuous screen printing of 500 pieces per batch, with 10 pieces randomly sampled from each batch (5 pieces at the beginning and 5 pieces at the end).

[0090] Acceptable standards: No broken lines or ink overflow in the printed pattern, dimensional tolerance ±0.05mm, and registration difference between slots ≤0.06mm.

[0091] Screen life monitoring: The tension is checked every 50,000 prints, and the screen is replaced when the tension drops below 22N.

[0092] The process method for improving single-machine productivity in cover plate screen printing provided by this invention brings significant benefits through the systematic optimization and coordinated operation of film design, tooling fabrication, screen parameters, and debugging procedures. These benefits are specifically reflected in the following aspects:

[0093] 1. Significantly improves single-machine capacity and production efficiency

[0094] By creating high-precision screen printing fixtures capable of supporting multiple substrates (such as 4, 6, or 8 substrates), screen printing on multiple substrates can be completed simultaneously in a single printing operation. Compared with traditional single-substrate screen printing processes, the single-machine capacity is increased by more than 300% (taking a 4-substrate fixture as an example), significantly reducing the production time and equipment occupancy cost per unit product.

[0095] The optimized film compensation design and highly stable screen reduce the frequency of debugging during the production process (the debugging time percentage drops from 15% to 7%), enabling the equipment to maintain a continuous and stable production state for a longer period of time, and further improving the overall production efficiency.

[0096] 2. Significantly improve product printing quality and consistency

[0097] The film's dual compensation design (ink extension allowance + screen stretching gradient compensation) precisely offsets the physical deformation during the printing process, ensuring that the dimensional tolerance of the final printed pattern is stably controlled within ±0.05mm, and the graphic size qualification rate is increased to over 98%, effectively solving problems such as blurred and thickened lines caused by ink diffusion.

[0098] The high-precision laser grooving fixture (groove depth tolerance ±0.05mm) ensures the positioning flatness and consistency of each substrate, making the registration accuracy error between multiple substrates ≤0.06mm, completely solving the position difference problem when printing multiple substrates, and ensuring the high consistency of products within a batch.

[0099] 3. Extend the lifespan of critical consumables and reduce production costs.

[0100] Strict screen tension control (24±1N, corner difference ≤1N) greatly improves the stress distribution of the screen, reduces local tensile deformation and fatigue damage caused by scraper friction, and increases the average service life of the screen from the traditional 50,000 cycles to more than 120,000 cycles, an extension of 140%, significantly reducing the screen replacement frequency and procurement costs.

[0101] Due to the significant increase in product qualification rate (from 82% to 98%), the product rework rate and scrap rate have been significantly reduced, saving on raw material losses such as ink and substrates, and further reducing overall production costs.

[0102] 4. Enhance process stability and repeatability

[0103] This process establishes a standardized and quantifiable parameter system (such as precise compensation amounts, tension values, and groove depth tolerances), reducing reliance on human operational experience and making the production process highly repeatable and stable. It is easily replicated and promoted in different equipment and batches, ensuring consistently stable product quality.

[0104] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A process method for increasing single-machine productivity during cover plate screen printing, characterized in that, Includes the following steps: S1, Film Production; S2, Silk screen printing tooling production; S3, screen printing; S4. Equipment debugging; S5. Product debugging and manufacturing.

2. The process method for improving single-machine productivity during cover plate screen printing according to claim 1, characterized in that, The method for producing the film is as follows: S11, Graphic Design; S12, Screen stretching compensation; S13, Output film.

3. The process method for improving single-machine productivity during cover plate screen printing according to claim 1, characterized in that, The method for manufacturing the screen printing fixture is as follows: S21. Material selection; S22, Groove machining.

4. The process method for improving single-machine productivity during cover plate screen printing according to claim 1, characterized in that, The method for creating the screen print is as follows: S31. Frame selection; S32. Determine the netting parameters; S33, Film Transfer.

5. The process method for improving single-machine productivity during cover plate screen printing according to claim 1, characterized in that, The equipment debugging method is as follows: S41. Tooling and screen installation; S42, Screen distance setting.

6. The process method for improving single-machine productivity during cover plate screen printing according to claim 1, characterized in that, The product debugging and manufacturing method is as follows: S51, Trial Printing and Testing; S52, parameter fine-tuning; S53, mass production.

7. The process method for improving single-machine productivity during cover plate screen printing according to claim 1 or 2, characterized in that, The film production process involves creating a film based on the product graphic, reserving space for ink spread during the film design stage, and also includes compensation for screen stretching tolerances.

8. The process method for improving single-machine productivity during cover plate screen printing according to claim 1 or 3, characterized in that, The screen printing fixture is manufactured as follows: a screen printing fixture capable of supporting multiple substrates to be screen printed is manufactured, and the screen printing fixture has slots for accommodating the substrates.

9. The process method for improving single-machine productivity during cover plate screen printing according to claim 1 or 4, characterized in that, The screen printing process involves creating a screen with predetermined dimensions and tension parameters.

10. The process method for improving single-machine productivity in cover plate screen printing according to claim 1 or 5, characterized in that, The equipment debugging process involves installing the screen printing fixture and screen onto the screen printing equipment and setting the screen distance.

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