Digital Screen Printing Machine UV-Blocking Ink Process
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Solution Overview
Problem
The existing screen printing process is labor-intensive and inefficient, requiring multiple steps for preparing screens, including manual separation of colors, vacuum exposure, and chemical processing, which can be time-consuming and costly, especially with the need for costly film positives and extensive labor for setup and retrieval.
Innovation Solution
A digital screen printing machine that automates the process by digitally printing designs onto pre-stretched screens coated with UV-sensitive emulsion, allowing for simultaneous exposure and processing, reducing the need for manual labor and film positives by using a computer-to-screen system with UV light blocking agents and high-resolution inkjet technology for precise image generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual separation of colors and conventional screen preparation processes are used, then screen printing can be performed, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical processes with a digital printing system that uses computer-controlled inkjet printers to apply UV-blocking patterns directly to screens. This eliminates manual color separation and vacuum exposure processes, automatically printing designs onto pre-stretched screens coated with UV-sensitive emulsion.
Solution Approach 2:
The invention changes the fundamental parameters of screen preparation by using UV-sensitive emulsion that reacts to UV light blocking rather than traditional photoemulsion requiring vacuum exposure to film positives. This parameter change enables direct digital printing and eliminates multiple manual steps in the conventional process.
2Loss of time
If conventional vacuum exposure and chemical processing are used, then screen patterns are created, but the process requires extensive time and multiple steps
Solution Approach 1:
The patent merges multiple separate processes (printing, exposure, and pattern creation) into a single integrated digital printing operation. The inkjet printer applies UV-blocking ink that simultaneously serves as both the design pattern and the exposure mechanism, eliminating the need for separate vacuum exposure and chemical processing steps.
Solution Approach 2:
Screens are pre-stretched and pre-coated with UV-sensitive emulsion before the printing process. This preliminary preparation allows the digital printing step to directly create the final usable screen pattern without requiring subsequent exposure or chemical development steps.
3Ease of manufacture
If film positives and conventional materials are used, then screen patterns can be transferred, but costly materials are required
Solution Approach 1:
The patent uses digital copies of designs stored in computer memory to directly print patterns onto screens, eliminating the need for physical film positives. The digital printing system reads design data and reproduces patterns directly, removing the requirement for costly photographic film and related materials.
Solution Approach 2:
The invention replaces expensive, reusable film positives with inexpensive UV-blocking ink that is applied directly to each screen. The ink serves its purpose in a single use and is then discarded with the screen preparation process, eliminating the need for costly durable materials.
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 significantly reduces the time and labor required for screen preparation, enhances image detail and quality, and eliminates the need for vacuum hold-downs and costly film positives, resulting in a more efficient and cost-effective screen printing process.
Implementation Method 1
an applicator in fluid communication with the reservoir; a screen bed in operative alignment with the applicator; and a source of ultraviolet light in operative alignment with the screen bed... applying a quantity of the ultraviolet light blocking agent to the ultraviolet light sensitive emulsion coating
Implementation Method 2
exposing the ultraviolet light sensitive coating and the ultraviolet light blocking agent to the source of ultraviolet light... operates on a wavelength wherein a first region of a layer of emulsion deposited on an emulsion-coated, pre-stretched screen solidifies when exposed thereto
Data Source
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AI summary
A system or machine 10 is disclosed which take pre-stretched emulsion coated screens 34, digitally prints thereon and exposes them before further processing and use in a screen printing machine.