METHOD FOR PRINTING A STRUCTURED SILVER COATING HAVING IMPROVED CURRENT-CARRYING CAPACITY
20210053376 · 2021-02-25
Inventors
Cpc classification
H05B3/84
ELECTRICITY
H05B2203/011
ELECTRICITY
B41M1/12
PERFORMING OPERATIONS; TRANSPORTING
B41M3/006
PERFORMING OPERATIONS; TRANSPORTING
International classification
B41M3/00
PERFORMING OPERATIONS; TRANSPORTING
B41M1/12
PERFORMING OPERATIONS; TRANSPORTING
H05B3/12
ELECTRICITY
Abstract
A method for producing a silver coating on a glass pane, wherein the silver coating includes at least one busbar and/or at least one solder contact surface, wherein the method includes printing the silver coating onto the glass pane by screen printing with a printing pattern having printing and non-printing regions and baking the printed silver coating, wherein the printing region of the printing pattern for the busbar and/or the printing region of the printing pattern for the solder contact surface is provided at least partially with a dot matrix or a line matrix.
Claims
1. A method for producing a silver coating on a glass pane, wherein the silver coating includes at least one busbar and/or at least one solder contact surface, wherein the method comprises printing the silver coating onto the glass pane by screen printing with a printing pattern having printing and non-printing regions and baking the printed silver coating, wherein the printing region of the printing pattern for the busbar and/or the printing region of the printing pattern for the solder contact surface is provided at least partially with a dot matrix or a line matrix.
2. The method according to claim 1, wherein the silver coating includes at least one busbar and a plurality of heating conductors and, optionally, at least one solder contact surface for an alarm loop and/or an antenna.
3. The method according to claim 1, wherein the busbar has a maximum width in the range from 9 to 30 mm.
4. The method according to claim 1, wherein a height of the printed busbar and/or of the printed solder contact surface before baking at the locations that are printed with the printing region of the printing pattern provided with the dot matrix or the line matrix is in the range from 25 to 100 m.
5. The method according to claim 1, wherein the dots of the dot matrix have a diameter in the range from 0.14 mm to 0.22 mm, and/or wherein the lines of the line matrix have a width in the range from 0.1 mm to 0.4 mm.
6. The method according to claim 1, wherein a distance between adjacent dots of the dot matrix is in the range from 1.5 D to 2.5 D, where D is the dot diameter.
7. The method according to claim 1, wherein a layer thickness of the dots of the dot matrix or of the lines of the line matrix is in the range from 10 to 80 m.
8. The method according to claim 1, wherein 1 to 100% of the area of the printing region of the printing pattern for the busbar is provided with the dot matrix or the line matrix and/or 1 to 100% of the area of the printing region of the printing pattern for the solder contact surface is provided with the dot matrix or the line matrix.
9. The method according to claim 1, wherein the printing region of the printing pattern for the busbar is partially provided with the dot matrix or the line matrix and the printing region provided with the dot matrix or the line matrix is arranged in the vicinity of solder contact surfaces of the busbar.
10. The method according to claim 1, wherein the glass pane is a single-pane safety glass or a laminated glass pane.
11. The method according to claim 1, wherein the glass pane has a coating in one or a plurality of edge regions, and the busbar is printed onto the coating.
12. The method according to claim 1, wherein the glass pane provided with the silver coating is a heatable glass pane.
13. The method according to claim 1, wherein during production of the printing pattern after coating the screen in the non-printing regions and in the region of the dot matrix or of the line matrix, partial subsequent coating is carried out in the region of the dot matrix or of the line matrix in order to obtain an increased layer thickness of the dots or lines.
14. The method according to claim 1, wherein the dimensions of the dots of the dot matrix are below the resolution of the printing pattern or the dimensions of the lines of the line matrix are below the resolution of the printing pattern.
15. A glass pane with a silver coating that includes at least one busbar and/or at least one solder contact surface obtainable by a method according to claim 1, wherein the busbar and/or the solder contact surface includes a printed silver coating that is provided at least partially with a dot matrix or a line matrix and the layer thickness of the printed silver coating in the region of the dots of the dot matrix or of the lines of the line matrix is less than the layer thickness of the printed silver coating in the region of the dot matrix or line matrix surrounding the dots or lines.
16. The method according to claim 4, wherein the height is in the range from 30 to 80 m.
17. The method according to claim 5, wherein the diameter is in the range from 0.16 mm to 0.2 mm.
18. The method according to claim 6, wherein the distance between adjacent dots of the dot matrix is in the range from 1.9 D to 2.1 D.
19. The method according to claim 7, wherein the layer thickness is in the range from 10 to 30 m.
20. The method according to claim 8, wherein 15 to 75% of the area of the printing region of the printing pattern for the busbar is provided with the dot matrix or the line matrix and/or 15 to 75% of the area of the printing region of the printing pattern for the solder contact surface is provided with the dot matrix or the line matrix.
Description
[0024] The invention is explained in detail in the following.
[0025] In the following, the expressions left/right and top/bottom/refer to the installed position of the glass pane in a vehicle. The direction from top to bottom is then the longitudinal direction and the direction from left to right is the transverse direction. Top refers to the pane edge adjacent the roof edge of the car body in the installed position in a motor vehicle. On the other hand, bottom describes the pane edge pointing toward the engine edge in a windshield and toward the trunk opening in the case of a rear window. Left and right refer, in the case of a windshield, to the pane edges adjacent the A-pillars of the body, whereas the left and right pane edge of a rear window is adjacent the C-pillar or D-pillar, respectively, of the car body.
[0026] The expressions solder contact surface and solder surface are used synonymously in the following. A solder contact can be soldered onto the glass at the solder contract surface, with the solder contact constituting a connection element.
[0027] The silver coating on the glass pane includes at least one busbar and/or at least one solder contact surface. The silver coating preferably includes at least one busbar and, optionally, at least one solder contact surface for an alarm loop and/or at least one solder contact surface for an antenna. The silver coating particularly preferably includes at least one busbar and a plurality of heating conductors and, optionally, at least one solder contact surface for an alarm loop and/or at least one solder contact surface for an antenna.
[0028] Busbars are electrically conductive strips that are positioned on the glass pane. The busbar is also referred to as a current collector rail. Usually, two busbars running in a longitudinal direction are applied in the region of the right and/or left side edge of the glass pane, which busbars can also extend into the region of the top and bottom side edge. Also possible are two busbars running in a transverse direction in the region of the bottom and/or top side edge of the glass pane. Consequently, the silver coating preferably includes two busbars. There are also embodiments in which not just one busbar is applied in the region of the side edge of the glass pane, but instead two or more busbars separated from one another. In this case, more than two busbars are present.
[0029] If the silver coating includes at least one busbar, usually at least two busbars, the silver coating usually also forms a plurality of heating conductors that are positioned between the busbars, usually transverse thereto.
[0030] On the busbars, the coating also usually forms solder contact surfaces for the busbar. Connection elements via which supply lines for the power connection can be mounted can be attached or soldered to these solder contact surfaces. The current is highest in the region of the solder contact surfaces of the busbar, but with good design, the thermal output is provided via the heating surface to be defrosted (heating conductor) and the busbar and the solder contact remained as cold as possible.
[0031] Alternatively, or additionally, at least one solder contact surface that is not provided for the busbar can be formed by the coating. The solder contact surface can, for example, be a solder contact surface for an alarm loop or a solder contact surface for an antenna. Solder contacts or connection elements via which elements of the antenna or the alarm loop can be mounted can be attached or soldered onto these solder contact surfaces.
[0032] An alarm loop usually comprises an electrically conductive print or wire. In the activated state, the alarm loop receives a continuous quiescent current that is interrupted upon breakage of the pane and triggers an alarm. Such alarm loops are, for example, described in WO 2013/156184 A1.
[0033] The busbar can have a constant width over its length. Usually, however, the busbar has an irregular geometry, the width being different at different locations. In a preferred embodiment, the busbar has a maximum width in the range from 9 to 30 mm, preferably 9 to 16 mm.
[0034] The solder contact surfaces can, for example, have a rectangular, oval, or circular geometry. The solder contact surfaces can, for example, have a maximum dimension in the range from 4 to 24 mm. The maximum dimension in the case of the circle is the diameter; with a rectangle, the diagonal.
[0035] The method according to the invention includes the step of printing the silver coating onto the glass pane by screen printing with a printing pattern having printing and non-printing regions. The screen printing is carried out in particular with a silver paste or conductive silver paste as printing ink.
[0036] The printing pattern is a screen that is stretched in a frame and has non-printing regions in which the screen is provided with a coating, which is also referred to as a stencil, and printing regions in which the screen is free of coating. As a result of the stencil, the screen is impermeable to ink at all non-printing regions and permeable to ink at the printing regions. The frame is usually a metal frame; steel frames or aluminum frames are common, for example, with aluminum frames preferred.
[0037] The screen is usually a woven fabric made of plastic threads or metal threads. The threads are made, for example, of polyamide, polyester, carbon fiber, or stainless steel, with fabrics made of polyester threads particularly preferred. The thread diameter of the fabric, in particular of the polyester fabric can, for example, expediently be in the range from 30 to 150 m, preferably 77 to 120 m, and the screen denier of the fabric can, for example, be in the range from 43 to 180 threads per cm, preferably 77 to 150 threads per cm.
[0038] Situated at the non-printing regions of the printing pattern is the stencil, which constitutes a barrier layer or a coating situated on or in the screen and makes the printing pattern impermeable to ink at the locations that are not intended to print. Commonly used for production of the stencil are the direct method (direct stencil) and the indirect method (indirect stencil), the direct method being preferred. In the direct stencil, the fabric is coated with a light-sensitive layer, exposed, and developed. The stencil is thus produced directly on the fabric. In the indirect method, the stencil is first produced on a carrier and then transferred to the screen. The other steps for producing the stencil are analogous.
[0039] In general, the stencil is formed by a photomechanical process. For this, the screen or a carrier is coated with a light-sensitive composition, also referred to as an emulsion, or a light-sensitive film is applied to the screen or the carrier. Then, the desired pattern of light-impermeable regions and light-permeable regions is imaged onto the light-sensitive layer obtained, for example, by means of a slide projection or a copy or in the CTS method (computer to screen), and the layer is exposed to UV light. In the light-permeable regions, the layer is cured by the UV light and forms the stencil or the non-printing region. In the light-impermeable regions, the layer is not cured and can subsequently be washed out, forming the printing regions of non-coated fabric. In the indirect method, the stencil formed is subsequently transferred to the screen.
[0040] The printing pattern thus produced corresponds to the printing pattern normally used. However, according to the invention, it is essential to the invention that, additionally, the printing region of the printing pattern for the busbar and/or the printing region of the printing pattern for the solder contact surface is at least partially provided with a dot matrix or a line matrix. The dot matrix or dot pattern constitutes an arrangement of multiple rows of points arranged next to one another. The line matrix or line pattern constitutes an arrangement of multiple lines arranged in parallel (parallel line array).
[0041] The embodiment with a dot matrix is preferred since the construction of a dot matrix is easier to carry out and, thus, lower susceptibility to errors has been found in the printing process.
[0042] The dots of the dot matrix or the lines of the line matrix are formed, like the stencil, from a barrier layer situated on or in the screen by a photomechanical method. It goes without saying that the dots of the dot matrix or the lines of the line matrix are expediently formed together with the stencil, as described above. For this, the corresponding dot matrix or the line matrix must also be included for the imaging of the desired pattern on the light-sensitive coating, e.g., by means of slide projection, CTS process, or copying.
[0043] In the embodiment with the dot matrix, the dots can have any geometry. They can, for example, be rectangular, square, elliptical, or circular dots, circular dots being preferred.
[0044] It should be noted that the areas of the print pattern referred to as dots are the areas initially free of coating in the printing process, in which no silver print is applied, whereas according to the invention the region surrounding these dots is provided with silver print. This printed region of the solder contact surface is electrically conductively connected to the remaining area of the associated busbar. Usually, this is achieved by continuous silver printing between these regions with a common stencil. When the structured printing region is in the form of lines instead of a dot pattern, coating-free lines that are arranged alternatingly with the printed lines result. The lines applied by means of silver printing run substantially parallel to one another and parallel to the coating-free lines situated therebetween. Preferably, the structured printing region is dimensioned such that the structuring (points or lines) is too small for an exact printing result. The printing ink thus runs into the initially coating-free areas. According to the printing methods known in the customary prior art such running of the printing ink would be undesirable and constitute a rejection criterion for the resulting product. Consequently, it was surprising and unexpected for the person skilled in the art that by intentionally causing this, a significant improvement in the printing result and in the printing height can be achieved.
[0045] The dimensions of the dots of the dot matrix are below the resolution, preferably just below the resolution, of the printing pattern, i.e., the limit of printable dot finenesses, which is, in particular, a function of the thread diameter and the thread spacing of the screen mesh. Consequently, during printing, the ink below the dots runs together and the dot matrix is not visible in the printed coating. To the human eye, the region below the dot pattern will appear completely printed. Only with a microscope or in cross-section can relatively small hill and valley regions be detected (cf.
[0046] The dots of the dot matrix preferably have a diameter in the range from 0.10 mm to 0.3 mm, more preferably 0.16 to 0.2 mm. This applies to circular dots. If the dots are not circular, these ranges apply to largest dimension of the dots. The dots of the dot matrix can be of the same or different size but are preferably of the same size.
[0047] The distance between the dots of the dot matrix, i.e., the distance between the centers of adjacent dots is preferably in the range from 1 D to 3 D, preferably 1.75 D to 2.25 D, particularly preferably 1.9 D to 2.1 D, where D is the dot diameter or the largest dimension of the dot. This means, for example, in the case of a dot diameter of 0.2 mm, a distance of 0.3 to 0.5 mm, preferably 0.35 to 0.45 mm, and particularly preferably 0.38 to 0.42 mm.
[0048] In the alternative embodiment with the line matrix, the line matrix is formed by lines or straight lines running parallel to one another. The dimensions of the lines of the line matrix are below the resolution, preferably just below the resolution, of the printing pattern, i.e., the limit of printable line finenesses, which is, in particular, a function of the thread diameter and thread spacing of the screen mesh. Consequently, during printing, the ink below the lines runs together and the line matrix is not visible in the printed coating. To the human eye, the region below the line pattern will appear completely printed. Only with a microscope or in cross-section can relatively small hill and valley regions be detected.
[0049] The lines of the line matrix preferably have a line width in the range from 0.1 mm to 0.4 mm. The lines of the line matrix can have the same or different widths but are preferably of the same width. The distance between adjacent lines of the line matrix is, for example, in the range from 0.1 mm to 0.4 mm. The distance refers here to the distance of the central axis in the longitudinal direction of one line to the central axis of the adjacent line. The distance of the lines of the line matrix from one another is preferably in the range from 0.7 B to 2.5 B, preferably 0.8 B to 2.2 B, more preferably 0.8 B to 1.2 B, where B is the line width of the line.
[0050] Here, layer thickness of the stencil and layer thickness of the dots of the dot matrix and layer thickness of the lines of the line matrix means the total thickness of the coating in the region of the stencil or in the region of the dots of the dot matrix or in the region of the lines of the line matrix.
[0051] The layer thickness of the dots of the dot matrix and of the lines of the line matrix can, for example, be in the range from 10 to 100 m, preferably in the range from 10 to 80 m and particularly preferably in the range from 10 to 30 m.
[0052] The layer thickness of the stencil and the layer thickness of the dots of the dot matrix or of the lines of the line matrix can be the same or different. In a preferred embodiment, the layer thickness of the dots of the dot matrix or of the lines of the line matrix is greater than the layer thickness of the stencil. By means of a an increased layer thickness of the dots of the dot matrix or of the lines of the line matrix, an increase in the layer thickness of the busbar at the locations of the dot matrix or line matrix can be achieved. This can be achieved by partial subsequent coating of the regions in which the dot matrix or line matrix was applied. In other words, after coating of the non-printing regions and the regions of the dots of the dot matrix or the regions of the lines of the line matrix, the coating operation is repeated, but only in the region of the region of the dot matrix or line matrix.
[0053] Thus, in a preferred embodiment, during production of the printing pattern after coating the screen in the non-printing regions and in the region of the dot matrix or line matrix, a partial subsequent coating in the region of the dot matrix or line matrix is carried out in order to obtain an increased layer thickness of the dots or lines compared to the layer thickness of the stencil. The layer thickness of the dots or lines can, for example, be in the range of 1.5 to 2.5 times the layer thickness of the stencil.
[0054] The printing region surface of the printing pattern for the busbar can, if it is to be provided with a dot matrix or a line matrix, be provided, partially or completely, with the dot matrix or line matrix, with the printing region surface preferably partially provided with the dot matrix or line matrix. It is possible for example, for 1 to 100%, preferably 5 to 100%, particularly preferably 15 to 75%, of the area of the printing region of the printing pattern for the busbar to be provided with the dot matrix or line matrix.
[0055] If the busbar has wider and narrower sections, it usually suffices for the busbar to be printed thicker in the wider sections, in particular, in the sections with maximum width, such that only the printing regions of the printing pattern intended for this can be provided with the dot matrix or line matrix.
[0056] In a preferred embodiment, the printing region of the printing pattern for the busbar is partially provided with the dot matrix or the line matrix and the printing region provided with the dot matrix or the line matrix is arranged at the locations of the solder contact surface(s) of the busbar. As explained above, the highest current occurs at these locations such that a thicker busbar can effectively contribute to better current distribution at these locations.
[0057] The printing region surface of the printing pattern for the solder contact surface can, if it is to be provided with a dot matrix or line matrix, be provided, partially or completely, with the dot matrix or line matrix, with the printing region surface preferably provided partially with the dot matrix or line matrix. For example, 1 to 100%, preferably 5 to 100%, preferably 15 to 75%, of the area of the printing region of the printing pattern for the busbar can be provided with the dot matrix or the line matrix.
[0058] By using the dot matrix or the line matrix for the printing region of the printing pattern for the solder contact surface, a more robust solder contact surface can be obtained. This has the advantage that the functions of the solder contact surface, such as the stability of the adhesion to a connection element, can be achieved even with a lower layer thickness. At the same time, compared to the otherwise identical screenprint, but without a dot matrix or a line matrix, greater thickness of the silver is achieved, as a result of which the strength of the solder connection with the connection elements soldered thereon is improved, in particular in the case of lead-free connection elements.
[0059] Providing the area of the printing region of the printing pattern for the solder contact surface with the dot matrix or line matrix is suitable in particular for solder contact surfaces for an antenna, solder contact surfaces for an alarm loop, and for solder contact surfaces of busbars situated in the region of the top or bottom side edge of the glass pane. Providing the area of the printing region of the printing pattern for the solder contact surface with the dot matrix or line matrix is suitable in particular for solder contact surfaces that are not positioned in the region of the right or left side edge of the glass pane.
[0060] For the screen printing, the printing pattern produced with at least one dot matrix or one line matrix is used in a subregion of the printing region as described above. Otherwise, the screen printing is done as known in the prior art.
[0061] The printing pattern is positioned on the glass pane. The printing ink is applied and evenly distributed on the upper side of the right printing pattern. The printing ink is then doctored onto the glass pane through the mesh openings of the screen with a doctor blade into the printing regions. In general, the glass pane makes contact with the screen only in the immediate printing zone due to the doctor blade. By means of a higher distance, the so-called jump, the glass pane is more easily separated from the screen after the printing phase.
[0062] A silver paste or conductive silver paste is used as printing ink. Common commercial products can be used. Silver pastes or conductive silver pastes usually contain high amounts of silver or silver alloy, e.g., 30 to 88 wt.-%, as powder or flakes, organic binders, organic solvents, and, optionally, other additives.
[0063] At the points where the corresponding printing region of the printing pattern has a dot matrix or a line matrix, a thicker and more uniform layer thickness of the busbar is obtained compared to a screen print in which no dot matrix or line matrix is used, but which is otherwise the same.
[0064] The height of the printed busbar before baking is, for example, 25 to 100 m, preferably 30 to 80 m at the locations that are printed by the printing region of the printing pattern provided with the dot matrix or the line matrix. The height refers to the thickness before baking, i.e., to the wet layer thickness.
[0065] Depending on the silver paste or conductive silver paste used, the screen printing can be followed by a drying operation, which can, optionally, also be carried out at an elevated temperature.
[0066] The method according to the invention also includes the step of baking the printed silver coating. Baking temperature and duration depend on the type of silver paste used. The baking operation can, for example, be carried out at a temperature in the range from 400 to 700 C. The duration of the heat treatment can, for example, be 5 s to 200 s.
[0067] As usual, the glass pane can be made of inorganic glass, in particular silicate glass. Examples include soda lime glass, borosilicate glass, aluminosilicate glass, or quartz glass. The glass pane is preferably a single-pane safety glass or a laminated glass.
[0068] The glass pane can have a coating, preferably a coating with a ceramic paint, such as a black ceramic paint, in one or a plurality of edge regions, preferably all edge regions. The person skilled in the art is familiar with such opaque coatings in the edge region of vehicle glazings under the term masking print. A coating of the side edges with ceramic paint serves, for example, to conceal adhesive bonds used when mounting a glass pane on a vehicle. The busbars of the silver coating are preferably printed onto this coating, in particular onto the ceramic paint coating.
[0069] The glass pane provided with silver coating is preferably a heatable glass pane, in particular a heatable vehicle pane, in particular a rear window.
[0070] The invention also relates to a glass pane with a silver coating that includes at least one busbar and/or at least one solder contact surface that is obtainable in accordance with the method described above according to the invention. The product features disclosed in the description of the process are fully applicable to the glass pane according to the invention and need not be repeated here. Conversely, the features disclosed in the description of the product also apply to the method according to the invention.
[0071] The glass pane according to the invention includes at least one busbar and/or the solder contact surface with a printed silver coating that is at least partially provided with a dot matrix or a line matrix, wherein the layer thickness of the printed silver coating in the region of the dots of the dot matrix or of the lines of the line matrix is less than the layer thickness in the printing region of the dot matrix or line matrix surrounding the dots or lines. The size dimensions of the dots of the dot matrix and of the lines of the line matrix are below the resolution of the human eye, but are detectable on the product by microscopic examination. The structuring of the silver print of the glass pane is achieved by using the process according to the invention. A particular advantage of the glass pane according to the invention, as described for the method according to the invention, is the greater current-carrying capacity in the region of the dot matrix.
[0072] In a preferred embodiment of the glass pane according to the invention, the layer thickness of the printed silver coating in the region of the dots of the dot matrix or of the lines of the line matrix is in the range from 10 to 30 m and the layer thickness of the printed silver coating in the region surrounding the dots or lines of the dot matrix or line matrix is in the range from 30 to 80 m. The layer thickness in the region of the dots or lines is selected smaller than the layer thickness in the printing region surrounding the dots or lines. This ratio has proved to be particularly advantageous in terms of optimization of the current-carrying capacity while, at the same time, using as little material as possible. The layer thicknesses mentioned refer to the wet layer thickness.
[0073] In the following, the invention is explained based on nonrestrictive exemplary embodiments with reference to the accompanying drawings.
[0074] They depict:
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LIST OF REFERENCE CHARACTERS
[0082] 1 busbar (silver print) [0083] 2 width of the busbar [0084] 3 print shoulder [0085] 4 glass surface of the glass pane [0086] 5 printing pattern [0087] 6 matrix dot (coated screen) [0088] 7 region under matrix dot [0089] 8 uncoated screen surface [0090] 9 vertical dot spacing [0091] 10 horizontal dot spacing [0092] 11 coated screen mesh (stencil) [0093] 12 uncoated screen mesh for busbar [0094] 13 uncoated screen mesh for heating conductors [0095] 14 printing region of the screen with dot matrix [0096] 15 printing region between matrix dots [0097] 16 glass pane [0098] 17 heating conductor [0099] 18 coating with ceramic paint [0100] 19 region of the busbar printed with dot matrix [0101] 20 printing region of the screen with line matrix [0102] 21 matrix line (coated screen)