Double-Weave Screen Printing for Laminated Glass Pattern Definition
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Solution Overview
Problem
Existing screen printing processes on laminated glazing units with high surface roughness result in poor pattern definition, deformation, and uneven opacity due to the trapping and uneven distribution of the printing composition, leading to unacceptable optical density and gray levels.
Innovation Solution
A screen printing process using a screen with two superimposed fabrics, where one fabric has a smaller mesh opening than the other, with a difference in the range of 22 to 65 μm, to control ink behavior and improve opacity and optical density, while maintaining pattern definition and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen printing is performed on a sheet with high surface roughness using a conventional single-fabric screen, then the printing process can be completed, but the pattern definition deteriorates with deformation and smudging
Solution Approach 1:
The screen fabric is divided into two distinct layers with different mesh openings (first fabric: 80-120 μm, second fabric: 40-80 μm). The first fabric layer provides the primary printing function while the second fabric layer acts as a control layer to prevent ink migration and pattern deformation caused by surface roughness, thereby resolving the contradiction between maintaining pattern definition and dealing with rough surfaces.
Solution Approach 2:
The screen printing screen uses a composite structure of two different fabrics with distinct mesh characteristics. This composite screen combines the advantages of both fabrics: the larger mesh opening fabric allows adequate ink passage while the smaller mesh opening fabric controls ink distribution and prevents smudging on rough surfaces, thus improving pattern definition despite surface roughness challenges.
2Manufacturing precision
If screen printing is performed on a sheet with high surface roughness, then the printing process can proceed, but opacity deteriorates with excessive gray levels
Solution Approach 1:
The two-fabric screen structure segments the ink distribution control function. The first fabric (80-120 μm) provides adequate ink flow while the second fabric (40-80 μm) with its smaller mesh openings provides finer control over ink distribution, preventing excessive ink accumulation in surface grooves that would cause gray levels and maintain proper opacity.
Solution Approach 2:
The invention changes the mesh opening parameter by using two different values (80-120 μm and 40-80 μm) in the two fabric layers. This parameter variation allows the screen to adapt to surface roughness by controlling ink flow at two different scales, preventing both insufficient coverage and excessive ink pooling that would compromise opacity.
3Manufacturing precision
If screen printing is performed on a sheet with high surface roughness, then the printing process can be completed, but coverage deteriorates with pinholes and incomplete areas
Solution Approach 1:
The composite two-fabric screen structure ensures complete coverage by combining fabrics with complementary mesh characteristics. The first fabric (80-120 μm) provides sufficient ink flow to fill surface irregularities while the second fabric (40-80 μm) ensures uniform distribution, working together to eliminate pinholes and achieve complete coverage on rough surfaces.
4Manufacturing precision
If a single-fabric screen is used for screen printing, then the device complexity remains low, but the manufacturing precision of the printed pattern deteriorates
Solution Approach 1:
The screen is segmented into two fabric layers with different functions, where the first layer (80-120 μm) handles primary ink transfer and the second layer (40-80 μm) provides pattern refinement and smudge prevention. This segmentation improves pattern definition while maintaining a relatively simple dual-layer structure that can be manufactured and replaced as a single unit.
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 process achieves improved optical density, reduced gray levels, and uniformity in the printed pattern, enhancing the opacity and protective functions of laminated glazing units, with specific advantages in using a 28 to 43 μm mesh opening difference and polyvinyl butyral resin compositions.
Implementation Method 1
a screen printing screen comprising a part made of ink-permeable fabric, the shape of which defines the printing pattern, and a part rendered impermeable to the ink
Implementation Method 2
the fabric (I) intended to be placed opposite the face to be screen printed having a smaller mesh opening than the other fabric (S), the difference in mesh opening between the two fabrics lying in the range from 22 to 65 μm
Data Source
AI summary
The invention relates to a process for manufacturing a printed laminated glazing unit composed of two glass sheets separated by an interlayer adhesive sheet, comprising the steps consisting in screen printing, with a printing composition, at least one face of one of the sheets making up the glazing unit using a screen printing screen; and in assembling the various sheets making up the glazing unit, at least one of which has been screen printed. In this process a screen printing screen is used that comprises two superimposed fabrics, the fabric (I) intended to be placed opposite the face to be screen printed having a smaller mesh opening than the other fabric (S), the difference in mesh opening between the two fabrics lying in the range from 22 to 65 μm.