Method for processing a full-open single-layer metal sheet printing screen

Abstract

The application provides a processing method of a full-opening single-layer metal sheet printing screen plate, which reduces the manufacturing cost of the whole printing screen plate, and the single-layer metal sheet printing screen plate can be reliably applied to silk screen printing operation. The method comprises the following steps: S1, full-opening single-layer metal sheet printing plate manufacturing, cleaning the metal sheet, and then sequentially obtaining a line, an ink storage groove and a paste outlet groove on the center printing area of the S surface of the metal sheet through an etching process, and then obtaining a pad layer hole groove on the P surface of the metal sheet through the etching process; S2, screen stretching, sticking the periphery of the single-layer metal sheet obtained in the step S1 to the screen body of a prepared false frame through high-temperature hot melt glue, and removing the overlapped screen body of the false frame and the printing area of the single-layer metal sheet; and S3, top screen, placing the completed false frame on the platform of a top screen device, fixing a metal frame in the middle of the platform, and then driving the metal frame to rise, so that the upper edges of the metal frame around the screen body of the false frame are tightly attached.

Description

Technical Field

[0001] This invention relates to the technical field of screen printing, specifically to a method for processing a fully open single-layer metal sheet printing screen. Background Technology

[0002] Existing screen printing stencils for solar cells or battery cells all use tungsten wire mesh for printing. Tungsten wire mesh is made by threading several tungsten wires through warp and weft threads. During threading, each weft thread needs to pass through the upper and lower parts of the adjacent warp thread successively to form a reliable knot. The mesh density is relatively high, and current threading methods require manual threading of each wire individually, resulting in a long production cycle. If even one knot fails to be threaded (due to failure or a broken tungsten wire), the entire mesh can be scrapped, leading to significant material waste during the mesh production process. Furthermore, the high price of tungsten wire leads to high costs for tungsten wire mesh. To address this, existing technologies have developed electroforming to manufacture metal printing sheets. However, the process of obtaining a fully open single-layer metal sheet through electroforming is costly, and if the slots on a single metal printing sheet are not positioned correctly or processing fails, the entire sheet will be scrapped, resulting in high production costs. Consequently, the production cost of single-layer metal sheet printing screens is also high, severely hindering the promotion and use of single-layer metal sheet printing screens.

[0003] Therefore, there is an urgent need to develop a processing method that can effectively reduce the cost of printing screens on metal sheets. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a processing method for a fully open single-layer metal sheet printing screen, which reduces the overall production cost of the printing screen and allows the single-layer metal sheet printing screen to be reliably applied to screen printing operations.

[0005] A method for processing a fully open single-layer metal sheet printing screen, which is obtained by processing metal sheets, is characterized by comprising the following steps: The S1 fully open single-layer metal sheet printing board is made by cleaning the metal sheet, and then obtaining the texture, ink storage tank and ink outlet tank in sequence through etching process in the central printing area of ​​the S side of the metal sheet. Then, the pad layer hole groove is obtained through etching process on the P side of the metal sheet. S2. The outer periphery of the single-layer metal sheet obtained in step S1 is glued to the prepared dummy frame mesh body using high-temperature hot melt adhesive, and the overlapping mesh body of the dummy frame mesh body and the printing area of ​​the single-layer metal sheet is removed. For the S3 top net, the composite dummy frame is placed on the platform of the top net equipment. A metal frame is fixed in the middle of the platform. Then, the metal frame is driven to rise, so that the upper edges of the metal frame and the net body of the dummy frame are tightly attached. After reaching the predetermined tension, instant adhesive is used to stick the composite metal sheet and net body to the pre-placed metal frame. After the adhesive is completely dry, the excess net body is cut off along the metal frame.

[0006] Its further features are: The thickness of the metal sheet is 0.002 mm to 0.4 mm; The metal sheet is made of stainless steel, copper foil, nickel foil, nickel-cobalt alloy, or other metal materials suitable for precision etching. When the thickness of the metal sheet is no greater than 0.02mm, in step S1, after cleaning the metal sheet, a composite substrate film is required. The substrate film is used to prevent the metal sheet from being bent or scratched during the operation. The substrate film is shrunken relative to the size of the metal sheet, thereby reserving the composite attachment edge for the mesh. When the thickness of the metal sheet is less than 0.02 mm, step S1 is as follows: after cleaning the metal sheet, a substrate film is laminated on the p side. Then, the texture, ink storage tank, and ink discharge tank are sequentially obtained on the S side of the metal sheet through an etching process. After that, a padding layer clearance hole groove is formed on the substrate film. Then, a padding layer hole groove is obtained on the P side of the metal sheet through the padding layer clearance hole groove through an etching process. In step S2, the substrate film needs to be removed after the screen is stretched. In step S1, the S-surface texture, ink reservoir, and ink discharge tank of the metal sheet are obtained through independent etching processes. Each etching process includes coating, photolithography, development, etching, cleaning, and drying. In step S1, the padding layer grooves on the P side of the metal sheet are obtained by etching after flipping the metal sheet. The padding layer grooves are set to expand outward relative to both sides of the slurry outlet, so that there is a fluid channel between the slurry outlet and the substrate to be printed, so that the slurry can be accurately and reliably printed onto the substrate surface. In step S1, the texture of the S-side of the metal sheet is obtained through an etching process as required. The texture depth is 0.002-0.005mm. The overall texture is used to facilitate the flow of paste and quickly cover the entire printing area of ​​the metal sheet. In step S2, the dummy frame is obtained in advance by stretching polyester wire mesh. The area of ​​the polyester wire mesh of the dummy frame is larger than the area of ​​the metal frame. The outer periphery of the single-layer metal sheet is adhered to the polyester wire mesh of the dummy frame by high-temperature hot melt adhesive at 150℃~200℃.

[0007] By employing this invention, the metal sheet undergoes a three-stage etching process on the S-side to obtain textures, an ink reservoir, and a paste outlet. A layer of padding grooves is then formed through etching on the P-side. This allows the paste to quickly and evenly cover the entire printing area via the textures, flowing into the ink reservoir and then through the paste outlet to the substrate surface via the layer of padding grooves. The finished metal roll is then punched to obtain a metal sheet of a predetermined shape. Subsequently, the P-side and S-side of the metal sheet are etched to obtain the corresponding textures, ink reservoir, paste outlet, and layer of padding grooves. The etching process is mature and economical, significantly reducing the processing cost of the metal sheet. Furthermore, during processing, the ink reservoir, paste outlet, and layer of padding grooves can be pre-designed according to the shape to be screen-printed, further reducing the overall production cost of the printing screen. This allows single-layer metal sheet printing screens to be reliably applied to screen printing operations. Attached Figure Description

[0008] Figure 1 This is a longitudinal sectional view of the metal sheet of the present invention; Figure 2 This is a schematic diagram of the substrate film composite process in step S1 of a specific embodiment of the present invention; Figure 3 This is a schematic diagram of the texture of the S-side of the metal sheet and the arrangement of the ink reservoir of the present invention. Figure 4 This is a schematic diagram of the slurry outlet groove (fully open area of ​​the fine grid) of the metal sheet in a specific embodiment of the present invention; Figure 5 The slurry outlet (fine grid gradient region) of the metal sheet in a specific embodiment of the present invention A schematic diagram of ( ); Figure 6 This is a top view of the printing screen obtained by the present invention; The names corresponding to the serial numbers in the diagram are as follows: Metal sheet 10, texture 101, ink reservoir 102, ink outlet 103, padding layer hole groove 104, substrate film 20, polyester wire mesh 30, metal frame 40. Detailed Implementation

[0009] The processing method for a fully open single-layer metal sheet printing screen, which is obtained by processing metal sheet 10, is described in [reference needed]. Figures 1-6 It includes the following steps: S1 is made of a fully open single-layer metal sheet printing plate. The metal sheet 10 is cleaned, and then the texture 101, ink storage tank 102 and ink discharge tank 103 are sequentially obtained in the central printing area of ​​the S side of the metal sheet through etching process. Then, the pad layer hole groove 104 is obtained on the P side of the metal sheet 10 through etching process. S2. The outer periphery of the single-layer metal sheet obtained in step S1 is glued to the prepared dummy frame mesh body using high-temperature hot melt adhesive, and the overlapping mesh body of the dummy frame mesh body and the printing area of ​​the single-layer metal sheet is removed. For the S3 top net, the composite dummy frame is placed on the platform of the top net equipment. A metal frame is fixed in the middle of the platform. Then, the metal frame is driven to rise, so that the upper edges of the metal frame and the net body of the dummy frame are tightly attached. After reaching the predetermined tension, instant adhesive is used to stick the composite metal sheet and net body to the pre-placed metal frame. After the adhesive is completely dry, the excess net body is cut off along the metal frame.

[0010] In practice, the thickness of the metal sheet 10 is 0.002mm to 0.4mm; the shape of the metal sheet 10 is obtained according to actual needs. The metal sheet 10 is made of stainless steel, copper foil, nickel foil, nickel-cobalt alloy, or other metal materials suitable for precision etching. When the thickness of the metal sheet 10 is less than 0.02 mm, in step S1, after cleaning the metal sheet, a composite substrate film 20 is required. The substrate film 20 is used to prevent the metal sheet from being bent or scratched during the operation. The substrate film 20 is shrunk in size relative to the metal sheet 10, thereby reserving the composite attachment edge for the mesh. When the thickness of the metal sheet 10 is not greater than 0.02 mm, step S1 is to clean the metal sheet 10 and then laminate a substrate film 20 on the P side. Then, on the S side of the metal sheet 10, the texture 101, the ink storage tank 102, and the ink discharge tank 103 are sequentially obtained through an etching process. After that, a padding layer clearance hole groove is formed on the substrate film 20. Then, on the P side of the metal sheet 10, a padding layer hole groove 104 is obtained through an etching process via the padding layer clearance hole groove. In step S2, the substrate film 20 needs to be removed after the screen is stretched.

[0011] In a specific embodiment, it is used for photovoltaic cell printing. The metal sheet is made of 0.02mm thick stainless steel. The metal sheet 10 is pre-processed to obtain a corresponding 30cm*30cm square shape, which includes the following steps: S1 fully open single-layer metal sheet printing plate fabrication; S101 cleaning uses a fully automatic tunnel cleaning machine to degrease and clean the surface of metal sheets. The first cleaning uses a weak alkaline cleaning agent spraying method, the second cleaning uses pure water rinsing, the third process is drying the metal sheets, and the fourth process is material collection. S102, a PET substrate film 20 is laminated onto the P side of the metal sheet 10. The substrate film 20 is applied at room temperature. The size of the substrate film 20 is 1.6-2cm smaller than that of the metal sheet to ensure that a mesh lamination surface is reserved at the outer edge of the metal sheet 10. S103, texture 102 is processed by the first etching process; S1031, first coating, the coating material is precision photoresist, the coating adopts a fully automatic roller coating method, and a precision photoresist with a thickness of 0.04mm is coated on the S side of the metal sheet through a tunnel coating and baking integrated machine, the coating speed is 0.4m / min, and the baking temperature is 50℃. S1032, the first photolithography, uses LDI photolithography equipment with a precision of 0.001mm. It etches surface textures on the metal surface covered with photoresist to increase the roughness of the metal surface and increase the friction during the printing process. The texture design is diverse, with diagonal width of 0.002mm-0.08mm, diagonal spacing of 0.01mm-0.2mm, and diagonal angle of 1-180°. The diagonal lines adopt a cross design with an intersection angle of 0-179°. In specific implementation, the texture corresponding to the diagonal lines only exists within the spacing of the fine grid lines. The texture does not need to be retained in the area where the fine grid lines extend outward by 0.0015-0.2mm on one side. S1033, first development, the development adopts a fully automatic tunnel development line; the development sequence includes the first pure water rinse, the second developer rinse, the third pure water cleaning, and the fourth drying. S1034, first etching, etching depth 0.002-0.005mm; S1035, washing and drying, using a tunnel-type automatic washing machine for rinsing, drying temperature 45±5℃, and circulating air drying; S104, the ink storage tank 102 is processed by the second etching process; S1041, Second coating: The coating material is precision photoresist. The coating is carried out by a fully automatic roller coating method. A precision photoresist with a thickness of 0.04mm is coated on the S side of the metal sheet through a tunnel coating and baking integrated machine. The coating speed is 0.4m / min and the baking temperature is 50℃. S1042, the second photolithography, uses LDI photolithography equipment with a precision of 0.001mm. The ink reservoir is photolithographically etched on the metal surface covered with photoresist. The width of the ink reservoir is 0.06mm-0.3mm. The photolithography of the ink reservoir is performed by expanding the pattern outward on one side. S1043, second development, the development adopts a fully automatic tunnel development line; the development sequence includes the first pure water rinse, the second developer rinse, the third pure water cleaning, and the fourth drying. S1044, second etching, ink reservoir depth etched 0.008-0.01mm; S1045, washing and drying, using a tunnel-type automatic washing machine for rinsing, drying temperature 45±5℃, and circulating air drying; S105, the third etching process produces slurry tank 103; S1051, Third coating: The coating material is precision photoresist. The coating is carried out by a fully automatic roller coating method. A precision photoresist with a thickness of 0.04mm is coated on the S side of the metal sheet through a tunnel coating and baking integrated machine. The coating speed is 0.4m / min and the baking temperature is 50℃. S1052, the third photolithography, uses LDI photolithography equipment with a precision of 0.001mm. The photoresist-covered ink reservoir is photolithographically etched with a paste-ejection groove, and the width of the photoresist-ejection groove is 0.008-0.01mm. S1053, third development, the development adopts a fully automatic tunnel development line; the development sequence includes the first pure water rinse, the second developer rinse, the third pure water rinse, and the fourth drying. S1054, third etching, slurry outlet depth 0.008-0.01mm, the bottom of the slurry outlet and the P surface are left with a distance L, L is 0.001-0.002mm; S1055, washing and drying, using a tunnel-type automatic washing machine for rinsing, drying temperature 45±5℃, and circulating air drying; S106, a pad layer clearance groove is formed on the substrate film 20; S1061 flips the metal sheet 10 so that the substrate film 20 is arranged facing upwards; S1062, a padding layer clearance groove is obtained on the substrate film 20 through a preset laser processing path. The laser power will not affect the metal sheet 10, and the padding layer clearance groove is set according to the shape of the padding layer clearance groove. To prevent shading and displacement, the shape of the padding layer clearance groove is expanded outward on one side. The specific processing laser parameters are shown in Table 1 and Table 2:

[0012] Table 1

[0013] Table 2 S1063, Cleaning: After laser cutting, gently wipe with an alcohol-moistened dust-free sponge to remove carbonized dust from the surface. After wiping, rinse with a tunnel-type fully automatic cleaning machine and dry. S107, the fourth etching process is used to process the high-layer hole groove 104 of the pad; S1071, Fourth Coating: The coating material is precision photoresist. The coating is carried out using a fully automatic roller coating method. A precision photoresist with a thickness of 0.04mm is coated on the P-side substrate film of the metal sheet through a tunnel coating and baking integrated machine. The coating speed is 0.4m / min and the baking temperature is 50℃. S1072, the fourth photolithography, uses LDI photolithography equipment with a precision of 0.001mm. Photolithography is performed on the substrate film surface covered with photoresist to create pad high layer holes. The pad high layer holes are set to be extended outward relative to the ink storage tank. S1073, fourth development, the development adopts a fully automatic tunnel development line; the development sequence includes the first pure water rinse, the second developer rinse, the third pure water cleaning, and the fourth drying. S1074, fourth etching, depth L of the pad layer hole groove, the pad layer hole groove penetrates the corresponding position of the slurry outlet groove. S1075, washing and drying, using a tunnel-type automatic washing machine for rinsing, drying temperature 45±5℃, and circulating air drying; S2. The polyester wire mesh 30 is pre-stretched on the dummy frame. The mesh count and wire diameter of the polyester wire mesh 30 can be matched and set according to the requirements. The outer periphery of the single-layer metal sheet 10 obtained in step S1 is bonded to the polyester wire mesh 30 of the prepared dummy frame with high-temperature hot melt adhesive at a temperature of 150℃-200℃. The overlapping polyester wire mesh 30 of the dummy frame mesh body and the printing area of ​​the single-layer metal sheet 10 is removed. For the S3 top mesh, the composited dummy frame is placed on the platform of the top mesh equipment. A metal frame 40 is fixed in the middle of the platform. Then, the metal frame 40 is driven to rise, so that the upper edges of the metal frame 40 and the polyester mesh of the dummy frame are tightly attached. After reaching the predetermined tension, instant adhesive (fast-drying cyanoacrylate adhesive) is used to stick the composited metal sheet 10 and polyester mesh 30 to the pre-placed metal frame 40. After the adhesive is completely dry, the excess polyester mesh 30 is cut off along the metal frame 40. The metal frame 40 is a 45cm*45cm electroformed aluminum frame. In specific implementation, the tension can be adjusted according to customer needs. It is also possible to choose to have force in any of the X and Y directions, with no tension or slight tension in the other direction. Metal sheet 10 can be placed in the center or off-center according to customer needs.

[0014] In a specific embodiment, the main component of the etching solution in each etching process is ferric chloride (FeCl3). The additives include corrosion inhibitors to prevent seepage, surfactants as wetting agents, and stabilizers to prevent sedimentation. The etching rate for 301B stainless steel in an environment of 40-50℃ is 0.02-0.08 mm / min. The etching time is determined according to the etching thickness, and the etching operation is carried out by spraying the etching solution.

[0015] In the text, S side refers to the squeegee side surface, and P side refers to the printing substrate side surface.

[0016] 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.

[0017] 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 method for processing a fully open single-layer metal sheet printing screen, characterized by the use of metal sheets for fabrication and processing, wherein... It includes the following steps: The S1 fully open single-layer metal sheet printing board is made by cleaning the metal sheet, and then obtaining the texture, ink storage tank and ink outlet tank in sequence through etching process in the central printing area of ​​the S side of the metal sheet. Then, the pad layer hole groove is obtained through etching process on the P side of the metal sheet. S2. The outer periphery of the single-layer metal sheet obtained in step S1 is glued to the prepared dummy frame mesh body using high-temperature hot melt adhesive, and the overlapping mesh body of the dummy frame mesh body and the printing area of ​​the single-layer metal sheet is removed. For the S3 top net, the composite dummy frame is placed on the platform of the top net equipment. A metal frame is fixed in the middle of the platform. Then, the metal frame is driven to rise, so that the upper edges of the metal frame and the net body of the dummy frame are tightly attached. After reaching the predetermined tension, instant adhesive is used to stick the composite metal sheet and net body to the pre-placed metal frame. After the adhesive is completely dry, the excess net body is cut off along the metal frame.

2. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: The thickness of the metal sheet is 0.002 mm to 0.4 mm.

3. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: The metal sheet is made of stainless steel, copper foil, nickel foil, nickel-cobalt alloy, or other metal materials suitable for precision etching.

4. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: When the thickness of the metal sheet is no more than 0.02 mm, in step S1, after cleaning the metal sheet, a composite substrate film is required. The substrate film is used to prevent the metal sheet from being bent or scratched during the operation. The substrate film is shrunken relative to the size of the metal sheet, thereby reserving the composite attachment edge for the mesh.

5. The processing method of the fully open single-layer metal sheet printing screen according to claim 4, characterized in that: When the thickness of the metal sheet is less than 0.02 mm, step S1 is to clean the metal sheet and then laminate a substrate film on the p side. Then, on the S side of the metal sheet, the texture, ink storage tank, and ink discharge tank are sequentially obtained through an etching process. After that, a padding layer clearance hole groove is formed on the substrate film. Then, on the P side of the metal sheet, a padding layer clearance hole groove is obtained through an etching process. In step S2, the substrate film needs to be removed after the screen is stretched.

6. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: In step S1, the S-surface texture, ink reservoir, and ink outlet of the metal sheet are obtained through independent etching processes. Each etching process includes coating, photolithography, development, etching, cleaning, and drying.

7. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: In step S1, the padding high-level hole groove on the P side of the metal sheet is obtained by turning the metal sheet over and then etching it. The padding high-level hole groove is set outward relative to the two sides of the slurry outlet, so that there is a fluid channel between the slurry outlet and the substrate to be printed, so that the slurry can be accurately and reliably printed onto the substrate surface.

8. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: In step S1, the texture of the S-side of the metal sheet is obtained through an etching process as required. The depth of the texture obtained is 0.002-0.005mm. The overall texture is used to facilitate the flow of paste and quickly cover the entire printing area of ​​the metal sheet.

9. The processing method of the fully open single-layer metal sheet printing screen according to claim 1, characterized in that: In step S2, the dummy frame is obtained in advance by stretching polyester wire mesh. The area of ​​the polyester wire mesh of the dummy frame is larger than the area of ​​the metal frame. The outer periphery of the single-layer metal sheet is adhered to the polyester wire mesh of the dummy frame by high-temperature hot melt adhesive at 150℃~200℃.

Images