Nickel alloy wire mesh with thickened pattern edge

Abstract

The utility model discloses a nickel alloy wire mesh with a thickened pattern edge. The nickel alloy wire mesh comprises a composite area, a solid area and a pattern area, the composite area surrounds the outer edge of the screen printing plate; the solid area is arranged around the outer edge of the pattern area; the pattern area is formed by interweaving nickel alloy warps and wefts and is used for printing pattern ink penetration; the solid area and the pattern area are of an integrated structure. Seamless connection of the solid area and the graphic area is achieved through the electroforming integrated forming technology, and the problems that the edge of a traditional screen is prone to cracking and slurry leakage, and a DT adhesive tape is prone to falling off are solved through the solid thickening design; due to the adjustable design of the mesh structure, the printing precision is accurately controlled; and a photo-sensitive resist blocking procedure is omitted, and a plate making process is simplified. The utility model has the characteristics of good wear resistance, long service life, stable printing quality and the like, is suitable for high-precision printing of photovoltaic cell grid lines, and has remarkable economic benefit and application value.

Description

Technical Field

[0001] This utility model relates to the field of wire mesh technology, and in particular to a nickel alloy wire mesh with a thickened graphic edge design. Background Technology

[0002] Currently, the screen printing stencils used in the photovoltaic industry mainly rely on imported mesh fabric, which is not only costly to procure but also has a long supply cycle, severely restricting the production flexibility of the domestic photovoltaic industry. Therefore, domestic manufacturers have begun to adopt nickel alloy wire mesh. Compared with traditional materials, nickel alloy wire mesh has higher strength and wear resistance, theoretically extending the lifespan of the stencil. Regarding edge reinforcement technology, existing techniques generally use DT tape to enhance strength at the edges of the graphic, but this suffers from problems such as edge cracking, ink leakage, DT tape peeling and detachment, and poor wear resistance, leading to a significant reduction in stencil lifespan. Furthermore, the additional tape application and photosensitive adhesive sealing processes complicate the stencil-making process, increasing production costs and extending the stencil-making cycle, making it difficult to fully realize the advantages of nickel alloy wire mesh.

[0003] Chinese Patent Publication No. CN118024714A discloses a nickel alloy wire mesh for printing and its manufacturing method, which replaces traditional steel wire mesh with micro-electroforming integrated molding technology. Using a nickel alloy plate as the prototype, the process involves precise steps such as cleaning, chemical cathodic deposition electroforming, hot-melt bonding, top frame adjustment, PI film application, and laser scribing to ultimately produce a high-precision wire mesh with a wire diameter of 7-11μm. This solves the problems of uneven sizing and broken grids in high-mesh printing using traditional meshes, and offers lower costs and greater production flexibility, making it suitable for precision printing applications such as photovoltaic cells.

[0004] The aforementioned existing technology uses a nickel alloy wire mesh structure of uniform thickness, which relies on traditional weaving knots. This results in uneven ink penetration during printing and easy wear at the edges. It requires additional application of PI film to enhance edge strength, which is a complex process and carries the risk of peeling off.

[0005] Therefore, a nickel alloy wire mesh with a thickened graphic edge design is needed to solve the above-mentioned technical problems. Summary of the Invention

[0006] This invention overcomes the shortcomings of the prior art and provides a nickel alloy wire mesh with a thickened graphic edge design.

[0007] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a nickel alloy wire mesh with a thickened graphic edge design, comprising: a composite area surrounding the outer edge of the screen; a solid area surrounding the outer edge of the graphic area; the graphic area being composed of interwoven nickel alloy warp and weft threads for printing graphic ink penetration; the solid area and the graphic area are an integrated structure.

[0008] In a preferred embodiment of this invention, the composite region is an integrated composite structure of nickel alloy wire mesh and polyester mesh.

[0009] In a preferred embodiment of this utility model, the width of the composite region is 0.5-1.5cm.

[0010] In a preferred embodiment of this invention, the solid region is a solid nickel alloy layer without mesh structure, used to enhance the edge strength of the screen.

[0011] In a preferred embodiment of this invention, the outer contour shape of the solid region is consistent with the overall shape of the screen, forming a continuous closed annular structure.

[0012] In a preferred embodiment of this invention, the thickness of the solid region is 3-10 μm thicker than that of the graphic region.

[0013] In a preferred embodiment of this utility model, the longitude and latitude lines of the graphic area have a mesh count of 400-600 and a line diameter of 10μm.

[0014] In a preferred embodiment of this invention, the spacing between the meridians and parallels in the graphic area may be equal or unequal.

[0015] In a preferred embodiment of this utility model, the graphic area is provided with a slurry channel with a channel width of 100-500μm.

[0016] In a preferred embodiment of this utility model, the inner edge of the solid area is 300-600μm away from the outer edge of the graphic area, forming a smooth transition with the graphic area and connecting between the nickel alloy solid layer and the nickel alloy wire mesh.

[0017] This utility model solves the defects existing in the background technology, and has the following beneficial effects:

[0018] (1) The composite area designed in this utility model is precisely designed with a width of 0.5-1.5cm to ensure the bonding strength between the nickel alloy wire mesh and the polyester mesh, fully utilize the flexible characteristics of the polyester mesh, and improve the uniformity of screen tension. Compared with the prior art that relies on the top frame machine to continuously provide tension, the integrated composite structure of this utility model improves the initial tension stability of the screen and eliminates the need for traditional DT tape for fixation, further expanding the application range of the screen in irregular graphic printing and supporting more complex grid line design requirements.

[0019] (2) This invention achieves a breakthrough improvement in the edge performance of the screen printing plate through an innovative solid area structure design. The solid area adopts a non-mesh nickel alloy solid layer structure, and its outer contour shape is consistent with the overall screen printing plate, forming a continuous closed ring, with a thickness 3-10μm greater than that of the graphic area. This integrated design allows the edge area to maintain material continuity with the graphic area while achieving optimized stress distribution through thickness gradient changes, thus improving the wear resistance of the screen printing plate edge. Compared with the existing technology that relies on bonding PI film to enhance edge strength, this invention, through a solid metal design, completely avoids problems such as ink leakage, cracking, and DT tape detachment, lifting, and breakage at the graphic edge, reducing the edge deformation of the screen printing plate under high-speed printing conditions and extending the screen printing plate life. At the same time, the graphic edge no longer needs to be sealed with photosensitive adhesive, reducing material consumption and manual operation, which not only reduces production costs but also saves processes and shortens the plate-making cycle.

[0020] (3) This invention features a 300-600μm width transition zone between the solid and graphic areas. This thickness gradient transition not only ensures the smoothness of the printing paste from the graphic to the solid area, making the edge paste cutoff smoother and effectively eliminating edge paste accumulation, improving the uniformity of grid line width, but also guarantees structural integrity and achieves a smooth transition in mechanical properties. Compared with the existing technology that controls graphic precision through laser scribing, this invention achieves more fundamental precision assurance through structural optimization, significantly improving production stability and reducing edge smudging defects during high-viscosity paste printing.

[0021] (4) The design of the adjustable 400-600 mesh structure of the graphic area and the 100-500μm ink channel in this invention achieves a breakthrough improvement in printing accuracy. This structural feature improves the uniformity of ink penetration and reduces the breakage rate of the printed pattern. Compared with the fixed-shape mesh design in the prior art, this invention can flexibly adjust the parameters according to different printing needs, and is suitable for high-precision and high-ink-load printing of photovoltaic cell grid lines. Attached Figure Description

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments;

[0023] Figure 1 This is a schematic diagram of a nickel alloy wire mesh structure with equal warp and weft spacing, featuring a thickened graphic edge design according to this utility model.

[0024] Figure 2 This is a schematic diagram of a nickel alloy wire mesh structure with unequal warp and weft spacing, featuring a thickened graphic edge design.

[0025] In the diagram: 1. Composite area; 2. Solid area; 3. Graphic area; 4. Slurry channel. Detailed Implementation

[0026] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. These drawings are simplified schematic diagrams, which are only used to illustrate the basic structure of the present invention in a schematic manner, and therefore only show the components related to the present invention.

[0027] Example 1

[0028] like Figure 1 As shown, a nickel alloy wire mesh with a thickened graphic edge design includes: a composite region 1 surrounding the outer edge of the screen for bonding with a polyester mesh; a solid region 2 surrounding the outer edge of a graphic region 3; and a graphic region 3 composed of interwoven nickel alloy warp and weft threads for printing graphic ink penetration.

[0029] The screen in this embodiment adopts a design with equal spacing between the warp and weft lines. The warp and weft lines in graphic area 3 are both 600 mesh with a wire diameter of 10μm, forming a square mesh structure.

[0030] The solid region 2 has a width of ≥600μm and a thickness of 3-10μm greater than that of the graphic region 3. The two regions are connected by a 300-600μm width transition zone to achieve a gradient thickening, ensuring a smooth transition in mechanical properties.

[0031] The width of composite area 1 is 0.5-1.5cm. It is a composite structure of nickel alloy wire mesh and polyester mesh, which ensures uniform tension of the entire screen.

[0032] In this embodiment, the stainless steel substrate is first pretreated, including polishing, degreasing, and pickling. Then, a nickel layer is electroplated as the electroforming substrate, and the patterned area 3 is formed using a pulse electroforming process. The solid area 2 is thickened by adjusting the electroforming current density. A hot-pressing process ensures a firm bond between the nickel alloy mesh and the polyester mesh in the composite area 1.

[0033] This embodiment boasts excellent printing precision and a reduced grid breakage rate. The high-strength solid design of solid region 2 enhances its wear resistance at the silicon wafer edge, extends screen life, and meets the requirements for high-precision fine grid printing in photovoltaic cells.

[0034] Example 2:

[0035] like Figure 2 As shown, a nickel alloy wire mesh with a thickened graphic edge design includes: a composite region 1 surrounding the outer edge of the screen for bonding with a polyester mesh; a solid region 2 surrounding the outer edge of a graphic region 3; and a graphic region 3 composed of interwoven nickel alloy warp and weft threads for printing graphic ink penetration.

[0036] The difference between this embodiment and Embodiment 1 is that the screen in this embodiment adopts a design with unequal warp and weft spacing. The warp of the graphic area 3 is 600 mesh with a wire diameter of 10μm, and the weft is 400 mesh with a wire diameter of 10μm, forming a rectangular mesh structure. The graphic area 3 is provided with a paste channel 4 with a width of 100-500μm to meet the printing requirements of high viscosity paste.

[0037] The width of solid region 2 is ≥600μm, and its thickness is 3-10μm higher than that of graphic region 3. The two regions are connected by a 300-600μm transition zone to achieve a gradient thickness, ensuring structural stability and wear resistance.

[0038] The width of composite area 1 is 0.5-1.5cm. It is a composite structure of nickel alloy wire mesh and polyester mesh, which ensures uniform tension of the screen.

[0039] During the fabrication process, the substrate pretreatment was the same as in Example 1. Patterned region 3 was formed using a pulse electroforming process, while the solid region 2 was thickened by adjusting the electroforming current density. A hot-pressing composite process was used to ensure a strong bond between the nickel alloy mesh and the polyester mesh in composite region 1.

[0040] This embodiment is suitable for printing high-viscosity pastes, with excellent printing uniformity. The tensile strength of solid region 2 is much higher than that of traditional DT tape, solving the problems of tape lifting, falling off, and breakage; it eliminates the photosensitive emulsion sealing step, shortens the plate-making cycle, and significantly improves production efficiency; the screen life is extended, making it suitable for printing large-size grid lines or irregularly shaped graphics.

[0041] In use, the gradient thickening design of the solid region 2 effectively disperses stress concentration, improves edge wear resistance, and extends the screen life. The mesh structure with equal warp and weft spacing and square mesh shape is suitable for high-precision fine grid printing. The mesh structure with unequal warp and weft spacing and rectangular mesh shape, featuring ink channels 4, is suitable for printing high-viscosity inks. This design also enhances ink flowability, making it suitable for printing large-size grid lines or complex graphics. Both embodiments utilize integrated electroforming technology in the solid region 2 to solve problems such as screen edge cracking, ink leakage, and DT tape detachment, lifting, and damage, thus extending screen life. Embodiment 1 focuses on high-precision printing, while Embodiment 2 focuses on high-ink-load printing; the choice can be flexible according to actual needs, demonstrating the practicality and adaptability of this invention.

[0042] Based on the preferred embodiments of this utility model described above, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A nickel alloy wire mesh with a thickened graphic edge design, characterized in that, include: Composite region (1) surrounds the outer edge of the screen; The solid area (2) surrounds the outer edge of the graphic area (3); The graphic area (3) is composed of interwoven nickel alloy warp and weft threads, used for printing graphic ink penetration; The solid area (2) and the graphic area (3) are an integrated structure.

2. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The composite region (1) is an integrated composite structure of nickel alloy wire mesh and polyester mesh.

3. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The width of the composite region (1) is 0.5-1.5cm.

4. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The solid region (2) is a solid nickel alloy layer without mesh structure, used to enhance the edge strength of the screen.

5. The nickel alloy wire mesh according to claim 1, characterized in that: The outer contour shape of the solid area (2) is consistent with the overall shape of the screen, forming a continuous closed ring structure.

6. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The thickness of the solid region (2) is 3-10 μm thicker than that of the graphic region (3).

7. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The meridians and parallels of the graphic area (3) have a mesh count of 400-600 and a diameter of 10μm.

8. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The distances between the meridians and parallels in the graphic region (3) may be equal or unequal.

9. The nickel alloy wire mesh with a thickened graphic edge design according to claim 1, characterized in that: The graphic area (3) is provided with a slurry channel (4) with a channel width of 100-500μm.

10. The nickel alloy wire mesh according to claim 1, characterized in that: The inner edge of the solid region (2) is 300-600 μm away from the outer edge of the graphic region (3), forming a smooth transition with the graphic region (3), and connecting between the nickel alloy solid layer and the nickel alloy wire mesh.

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