Screen Printing Apparatus with Low Tension Flexible Screen
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Solution Overview
Problem
Current 3D screen printing methods are limited to substrates with smaller radii and single-axis curvature, are complex and costly, and cannot efficiently print on both convex and concave surfaces, especially for large format substrates, due to the need for custom machinery and additional moving parts.
Innovation Solution
A screen printing apparatus with a substantially rigid, planar frame and a screen with a fixed tension of less than 20 N/cm, allowing for printing on three-dimensional substrates with varying curvatures, including concave and convex surfaces, using a standard 2D printing process with a fixed off-contact distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional 3D screen printing methods are used with extra moving parts and articulated substrates or screens, then printing on curved surfaces is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
Instead of articulating the substrate or screen to follow the curvature, the patent inverts the approach by using a rigid planar frame with a flexible screen that can conform to the substrate. The flexibility is achieved through reduced screen tension (less than 20 N/cm) and increased frame-to-substrate distance, allowing the screen to naturally adapt to curved surfaces without additional moving parts or articulation mechanisms.
Solution Approach 2:
The patent applies the principle of flexible thin films by using a screen with reduced tension that can flex and conform to the contours of three-dimensional substrates. The flexible screen material, combined with increased off-contact distance, enables the screen to adapt to various curvatures without requiring articulated mechanisms or custom-shaped frames.
2Manufacturing precision
If custom-tailored printing machines and components are used, then printing precision on specific substrate shapes is improved, but manufacturing cost increases
Solution Approach 1:
The patent achieves universality by designing a system that can print on various substrate shapes and sizes using a standard rigid planar frame and flexible screen combination. The same basic apparatus can accommodate different curvatures and formats by adjusting the off-contact distance and screen tension, eliminating the need for custom-tailored machines for each substrate type while maintaining printing precision.
Solution Approach 2:
The patent uses parameter changes, specifically reducing screen tension below 20 N/cm and increasing the off-contact distance between the frame and substrate, to enable the screen to conform to various substrate geometries. These parameter adjustments allow a single standard apparatus to achieve precision printing on diverse three-dimensional substrates without custom tooling.
3Measurement precision
If screen tension is increased to maintain screen flatness, then image resolution is improved, but ability to print on curved surfaces is reduced
Solution Approach 1:
The patent applies dynamics by transitioning from a static, high-tension screen system to a dynamic, low-tension system where the screen can adapt its shape. By reducing screen tension below 20 N/cm, the screen becomes dynamically flexible, allowing it to conform to curved substrates while maintaining sufficient tension to preserve image resolution during the printing process.
Solution Approach 2:
The patent changes the screen tension parameter from conventional high values to less than 20 N/cm, and increases the off-contact distance, creating a new operating regime where the screen maintains adequate resolution while gaining the flexibility needed to print on curved surfaces. This parameter change resolves the contradiction between flatness and adaptability.
4Manufacturing precision
If off-contact distance is reduced to maintain constant gap, then printing consistency is improved, but ability to accommodate various substrate curvatures is reduced
Solution Approach 1:
The patent moves the solution into another dimension by significantly increasing the off-contact distance between the rigid frame and the substrate. This increased distance in the vertical dimension allows the flexible screen to accommodate various substrate curvatures while maintaining consistent printing pressure and image quality, effectively decoupling off-contact distance from curvature accommodation.
Data Source
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AI summary
Disclosed herein are apparatuses for screen printing on a surface of a three- dimensional substrate comprising a substantially rigid, substantially planar frame having a perimeter defining a region within the perimeter having a given surface area; and a screen attached to the frame and extending across at least a portion of the surface area, wherein the screen comprises a first portion through which a liquid printing medium can pass onto a proximate three-dimensional substrate; and a second portion coated with an emulsion substantially preventing the liquid printing medium from passing through the second portion of the screen, wherein the screen has a fixed tension of less than about 20 N/cm. Methods and systems for screen printing on a surface of a three-dimensional substrate are also disclosed herein.