Ceramic Ink Registration on Glass Panels
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Solution Overview
Problem
Existing methods for ceramic printing on glass panels face challenges in achieving exact registration of multiple layers, particularly when one layer contains glass frit, as the removal of the resin and plasticiser matrix during firing can lead to defects and optical distortion, and prior art lacks methods for using a single layer of glass frit to define a pattern with alternate printed and unprinted portions.
Innovation Solution
A method involving the application of multiple layers of ceramic ink to a glass panel, where one layer contains glass frit in a print pattern, subjected to heat treatment to fuse the glass frit with the glass and bind other layers, while the non-pattern layers are removed, utilizing mechanisms like gravity, capillary action, or vacuum to ensure precise registration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple layers of ceramic ink are applied to glass panels using existing methods, then the panels can be produced with various designs, but the registration of layers is not exact and defects occur during firing
Solution Approach 1:
A transfer sheet acts as an intermediary carrier that holds multiple ink layers in precise registration during application. The transfer sheet includes a release layer that allows controlled transfer of ink layers to the glass panel, ensuring exact alignment without requiring complex multi-step printing processes.
Solution Approach 2:
Multiple ink layers are pre-applied to the transfer sheet in the desired sequence and alignment before being transferred to the glass panel. This preliminary arrangement on the transfer sheet ensures that when transferred, the layers maintain exact registration, eliminating alignment issues that would occur with sequential direct printing.
2Strength
If glass frit is included in ceramic ink layers, then the ink binds to glass during firing, but the resin and plasticiser matrix removal causes optical distortion and defects
Solution Approach 1:
The firing process uses controlled parameter changes, including a two-stage temperature regime with holding periods. The first stage removes the resin and plasticiser matrix at lower temperatures, while the second stage fuses the glass frit to the glass at higher temperatures. This controlled parameter progression minimizes thermal shock and optical distortion while ensuring proper binding.
Solution Approach 2:
The firing process employs periodic action through a two-stage heating cycle with intermediate holding periods. The first stage operates at a temperature sufficient to remove organic materials, then holds to complete removal before proceeding to the second stage for frit fusion. This periodic temperature adjustment allows complete matrix removal without causing defects from rapid heating.
3Manufacturing precision
If a single layer of glass frit is used to define a print pattern, then precise pattern definition is achieved, but the removal of non-pattern layers becomes challenging
Solution Approach 1:
Non-pattern areas of the ink layers are selectively removed through the firing process. The organic matrix in non-pattern areas is completely burnt off during the first firing stage, leaving only the glass substrate. The glass frit in pattern areas remains as a binding agent, creating a clear distinction between pattern and non-pattern regions without requiring additional masking or removal steps.
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 method achieves substantially exact registration of ceramic ink layers with improved optical clarity and reduced defects, enabling the production of durable, high-strength glass panels with precise designs, such as one-way vision panels and architectural signs, by minimizing pigment migration and optical distortion.
Implementation Method 1
subjecting the sheet of glass and the plurality of layers to a heat treatment process wherein the glass frit melts and fuses with the sheet of glass
Implementation Method 2
the glass frit melts and fuses with the sheet of glass and binds the at least one other layer within the print pattern
Implementation Method 3
utilizing mechanisms like gravity, capillary action, or vacuum to ensure precise registration
Implementation Method 4
utilizing mechanisms like gravity, capillary action, or vacuum to ensure precise registration
Implementation Method 5
utilizing mechanisms like gravity, capillary action, or vacuum to ensure precise registration
Implementation Method 6
Removal of this resin and plasticiser matrix in the firing of ceramic inks
Data Source
AI summary
A glass panel is partially printed with a plurality of layers in the form of a print pattern which subdivides the panel into a plurality of discrete printed areas and/or a plurality of discrete unprinted areas, the layers being in substantially exact registration. Exact registration is achieved by the application of a plurality of superimposed layers to a sheet of glass. One layer contains-ceramic ink comprising glass frit. The glass sheet and layers are subjected to a heat treatment process which causes the glass frit to fuse to the glass and bind at least one other layer of ink within the print pattern. Ink outside the print pattern is burnt off and/or vaporised during the heat treatment process and/or removed by a subsequent finishing process, to leave the desired layers in substantially exact registration within the print pattern.