Platen Release Fluid Control for Direct to Mesh Stencil Creation
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Solution Overview
Problem
The current screen printing process for creating stencils is labor-intensive, requires numerous chemical products and water, and lacks automation, making it inefficient and prone to errors.
Innovation Solution
A Direct to Mesh (DtM) screen printing process that uses inkjet technology to directly apply and activate a UV-activated emulsion onto a screen mesh, utilizing a release fluid control system and a non-woven fabric to ensure even distribution and encapsulation of the emulsion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional screen printing stencil creation process is used, then manual operation and chemical processing are required, but the process becomes labor-intensive and requires numerous chemical products and water
Solution Approach 1:
The patent extracts and eliminates the need for traditional chemical emulsions and washing processes by directly printing UV-curable ink onto the mesh. This removes the harmful chemical substances from the stencil creation process while maintaining the essential function of creating printable stencils.
Solution Approach 2:
The patent replaces manual mechanical application of emulsion with automated inkjet printing technology. The inkjet system precisely deposits UV-curable ink droplets onto the mesh in digital patterns, eliminating manual labor and chemical processing steps.
2Adaptability or versatility
If traditional manual stencil creation process is used, then flexibility in design is maintained, but automation and precision are lost
Solution Approach 1:
The patent replaces manual stencil creation with an automated inkjet printing system that uses digital design files. This allows complete automation while maintaining design flexibility through software-based pattern generation and easy modification of digital designs.
Solution Approach 2:
The patent changes the state of the ink from traditional liquid emulsion to UV-curable ink that transitions from liquid to solid upon UV exposure. This parameter change enables automated deposition with precise control over placement and quantity, while the uncured ink remains flexible for pattern modification.
3Manufacturing precision
If traditional emulsion coating process is used, then coverage is achieved, but uneven distribution and waste occur
Solution Approach 1:
The patent replaces manual or mechanical emulsion coating with precision inkjet printing technology. The inkjet system deposits UV-curable ink droplet by droplet with precise control over placement, quantity, and distribution, eliminating uneven coating and material waste.
Solution Approach 2:
The patent applies UV-curable ink only where needed in the stencil pattern rather than coating the entire mesh surface. This localized application achieves precise coverage exactly where required, eliminating waste from coating unnecessary areas and ensuring uniform distribution through digital precision.
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 DtM process simplifies stencil creation, reduces chemical and water usage, and automates the application process, resulting in a more efficient, accurate, and cost-effective method for producing screen printing stencils.
Implementation Method 1
utilizing a release fluid control system and a non-woven fabric to ensure even distribution and encapsulation of the emulsion
Data Source
AI summary
A direct to mesh (DtM) screen printer for creating a screen stencil is provided. The DtM screen printer includes a fixture to hold a frame. which holds a pre-stretched mesh in place during application of a jettable emulsion. a platen having a cavity and an array of holes in a top surface of the platen, a non-woven fabric placed on the top surface of the platen and saturated with a release fluid located against one side of the pre-stretched mesh, and a printer carriage supporting a print head for printing the jettable emulsion on a side of the pre-stretched mesh opposite the non-woven fabric.