Printing – Stenciling – Stencils
Reexamination Certificate
1998-12-31
2001-06-12
Funk, Stephen R. (Department: 2854)
Printing
Stenciling
Stencils
C428S373000, C428S379000, C442S060000, C442S229000, C442S364000, C442S377000
Reexamination Certificate
active
06244173
ABSTRACT:
TECHNICAL FIELD
The present invention relates to a screen-formed plated article comprising mesh cloth produced by using a core-sheath composite filament, which is a product suitable for a screen for printing, a cylinder for rotary printing, an electromagnetic wave shielding material, a shadow mask, and the like.
BACKGROUND ART
As a material for mesh fabrics for screen printing, silk, stainless steel, nylon, polyester and composite fibers have been conventionally used. However, because silk has problems in strength and dimensional stability, and stainless steel has problems in elastic recovery properties, these are replaced by ones made of polyester and nylon. Particularly, mesh fabric made of polyester is being frequently used from the standpoint of dimensional stability.
However, since these screens made of synthetic fibers generate static charge by friction, etc. attraction and adsorption dust may occur. The static charge may also cause ceasing of ink during printing, making precise printing impossible. Thus, a screen having been subjected to an anti-static treatment (Unexamined Published Japanese Patent Application No.6-1089) is being used, and in super precise printing, a stainless steel printing plate and a combination printing plate comprising stainless steel attached to a synthetic fiber screen plate are being used.
A metallic plate made by an electrocasting method was used instead of stainless steel for the combination plate. However, because clogging often occurs in the metallic plate made by the electrocasting method, and a large article of 1 m or larger cannot be produced, its production has been terminated.
In order to replace it, a regitide plate, in which stainless steel is spread and plating is conducted for the stainless steel plate, is used in a certain part, but it is very expensive since a large sized stainless steel plate is plated, and the production efficiency of the plate is poor.
On the other hand, as a screen mesh for textile printing, a cylindrical screen mesh (cylinder) is produced by conducting a plating method, multi-layer plating and double-side plating on a form (mother roll) to form the cylinder, as the screen textile printing of rotary type is conducted to achieve high speed textile printing. However, it is required for a long period of time to reach a certain thickness, and the production process is complicated and very expensive.
Furthermore, there are a shadow mask and an electromagnetic wave shielding material obtained by subjecting metal fabric to metal vapor deposition and coating with a black urethane, those obtained by conducting electroless vapor deposition and electrolytic plating of carbon, and those obtained by the combination of these methods. However, because the screen as a support is fabric, the point of intersection is protruded, and the cross is liable to swerve. When the thickness of the plating part is thickened to prevent swerving of the cross, the opening of the cross becomes narrow, which is not suitable for the usage of a shadow mask.
Unexamined Published Japanese Patent Application No. 4-136232 discloses mesh fabric for a screen produced by using a core-sheath composite filament using a sheath comprising a component having a lower melting point than a core, in which the point of intersection of the warp and the woof is fixed in the state that the core threads are adhered, and the surface of the warp and the woof are uniformly covered with the sheath component throughout the fabric. However, while the fabric is easy to be handled since the mesh is stably maintained, it is not considered to be formed into a screen for the screen textile printing of rotary type by weaving into a cylindrical sack form.
It is also not considered that the conventional two steps of vapor deposition of carbon and coating of black urethane can be integrated into one step by conducting black chromium plating, and the thickness of the plating can be reduced since the point of intersection is flat.
For example, it is proposed that plating is conducted on mesh fabric, but it is difficult to conduct plating without applying tension on the mesh fabric. Furthermore, since cracks are formed at the part of the point of intersection on putting up on a frame, it cannot be used for screen printing, and thus plating is conducted after putting up on a frame.
In the combination production process of a screen printing plate using an electrocasting screen mesh, the production cannot be conducted at low cost since the electrocasting mesh itself is expensive. Furthermore, since the electrocasting screen mesh is in the course of development, it is not currently available for screen printing.
Examined Published Japanese Patent Application No. 51-20630 discloses a production process of a rotary screen by weaving into a sack. However, swerving of the intersection points of the mesh occurs in a coarse mesh because the point of intersection is not fused. Because the point of intersection is not flat and the material fabric is poor in stiffness, the thickness of the plating must be increased to make the production difficult. Further, clogging occurs by scratching of the thread and feather-like dusts, and thus it cannot be subjected to practical use.
The object of the invention is to provide a screen-formed plated article comprising mesh cloth, which does not bring about clogging and has uniform openings throughout the surface, and the screen-formed plated article can be stably used as a printing screen and a cylinder for rotary printing and is also useful as an electromagnetic wave shielding material and a shadow mask.
DISCLOSURE OF THE INVENTION
In the invention, the above object is accomplished by using mesh cloth produced by using a core-sheath composite filament using a sheath comprising a component having a lower melting point than a core.
That is, the product of the invention comprises mesh cloth produced by using a core-sheath composite filament using a sheath comprising a component having a lower melting point than a core, wherein a metal plating is provided on a surface of the mesh cloth, in which core threads of threads crossing at a point of intersection of the threads are adhered to each other at the point of intersection; a surface thereof is uniformly covered by the sheath component; the cloth has a thickness at the point of intersection of from 85% to 60% of the total thickness of the crossing threads.
In the mesh cloth of the invention, since the point of intersection of crossing threads is completely fixed to prevent swerving of the intersection points, plating can be conducted without spreading on a frame. Thus, a plated plate can be easily obtained without plating with applying tension. Furthermore, owing to melting of the sheath component, the cloth has sufficient stiffness, and the thickness of the plating can be small. The feather-like dusts before melting are unified with the thread, to prevent clogging and maintain uniform openings throughout the whole surface.
Since the mesh cloth where the point of intersection is fused to be fixed has substantially no contraction and expansion property, it is substantially not stretched when it is attached to a screen plate after metal plating. Thus, metal plating can be stacked before attaching to a screen plate, and it is very easy to handle as applied to a precise printing screen.
While the mesh cloth of the invention is a plane fabric for an ordinary printing screen, it is preferably woven into a cylindrical sack. In this case, a precise cylindrical product without juncture can be obtained by putting the mesh cloth of this invention on a cylinder having a TEFLON (polytetrafluoroethylene coating and applying heat thereto. Furthermore, the cylindrical product can be effectively produced in such a manner that while the core-sheath composite filament is not woven, it is wound doubly on a cylinder with bias to make a mesh form, the point of intersection of the filament is adhered by fusion of the sheath component.
In the invention, an electromagnetic wave shielding material or a shadow mask can be obtained by a
Noguchi Shoichiro
Tanaka Toyohiro
Tomikawa Toshihide
Funk Stephen R.
Hogan & Hartson LLP
Kanebo Ltd.
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