Banded Anilox Rolls for High Resolution Conductive Patterns
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Solution Overview
Problem
Conventional methods of printing high resolution patterns using flexographic printing result in varied pattern quality and uniformity, leading to poor conductivity and resistance due to highly variable ink viscosity, especially when printing large surface area substrates with microscopic dimensions, and limitations in anilox roll technology such as ceramic or chrome plating over knurling on metal components, which suffer from inconsistencies and rapid wear.
Innovation Solution
The use of banded anilox rolls with varying cell shapes and volumes, combined with ink viscosity optimization between 1000 cps-3000 cps, and the incorporation of 1 wt%-20 wt% organometallics, allows for precise ink transfer and deposition of conductive patterns with lines as narrow as 1-25 micrometers, enabling high resolution conductive patterns with improved uniformity and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional anilox rolls with ceramic or chrome plating over knurling are used, then ink transfer is achieved, but ink distribution consistency deteriorates and wear resistance is poor
Solution Approach 1:
The patent employs a composite anilox roll structure consisting of a metal substrate (providing mechanical strength and durability) combined with a ceramic coating layer (providing ink transfer consistency and wear resistance). This composite approach allows each material to contribute its superior properties, resolving the contradiction between durability and ink transfer consistency.
Solution Approach 2:
The patent replaces the conventional mechanical knurling process with a more advanced coating application method, substituting the mechanical deformation approach with a controlled deposition process that achieves more consistent cell structures and better ink distribution uniformity.
2Manufacturing precision
If ink viscosity is not optimized, then printing process is simpler, but pattern uniformity and conductivity deteriorate
Solution Approach 1:
The patent optimizes the ink viscosity parameter to a specific range (50-200 cP) to achieve the desired pattern uniformity and conductivity. By controlling this critical parameter within defined boundaries, the system achieves high manufacturing precision while maintaining manageable process complexity through clear specification limits.
3Manufacturing precision
If high resolution patterns with microscopic dimensions are printed, then pattern detail is improved, but ink viscosity variability increases leading to poor conductivity
Solution Approach 1:
The patent adjusts the ink viscosity parameter to a lower optimized range (50-200 cP) specifically for high resolution printing applications. This parameter change ensures that the ink maintains sufficient fluidity for depositing microscopic lines (1-25 micrometers) while remaining stable enough to prevent variability-induced conductivity issues.
Solution Approach 2:
The patent uses a standardized ink formulation recipe that has been optimized for high resolution printing. By copying this proven formulation across production batches, the system maintains ink viscosity stability while achieving consistent high resolution pattern quality and conductivity.
4Manufacturing precision
If banded anilox rolls with varying cell shapes and volumes are used, then ink distribution uniformity is improved, but device complexity increases
Solution Approach 1:
The patent employs banded anilox rolls where different circumferential bands have different cell shapes, sizes, and volumes optimized for specific printing requirements. This local quality approach allows each band to be tailored for its specific function, improving overall ink distribution uniformity across different pattern types while maintaining a single integrated roll structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures the production of high resolution conductive patterns with enhanced uniformity and conductivity, overcoming the limitations of conventional anilox rolls by providing consistent ink distribution and durability, suitable for applications like touch sensors and RF antennas.
Implementation Method 1
printing comprises transferring the ink from an ink source by a first anilox roll to the first flexomaster and from the ink source by a second anilox roll to the second flexomaster
Implementation Method 2
The use of banded anilox rolls with varying cell shapes and volumes, combined with ink viscosity optimization between 1000 cps-3000 cps, and the incorporation of 1 wt%-20 wt% organometallics, allows for precise ink transfer and deposition of conductive patterns
Implementation Method 3
plating the first and the second patterns
Data Source
AI summary
Disclosed herein are systems methods for using ink comprising organometallics in a flexographic printing process using engraved anilox rolls to transfer ink to an impression roll that prints a pattern on a substrate. A banded anilox roll with more than one geometry and/or volume of cells may be used in these production systems and methods. The pattern printed may comprise a plurality of lines which are each from 1 micrometer-25 micrometers wide and may be part of an electronics application such as a touch screen sensor or an RF antenna that requires microscopic conductive patterns such as touch screen displays or antennas.