Apparatus and process for screen printing

A printer for depositing conductive inks onto a non-conductive substrate in a predetermined pattern, comprising:

• a platen for supporting said substrate, said platen having a plurality of apertures therein;
• a product carrier separate from said platen having an upper surface in contact with said platen, said upper surface having a plurality of channels therein, each of which is aligned with at least one of said apertures;
• a flexible printing screen;
• a screen holder to which said flexible printing screen is securable in spaced relationship from said substrate, thereby defining a region between said screen and said substrate;
• first means for adjusting the position of said screen holder, whereby said printing screen may be registered with said substrate;
• means for applying a first partial vacuum to said region to deflect a portion of said screen containing said predetermined pattern into contact with said substrate, whereby said ink is transferred onto said substrate in said predetermined pattern,
• wherein said first means comprises:
• means for adjusting the position of said screen holder around a first axis orthogonal to the upper surface of said product carrier and along a second axis orthogonal to said first axis;
• and
• means for adjusting the position of said screen holder along a third axis orthogonal to said first axis and said second axis.

A printer for depositing conductive inks onto a non-conductive substrate in a predetermined pattern, comprising:

• a platen for supporting said substrate, said platen having a plurality of apertures therein;
• a product carrier separate from said platen having an upper surface in contact with said platen, said upper surface having a plurality of channels therein, each of which is aligned with at least one of said apertures;
• a flexible printing screen;
• a screen holder to which said flexible printing screen is securable in spaced relationship from said substrate, thereby defining a region between said screen and said substrate;
• first means for adjusting the position of said screen holder, whereby said printing screen may be registered with said substrate;
• means for applying a first partial vacuum to said region to deflect a portion of said screen containing said predetermined pattern into contact with said substrate, whereby said ink is transferred onto said substrate in said predetermined pattern;
• second means for adjusting the position of said product carrier along a first axis orthogonal to the upper surface thereof,
• wherein said product carrier comprises a plate having a plurality of threaded apertures symmetrically spaced therein.

A method for depositing ink onto a substrate in a predetermined pattern, comprising:

• positioning a platen having a plurality of apertures therein onto a threaded movable product carrier having a plurality of channels therein, each of which channels is aligned with at least one of said apertures;
• positioning said substrate onto said platen;
• applying a first partial vacuum to said substrate through said channels and said apertures to secure said substrate to said platen;
• positioning a screen having said predetermined pattern defined therein into registration with said substrate at a predetermined distance above said substrate, wherein a region is defined between said substrate and said screen;
• coating said screen with said ink;
• and
• applying a second partial vacuum to said region, whereby said screen is deflected into contact with said substrate and a portion of said ink is transferred through said screen onto said substrate in said predetermined pattern,
• wherein said screen positioning comprises:
• securing said screen to a screen holder;
• rotating said screen holder about a first axis normal to surface of said screen;
• positioning said screen holder along a second axis orthogonal to said first axis;
• and
• positioning said screen holder along a third axis orthogonal to said first axis and said second axis.

An improved printer for depositing a viscous material onto a substrate comprising:

• a platen having a first surface for supporting said substrate and having a plurality of apertures therein;
• carrier means separate from said platen and in contact with said platen for moving said platen along a first axis perpendicular to said first surface;
• means for temporarily adhering said substrate to said platen by applying a first partial vacuum to said platen through said apertures;
• a printing screen having a second surface upon which said viscous material is stored prior to deposition thereof on said substrate;
• a screen holder for aligning said second surface essentially parallel to said first surface and in spaced relationship therefrom before said viscous material is deposited on said second surface, said spaced relationship defining a region between said substrate and said printing screen;
• and
• means for applying a second partial vacuum to said region to deflect said printing screen into temporary contact with said substrate, whereby said viscous material is transferred from said second surface onto said first surface,
• wherein said means for applying said second partial vacuum comprises:
• a vacuum pump;
• a plurality of pilot activated valves coupled between said vacuum pump and said region;
• a plurality of solenoid activated valves, each of which is coupled to and controls each of said pilot activated valves;
• and
• a controller for activating said solenoid activated valves in a predetermined manner.

A printer for transferring ink deposited on a screen through said screen onto a substrate in a predetermined pattern comprising:

• a screen holder in which said screen may be inserted;
• a platen for supporting said substrate in a normally spaced relationship from said screen, said spaced relationship defining a region between said substrate and said screen;
• a product carrier having an upper surface in contact with said platen;
• a support frame having a recess therein for receiving said product carrier;
• a plurality of adjusting bolts coupled to said support frame and said product carrier for adjusting the position of said product carrier relative to said support frame along a first axis;
• second means coupled to said screen holder for adjusting the position thereof around said first axis, along a second axis orthogonal to said first axis and along a third axis orthogonal to said first axis and said second axis, whereby said screen may be registered with said substrate;
• and
• means for applying a first partial vacuum to said region to deflect a portion of said screen containing said predetermined pattern into contact with said substrate, whereby said ink is transferred onto said substrate.

An improved printer for depositing a viscous material onto a substrate comprising:

• a platen having a first surface for supporting said substrate and having a plurality of apertures therein;
• carrier means separate from said platen and in contact with said platen for moving said platen along a first axis perpendicular to said first surface;
• means for temporarily adhering said substrate to said platen by applying a first partial vacuum to said platen through said apertures;
• a printing screen having a second surface upon which said viscous material is stored prior to deposition thereof on said substrate;
• a screen holder for aligning said second surface essentially parallel to said first surface and in spaced relationship therefrom before said viscous material is deposited on said second surface, said spaced relationship defining a region between said substrate and said printing screen;
• and
• means for applying a second partial vacuum to said region to deflect said printing screen into temporary contact with said substrate, whereby said viscous material is transferred from said second surface onto said first surface,
• means for adjusting the position of said printing screen along a second axis perpendicular to said first axis and along a third axis perpendicular to said first axis and said second axis.

A method for depositing viscous material through a printing screen having apertures therethrough onto a substrate in a predetermined pattern, comprising:

• positioning a platen having an upper surface and apertures therethrough onto a separate movable product carrier having a plurality of channels on an upper surface thereof, wherein said upper surface is perpendicular to a first axis and each of said channels is aligned with at least one of said apertures;
• positioning said substrate onto said platen;
• positioning said printing screen perpendicular to said first axis;
• spacing said substrate a predetermined distance from said screen, thereby defining a region between said substrate and said screen;
• applying said viscous material to said printing screen;
• applying a partial vacuum to said region, whereby said printing screen is deflected into contact with said substrate;
• laterally positioning said screen, whereby apertures in said screen are aligned in registration with apertures in said substrate.