Printing Stencil Gap Structure for Narrow PV Conductor Tracks
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Solution Overview
Problem
Existing screen printing plates struggle to form narrow, straight-line structures on substrates for semiconductor components and photovoltaic solar cells while maintaining stability, durability, and high throughput, leading to inefficiencies due to variations in cross-sectional area and increased line resistance.
Innovation Solution
A planar printing stencil with defined printing gaps, featuring a larger printing medium supply region and smaller print definition region, allows for stable and precise application of printing medium, enabling the formation of narrow, straight-line structures without the need for supporting structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the printing stencil is made thicker to increase stability and durability, then the printing gap thickness increases, but this leads to disadvantages in supplying and uniformly applying the printing medium to the substrate
Solution Approach 1:
The printing stencil is segmented into two distinct functional regions within each printing gap: a printing medium supply region with larger cross-section for medium reservoir and flow, and a print definition region with smaller cross-section for precise pattern formation. This segmentation allows the stencil to maintain sufficient thickness for stability while ensuring uniform printing medium application.
Solution Approach 2:
Different regions of the printing gap are assigned different cross-sectional characteristics: the supply region has a larger cross-section optimized for medium storage and supply, while the print definition region has a smaller, precisely controlled cross-section optimized for forming narrow straight-line structures. This local differentiation resolves the contradiction between stencil thickness and printing uniformity.
2Area of stationary object
If the printing gaps are made narrower to form narrow straight-line structures, then shadowing is reduced, but the cross-sectional area variations increase leading to efficiency losses
Solution Approach 1:
The printing gap is divided into supply and print definition regions, allowing the narrow print definition region to form thin conductor tracks with minimal shadowing, while the larger supply region ensures sufficient printing medium is available to maintain consistent flow and prevent cross-sectional variations that would reduce efficiency.
3Duration of action of stationary object
If a planar printing stencil is used instead of traditional screen printing fabric, then stability and durability are improved, but the thickness of printing gaps increases affecting printing medium supply
Solution Approach 1:
The planar printing stencil incorporates a supply region with enlarged cross-section specifically designed to increase printing medium capacity and flow, while maintaining narrow print definition regions for precise patterning. This local quality differentiation allows the durable planar stencil to overcome its inherent thickness disadvantage by providing sufficient medium supply through the strategically designed supply region.
Data Source
AI summary
A printing stencil (1) for forming conductor tracks on a substrate. The printing stencil (1) has a plurality of cutouts in the form of printing gaps (4) for forming the conductor tracks. Each printing gap (4) of the plurality of printing gaps (4) has at least one print definition region (3) adjacent to the printing side and at least one printing medium supply region (2) adjacent to the squeegee side, the volume of the print definition region (3) being smaller than the volume of the printing medium supply region. Moreover, a printing device for forming conductor tracks on a substrate and a method for producing a metallic contact structure of a photovoltaic solar cell are also provided.