Screen Printing Form Layout for Homogeneous Narrow Paste Lines
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Solution Overview
Problem
Existing screen printing forms produce inhomogeneous structures due to junctions where woven fabric elements cross, leading to fluctuations in screen printing paste application, especially when producing narrow, straight structures, which can result in increased line resistances and reduced stability and usability.
Innovation Solution
A screen printing form with woven fabric elements arranged at specific angles and spacings, featuring a stencil with straight channels that minimize or eliminate junctions within the channel area, ensuring consistent paste application and improved stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional screen printing forms with woven fabric elements are used, then screen printing paste can be applied to substrates, but junctions where woven fabric elements cross cause inhomogeneous paste application and fluctuations in material deposition
Solution Approach 1:
The patent removes the problematic junctions by extracting only the necessary woven fabric elements to form straight channels. The screen printing form uses minimal woven fabric elements arranged in straight parallel channels, eliminating crossing points entirely. This extraction principle resolves the contradiction by removing the source of inhomogeneity (junctions) while maintaining the essential function of paste application.
Solution Approach 2:
The patent applies local quality by creating regions with different woven fabric element configurations. Straight channel regions have no junctions for homogeneous paste flow, while end regions may have junctions that do not affect the main channel quality. This localized differentiation ensures high manufacturing precision in critical areas while managing overall device complexity.
2Manufacturing precision
If 0° grids are used to eliminate junctions, then homogeneous paste application is achieved, but stability and lifetime of the screen printing form are significantly reduced
Solution Approach 1:
The patent changes the geometric parameters of the screen printing form by using straight parallel channels at specific angles (0° to 30° relative to woven fabric elements) rather than conventional 22.5° diagonals. This parameter change achieves homogeneous paste application while maintaining structural stability, resolving the contradiction between manufacturing precision and reliability.
Solution Approach 2:
The patent creates a composite structure combining straight channel geometry with woven fabric elements at optimized angles. This composite approach integrates the benefits of junction-free channels with the mechanical strength of properly angled fabric elements, achieving both homogeneity and reliability simultaneously.
3Manufacturing precision
If 0° grids are used to eliminate junctions, then paste application homogeneity improves, but production wastage increases due to faulty alignment sensitivity
Solution Approach 1:
The patent optimizes the angular parameter of channel orientation to 0°-30° relative to woven fabric elements, which provides tolerance to alignment faults. This parameter optimization reduces production wastage while maintaining paste application homogeneity, resolving the contradiction between manufacturing precision and loss reduction.
4Object-affected harmful factors
If narrow straight structures are produced with width comparable to or smaller than woven fabric element spacing, then shading and recombination losses are reduced, but fluctuations in applied paste quantity increase due to junctions
Solution Approach 1:
The patent extracts and eliminates junctions from the channel path, ensuring that even narrow structures receive uniform paste application. By removing the source of fluctuations, the patent enables production of narrow structures with both low shading effects and high paste quantity consistency.
Solution Approach 2:
The patent optimizes channel width parameters to be less than the spacing of woven fabric elements perpendicular to the channel direction. This parameter optimization ensures that narrow structures achieve low shading while the junction-free design maintains paste application consistency.
Data Source
AI summary
A screen printing form (1, 1′) for use in screen printing, in particular for producing a metallic contact structure of a photovoltaic solar cell, having a woven screen printing fabric (1b) with a plurality of elongate woven fabric elements, which are arranged in a first element direction and a second element direction perpendicular thereto, and a stencil (1c), arranged on the woven screen printing fabric (1b) that has at least one opening formed as straight channel with a channel width BK. The woven fabric elements have a spacing AF in the first element direction and a spacing which deviates by less than 5% from AF in the second element direction, and the woven fabric elements have a diameter DG in the first element direction and a diameter which deviates by less than 5% from DG in the second element direction. A screen printing device and screen printing form are also provided.