Method for manufacturing shadow mask and etching-resistant layer-coating apparatus

A method of manufacturing a shadow mask, said method comprising:

• preparing a strip-like metallic thin plate having a first main surface previously etched and having a plurality of concave sections formed thereon and a second main surface previously formed with a resist layer, the resist layer having a plurality of openings;
• coating an etching resistant liquid to said first main surface by means of a first etching resistant layer-coating apparatus;
• feeding in a substantially horizontal direction said metallic thin plate in such a manner that said first main surface faces downward;
• (i) coating said etching resistant liquid on said first main surface, and (ii) filling said concave sections with said etching resistant liquid while coating said etching resistant liquid, coating said etching resistant liquid by making use of a second etching resistant layer-coating apparatus which is disposed beneath said first main surface of the metallic thin plate, thereby forming an etching resistant layer on said first main surface while regulating a thickness of said etching resistant layer coated by said first etching resistant layer-coating apparatus;
• said second etching resistant layer-coating apparatus being provided with a gravure roll 20 mm to 60 mm in diameter, a member for feeding said etching resistant liquid onto said gravure roll, and a doctor blade disposed over said gravure roll;
• wherein said coating of said etching resistant liquid on said first main surface by said second apparatus is performed by (i) contacting a portion of said first main surface with a surface of said gravure roll carrying said etching resistant liquid after an excessive amount of said etching resistant liquid is wiped away by means of said doctor blade, while a portion of said second main surface which is located opposite to said portion of said first main surface remains free of contact by said gravure roll, and (ii) under conditions that said gravure roll is rotated in a direction opposite to that of said metallic thin plate and at a peripheral speed of 4 to 25 times as high as that of a feeding speed of said metallic thin plate;
• and
• etching said second main surface to form a plurality of through holes from said plurality of openings, each through hole (i) corresponding to one of the plurality of openings and (ii) passing from said second main surface to one concave section of said plurality of concave sections formed on said first main surface.