網(wǎng)板印刷技術(shù)課件

1、網(wǎng)板印刷技術(shù)2022/7/28網(wǎng)板印刷技術(shù)網(wǎng)板印刷圖解說(shuō)明 刮刀以一定的方向推動(dòng)油墨使其通過(guò)網(wǎng)目 乳劑確定圖騰的界限及襯墊 影響出墨的是網(wǎng)目、網(wǎng)徑及乳劑基板(承印物) Substrate刮刀 Squeegee油墨I(xiàn)nk網(wǎng)目(網(wǎng)孔)Screen Mesh乳劑Emulsion細(xì)網(wǎng)目Fine Mesh粗網(wǎng)目 Coarse Mesh 網(wǎng)板印刷技術(shù)網(wǎng)印術(shù)語(yǔ)網(wǎng)目 Mesh CountNumber of wires per linear inch/cm in a screen mesh網(wǎng)目角度 Mesh AngleOrientation or “bias” of wire mesh relative to

2、the screen frame網(wǎng)版張力 Mesh TensionLevel of tightness in screen or resistance to deflection (牛頓/公分)感光乳劑 EmulsionPolymer coating in the mesh that defines and gaskets print刮刀 SqueegeePolymer blade used to move ink across and through mesh刮刀硬度 DurometerHardness or flexibility of squeegee or emulsion (Shor

3、e A units)刮刀壓力 Squeegee PressureAmount of effective, downward force applied by the squeegee刮刀行程 Squeegee TravelMechanical limit to horizontal squeegee travel across screen刮刀下刀量 DownstopMechanical limit to vertical squeegee travel to the substrate網(wǎng)板印刷技術(shù)攻角 Attack AngleForward printing angle of squeege

4、e (affects hydraulic forces)離板 Snap OffDistance between underside of screen and substrate surface回墨 FloodCoats mesh surface with fresh ink in preparation for next print一次性印刷 Print/Flood Printing in one direction with a flood coat in the opposite direction同向印刷二次 Print/Print Printing substrate w/two p

5、asses of ink, one in each direction異向印刷二次 Print/AlternatePrinting substrate w/one pass of ink, in alternating directions刮清網(wǎng)版油墨 ScavengingSqueegee edge scrapes some ink from mesh openings after transfer黏度 ViscosityInternal resistance of a fluid relative to motion under external shear流變 RheologyCharac

6、terization of viscous flow relative to shear forces and/or time網(wǎng)印術(shù)語(yǔ)網(wǎng)板印刷技術(shù)網(wǎng)版結(jié)構(gòu)說(shuō)明可再使用的網(wǎng)框 Re-usable Frame網(wǎng)布 +底層乳劑Screen Mesh +Base Coat Emulsion乳劑遮蔽區(qū)Emulsion Buildup線(xiàn)路/圖案開(kāi)口印刷區(qū)Pattern Opening網(wǎng)板印刷技術(shù)網(wǎng)板感光乳劑 聚合物與感光劑 Base Polymer & Sensitizer 聚醋酸乙烯酯(重鉻酸鹽) PVA/PVOH (Dichromate) 舊材料，環(huán)境因素考量停止使用聚醋酸乙烯酯(二氮化鹽) PVA/

7、PVOH (Diazo Salt) 一般使用，較佳的防水性或防溶劑，但通常不能同時(shí) 較慢曝光速度，標(biāo)準(zhǔn)解析度，30 天的耐儲(chǔ)時(shí)間聚醋酸乙烯酯(光聚合物) PVA (Photopolymer SBQ) 大約 1/4 曝光速度， 細(xì)緻解析度， 除醋酸鹽外，好的 防溶劑; 1年的耐儲(chǔ)時(shí)間，對(duì)水性油墨較好，極佳防刮性聚醋酸乙烯酯 PVA (Diazo/Photopolymer) 最後的技術(shù); 1/2 曝光速度，改善防溶劑，90天的耐儲(chǔ)時(shí)間 雙固化型 “Dual-Cure” 較寬的曝光範(fàn)圍提供最佳線(xiàn)的解析度，可用於許多特殊種類(lèi)未感光網(wǎng)版使用 ( For “Pre-Sensitized” screens

8、)網(wǎng)板印刷技術(shù)網(wǎng)版印刷的製版工藝 Application Methods 直接塗佈 Liquid Direct 使用最廣，但圖文輪廓邊緣易出現(xiàn)鋸齒現(xiàn)象，線(xiàn)條不太光滑但耐磨損 直接製版法 Direct Capillary Film 首先在繃緊的網(wǎng)上塗佈感光膠。陽(yáng)片上的空白區(qū)域經(jīng)光照射后在網(wǎng)版上 形成感光固化膜陽(yáng)片上圖文區(qū)域阻擋光線(xiàn)，網(wǎng)版上的膠膜未感光 用水顯影后，呈現(xiàn)出通透的網(wǎng)孔，可提供較不粗糙的圖文 間接製版法 Indirect Film 類(lèi)似直接法，間接法的感光膠不是塗佈在網(wǎng)版上，而是預(yù)先塗佈在薄片基上 對(duì)細(xì)網(wǎng)絲處理較困難，製版成本較高，耐印力低 直接/間接製版法 Direct / Dire

9、ct (Indirect) 先在薄片基上塗佈感光膠，把感光膠膜貼到繃緊的網(wǎng)上 在網(wǎng)框內(nèi)再塗佈感光膠，使感光膜同絲網(wǎng)粘合，吹乾後揭去薄片基 感光膠膜完全附著在網(wǎng)版上。 網(wǎng)板感光乳劑 網(wǎng)板印刷技術(shù)Liquid Direct網(wǎng)板感光乳劑 網(wǎng)版 Screen感光乳劑 Emulsion 塗佈乳 劑 塗 佈1. 繃好的網(wǎng)版最少存放24小時(shí)再使用2. 全面脫脂：使用軟刷且具有一定壓力的水進(jìn)行清洗3. 在低於40的溫度下烘乾4. 提前12小時(shí)將感光膠配好5. 塗膠的面積至少要比網(wǎng)框內(nèi)徑小106. 烘乾網(wǎng)版時(shí)，應(yīng)將印刷面朝下擺放網(wǎng)板印刷技術(shù)底片對(duì)位 Align Artwork底片藥膜對(duì)網(wǎng)版藥膜網(wǎng) 版底 片(藥膜

10、面)1.保持曝光機(jī)的玻璃真空橡皮布的清潔2.檢查底片是否正確3.藥膜面是否貼合網(wǎng)版4.黑度是否達(dá)到要求，擺放是否正確5.曝光機(jī)有足夠的抽真空時(shí)間6.已曝光的網(wǎng)版遠(yuǎn)離光源網(wǎng)板印刷技術(shù)UV-網(wǎng)版曝光網(wǎng) 版 Screen底 片感光乳劑曝光不足：1. 感光膠層減薄太多容易出現(xiàn)針孔2. 圖紋或?qū)Ь€(xiàn)的邊沿容易産生鋸齒3. 網(wǎng)版的耐印次數(shù)下降4. 網(wǎng)版回收難，在脫過(guò)膜的絲網(wǎng)上易出現(xiàn)圖紋陰影曝光過(guò)頭：1. 圖紋會(huì)失真，細(xì)線(xiàn)條會(huì)更細(xì)，低調(diào)網(wǎng)點(diǎn)擴(kuò)大，高光網(wǎng)點(diǎn)縮小2. 沖顯困難，漏空部分出現(xiàn)殘膠從而使油墨不過(guò)網(wǎng)孔3. 模版變脆。網(wǎng)板印刷技術(shù)顯影 & 沖 洗網(wǎng)框乳劑遮蔽區(qū)印刷區(qū)網(wǎng)版 Screen感光乳劑網(wǎng)版過(guò)早損壞的

11、原因：1.脫脂不足2.曝光之前烘乾不足3.曝光時(shí)間不足4.網(wǎng)距太高5.回墨刀過(guò)於鋒利，壓力過(guò)大6.使用了錯(cuò)誤 的清洗溶劑進(jìn)行清洗（包括少量的水源）網(wǎng)板印刷技術(shù)刮刀種類(lèi)正方形直角刮 刀 Square or “Diamond-Cut” 較堅(jiān)固與硬度，刮刀平行必須準(zhǔn)確的 More rigid vs. durometer; parallelism must be accurate 對(duì)印刷設(shè)定非常敏感，斜刮提供最大的適應(yīng)性(印刷壓力、印刷下刀角度，等) Much more sensitive to printer settings (pressure, angle of attack, etc.) 使用

12、更精確的印刷應(yīng)用(印刷區(qū)小、纖細(xì)網(wǎng)徑/間隔) Used for more precise printing applications (small area, fine lines/spaces)長(zhǎng)方形直角刮 刀 Rectangular or “Flexible” 較少敏感對(duì)刮刀平行及基板平整的變動(dòng) Less sensitive to variations in parallelism and substrate flatness 較少敏感對(duì)印刷設(shè)定(少控制在膜厚方面) Less sensitive to changes in printer settings (less control ov

13、er thickness) 主要使用在大印刷面積，高速印刷設(shè)備 Used mainly for large area graphics, high-speed printing equipment雙層或三層刮 刀 Dual or Triple “Composite” Durometer 堅(jiān)固或高硬度支持降低刮刀彈性 Rigid or high durometer backing reduces overall squeegee flexibility 允許柔軟硬度材料在正邊緣做大部份工作 Allows softer durometer material at the very edge to

14、do most of the work 對(duì)印刷設(shè)定非常敏感 Sensitive to changes in printer settings 使用導(dǎo)電油墨印刷在大面積要更精確 Used to print large area electronic inks with more precision刮刀通常是由聚氨酯製成網(wǎng)板印刷技術(shù)絲網(wǎng)印刷技能優(yōu)勢(shì) Advantages: 在不同基板添加電路製程 Additive process for electronic circuitry on various substrate types 厚的油墨少穿過(guò) VS. 噴墨或凹版印刷 Thicker ink d

15、eposits in far fewer passes versus inkjet or flexo / gravure 製造基礎(chǔ)與製程知識(shí)；成熟工業(yè) Broad base of manufacturers and process knowledge; mature industry 對(duì)新的及現(xiàn)有應(yīng)用持續(xù)更新技術(shù) Continually updated technology for new and current applicationsExamples: 改善油墨技術(shù)(細(xì)微分散 & 高級(jí)延展劑) Improvements in ink technology (finer dispersion

16、s & advanced vehicles) 非常細(xì)的鋼絲及聚合網(wǎng)可更寬廣的使用(高開(kāi)口率及張力) Ultra-fine steel & polymer wire meshes more widely available (higher open area & tension) 高速曝光、較細(xì)及平坦網(wǎng)版乳劑(較清晰輪廓) High photo-speed, thinner & flatter screen emulsion technology (better edge definition) 精密電腦影像對(duì)位技術(shù)(較大的印刷及細(xì)微電路) Precise, computer-controlle

17、d visual alignment technology for printing larger & finer circuitry 較佳的網(wǎng)線(xiàn)小的如同50微米提供選擇減去製程 Fine lines as low as 2-mil (50 micron) offer an alternative to subtractive process網(wǎng)板印刷技術(shù)印刷主要變數(shù)油墨合成物 Ink Composition 固成分 Solids Content 黏度 Viscosity 流變性 Rheology 揮發(fā)率 Evaporation Rate 散佈/型態(tài) Dispersion / Morpholog

18、y網(wǎng)板 Screen / Stencil 網(wǎng)目 Mesh Count 紗網(wǎng)直徑 Wire Diameter 開(kāi)口率 % Open Area 乳膠厚度 Emulsion Thickness 網(wǎng)板張力 Mesh Tension印刷設(shè)定 Printer Setup 刮刀硬度/形狀 Squeegee Durometer / Shape 印刷角度 Attack Angle 刮刀壓力 Squeegee Pressure 印刷速度 Print Speed 離板高度 Snap Off 設(shè)定控制 Registration Control環(huán)境/品質(zhì) Environment / Quality 室溫 Room Te

19、mperature 濕度 Humidity 氣流 Air Turbulence 潔淨(jìng) Cleanliness 基板表面 Substrate Surface 儲(chǔ)存時(shí)間 Shelf Life (Ink & Screens)網(wǎng)板印刷技術(shù)AISI Type 304 Stainless Steel網(wǎng) 目 規(guī) 格網(wǎng)板印刷技術(shù)網(wǎng)布選擇 Screen Mesh Selection公式 Formula% Open = (a - b)2 a2abExample: 200 Mesh (網(wǎng)目數(shù)) a = 1/200 = .005”絲徑 Wire Diameter 開(kāi)口率 % Openb = .0021”(.005 -

20、 .0021)2= 33.6% .0052b = .0016” = 46.2%b = .0014”= 51.8%cInkcInk網(wǎng)板印刷技術(shù)網(wǎng) 布 參 數(shù)%Open: 開(kāi)口率 = (a - b)2 =(1-a*b) = (a*c) a2b: 絲徑 Wire Diameter a: 網(wǎng)目數(shù) Mesh Count c: 網(wǎng)目開(kāi)口.=1/ a-bl: 最小線(xiàn)距= (1+a*b)/ ah: 最小線(xiàn)寬=1/ ar: 切變速率=2*t*v/cabcInklh網(wǎng)板印刷技術(shù)t cv刮刀 Squeegee 油墨 Ink S網(wǎng)版乳劑Stencil TIS基板 Substrate %Open: 開(kāi)口率 =(1-a*

21、b) = (a*c) t : 網(wǎng)布厚度T : 油墨印刷總厚 = Ih+Sh S : 乳劑膜厚I : 網(wǎng)目中膜厚 = t*A= t*(1-a*b) a : 網(wǎng)目數(shù)c : 網(wǎng)目開(kāi)口 = 1/ a-b v : 刮印刀速度r : 切變速率= 2*t*v/c網(wǎng) 布 參 數(shù)網(wǎng)板印刷技術(shù)網(wǎng)目 Mesh vs. 厚度 Thickness Mesh Wire Mesh Mesh Open Wet Print Count Diameter Thickness Opening Area Thickness(#/inch) (mils) (mils) (mils) (%) (microns) 200 2.1 4.4

22、2.9 33.6 25 200 1.6 3.4 3.4 46.2 26 250 1.4 2.9 2.4 42.3 21 325 1.1 2.3 2.0 41.3 16 較厚的網(wǎng)徑增加網(wǎng)目厚度=轉(zhuǎn)印長(zhǎng)柱狀油墨 Thicker wire increases mesh thickness for a given mesh count = taller columns of ink transferred 然而，厚的網(wǎng)徑減少開(kāi)口率=分離的窄柱狀油墨空間 However, thicker wire also reduces % open area = narrower columns of ink sp

23、aced farther apart 避免使用過(guò)粗的網(wǎng)徑在精密印刷的應(yīng)用 Avoid using “heavy duty” wire in precision printing applications 使用網(wǎng)目與網(wǎng)徑適用於乳劑增長(zhǎng)獲得印刷膜厚 Use the mesh count/wire diameter in proportion to the emulsion buildup to obtain print thickness網(wǎng)板印刷技術(shù)網(wǎng)徑 Wire Diameter200m .0021” 網(wǎng)徑 Wire .0533mm200m .0014” 網(wǎng)徑 Wire .0356mm粗網(wǎng)徑 T

24、hicker Wire 較小開(kāi)口率 Lesser open area 細(xì)長(zhǎng)窄柱狀Taller. narrower columns 增大網(wǎng)目印 Increased mesh marks 增加針孔 Increased pinholes & voids細(xì)網(wǎng)徑 Thinner Wire 較大開(kāi)口率 Greater open area 寬短粗柱狀Shorter, wider columns 減少網(wǎng)目印 Reduced mesh marks 減少針孔 Reduced pinholes & voids油墨柱狀 Ink Columns網(wǎng)板印刷技術(shù)開(kāi)口率 Open Area vs. 網(wǎng)徑 Wire Diamet

25、er34 %46 %52 %.0406mm/.0016 “.0356mm/.0014 “ 油墨的轉(zhuǎn)印抬版最佳化於纖細(xì)網(wǎng)徑及較大的開(kāi)口率 Ink transfer and peel is best with finer wires and higher % open area 在網(wǎng)目最小開(kāi)口必須大於油墨最大粒子的2.5倍 Minimum opening in mesh should be greater than 2.5x the largest ink particle 粗網(wǎng)徑促成網(wǎng)印、針孔、不完整乳膠缺口 Coarser wires contribute to mesh marks, pin

26、 holing, and incomplete emulsion washout 開(kāi)口率及網(wǎng)徑影響剪力適用於油墨 Open area % & wire diameter affect shear forces applied to an ink在轉(zhuǎn)角處殘留乳膠 (Leftover emulsion in corners)200 mesh.0533mm/.0021 “網(wǎng)板印刷技術(shù)網(wǎng)目角度 Mesh Angle.196mm/.008”.076mm/.003”0.254mm/.010”.152mm/.006”90oMeshAngle45oMeshAngle 實(shí)際線(xiàn)寬規(guī)格從插圖舉例 Actual li

27、ne width specifications from artwork in this example are .010” & .006” 偶爾，關(guān)於線(xiàn)路/圖騰網(wǎng)徑將干擾乳膠的沖洗依照網(wǎng)目角度，引起線(xiàn)寬規(guī)格降低 Occasionally, wires will interfere with emulsion washout depending on the angle of the mesh in relation to the pattern, causing line width specifications to decrease.網(wǎng)板印刷技術(shù)斜網(wǎng)或刮印刀打斜印刷之利益有機(jī)械利益(Me

28、chanical Advantage) 機(jī)械利益 = Cos (Mechanical Advantage)刮印刀受到支持 (Squeegee Support) 刮印刀squeegee 成像Image刮印刀未受膜厚支持Squeegee unsupported by stencil刮印刀受膜厚支持Squeegee supported by stencil網(wǎng)板印刷技術(shù)22.5Image網(wǎng)目Mesh刮刀Squeegee 刮印方向 Direction of Squeegee Movement刮印刀打斜(Skew)一般約 610斜張網(wǎng) 22.5或45 (圖案正貼)斜張網(wǎng)及打斜印刷不但可增加油墨印刷時(shí)的剪力

29、(Cos ),也能減低平行印刷時(shí)因刮印刀隨著線(xiàn)路高低起伏所形成“洗衣搓板”效應(yīng),造成印刷油墨混入氣泡.所以可得到比較好的解像度及邊緣準(zhǔn)值性,並有助於氣泡,跳印(Skipping),髒印(Smearing)等之消除.網(wǎng) 版印刷邊緣易變形使用斜刮網(wǎng)板印刷技術(shù)網(wǎng)印離板距離 Snap-Off Distance基板 Substrate網(wǎng)板 Screen外框尺寸 Nominal Snap-Off Typical Frame Size 200 : 1 (mils) Range5 x 5” 25 20 - 308 x 10 45 30 - 5012 x 12 60 50 - 7015 x 15 75 70 -

30、 9029 x 29 145140 - 200 Typical range for a 325-mesh, 1.1 mil wire screen with print area 50% of frame width. Snap-off distance depends on durability of mesh, initial tension, & maximum print area. Consult with screen supplier for recommended snap-off settings.網(wǎng)板印刷技術(shù)不良的網(wǎng)印離板SqueegeeaInk VolumeHigh= L

31、ength of screen behind squeegee not released距離根據(jù)於 Distance (a) depending on: 印刷區(qū)域與網(wǎng)框大，網(wǎng)距大 Print area vs. frame size 油墨黏度及擾變性 Ink viscosity & rheology 刮刀速度 Squeegee speed 網(wǎng)版張力大，網(wǎng)距則小 Screen tension 刮刀前的油墨量 Amount of ink in front of squeegee 網(wǎng)徑與網(wǎng)目 Wire diameter vs. mesh count 網(wǎng)距小不能立即彈離工件，使圖紋增髒 Snap-off

32、 setting 刮刀壓力與液壓 Squeegee pressure vs. hydraulic force抬版力量太小Less Peel Force印刷速度過(guò)快Print Speed High離版距離太低Snap-Off Low工作壓力過(guò)低Working Pressure Low網(wǎng)板印刷技術(shù)網(wǎng)印離板最佳化Squeegeea距離減少於 Distance (a) reduced by: 最大的印刷區(qū)低於網(wǎng)版面積 50% Maximum print area 50% of frame 降低印刷速度符合黏度 Reducing print speed to match viscosity 維護(hù)適當(dāng)?shù)木W(wǎng)

33、版張力 Maintaining proper screen tension 有限的網(wǎng)版油墨使用量 Limiting amount of ink on screen 離版由相關(guān)的網(wǎng)版張力設(shè)定 Setting snap-off relative to screen tension 選擇適合的網(wǎng)目規(guī)格 Selecting proper mesh specifications 增加充分的刮刀壓力 Adding sufficient squeegee pressure 保持網(wǎng)版上油墨的變乾狀況 Keeping ink from drying out on screen最大抬版力量Greater Peel

34、 Force有效的印刷力量Efficient Printing Forces網(wǎng)板印刷技術(shù)基板 (Substrate)網(wǎng)框 (Frame)OCDFOCD = Off Contact Distance (駕空距離)OCDIDDLPOCDP成像 (Image)ID : 網(wǎng)框內(nèi)部尺寸D : 刮印刀與網(wǎng)框之距離OCD: 離版距離 Snap Off Distance LP : 已被拉伸之網(wǎng)布長(zhǎng)度P : 成像變形量E : 伸張長(zhǎng)度LP = D+OCD + (ID-D) +OCD If DID/2 then P = E*1-D/(ID-D)If DID/2 then P = E*1-(ID-D)/DE = L

35、P-ID離板高度 Snap-Off Distance網(wǎng)板印刷技術(shù)網(wǎng)印刮刀行程 ( squeegee flood )( flood bar )印刷 Print停止 StopPeel 停止Stop回墨 Flood 3 cm 3 cm網(wǎng)板印刷技術(shù)刮刀跨距Squeegee Holder 刮刀長(zhǎng)度小於網(wǎng)版50%距離 Maximum squeegee length 50% of frame width (a) 印刷區(qū)包括0.5cm 未在印刷區(qū)的刮刀 Minimum 0.5 cm overhang of usable squeegee over print area (b) 基板小於等於刮刀0.5cm Cu

36、t squeegee to limit overhang of substrate to 0.5 cm (c)bca張力 Tension有效寬度 20mm30mm有效寬度要增加（有時(shí)大於30mm）、硬度降低，印刷速度降低並且要增加印刷角度網(wǎng)板印刷技術(shù)平行刮刀及行程 Parallel Squeegee & Travel使用刮刀時(shí)浮動(dòng)樞軸必須置中( Floating pivot must be centered to usable squeegee edge ) FloatingFixedFixedTool PlateTension網(wǎng)板印刷技術(shù)刮刀下刀量 .13mm - .18mm正確 Corre

37、ct過(guò)高 Too High過(guò)低 Too Low 漏印 Voiding / Starving 過(guò)多印刷厚度 Excessive print thickness 差的厚度控制 Poor thickness control 印記 Coining 撐大 Stretching 刺破 Punctures 差印刷解析 Poor print resolution網(wǎng)板印刷技術(shù)刮刀尺寸 Squeegee Size & 下刀量 Downstop過(guò)多的刮刀及下刀量Excessive Overhang & Downstop不足的刮刀及下刀量Insufficient Overhang & Downstop 增加刮刀在網(wǎng)目

38、拖網(wǎng) Squeegee drag on mesh increased 中央印厚 Thicker print in the center 導(dǎo)致網(wǎng)目印記 Leads to “coining” of screen mesh 網(wǎng)版張力拉至邊緣 Screen tension pulls at the edges 邊緣印厚 Thicker print at the edges 嚴(yán)重缺印在邊緣 Severe voiding may occur at edges網(wǎng)板印刷技術(shù) 刮刀夾具(Squeegee Holder) 刮刀刀片(Squeegee Blade) 攻角()(Angle of Attack) 刮刀壓

39、力(Squeegee Pressure) 網(wǎng)布(Screen)網(wǎng)框(Frame)刮刀硬度 Durometer 刮刀太硬無(wú)法有效貼合印刷物起伏面,太軟不易維持該壓力下應(yīng)有的攻角攻角() Attack Angle 不宜太大以防刮刀太接近垂直而失去施加壓力時(shí)應(yīng)有之彈性刮刀壓力 Squeegee Pressure 設(shè)定宜低,在既定速度及攻角不變下,只要保持網(wǎng)板與基板可連續(xù)接觸即可刮刀速度 Squeegee Speed 在可能情況下,刮印速度要快,以符合油墨黏度及網(wǎng)布所產(chǎn)生的剪速.但需避免印墨不均勻的現(xiàn)象網(wǎng)板印刷技術(shù)印刷/圖騰歪曲 Print / Pattern Distortion網(wǎng)版拖長(zhǎng)/刮刀拖拉

40、Screen Stretching w/Excessive Squeegee Drag多方向扭曲/過(guò)份的離版Multi-directional Distortion w/ Excessive Snap-off 印刷方向Print Direction 過(guò)寬刮 刀 Wide squeegee overhang 下刀量設(shè)定太低 Downstop set too low 壓力設(shè)定太高 Pressure setting too high 高黏度加上細(xì)網(wǎng)目 High viscosity w/ fine mesh 網(wǎng)板張力鬆弛 Loss of screen tension 離板過(guò)高 Excessive sn

41、ap-off added 對(duì)位不正確 Alignment un-correctable網(wǎng)板印刷技術(shù)印刷刮刀角度 Attack Angle60 o45 o30 o註釋 Notes : 刮刀角度影響油墨轉(zhuǎn)印技巧，大部份在刮刀刀口，銳利的刮刀提供最小的下墨量和最精細(xì)的圖像 Attack angle affects ink transfer mechanism, mainly at the edge of the squeegee 較高的刮刀角度推動(dòng)網(wǎng)版上的油墨比穿透網(wǎng)版的多 Higher attack angle pushes more ink across the screen than thro

42、ugh it 較低的刮刀角度穿透網(wǎng)版的多，通常在線(xiàn)路/圖騰的前端 Lower attack angle forces more ink through the screen, often ahead of the pattern 最大的影響在刮刀硬度、壓力、速度及油墨黏度 Greatly affected by squeegee durometer, pressure, speed, & ink viscosity 改變離版將改變刮刀角度 Changing snap-off will change attack angle印刷角度小、印刷壓力減小，下墨量大，墨層增厚，印刷效果不理想解決辦法是刮

43、刀硬度增加、刮刀角度增加網(wǎng)板印刷技術(shù)刮刀角度與硬度 Attack Angle vs. Durometer608090 18 o 33 o 40 o固定印刷速度、刮刀壓力、離版Given speed, pressure, & snap-off : 硬度軟的刮刀=低的刮刀角度 Softer squeegee = lower attack angle 低的刮刀角度=減少油墨漏印 Lower angle = reduced ink scavenging 減少油墨漏印=較厚的印刷 Reduced scavenging = thicker print 低的刮刀角度=較大的轉(zhuǎn)印 Lower attack a

44、ngle = greater transfer註釋 Notes : Durometer expressed in Shore A units Color-coded by manufacturers Higher durometer stay sharper longer 較高硬度持續(xù)較銳利較久 Softer durometer conform to substrates 較軟硬度適合於基板彎曲度是有效寬度的立方值網(wǎng)板印刷技術(shù)刮刀角度與膜厚 Attack Angle vs. ThicknessThickness (microns)印刷刮刀角度 Attack Angle3045607530262

45、220182824刮刀硬度SqueegeeDurometer60708090膜厚硬度值用蕭氏A硬度計(jì)測(cè)量55A-65A是低硬刮刀66A-75A是中硬超過(guò)75A是高硬高硬度刮刀唯一缺陷是不能滿(mǎn)足不同形狀基板的印刷網(wǎng)板印刷技術(shù)刮刀速度與膜厚 Squeegee Speed vs. ThicknessThickness (microns)刮刀速度Squeegee Speed (cm/sec)12PTF Ag 1241814121020162226283571020Pd Ag 1Pd Ag 2Resistor 1Resistor 2膜厚網(wǎng)板印刷技術(shù)印刷刮刀的保養(yǎng)1.儲(chǔ)存刮刀時(shí)要平放，不可卷成圈，卷成圈可

46、能會(huì)造成永久彎曲.2.鋁刮柄應(yīng)朝下放置，不可將刀口朝下放置.3.剛印刷完畢就要立即清洗刮刀，此時(shí)很容易洗掉油墨，否則要擦掉凝結(jié) 的油墨以免損傷刀口.4.不可將刮刀浸泡在溶劑中。儘管刮刀是耐溶劑的但刮刀會(huì)因吸收溶劑而 變脆。.5.剛清洗完的刮刀依然軟、溶劑未完全揮發(fā)，不可立即打磨。經(jīng)過(guò)12小時(shí) 到24小時(shí)的“休複”後才可再次使用。這樣不僅可以提高打磨效果也可提 高印刷效果。.6.根據(jù)具體的印刷質(zhì)量要求要經(jīng)常打磨刮刀和清洗，打磨時(shí)要盡可能減少 刮刀的損耗.網(wǎng)板印刷技術(shù)感光乳劑與膜厚 Emulsion Buildup vs. Thickness30 mil5 mil10 milaSqueegee F

47、acebThicknessbaExample: 325 mesh w/ 1-mil (a) and 2-mil (b) emulsion buildup網(wǎng)板印刷技術(shù)感光乳劑與膜厚 Emulsion Buildup vs. Thickness30 mil5 mil10 milExample: 325 mesh w/ 0.4 mil emulsion buildup (minimum for gasketing)Squeegee Face網(wǎng)板印刷技術(shù)網(wǎng)徑與膜厚 Line Width vs. ThicknessThickness (microns)網(wǎng)徑 Line Width (mils)805020

48、1410861612182230201065Gold Lot# 1Gold Lot# 2Gold Lot# 34 Screen: 325 mesh, 1.1 mil wire, + 1.0 mil emulsion buildup膜厚網(wǎng)板印刷技術(shù)網(wǎng)徑與膜厚 Line Width vs. ThicknessThickness (microns)網(wǎng)徑 Line Width (mils)8050201410861612182230201065Gold Lot# 1Gold Lot# 2Gold Lot# 34 Screen: 325 mesh, 1.1 mil wire, + 0.4 mil emu

49、lsion buildup膜厚網(wǎng)板印刷技術(shù)AISI Type 304 Stainless Steel感光乳劑與網(wǎng)徑 Emulsion Buildup & Line WidthMesh Count / WireMinimum LineEmulsion Buildup290 / .00082 mil0.2 - 0.3 mil400 / .0007” 3 mil0.2 - 0.3 mil325 / .0011” (calendered) 3 mil0.2 - 0.3 mil325 / .0009” 4 mil0.2 - 0.4 mil325 / .0011” 5 mil0.3 - 0.5 mil28

50、0 / .0012” 6 mil0.4 - 0.6 mil200 / .0014” 10 mil0.6 - 0.8 mil200 / .0016” 10 mil0.8 - 1.2 mil200 / .0021” 15 mil1.2 - 1.6 mil180 / .0018” 12 mil1.0 - 1.4 mil165 / .0020” 15 mil1.2 - 1.6 mil120 / .0026” 30 mil1.5 - 2.0 mil80 / .0037” 60 mil2.5 - 4.0 mil網(wǎng)板印刷技術(shù)Thickness (microns)刮刀壓力Squeegee Pressure (

51、lbs/linear inch)4535252015.25.502468104030刮刀壓力與膜厚 Pressure vs. Thickness刮除殘墨 Scavenging受擠壓出 Extruding刮刀低角度 Low Attack Angle刮刀壓擠Compression刮刀硬度SqueegeeDurometer60708090膜厚網(wǎng)板印刷技術(shù)輕壓擠出 “Extruding”30 mil5 mil10 milSqueegee FacePressure: 0.09 kg/cm在非常低印刷壓力中刮刀飄浮於黏著油墨 Squeegee “hydroplanes” over viscous ink

52、at very low printing pressures網(wǎng)板印刷技術(shù)刮除殘墨 “Scavenging”30 mil5 mil10 milSqueegee FacePressure: 0.35 kg/cm刮刀利邊切入網(wǎng)目開(kāi)口減少殘存油墨Sharp edge of squeegee cuts into open area of mesh to reduce ink deposit網(wǎng)板印刷技術(shù)低印刷角度 “Low Attack Angle”30 mil5 mil10 milSqueegee Face壓力 Pressure: 0.7 kg/cm刮刀邊偏斜，低印刷角度，網(wǎng)目偏斜抵銷(xiāo) Squeegee

53、 edge deflects, lowering attack angle; countered by some mesh deflection網(wǎng)板印刷技術(shù)壓擠 “Compression”30 mil5 mil10 milSqueegee FacePressure: 1.4 kg/cm在高壓下劇烈壓擠，減少全面的出墨量Severe compression of screen under high pressure, reducing overall deposit網(wǎng)板印刷技術(shù) 成像寬度200mil以上 Image Width 5.08mm Up 總厚=紗厚膜厚只有邊緣效應(yīng)及擋墨作用總厚=紗厚+

54、膜厚*50%刮刀 Squeegee 油墨 (Ink) 成像寬度1050mil Image Width 0.2541.27mm 成像寬度50200mil Image Width 1.255.08mm 基板 Substrate 紗厚形成之印刷厚度 Ink Deposited by Screen 膜厚形成之印刷厚度 Ink Deposited by Stencil 總厚=紗厚+膜厚網(wǎng)版參數(shù)對(duì)印刷膜厚的影響網(wǎng)板印刷技術(shù)高速低壓正確速度及印壓慢速高壓墨量正常墨量過(guò)多 (溢墨)刮印刀 Squeegee 墨量不足油墨 Ink 網(wǎng)布 Screen 網(wǎng)版膜厚Stencil 基板Substrate網(wǎng)板印刷技術(shù)SM

55、P線(xiàn)路(Pattern)膜厚(Stencil)網(wǎng)布(Mesh)W=M+S+PLW+P基板(Substrate)版膜厚度效應(yīng) 當(dāng)線(xiàn)路或膜厚或網(wǎng)布厚度增加時(shí)會(huì)使印刷區(qū)與成像邊緣距離(W)加大,所以在選定網(wǎng)布時(shí)應(yīng)盡量於達(dá)成所需印刷厚度之原則下,相關(guān)厚度(M,S,P)愈小愈好.線(xiàn)路(Pattern)膜厚(Stencil)網(wǎng)布(Mesh)基板(Substrate)無(wú)法控制的流膜區(qū)(Areas of Uncontrolled Ink Flow)印刷時(shí)膜厚處需與基板緊密接觸才不致使油墨失控產(chǎn)生溢出現(xiàn)象.溢墨效應(yīng)網(wǎng)板印刷技術(shù)Thickness (microns)刮刀壓力 Squeegee Pressure (

56、lbs/linear inch)4535252015.25.502468104030刮刀壓力、膜厚與網(wǎng)徑 Pressure vs. Thickness vs. Line width網(wǎng)徑Line width51030ScavengingExtrudingLow Attack AngleCompression( 60 Durometer Squeegee )膜厚網(wǎng)板印刷技術(shù)TMo切變速率 :切變速率 (Shear Rate) R=2T*V/Mo (1/sec=sec)V: 刮印刀速度.F切變應(yīng)力 :切變應(yīng)力(Shear Stress) S=F/A (dyne/cm )網(wǎng)布MeshV面積 “A” A

57、rea網(wǎng)布中的墨流 (Ink Flow Within The Mesh)黏度 V (Viscosity)液體抗拒流動(dòng)的表現(xiàn) V=S/R (Poise)1P(Poise)=100CP(Centi-Poise)黏度與切變應(yīng)力及切變速率之關(guān)係油墨特性與印刷之關(guān)係網(wǎng)板印刷技術(shù)牛頓黏度曲線(xiàn)(Newtonian Curve)假性可塑曲線(xiàn)(Psuedoplastic Curve)牛頓流體:係指流動(dòng)中能保持“切變應(yīng)力/切變速率”(黏度)之比率不變者假性可塑流體:係指物質(zhì)會(huì)在切變應(yīng)力或切變速率增加時(shí)使黏度降低進(jìn)而導(dǎo)致流速增加黏度(Viscosity)切變應(yīng)力(Shear Stress)切變速率(Shear Ra

58、te)R1R2R3S3S2S1R1R2R3S1S2S3V1V1,V2,V3V3V20網(wǎng)板印刷技術(shù)Downstop 刮刀下刀量 Flood 回墨 Screen Release Peel 上刀抬版 Squeegee Travel 網(wǎng)印刮刀行程 抗垂流性(Thixotropy)又稱(chēng)凝立性.在切速率不變的情況下(再限度內(nèi))凝立劑可使黏度降低,並需要一段時(shí)間以恢復(fù)到原來(lái)的黏度,此特性對(duì)高黏度油墨很重要,因?yàn)殛P(guān)係到印刷後油墨繼續(xù)流出時(shí)間的長(zhǎng)短.TimeViscosityTimeViscosity“假塑性”物質(zhì)在切速率不變的情況下將保持相同的黏度且當(dāng)應(yīng)力消失的瞬間,此流質(zhì)又會(huì)恢復(fù)原黏度值.網(wǎng)板印刷技術(shù)油墨與

59、基板間各自具有“表面自由能”(Free surface energy) ,通常是指油墨的表面張力(Surface Tension)及基板的臨界表面張力(Critical Surface Tension).其單位為:達(dá)因/公分(dyne/cm)若要使油墨能順利與基板緊密結(jié)合,油墨的表面張力需小於基板的臨界表面張力,差距愈大附著愈好(即油墨表面張力愈小),但由於油墨散佈性增加印刷之邊緣準(zhǔn)直性較不易控制,容易產(chǎn)生鋸齒現(xiàn)象 印刷物表面清潔與否關(guān)係印刷成敗致巨,必須慎重水滴低張力表面高張力表面網(wǎng)板印刷技術(shù)影響印刷膜厚 Effects on ThicknessInk刮刀硬度Durometer刮刀角度設(shè)定A

60、ttack AngleSetting印刷速度Print Speed刮刀口角度Attack Angleat Edge印刷壓力Pressure刮除殘墨 “Scavenging”感光乳膠厚度Emulsion Thickness網(wǎng)目Mesh Count網(wǎng)徑Wire Diameter離版高度 (網(wǎng)距)Snap-Off刮刀銳利SqueegeeSharpness網(wǎng)版張力Mesh Tension膠黏度Viscosity抬版Screen Peel網(wǎng)板印刷技術(shù)最佳的實(shí)踐 Best Practices (1) 使用網(wǎng)目控制膜厚 Use the screen mesh count as the primary thi