Patent Grant
10099471
1. Field of the Invention
The present invention relates to a mask for screen printing and methods for manufacturing the same.
2. Description of the Related Art
Heating wires are typically disposed on the rear glass (rear window or rear windshield) of an automobile to prevent or clear fogging (condensation). Specifically, two bus bars extend in the vertical direction and are disposed on the left and right sides of the rear glass. A plurality of heating wires extends in the transverse direction (horizontal direction) between the two bus bars. The pair of bus bars and the heating wires are typically applied to the rear glass by screen printing.
In addition, a border (black enamel coating or “frit”) formed by a black ceramic ink is typically disposed along the peripheral edge of the front glass (front window or front windshield) of the automobile. A main portion of the border is filled in with the ceramic ink, i.e. it is continuous and opaque, while a discontinuous pattern, e.g., made up of a plurality of dots (i.e. a dot matrix), is disposed along the inner edge of the continuous opaque band. The border is also typically applied to the front glass by screen printing.
Screen printing generally includes the following features. A printing mask is prepared by forming a liquid-impermeable resin layer (stencil or blocking stencil) on a mesh material (main mesh), such as, e.g., a woven fabric having minute openings or a metal screen. One or more through-holes (openings or open spaces) is (are) formed in the resin layer (main resin layer) in accordance with a predetermined printing pattern. The stencil with the through-hole(s) appears as a negative image of the pattern to be printed on a substrate Ink is then placed on the mesh, and a squeegee is moved (slid) across the mesh while pressing the ink and the mesh. As a result, ink passes through the through-hole(s) of the resin layer, and the predetermined pattern is printed on the substrate (material to be printed). In doing so, the ink is printed on the substrate substantially uniformly (i.e. the ink is applied with an identical thickness across the pattern), and the thickness of the ink basically corresponds to the thickness of the mesh (also referred to as the “mesh thickness”).
The bus bars disposed on the rear glass of automobiles are ordinarily designed to have one or more parts (portion(s) or area(s)) that is (are) thicker than the remaining portions of the bus bars. Specifically, the greater part of the bus bars is formed to be very thin, e.g., to minimize manufacturing costs, while one or more parts of the bus bars is (are) formed thicker than other portions, e.g., in order to moderate (reduce) the electrical resistance of the bus bars, or to provide a contact pad for an antenna terminal therein.
With respect to the border provided along the peripheral edge of the front glass of automobiles, the continuous portion of the border has to be printed thickly, since a thin border might be light permeable (i.e. the border should be opaque for aesthetic and technical reasons). Furthermore, the continuous portion (more accurately, the greater part thereof, excluding the peripheral edge) can be printed roughly (i.e. with a rough surface) without any problems. On the other hand, the dot matrix printed along the inner edge of the border has to be printed finely/precisely, since both printed and non-printed sites are intricately present within the dot matrix. That is, the dots of the dot matrix should have precise or sharp circular shapes/edges, e.g., to provide an appealing aesthetic appearance.
In order to increase the thickness of certain portions (i.e. to form thick sections) of the resulting printed pattern, conventional screen printing involves the following steps. First, screen printing is performed once, across the entire design, at the same thickness. Subsequently, only the portion(s) at which a thick section must be formed is (are) screen-printed again a second time. However, this approach is inefficient, since the screen printing operation has to be carried out twice. Furthermore, two printing masks are required, which entails higher costs. Moreover, special alignment measures/devices may be necessary to ensure that the thick portion(s) is (are) accurately printed at the intended location(s) within the think portion(s) of the printed design/structure.
As was mentioned above, the thickness of the printed ink applied by screen printing is determined by the thickness of the mesh (mesh thickness). Thus, if a relatively thick mesh is used, the amount of printing liquid (ink) that is held in the mesh (i.e. in the through-holes) is relatively large. Accordingly, the printing agent can be applied relatively thickly onto the substrate (material to be printed) using a relatively thick mesh.
Coarse or rough printing results when a mesh having a large mesh thickness is used, whereas fine (precise) printing results when a mesh having a small (thin) mesh thickness is used.
It is noted that U.S. Pat. No. 4,958,560 and its counterpart Japanese Patent Application Publication No. S63-233838 disclose a printing technique for increasing the thickness of certain portions of the printed design. This technique involves providing a local support between the screen material (main mesh) and the substrate. The local support is formed as a patch comprised of a plurality of spots, or comprised of another screen material (mesh).
However, the specific manner in which the local support (in particular, the spots) is provided in the main mesh is unclear. Furthermore, if the patch is a screen material and is bonded to the main screen (main mesh) using an adhesive, some of the adhesive may clog the openings and may thus create a printing problem if the printing agent (ink) can no longer pass through the screen.
It is an object of the present invention to disclose one or more techniques for printing one or more portions of a screen printed design more thickly than one or more other portions thereof in a simple and reliable manner.
In a first aspect of the present teachings, a screen printing mask for performing screen printing on a material to be printed on (substrate) may include a main resin layer provided on a main mesh by curing, through absorption of light, photocurable resin that is applied onto the main mesh. The main resin layer has at least one through-hole. Furthermore, at least one additional net-like section is provided on the main mesh by curing, through absorption of light, photocurable resin that is applied onto the main mesh. The additional net-like section(s) is (are) disposed within the through-hole(s) of the main resin layer.
Screen printing masks according to the present teachings can be utilized in the following manner to achieve the following functions and effects. Specifically, ink is placed on the printing mask and a squeegee is moved (slid) over the main mesh and main resin layer while pressing the ink and the main mesh. As a result, ink passes through the through-hole(s) of the main resin layer, and the material to be printed on (substrate) is printed according to the predetermined pattern defined by the main resin layer.
The thickness (mesh thickness) of the portion (which will be referred to as the “thick mesh section”) at which the additional net-like section(s) is (are) provided on the main mesh is greater than the thickness (mesh thickness) of the main mesh alone. Accordingly, more ink is held in the additional net-like section(s) than in the main mesh alone. When the ink migrates to the substrate (material to be printed on), the portion(s) of the printed design corresponding to (underneath) the thick mesh section(s) is (are) thicker than the portion(s) of the printed design corresponding to (underneath) the main mesh alone. Thus, the portion(s) of the printed material (design) that corresponds to the portion of the main mesh alone is (are) printed relatively thinly (i.e. it/they will have a thickness corresponding to the mesh thickness of the main mesh alone), whereas the portion(s) corresponding to the thick mesh section(s) is (are) printed relatively thickly (i.e. it/they will have a thickness corresponding to the mesh thickness of the thick mesh section), so that a thick section is formed in the printed design at the (each) thick mesh section.
In such a printing mask, the additional net-like section(s) is (are) provided on the main mesh by curing, through absorption of light, photocurable resin that has been applied onto the main mesh. As a result, the (each) additional net-like section becomes solidly affixed (bound) to the main mesh, without the need for any adhesive. As a result, one or more predetermined portions is (are) printed thickly (thick section(s) is (are) formed), easily and reliably, without the occurrence of problems such as positional deviation (alignment errors) of the additional net-like section(s) with respect to the main mesh, or clogging of the main mesh by an adhesive.
In a second aspect of the present teachings, the (each) additional net-like section is comprised of a first additional layer and a second additional layer disposed on (bound to) the first additional layer. The first additional layer is provided (formed), together with the main resin layer, by a photocurable resin.
In such a screen printing mask, the positional relationship of the main resin layer (through-hole) relative to the additional resin layer(s) that form(s) the additional net-like section(s) can be easily and reliably set to a predetermined positional relationship by forming the main resin layer and the first additional layer using one photomask. That is, alignment errors between the thin and thick sections of the printed designs can be reliably eliminated. The second additional layer is formed using the first additional layer, which has already been provided on the main mesh, as a guide, and is therefore provided easily and reliably at a predetermined position (i.e. aligned with the first additional layer).
Consequently, in such a screen printing mask, the positional relationship of the main resin layer (through-hole) relative to the additional resin layer can be easily set at a predetermined positional relationship. Furthermore, a (each) thick section can be easily and reliably formed, at a (each) predetermined position, on a (each) portion of the substrate (material to be printed on) that is to be printed thinly.
In another aspect of the present teachings, a screen printing mask may be produced as follows. First, in a first photocurable resin coating step, a first photocurable resin layer is formed by coating a main mesh with a photocurable resin. Then, in a first photomask overlaying step, a first photomask overlaid entity is formed by disposing, on the first photocurable resin layer, a first photomask having one or more light transmission sections corresponding to a structure of a main resin layer. Thereafter, in a first light irradiation step, a main resin layer is formed (latently formed) by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure a (each) portion, in the first photocurable resin layer, corresponding to the light transmission section(s) of the first photomask. Next, in a first uncured resin removal step, a main resin layer appears (is revealed) by removing the first photomask from the first photomask overlaid entity, and by removing uncured photocurable resin in the first photocurable resin layer.
Subsequently, in a second photocurable resin coating step, a second photocurable resin layer is formed by coating the main mesh with a photocurable resin at least in one or more through-hole(s) formed in the main resin layer. Then, in a second photomask overlaying step, a second photomask overlaid entity is formed by disposing, on the second photocurable resin layer, a second photomask having one or more light transmission sections corresponding to a structure of one or more additional net-like sections. Thereafter, in a second light irradiation step, the additional net-like section(s) is (are) formed (latently formed) by irradiating light, onto the second photomask overlaid entity from the second photomask side to thereby cure a (each) portion, in the second photocurable resin layer, corresponding to the light transmission section(s) of the second photomask. Finally, in a second uncured resin removal step, the additional net-like section(s) appear(s) (is (are) revealed) by removing the second photomask from the second photomask overlaid entity, and by removing uncured photocurable resin of the second photocurable resin layer. The screen printing mask of the first aspect can be produced easily by utilizing such a method.
In another aspect of the present teachings, a screen printing mask may be produced as follows. First, in a first photocurable resin coating step, a first photocurable resin layer is formed by coating a main mesh with a photocurable resin. Then, in a first photomask overlaying step, a first photomask overlaid entity is formed by disposing, on the first photocurable resin layer, a first photomask having one or more light transmission sections corresponding to a structure of a main resin layer. Next, in a first light irradiation step, a main resin layer is formed (latently formed) by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure a (each) portion, in the first photocurable resin layer, corresponding to the light transmission section(s) of the first photomask. Thereafter, in a first photomask removal step, the first photomask is removed from the first photomask overlaid entity.
Subsequently, in a second photocurable resin coating step, a fused (intermixed or combined) photocurable resin layer is formed together with uncured photocurable resin of the first photocurable resin layer, by further coating a (e.g., the same) photocurable resin onto the uncured photocurable resin of the first photocurable resin layer. Next, in a second photomask overlaying step, a second photomask overlaid entity is formed by disposing, on the fused photocurable resin layer, a second photomask having one or more light transmission sections corresponding to a (each) structure of one or more additional net-like sections. Then, in a second light irradiation step, one or more additional net-like sections is (are) formed (latently formed) by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a (each) portion, in the fused photocurable resin layer, corresponding to the light transmission section(s) of the second photomask. Finally, in an uncured resin removal step, the additional net-like section(s) appear(s) (is (are) revealed) by removing the second photomask from the second photomask overlaid entity, and by removing uncured photocurable resin of the fused photocurable resin layer. The screen printing mask of the first aspect can also be produced easily by utilizing such a method.
In another aspect of the present teachings, a screen printing mask may be produced as follows. First, in a first photocurable resin coating step, a first photocurable resin layer is formed by coating a main mesh with a photocurable resin. Next, in a first photomask overlaying step, a first photomask overlaid entity is formed by disposing, on the first photocurable resin layer, a first photomask having light transmission sections corresponding to a structure of a main resin layer and one or more first additional layers to form one or more foundations for one or more additional net-like sections. Then, in a first light irradiation step, the main resin layer and the first additional layer(s) are formed (latently formed) by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure the portions, in the first photocurable resin layer, corresponding to the light transmission sections of the first photomask. Subsequently, in a first uncured resin removal step, the main resin layer and the first additional layer(s) appear (are revealed) by removing the first photomask from the first photomask overlaid entity, and by removing uncured photocurable resin in the first photocurable resin layer.
Next, in a second photocurable resin coating step, a second photocurable resin layer is formed by coating the first additional layer with a (e.g., the same) photocurable resin. Thereafter, in a second photomask overlaying step, a second photomask overlaid entity is formed by disposing, on the second photocurable resin layer, a second photomask having one or more light transmission sections corresponding to one or more structures of one or more second additional layers that will be cross-linked (bound) to the first additional layer(s) to form the additional net-like section(s). Further, in a second light irradiation step, the second additional layer(s) is (are) formed (latently formed) by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a (each) portion, in the second photocurable resin layer, corresponding to the light transmission section(s) of the second photomask. Finally, in a second uncured resin removal step, the second additional layer(s) appear(s) (is (are) revealed) by removing the second photomask from the second photomask overlaid entity, and by removing uncured photocurable resin of the second photocurable resin layer. The screen printing mask of the second aspect can be produced by utilizing such a method.
In another aspect of the present teachings, a screen printing mask may be produced as follows. First, in a first photocurable resin coating step, a first photocurable resin layer is formed by coating a main mesh with a photocurable resin. Then, in a first photomask overlaying step, a first photomask overlaid entity is formed by disposing, on the first photocurable resin layer, a first photomask having light transmission sections corresponding to a structure of a main resin layer and of one or more first additional layers to form one or more foundations for one or more additional net-like sections. Next, in a first light irradiation step, the main resin layer and the first additional layer(s) are formed (latently formed) by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure the portions, in the first photocurable resin layer, corresponding to the light transmission sections of the first photomask. Subsequently, in a first photomask removal step, the first photomask is removed from the first photomask overlaid entity.
Then, in a second photocurable resin coating step, a fused (intermixed or combined) photocurable resin layer is formed together with uncured photocurable resin of the first photocurable resin layer by coating the first additional layer(s) with a (e.g., the same) photocurable resin. Thereafter, in a second photomask overlaying step, a second photomask overlaid entity is formed by disposing, on the fused photocurable resin layer, a second photomask having one or more light transmission sections corresponding to one or more structures of one or more second additional layers that will be cross-linked to the first additional layer(s) to form the additional net-like section(s). Next, in a second light irradiation step, the second additional layer(s) is (are) formed (latently formed) by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a (each) portion, in the fused photocurable resin layer, corresponding to the light transmission section(s) of the second photomask. Finally, in an uncured resin removal step, the second additional layer(s) appear(s) (is (are) revealed) by removing the second photomask from the second photomask overlaid entity, and by removing uncured photocurable resin of the fused photocurable resin layer. The screen printing mask of the second aspect can also be produced by utilizing such a method.
In another aspect of the present teachings, in the screen printing masks of the first and second aspects, the additional net-like section(s) is (are) provided on the main mesh by forming a plurality of interconnected resin pieces that are substantially perpendicular to the main mesh.
The term “substantially perpendicular” encompasses “perpendicular”. The same definition also applies to other aspects of the present teachings.
In this aspect of the present teachings, the resin pieces are more reliably prevented from coming off the main mesh, as compared with embodiments in which the resin pieces are provided individually or separately on the main mesh. The screen printing mask can thus be used over long periods of time, i.e. it is more durable.
Such a screen printing mask may be modified as follows.
The (each) first additional layer may be provided on the main mesh by forming a plurality of mutually connected first layer resin pieces that are (extend) substantially perpendicular to the main mesh.
Furthermore, the (each) second additional layer may be provided on the (each) first additional layer by forming a plurality of mutually connected second layer resin pieces that are (extend) substantially perpendicular to the main mesh.
In such a modified screen printing mask as well, the first layer resin pieces are more reliably prevented from coming off the main mesh, as compared with embodiments in which the first layer resin pieces are provided individually or separately on the main mesh. The screen printing mask can thus be used over longer periods of time, i.e. it is more durable.
In another aspect of the present teachings, in the screen printing masks of the first and second aspects, the additional net-like section(s) has (have) a honeycomb shape.
Because the additional net-like section of this embodiment has a honeycomb shape, the screen printing mask exhibits higher strength and durability, and can be used over yet longer periods of time.
Further objects, embodiments, advantages and effects of the present teachings will become apparent upon reading the following detailed description, together with drawings showing exemplary embodiments of the present teachings.
Embodiment 1A of the present teachings will first be explained with reference to
The screen printing mask (also simply referred to as “printing mask”) 10 shown in
In addition, printing masks 10 according to the present teachings also (instead) may be used (designed) to form, for instance, a border (e.g., an opaque enamel band) 522 on a front glass (front window or windshield) 500B (500) (
The filled-in portion (opaque band) is printed thickly with a rough surface to promote adhesion (this portion will be referred to herein as thick section 525B (525)), whereas other portions, e.g., the dot matrix, are printed thinly and finely (precisely). The dot matrix is designed to permit some light to pass through it and is provided to improve the aesthetic appearance and/or for shading purposes.
As illustrated in
The main mesh 20 is attached to a frame 25 (
The main resin layer 30 is attached (adhered, affixed, bound) to the lower face of the main mesh 20 (the lower face as defined in the state in which the printing mask 10 is being used to print a pattern on a substrate). The main resin layer 30 may be formed, e.g., from a photocurable resin and constitutes a stencil (blocking stencil), i.e. a liquid-impermeable layer that blocks ink (liquid) from passing through the main mesh 20 to the substrate (material to be printed on) during the screen printing operation. For example, the main resin layer 30 may be formed by curing an emulsion (a photo emulsion) of an (uncured) photocurable resin, by irradiating it with (exposing it to) a light source, such as ultraviolet light. The main resin layer 30 may be one continuous layer or may be two or more discontinuous (discrete) layers that are located in the same plane.
One or more through-holes (opening(s) or open space(s)) 35 is/are formed in the main resin layer 30 as a result of the photo emulsion process. The through-hole(s) 35 is (are) formed so as to correspond to the bus bars 520 and heating wires 510 (
One or more additional net-like sections 50A is (are) provided, on the main mesh 20, at one or more locations within the through-hole(s) 35 of the main resin layer 30. The additional net-like section(s) 50A is (are) formed and located so as to correspond to (thereby form) the thick section(s) 525A in the bus bars 520 (
The portion(s) at which the additional net-like section(s) 50A is (are) provided on the main mesh 20, i.e. the portion(s) at which the additional net-like section(s) 50A is (are) superimposed on (overlap) the main mesh 20, will also be referred to as thick mesh section(s) 15 (
As utilized herein, the term “additional net-like section” is intended to encompass structures having a lattice, network or grid structure that defines a plurality of hollow cells or columns, which are interconnected and/or share common vertical walls (i.e. walls that extend perpendicular to the plane of the main mesh 20 and the main resin layer 30). In other words, a plurality of interconnected vertical walls defines a plurality of hollow or open compartments for ink to pass through to the substrate to be printed on. The interconnected vertical walls typically exhibit polygonal shapes in horizontal cross-section, preferably regular or repeating polygonal shapes, although irregular and/or non-repeating hollow cell structures may be utilized. In other words, the net-like section(s) may be an array, grid, network, lattice or repeating structure of hollow cells wherein the vertical walls have a length (depth of the net-like section) that is greater than the thickness of the vertical walls in the horizontal cross-section (i.e. the direction parallel to the plane of the main mesh 20 and the main resin layer 30). In the horizontal cross-section through the net-like section, the through-holes or open spaces may comprise, e.g., at least 50% of the total area of the net-like section, i.e. the vertical walls comprise less than 50% of this surface area. More preferably, the through-holes or open spaces comprise at least 60% or at least 70% of the total surface area. However, variations of these structures are permissible as long as the (each) net-like section 50A is ink-permeable (i.e. it permits ink to pass through the main mesh 20 to the substrate) and the (each) net-like section 50A has a greater thickness than the main resin layer 30. Preferably, the (each) net-like section 50A is not compressible, or is not significantly compressible, when pressed during a screen printing operation. Furthermore, during the screen printing operation, the (each) net-like section 50A preferably spaces the main mesh 20 farther away from the substrate when pressed, e.g., by a squeegee or floodbar, than the main resin layer 30.
The (each) additional net-like section 50A (
In Embodiment 1A, the (each) additional net-like section 50A is formed by a first additional layer 50Aa and a second additional layer 50Ab, which is superimposed on and fused with (e.g., covalently bound to) the first additional layer 50Aa. The thickness of the first additional layer 50Aa (i.e. the length of the vertical walls in the depth direction) is, for instance, 6 μm, which is the same as or similar to the thickness of the main resin layer 30 (other than the through-hole(s) 35). The thickness of the second additional layer 50Ab (i.e. the length of the vertical walls in the depth direction) is, for instance, 60 μm. Accordingly, the combined thickness of the additional net-like section 50A is for instance 66 μm.
Thus, in the printing mask 10, the thickness (mesh thickness) of the main mesh 20 is for instance 60 μm, as described above, while the overall thickness (mesh thickness) of the thick mesh section 15 is for instance: 60 μm (thickness of the main mesh 20)+66 μm (thickness of the additional net-like section 50A)=126 μm.
The first and second additional layers 50Aa and 50Ab preferably comprise the same chemical composition and are covalently bound together by direct cross-linking, i.e. without the use of any additional adhesive having a different chemical composition.
The hollow cell structure of a first representative additional net-like section 50A will be now explained in greater detail. As illustrated in
To form the network of regular hexagonal shapes in the first additional layer 50Aa, multiple first layer resin pieces (vertical walls) 52Aa that form the respective sides of regular hexagonal shapes are vertically erected on the main mesh 20, such that adjacent first layer resin pieces 52Aa are interconnected. In the second additional layer 50Ab as well, multiple second layer resin pieces (vertical walls) 52Ab that form the respective sides of the regular hexagonal shapes are similarly erected, on the first additional layer 50Aa, perpendicularly to the main mesh 20, so that adjacent second layer resin pieces 52Ab are interconnected to each other and to the adjacent (underlying) first layer resin pieces 52Aa.
The height of the first layer resin pieces 52Aa in the first additional layer 50Aa is the thickness of the first additional layer 50Aa, and is for instance 6 μm, as described above. The height of the second layer resin pieces 52Ab in the second additional layer 50Ab is the thickness of the second additional layer 50Ab, and is for instance 60 μm, as described above.
The additional net-like section(s) 50A may have a configuration in which the network of the regular hexagonal shapes of the first additional layer 50Aa and the network of the regular hexagonal shapes of the second additional layer 50Ab match (coincide with) each other, or a configuration in which the hollow cells of the layers 50Aa, 50Ab are offset from each other. The overall size (area) of the network of the first additional layer 50Aa (the overall size (area) of the regular hexagonal shapes) may be the same as or different than the overall size (area) of the network of the second additional layer 50Ab (the overall size (area) of the regular hexagonal shapes).
A first method for manufacturing the printing mask 10 of Embodiment A1 will be explained in the following with reference to
As illustrated in
As used herein, the term “photocurable resin” is intended to encompass polymer preparations that change their properties when exposed to light, such as ultraviolet light or visible light. Typically, the change of properties results from cross-linking that causes a liquid polymer material to change into a solidified polymer layer that is affixed, adhered, bound, and/or cross-linked to the mesh 20.
Representative, non-limiting examples of polymers that may be cross-linked according to the present teachings are vinyl polymers (vinyl resins), such as polyvinyl acetate and polyvinyl alcohol. Of course, other types of cross-linking polymers may be advantageously utilized with the present teachings, as appropriate.
A sensitizer or initiator may be added to the polymer solution, e.g., to form an emulsion, in order to effect the cross-linking. For example, the sensitizer or initiator may react to (e.g. absorb) the light (e.g., UV light) and either catalyze the cross-linking or be incorporated into the cross-linked structure. Diazo compounds are often used in photo emulsions for this purpose.
Photopolymers may also be used that directly absorb light to undergo cross-linking. For example, a polyvinyl alcohol having a grafted photosensitive group may be utilized in the present teachings.
Thus, the main resin layer (stencil) 30 and the net-like section(s) 50A may be comprised of a cross-linked polymer (cross-linked resin), e.g., a cross-linked vinyl polymer (resin).
Next, as illustrated in
The image on the first photomask 60a corresponds to the structure (design) of the main resin layer 30 and the first additional layer(s) 50Aa of the additional net-like section(s) 50A (
More specifically, within the first photomask 60a, the portion(s) that correspond(s) to the through-hole(s) (open space(s)) 35 (
Within the first photomask 60a, the portion(s) that correspond(s) to the first additional layer(s) 50Aa in the additional net-like section(s) 50A, which are located within the through-hole(s) 35 (
As illustrated in
Then, the first photomask 60a is removed from the above-described first photomask overlaid entity, to yield a first photomask-removed entity (not shown). The uncured (liquid) resin 41a is removed, for instance, by immersing the first photomask-removed body in water or another solvent or by spraying the first photomask-removed body with water or another solvent. The main resin layer 30 having the through-hole(s) 35 thus appears (is revealed), as illustrated in
Thereafter, each first additional layer 50Aa (including, in some instances, a peripheral portion thereof) is coated with an emulsion of a photocurable resin, as illustrated in
Next, as illustrated in
As illustrated in
The image on the second photomask 60b corresponds to the structure (design) of the second additional layer(s) 50Ab (
Light (e.g., ultraviolet light) is then irradiated again, from the side of the second photomask 60b, onto the second photomask overlaid entity, as illustrated in
The second photomask 60b is then removed from the above-described second photomask overlaid entity, to yield a second photomask-removed entity (not shown). The uncured resin 41b is removed again as was described above, for instance, by immersing or spraying the second photomask-removed body in (with) water or another solvent. The second additional layer(s) 50Ab appear(s) (is (are) revealed) over (under, when in use) the first additional layer(s) 50Aa, as illustrated in
A second method for manufacturing the printing mask 10 will be now explained with reference to
In summary, the second manufacturing method differs from the first manufacturing method only in that the first uncured resin removal step is omitted. That is, when the first photomask 60a is removed after the first light irradiation step, additional photocurable resin 41a is disposed on the first additional layer(s) 50Aa without removing the photocurable resin 41a that remains uncured after the first light irradiation step. Otherwise, the first and second manufacturing methods may be identical, as will become apparent from the following description of the second manufacturing method.
Similar to the first manufacturing method, the main mesh 20 is prepared first, as illustrated in
As illustrated in
As illustrated in
The image (negative image) on the first photomask 60a again corresponds to the structure of the main resin layer 30 and the first additional layer 50Aa of the additional net-like section 50A (
As illustrated in
As illustrated in
Next, each first additional layer 50Aa (including, in some instances, one or more portions other than the first additional layer(s) 50Aa) is coated with an emulsion of a photocurable resin, as illustrated in
Consequently, any uncured resin 41a of the first photocurable resin layer 40a still present (including any uncured section(s) corresponding to the light transmission blocking section(s) of the first additional layer negative corresponding section(s) 65a) (
As illustrated in
The image (negative image) on the second photomask 60b again corresponds to the structure (design) of the second additional layer(s) 50Ab (
Similar to the first manufacturing method, in the second light irradiation step, light is irradiated, from the side of the second photomask 60b, onto the second photomask overlaid entity, as illustrated in
Thereafter, the second photomask 60b is removed from the above-described second photomask overlaid entity, to yield a second photomask-removed body (not shown). The uncured resin 41ab is again removed in the same manner that was described above. As illustrated in
A representative method of using the above-prepared printing mask 10, as well as the function and effects thereof, will be explained in the following with reference to FIG. 7A to
Still referring to
Then, a squeegee (floodbar) 450 is moved over the main mesh 20 while downwardly pressing the ink 300 and the main mesh 20, as illustrated in
As was described above, the thickness (mesh thickness) of the thick mesh section(s) 15 (portion(s) at which the additional net-like section(s) 50A is (are) provided on the main mesh 20) is thicker than the thickness (mesh thickness) of the main mesh 20 alone (i.e. the portion(s) where the through-hole(s) 35 is (are) provided in the main resin layer 30). Accordingly, a greater amount of ink is held in the thick mesh section(s) 15 than in the main mesh 20 (through-hole(s) 35) where there is no thick mesh section 15.
Accordingly, a relatively small amount of ink 300 migrates onto the portion(s) of the material to be printed on (substrate) 500 that correspond to (is/are underneath) the portion(s) of the main mesh 20 where only the through-hole(s) 35 are present in the main resin layer 30 (i.e. portion(s) at which the additional net-like section(s) 50A is (are) not provided). Consequently, the substrate 500 is thinly printed with the ink 300 at these locations.
On the other hand, a relatively large amount of ink 300 migrates onto the portion(s) of the substrate 500 that correspond(s) to (is/are underneath) the thick mesh section(s) 15 (portion(s) at which the additional net-like section(s) 50A is (are) provided). Consequently, the substrate 500 is thickly printed with the ink 300 at these locations.
The ink becomes uniformly thick, at the respective thinly printed portions and thickly printed portions, through bleeding (spreading) of the ink that has migrated onto the surface of the substrate 500 as described above.
Thus, one or more predetermined portions (i.e. the thick section(s) 525 (
Embodiment 1B, which is a variation of Embodiment 1A, will now be explained with reference to
As illustrated in
Embodiment 1C, which is another variation of Embodiment 1A, will now be explained with reference to
As illustrated in
Embodiment 1D, which is yet another variation of Embodiment 1A, will now be explained with reference to
As illustrated in
First layer connecting pieces 54Da may be provided to link or connect the respective ends of the first layer resin pieces 52Da to each other. Similarly, second layer connecting pieces 54Db may be provided to link or connect the respective ends of the second layer resin pieces 52Db to each other.
The first layer resin pieces 52Da of the first additional layer 50Da and the second layer resin pieces 52Db of the second additional layer 50Db extend in different directions. In the present example, the first layer resin pieces 52Da of the first additional layer 50Da are perpendicular the second layer resin pieces 52Db of the second additional layer 50Db, although the first layer resin pieces 52Da of the first additional layer 50Da may be simply oblique to the second layer resin pieces 52Db of the second additional layer 50Db.
If the two layers are perpendicular, the additional net-like section 50D as a whole has a grid-like, i.e. square (or rectangular), network.
The printing masks of Embodiment 1B to Embodiment 1D may be produced in the same way as the printing mask 10 of Embodiment 1A, may be used in the same way as the printing mask 10 of Embodiment 1A, and may exhibit similar functions and effects as the printing mask 10 of Embodiment 1A.
Embodiment 2A of the present teachings will be explained in the following with reference to
As illustrated in
The main resin layer 30 is attached to the lower face of the main mesh 20 (lower face in a state in which the printing mask 110 will be used). The main resin layer 30 is formed from a photocurable resin. One or more through-holes 35 is (are) again formed in the main resin layer 30. The (each) through-hole 35 is formed so as to correspond to the bus bars 520 and heating wires 510 (
One or more additional net-like sections 150A is (are) provided, on the main mesh 20, at one or more locations within the through-hole(s) 35 of the main resin layer 30. The additional net-like section(s) 150A is (are) formed so as to correspond to the thick section(s) 525A in the bus bars 520 (
The additional net-like section(s) 150A may also be formed from the photocurable resin that was used to form the main resin layer 30. The additional net-like section(s) 150A is (are) formed of one layer. The thickness of the additional net-like section(s) 150A is again for instance 66 μm. In the printing mask 110, the thickness (mesh thickness) of the main mesh 20 is thus for instance 60 μm, as described above, while the thickness (mesh thickness) of the thick mesh section 115 (
The additional net-like section 150A will now be explained in greater detail. As illustrated at the bottom of
A third method for manufacturing a printing mask (in this case, the printing mask 110) will be explained in the following with reference to
As illustrated in
Next, as illustrated in
The image (negative image) on the first photomask 160a corresponds to the structure (design) of the main resin layer 30 (
As illustrated in
Thereafter, the first photomask 160a is removed from the above-described first photomask overlaid entity, to yield a first photomask-removed body (not shown). The uncured resin 141a may then be removed in a manner similar to the first and second manufacturing methods described above, although in the fourth manufacturing method (described below) it is possible to omit this step. The main resin layer 30 having the through-hole(s) 35 appears (is revealed), as illustrated in
Next, the portions on the top face of the main mesh 20 (including, in some instances, the periphery of such portions), which correspond to the additional net-like sections 150A (
Next, as illustrated in
As illustrated in
The image (negative image) on the second photomask 160b corresponds to the structure (design) of the additional net-like sections 150A (
Light is then irradiated, from the side of a second photomask 160b, onto the second photomask overlaid entity, as illustrated in
Finally, the second photomask 160b is removed from the above-described second photomask overlaid entity, to yield a second photomask-removed body (not shown) and the uncured resin 141b is removed, in a manner similar to the first and second manufacturing methods described above. As illustrated in
A fourth method for manufacturing a printing mask (again, the printing mask 110) will be explained in the following with respect to
The main mesh 20 is prepared first, as illustrated in
As illustrated in
Next, as illustrated in
The image (negative image) on the first photomask 160a again corresponds to the structure (design) of the main resin layer 30 (
As illustrated in
As illustrated in
Next, without first removing the uncured resin 141a (
The newly-applied resin thus mixes and becomes integral with the uncured resin 141a (
Next, as illustrated in
The image (negative image) on the second photomask 160b again corresponds to the structure (design) of the additional net-like section(s) 150A (
Light is then irradiated, from the side of a second photomask 160b, onto the second photomask overlaid entity, as illustrated in
Next, the second photomask 160b is removed from the above-described second photomask overlaid entity, to yield a second photomask-removed body (not shown), and the uncured resin 141ab is removed, e.g., in the same manner as was described above, so that the additional net-like sections 150A appear (are revealed) over (under, when in use) the main mesh 20, as illustrated in
The printing mask 110 of Embodiment 2A may be used in the same way as the printing mask 10 of Embodiment 1A, and may exhibit similar functions and effects to those of the printing mask 10 of Embodiment 1A.
Embodiment 2B, which is a variation of Embodiment 2A, will now be explained with reference to
In this printing mask as well, an additional net-like section 150B is formed as one layer. The additional net-like section 150B as a whole has thus a grid-like, i.e. square (or rectangular), network. To form such a network, multiple first layer resin pieces 152B that form the respective sides of the squares (or rectangles) are erected perpendicularly to the main mesh 20 (
Embodiment 2C, which is another variation of Embodiment 2A, will now be explained with reference
In this printing mask as well, an additional net-like section 150C is formed as one layer. The additional net-like section 150C has a network of equilateral triangles. To form such a network, multiple first layer resin pieces 152C that form the respective sides of the equilateral triangles are erected perpendicularly to the main mesh 20 (
Embodiment 2D, which is yet another variation of Embodiment 2A, will now be explained with reference to
In this printing mask as well, an additional net-like section 150D is formed as one layer. The additional net-like section 150D has a striped shape, i.e. a shape having a plurality of parallel straight lines. Specifically, multiple resin pieces 152D that form the straight lines are erected perpendicularly to the main mesh 20 (
The printing masks in Embodiment 2B to Embodiment 2D may be produced in the same way as the printing mask 10 of Embodiment 2A, may be used in the same way as the printing mask 10 of Embodiment 2A, and may exhibit similar functions and effects to those of the printing mask 10 of Embodiment 2A.
The features described above are merely representative exemplary embodiments of the present teachings, and it should be evident that the present teachings can be carried out in forms that include various modifications based on the knowledge of a person skilled in the art.
As a variation of Embodiments 1A to 1D, for instance, the additional net-like section(s) (50A to 50D) may be formed as a combination of any one of the first additional layers 50Aa to 50Da of Embodiments 1A to 1D, and any one of the second additional layers 50Ab to 50Db of Embodiments 1A to 1D.
As a variation of Embodiment 1A to 1D, the first layer resin pieces (52Aa to 52Da) in the first additional layer (50Aa to 50Da) of the additional net-like section (50A to 50D) need not be interconnected.
Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved screen printing masks and methods of making and using the same.
Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.
All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.
Although some aspects of the present invention have been described in the context of a device or apparatus, it is to be understood that these aspects also represent a description of a corresponding method, so that a block or a component of a device or apparatus is also understood as a corresponding method step or as a feature of a method step. In an analogous manner, aspects which have been described in the context of or as a method step also represent a description of a corresponding block or detail or feature of a corresponding device.
Additional embodiments disclosed herein include but are not limited to:
1. A screen printing mask for performing screen printing on a material to be printed on, comprising a main mesh; a main resin layer provided on the main mesh by curing, through absorption of light, photocurable resin that is applied onto the main mesh, the main resin layer having a through-hole; and an additional net-like section provided on the main mesh by curing, through absorption of light, photocurable resin that is applied onto the main mesh, the additional net-like section being disposed within the through-hole of the main resin layer.
2. The screen printing mask according to the above-mentioned embodiment 1, wherein the additional net-like section has a first additional layer provided on the main mesh together with the main resin layer by curing, through absorption of light, the photocurable resin that is applied onto the main mesh, in the through-hole of the main resin layer; and a second additional layer provided on the first additional layer by curing, through absorption of light, a photocurable resin that is applied onto the first additional layer.
3. A screen printing mask manufacturing method for producing a screen printing mask that includes a main mesh, a main resin layer provided on the main mesh and having a through-hole, and an additional net-like section provided on the main mesh and within the through-hole of the main resin layer, the method comprising:
a first photocurable resin coating step of forming a first photocurable resin layer by coating the main mesh with photocurable resin;
a first photomask overlaying step of forming a first photomask overlaid entity by disposing, on the first photocurable resin layer, a first photomask having a light transmission section corresponding to a structure of the main resin layer;
a first light irradiation step of forming the main resin layer by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure a portion, in the first photocurable resin layer, corresponding to the light transmission section of the first photomask;
a first uncured resin removal step of removing the first photomask from the first photomask overlaid entity, and removing uncured photocurable resin in the first photocurable resin layer;
a second photocurable resin coating step of forming a second photocurable resin layer by coating the main mesh with photocurable resin within the through-hole of the main resin layer;
a second photomask overlaying step of forming a second photomask overlaid entity by disposing, on the second photocurable resin layer, a second photomask having a light transmission section corresponding to a structure of the additional net-like section;
a second light irradiation step of forming the additional net-like section by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a portion, in the second photocurable resin layer, corresponding to the light transmission section of the second photomask; and
a second uncured resin removal step of removing the second photomask from the second photomask overlaid entity, and removing uncured photocurable resin in the second photocurable resin layer.
4. A screen printing mask manufacturing method for producing a screen printing mask that includes a main mesh, a main resin layer provided on the main mesh and having a through-hole, and an additional net-like section provided on the main mesh and within the through-hole of the main resin layer, the method comprising:
a first photocurable resin coating step of forming a first photocurable resin layer by coating the main mesh with photocurable resin;
a first photomask overlaying step of forming a first photomask overlaid entity by disposing, on the first photocurable resin layer, a first photomask having a light transmission section corresponding to a structure of the main resin layer;
a first light irradiation step of forming the main resin layer by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure a portion, in the first photocurable resin layer, corresponding to the light transmission section of the first photomask;
a first photomask removal step of removing the first photomask from the first photomask overlaid entity;
a second photocurable resin coating step of further coating, with photocurable resin, uncured photocurable resin of the first photocurable resin layer to thereby form an intermixed photocurable resin layer together with uncured photocurable resin of the first photocurable resin layer;
a second photomask overlaying step of forming a second photomask overlaid entity by disposing, on the intermixed photocurable resin layer, a second photomask having a light transmission section corresponding to a structure of the additional net-like section;
a second light irradiation step of forming the additional net-like section by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a portion, in the intermixed photocurable resin layer, corresponding to the light transmission section of the second photomask; and
an uncured resin removal step of removing the second photomask from the second photomask overlaid entity, and removing uncured photocurable resin in the intermixed photocurable resin layer.
5. A screen printing mask manufacturing method for producing a screen printing mask that includes a main mesh, a main resin layer provided on the main mesh and having a through-hole, and an additional net-like section provided on the main mesh and within the through-hole of the main resin layer, the additional net-like section having a first additional layer and a second additional layer, the method comprising:
a first photocurable resin coating step of forming a first photocurable resin layer by coating the main mesh with photocurable resin;
a first photomask overlaying step of forming a first photomask overlaid entity by disposing, on the first photocurable resin layer, a first photomask having light transmission sections corresponding to a structure of the main resin layer and a structure of the first additional layer;
a first light irradiation step of forming the main resin layer and the first additional layer by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure portions, in the first photocurable resin layer, corresponding to the light transmission sections of the first photomask;
a first uncured resin removal step of removing the first photomask from the first photomask overlaid entity, and removing uncured photocurable resin in the first photocurable resin layer;
a second photocurable resin coating step of forming a second photocurable resin layer by coating the first additional layer with photocurable resin;
a second photomask overlaying step of forming a second photomask overlaid entity by disposing, on the second photocurable resin layer, a second photomask having a light transmission section corresponding to a structure of the second additional layer;
a second light irradiation step of forming the second additional layer by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a portion, in the photocurable resin layer, corresponding to the light transmission section of the second photomask; and
a second uncured resin removal step of removing the second photomask from the second photomask overlaid entity and removing uncured photocurable resin in the second photocurable resin layer.
6. A screen printing mask manufacturing method for producing a screen printing mask that includes a main mesh, a main resin layer provided on the main mesh and having a through-hole, and an additional net-like section provided on the main mesh and within the through-hole of the main resin layer, the additional net-like section having a first additional layer and a second additional layer, the method comprising:
a first photocurable resin coating step of forming a first photocurable resin layer by coating the main mesh with photocurable resin;
a first photomask overlaying step of forming a first photomask overlaid entity by disposing, on the first photocurable resin layer, a first photomask having light transmission sections corresponding to a structure of the main resin layer and a structure of the first additional layer;
a first light irradiation step of forming the main resin layer and the first additional layer by irradiating light onto the first photomask overlaid entity from the first photomask side to thereby cure portions, in the first photocurable resin layer, corresponding to the light transmission sections of the first photomask;
a first photomask removal step of removing the first photomask from the first photomask overlaid entity;
a second photocurable resin coating step of forming an intermixed photocurable resin layer together with uncured photocurable resin of the first photocurable resin layer, by coating the first additional layer with photocurable resin;
a second photomask overlaying step of forming a second photomask overlaid entity by disposing, on the intermixed photocurable resin layer, a second photomask having a light transmission section corresponding to a structure of the second additional layer;
a second light irradiation step of forming the second additional layer by irradiating light onto the second photomask overlaid entity from the second photomask side to thereby cure a portion, in the photocurable resin layer, corresponding to the light transmission section of the second photomask; and
an uncured resin removal step of removing the second photomask from the second photomask overlaid entity, and removing uncured photocurable resin in the intermixed photocurable resin layer.
7. The screen printing mask according to the above-mentioned embodiment 1 or 2, wherein the additional net-like section is provided on the main mesh by forming a plurality of interconnected resin pieces that are substantially perpendicular to the main mesh.
8. The screen printing mask according to the above-mentioned embodiment 1, 2 or 7, wherein the additional net-like section has a honeycomb shape.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-229608 | Nov 2014 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4958560 | Collins | Sep 1990 | A |
| 5361695 | Takagi | Nov 1994 | A |
| 5645975 | Gybin | Jul 1997 | A |
| 20090173245 | Irisawa | Jul 2009 | A1 |
| 20110259218 | Becker | Oct 2011 | A1 |
| 20130032048 | Falcon | Feb 2013 | A1 |
| 20140103563 | Gray | Apr 2014 | A1 |
| 20150101500 | van Heijningen | Apr 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| 102214725 | Oct 2011 | CN |
| 0281351 | Sep 1988 | EP |
| S63233838 | Sep 1988 | JP |
| H0392390 | Apr 1991 | JP |
| H05338369 | Dec 1993 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20160129685 A1 | May 2016 | US |
