Two-Layer Screen Mask Structure for Precise Bezel Printing
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Solution Overview
Problem
Screen printing methods for forming bezel parts on display device cover glasses often result in defects such as thread-type and black/white spot defects due to unwanted ink residue.
Innovation Solution
A screen mask comprising a mesh with a first mask layer and a second mask layer, where the second layer is either photosensitive or non-photosensitive and partially embedded in the first layer, is used to prevent ink residue by ensuring precise ink passage and blockage, with the inner boundary of the opening matching the second mask layer boundary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer mask is used for screen printing, then the manufacturing process is simple, but ink leakage and printing defects occur
Solution Approach 1:
The mask is divided into two distinct layers: a first mask layer with openings for ink passage and a second mask layer with different thickness in different regions. This segmentation allows each layer to perform its specific function - the first layer controls where ink should pass through while the second layer prevents ink leakage at critical areas, thereby resolving the contradiction between manufacturing simplicity and printing precision.
Solution Approach 2:
The invention uses a composite mask structure combining two mask layers with different material properties and thicknesses. The first mask layer and second mask layer are composed of different materials with different thickness characteristics, creating a composite structure that simultaneously achieves precise ink passage control and effective ink leakage prevention, thus improving printing precision without significantly complicating the manufacturing process.
2Object-affected harmful factors
If thick mask layer is used to prevent ink leakage, then ink leakage is reduced, but ink passage control becomes difficult
Solution Approach 1:
The second mask layer is designed with different thicknesses in different regions - a first thickness in a first region and a second thickness in a second region. This local quality variation allows the mask to provide strong ink leakage prevention (thicker region) while maintaining precise ink passage control (thinner region with opening), thereby resolving the contradiction between preventing ink leakage and controlling ink passage.
3Productivity
If conventional screen printing is used for bezel part, then the process is simple, but defects such as thread-type and black spot defects occur
Solution Approach 1:
The mask is prepared in advance with a specific two-layer structure where the opening in the first mask layer is positioned to correspond with the boundary of the second mask layer. This preliminary action of pre-configuring the mask structure before printing ensures that ink passes through precisely at the desired location while being blocked where not needed, thereby improving printing quality without reducing printing efficiency.
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
Prevents uneven printing and ink leakage by ensuring precise ink application, thereby reducing defects in the bezel part of the cover glass.
Implementation Method 1
exposing the first emulsion layer and the second emulsion layer to a light through the mask, and developing the first emulsion layer and the second emulsion layer to form openings
Data Source
AI summary
A screen mask for screen printing and a manufacturing method of the same are disclosed. A screen mask includes a mesh, a first mask layer having a first thickness and located in a first region of the mesh, a second mask layer having a second thickness and located in a second region of the mesh, and the first mask layer has an opening adjacent to a boundary of the second mask layer.