Core-Sheath Screen Gauze Monofilament for UV Halation Control
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Solution Overview
Problem
Existing screen gauzes for high-definition screen printing suffer from halation due to high ultraviolet reflectance, leading to printing accuracy issues, and the dyeing process to prevent halation poses environmental concerns and requires specific dye types and ultraviolet curable resin compatibility, which complicates the process.
Innovation Solution
A core-sheath composite monofilament with a light-absorbing agent in the core and a specific reflectance of 20% or less across 300-450 nm, using a polyester core and sheath structure to prevent halation without dyeing, ensuring strength and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a light-absorbing agent is contained in the core component of a core-sheath composite monofilament to prevent halation, then the halation preventing effect is improved, but the monofilament strength deteriorates due to high concentration requirements
Solution Approach 1:
The patent applies local quality by containing the light-absorbing agent only in the core component rather than uniformly throughout the entire monofilament. This localized placement allows the sheath component to maintain high strength and abrasion resistance while the core provides the necessary light absorption to prevent halation during UV exposure.
Solution Approach 2:
The patent uses a core-sheath composite structure where the core contains the light-absorbing agent and the sheath provides mechanical strength. This composite approach allows optimization of each component for its specific function: the core for light absorption and the sheath for structural integrity, resolving the contradiction between halation prevention and strength maintenance.
2Manufacturing precision
If the reflectance is reduced to 20% or less across the entire ultraviolet wavelength region (300-450 nm) to prevent halation, then the printing accuracy is improved, but the complexity of achieving broad-spectrum absorption increases
Solution Approach 1:
The patent employs a light-absorbing agent that functions across the entire ultraviolet wavelength region (300-450 nm), providing broad-spectrum absorption with a single substance or combination. This multi-functional approach ensures uniform reflectance reduction throughout the UV range used in screen printing, simplifying the solution while achieving comprehensive halation prevention and high printing accuracy.
3Object-affected harmful factors
If a light-absorbing agent is contained in the entire fiber cross-section to prevent halation, then the halation preventing effect is improved, but the abrasion resistance deteriorates due to surface exposure
Solution Approach 1:
The patent applies local quality by restricting the light-absorbing agent to the core component only, keeping it away from the fiber surface. The sheath component forms a protective outer layer that maintains abrasion resistance, while the core provides the necessary light absorption. This spatial separation resolves the contradiction between halation prevention and surface durability.
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
The composite monofilament effectively prevents halation, allowing for high-definition printing without dyeing, maintaining strength and reducing environmental impact.
Implementation Method 1
a light-absorbing agent is contained only in the core... a reflectance in the entire region of a light wavelength of 300 nm to 450 nm is 20.0% or less
Implementation Method 2
the ultraviolet curable resin in the other part is exposed to ultraviolet rays and solidified by a photochemical reaction
Data Source
AI summary
The problem to be solved by the invention is to provide a core-sheath composite monofilament for a screen gauze, the core-sheath composite monofilament having excellent abrasion resistance when woven into a high-definition mesh fabric and excellent anti-halation effects when forming a printing pattern on a screen without requiring a dyeing process. This core-sheath composite monofilament for a screen gauze satisfies requirements (a) to (c). (a) The reflectance in the entire region having an optical wavelength of 300 to 450 nm is 20.0% or less. (b) Only the core section contains a light-absorbing agent. (c) The breaking strength is between 7.0 cN/dtex and 9.0 cN/dtex.