Substrate Integrated Gasket Screen Printing Shape Control
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Solution Overview
Problem
The existing method of screen printing for manufacturing substrate integrated gaskets often results in an unstable cross-sectional shape and varying height of the gasket, leading to inconsistent sealing performance due to the collapse of the application layer during substrate separation.
Innovation Solution
A method involving the formation of a gasket forming paste application layer on a substrate using screen printing, followed by the application of a correcting member to adjust and cure the layer, ensuring a precise cross-sectional shape, and optionally using ultraviolet curable liquid rubber and a transparent plate for rapid curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If screen printing is used to form the application layer, then the gasket can be manufactured with relatively simple process, but the cross sectional shape becomes curved and height disperses due to layer collapse during substrate separation
Solution Approach 1:
The patent applies a release agent to the screen plate before screen printing the application layer. This preliminary action prevents the application layer from adhering to the screen plate, eliminating collapse during substrate separation and ensuring the layer maintains its intended cross-sectional shape and height consistency throughout manufacturing
Solution Approach 2:
The release agent acts as an intermediary substance between the screen plate and the application layer. This intermediary prevents direct adhesion between the paste and screen plate, allowing the application layer to be transferred to the substrate without deformation while maintaining manufacturing simplicity
2Ease of manufacture
If screen printing is used without release agent, then the process remains simple, but sealing performance becomes unstable due to height dispersion
Solution Approach 1:
The release agent is applied to the screen plate before screen printing, preventing application layer collapse during substrate separation. This ensures consistent layer height and cross-sectional shape, thereby stabilizing sealing performance while maintaining process simplicity
Solution Approach 2:
The release agent serves as a mediator that enables reliable transfer of the application layer from screen plate to substrate without adhesion issues. This intermediary ensures uniform height and shape consistency, directly improving sealing performance reliability
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 allows for the formation of gaskets with high precision and improved sealing performance by maintaining a consistent height and flat upper surface, reducing dimensional dispersion and enhancing manufacturing efficiency.
Implementation Method 1
the gasket forming paste is made of an ultraviolet curable liquid rubber, the application layer correcting member is constructed by a transparent plate, and the application layer is cured by irradiating ultraviolet light to the application layer via the application layer correcting member
Data Source
AI summary
Disclosed is a method for manufacturing a substrate-integrated gasket using screen printing. The method includes: a step for forming, on a surface of a substrate by means of screen printing, a coating layer of a paste for forming a gasket; and a step for hardening the coating layer by pressing, at a predetermined height, a coating layer correction member to the coating layer. The cross-sectional shape of the coating layer formed on the surface of the substrate is corrected by means of the coating layer correction member, and in such state, the coating layer hardens to be a gasket, thereby forming a gasket having a highly accurate cross-sectional shape.