WO2019074800A1

WO2019074800A1 - Methods for fixturing and printing curved substrates

Info

Publication number: WO2019074800A1
Application number: PCT/US2018/054722
Authority: WO
Inventors: Wesley J. Buth; Matthew John CEMPA; Christopher Paul Daigler; Mark Stephen Friske; Kevin Ray Maslin
Original assignee: Corning Incorporated
Priority date: 2017-10-09
Filing date: 2018-10-05
Publication date: 2019-04-18

Abstract

Apparatus for printing on a surface of a substrate (110) including a fixturing member (200) having a base (100) with a fixturing surface (101) having a predetermined contour, a frame member (105) attached to the base (100), at least one sealing panel (120) attached to the frame member (105), at least one vacuum component (102) and at least one printing component. A method for fixing a substrate (110) and printing on a surface thereof is also disclosed.

Description

M ETHODS FOR FIXTURING AND PRI NTING CURVED SUBSTRATES

CROSS-REFERENCE TO RELATED APPLICATIONS

FIELD OF THE DISCLOSURE

[0001] This application claims the benefit of priority under 35 U.S.C. § 1 19 of U.S. Provisional Application Serial No. 62/569,797 filed on October 09, 2017, the content of which is relied upon and incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] The disclosure relates generally to methods for fixturing and printing a pattern on a substrate, and more particularly to methods for vacuum fixturing and screen printing on a substrate having at least one curved surface.

BACKGROUND

[0003] Three-dimensional (3D) screen printing is widely used in various industries, e.g., for printing on rounded containers such as bottles and cans or on shaped automotive parts such as windshields. 3D screen printing as yet is generally limited to substrates with a smaller radius of curvature (e.g., less than about 500 mm) and/or a single axis of curvature. For the most part, 3D printing is also limited to printing on the outside, or convex, surface of semi-circular or parabolic substrates and cylindrical substrates with circular or oval cross-sections.

[0004] The ability to screen print on larger format, larger radius, and/or multiple radius three-dimensional substrates is increasingly relevant to various industries, such as the automotive industry. Larger format 3D substrates

conventionally can be printed while the substrate is still flat, followed by shaping of the substrate to achieve a 3D shape, e.g., by softening a glass or plastic substrate at elevated temperatures, or the like. However, because the printing medium can be thermally incompatible with the conditions necessary to shape the substrate after printing, there is a growing need to print on curved surfaces of large format 3D substrates. This is particularly true in the case of glass substrates, which may be heated to relatively high forming or softening temperatures during the shaping process. [0005] Current methods for decorating the surfaces of a 3D substrate include masking a portion of the surface and spray coating the substrate to create an image; however, such methods can be costly and/or time consuming and generally do not provide a suitable image resolution. Screen printing and inkjet printing on large format curved surfaces have also been attempted, but with various drawbacks, complications, and/or limitations. For example, manufacturing and/or processing disparities can produce minor variations in substrate shape and/or curvature, which can negatively impact the reproducibility of a given pattern from substrate to substrate.

[0006] Additionally, 3D printing devices typically comprise one or more extra moving parts as compared to two-dimensional (2D) printing devices for purposes of maintaining a constant "off-contact" distance, or gap, between the substrate and the screen mesh. 3D printing devices conventionally compensate for off-contact variability by articulating the substrate under the screen or articulating the screen above or around a fixed substrate, thus requiring additional moving parts as compared to a 2D printing process. Current 3D printing methods may also contact and potentially contaminate the surface to be printed, e.g., with mechanical components for holding or moving the substrate during printing. Other methods may include using forced air flow to partially or fully flatten a 3D substrate, but such methods may introduce dust or particulate contamination due to air flow on the surface to be printed.

[0007] Accordingly, it would be advantageous to provide methods and apparatuses for fixturing large 3D substrates for printing that reduce or avoid contact with the printed surface and/or the application of pressure to the printing surface. It would also be advantageous to provide methods and apparatuses for reliably positioning substrates for printing with repeatable accuracy. Additionally, it would be advantageous to provide methods and apparatuses capable of compensating for variations in substrate shape. It would furthermore be advantageous to provide methods and apparatuses for printing on concave and/or convex substrates and/or substrates with a complex curvature, e.g., curvature around plural radii.

SUMMARY

[0008] The disclosure relates, in various embodiments, to methods for printing on a surface of a substrate, the methods comprising positioning a substrate comprising a first major surface and an opposing second major surface in a recess of a fixturing member, wherein the first major surface is at least partially in contact with a fixturing surface having a predetermined contour; placing at least one sealing panel over at least one interior edge of the recess to cover a gap between a perimeter of the substrate and an interior edge of the recess; applying negative pressure to the first major surface of the substrate to conform the first major surface to the predetermined contour of the fixturing surface; and printing on the opposing second major surface of the substrate.

[0009] According to various embodiments, positioning the substrate in a recess of the fixturing member comprises placing a frame member in contact with a base member and placing the substrate on the base member within a perimeter of the frame member, wherein the base member and frame member together define the recess in the fixturing member. In additional embodiments, the frame member and the at least one sealing panel may be removed prior to printing on the second major surface. According to various embodiments, applying a negative pressure can comprise drawing a vacuum through at least one orifice in the fixturing member. In certain embodiments, the substrate can comprise at least one of a glass, ceramic, glass-ceramic, metal, plastic, or polymeric material. According to other

embodiments, the substrate can comprise a three-dimensional substrate having at least one non-planar surface with at least one radius of curvature. In further embodiments, the substrate can have a thickness extending between the first major surface and the opposing second major surface ranging from about 0.1 mm to about 5 mm.

[0010] According to non-limiting embodiments, the first major surface of the substrate can have an initial non-planar shape and the predetermined contour of the fixturing surface can be substantially planar. In alternative embodiments, the first major surface of the substrate can have an initial non-planar shape and the predetermined contour of the fixturing surface can also be non-planar, e.g., a non- planar shape different from the shape of the first major surface. According to additional embodiments, the second major surface of the substrate may be substantially planar during printing. The fixturing surface can, in some embodiments, comprise at least one extended contour extending a predetermined distance beyond at least one edge of the substrate. [0011] The disclosure also relates to apparatuses for printing on a surface of a substrate, the apparatuses comprising a fixturing member comprising a base member comprising a fixturing surface having a predetermined contour and at least one orifice extending through a thickness of the base member, and a frame member attached to the base member, the frame member comprising an interior edge at least partially defining a recess; at least one sealing panel attached to the interior edge of the frame member and configured to cover at least one gap between a perimeter of a substrate positioned in the recess and the interior edge of the frame member; at least one vacuum component configured to apply negative pressure to a first major surface of the substrate through the at least one orifice; and at least one printing component for printing on an opposing second major surface of the substrate.

[0012] Additional features and advantages of the disclosure will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the methods as described herein, including the detailed description which follows, the claims, as well as the appended drawing.

[0013] It is to be understood that both the foregoing general description and the following detailed description present various embodiments of the disclosure, and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawing is included to provide a further understanding of the disclosure, and is incorporated into and constitutes a part of this specification. The drawing illustrates various aspects of the disclosure and together with the description serves to explain the principles and operations of the disclosure.

BRIEF DESCRIPTION OF THE DRAWING

[0014] The following detailed description can be best understood when read in conjunction with the following drawing, which are not necessarily drawn to scale, and in which:

[0015] FIGS. 1A-B illustrate side views of exemplary base members according to embodiments of the disclosure;

[0016] FIG. 2 illustrates a top view of an exemplary fixturing member comprising a base member and a frame member according to additional

embodiments of the disclosure; [0017] FIGS. 3A-B illustrate top and cross-sectional views of a substrate positioned in a recess of an exemplary fixturing member according to certain embodiments of the disclosure;

[0018] FIGS. 4A-B illustrate side views of a concave substrate positioned on a base member before and after drawing a vacuum according to various embodiments of the disclosure;

[0019] FIGS. 5A-B illustrate side views of a convex substrate positioned on a base member before and after drawing a vacuum according to various embodiments of the disclosure; and

[0020] FIG. 6A-B illustrate side views of an exemplary squeegee printing apparatus in contact with different base members.

DETAILED DESCRIPTION

[0021] Various embodiments of the disclosure will now be discussed with reference to FIGS. 1-6, which illustrate exemplary embodiments of fixturing apparatuses and components thereof. The following general description is intended to provide an overview of the claimed methods and apparatuses, and various aspects will be more specifically discussed throughout the disclosure with reference to the non-limiting depicted embodiments, these embodiments being

interchangeable with one another within the context of the disclosure.

Fixturing Apparatuses

[0022] Disclosed herein are apparatuses for printing on a surface of a substrate, the apparatuses comprising a fixturing member comprising a base member comprising a fixturing surface having a predetermined contour and at least one orifice extending through a thickness of the base member, and a frame member attached to the base member, the frame member comprising an interior edge at least partially defining a recess; at least one sealing panel attached to the interior edge of the frame member and configured to cover at least one gap between a perimeter of a substrate positioned in the recess and the interior edge of the frame member; at least one vacuum component configured to apply negative pressure to a first major surface of the substrate through the at least one orifice; and at least one printing component for printing on an opposing second major surface of the substrate. [0023] FIGS. 1A-B illustrate exemplary base members 100 used to fixture substrates for printing according to various methods disclosed herein. The base member 100 can comprise a fixturing surface 101 having a predetermined contour. In FIG. 1A, a fixturing surface 101 with a concave contour is depicted, whereas a fixturing surface 101 with a convex contour is depicted in FIG. 1 B. Other contours are also possible and are intended to fall within the scope of the disclosure, including flat contours and complex contours comprising one or more segments with convex, concave, and/or flat portions. In certain non-limiting embodiments, the base member 100 may comprise a recess into which the substrate may be placed before printing. For instance, the fixturing surface 101 of the base member may define a recess, as shown in FIGS. 4A and 5A. In other embodiments, a recess in the fixturing member may be defined, e.g., by a combination of two or more components, as shown in FIG. 3B.

[0024] Referring again to FIGS. 1A-B, the base member 100 can also comprise at least one orifice 102 for drawing a vacuum, e.g. , a vacuum port for applying negative pressure to a substrate positioned on the fixturing surface 101. The orifices 102 can extend through a thickness of the base member 100, e.g., from the fixturing surface 101 to the opposing surface 103. Such orifices may be used, for example, by placing the base member 100 on a vacuum table configured to draw a vacuum through the orifices 102. However, other configurations are also possible, including orifices 102 that extend from the fixturing surface 101 to other, e.g., adjoining, surfaces of the base member 100. The base member 100 may also itself be equipped to draw a vacuum on the fixturing surface 101 or otherwise or configured to connect to a vacuum component other than a vacuum table. Although not depicted in FIGS. 1A-B, the base member 100 may also include one or more valves for applying and/or controlling the negative pressure exerted on the substrate. The base member 100 can be constructed from any suitable material including, but not limited to, metals, polymers, wood, ceramics, glass, and other machinable materials. In a non-limiting embodiment, the base member may comprise polyurethane.

[0025] Referring to FIG. 2, a fixturing member 200 may comprise a base member 100, e.g., the base members depicted in FIGS. 1A-B or any other suitable base member, and a frame member 105. The frame member 105 may be configured to circumscribe the fixturing surface 101 of the base member 100. The frame member 105 can be constructed from any suitable material including those listed above with respect to the base member 100. The frame member 105 may have any shape and/or size as desired to form a sealing perimeter around a substrate (not depicted). In some embodiments, the frame member 105 may have a regular shape, such as a circle, oval, square, rectangle, rhombus, or any other polygonal shape, or the frame member may also have any irregular shape, such as shapes including one or more linear and/or curvilinear edges. According to various embodiments, the frame member 105 can comprise four sides, e.g., defining a square or rectangular perimeter. In additional embodiments, the frame member 105 may have a dimension corresponding to a dimension of the substrate to be printed. For example, a length, width, and/or diameter of the frame member 105 may be within about 2 mm of a length, width, and/or diameter of the substrate, such as ranging from about 0.1 mm to about 1 .5 mm, from about 0.25 mm to about 1 mm, or from about 0.5 mm to about 0.75 mm, including all ranges and subranges therebetween.

[0026] As discussed in more detail below with respect to FIGS. 3-4, the frame member 105 and the base member 100 may interlock or otherwise mate together to form a fixturing member 200. These two members together may define a recess of the fixturing member 200 into which the substrate may be positioned prior to printing. Exemplary mating mechanisms include, but are not limited to, mechanically interlocking parts, such as a tongue and groove, dovetail, and like parts, matching contact surface contours, sealing gaskets, and any other mechanism suitable for promoting a vacuum seal between the frame member 105 and the base member 100.

[0027] Referring again to FIG. 2, the base member 100 may further comprise one or more locators 104, which can be used to position the substrate on the fixturing surface 101 in an accurate and/or repeatable manner. The locators 104 may be in any position on the base member 100, including the fixturing surface 101 , as shown in FIG. 2. Although not depicted, locators may also be included on the base member surface in regions outside of the fixturing surface 101 , e.g., exterior to the frame member 105. Locators 104 may also, in certain embodiments, be used to locate and/or position the frame member 105 on the base member 100 in an accurate and/or repeatable manner. Of course, the embodiment depicted in FIG. 2 is exemplary only and the locators 104 may have any configuration, position, size, type, and/or number, without limitation. While not illustrated in FIG. 2, the frame member 105 may also comprise one or more locators, which may or may not correspond to locators 104 on the base member 100. Locators on the frame member 105 may be used to position the frame member 105 with respect to the base member 100, to position the substrate with respect to the frame member 105, or both. For instance, the frame member 105 may comprise one or more locator pins, which can engage with one or more holes in the base member 100. Exemplary mechanical locators can include locator pins, which can be fixed, retractable, or spring-loaded, to name a few. Additional non-limiting examples of locators can include electronic sensors and other like devices.

[0028] FIG. 3A shows a top view of a substrate 1 10 positioned in a recess (not labeled) of a fixturing member 200 comprising a base member 100 having a fixturing surface 101 and a frame member 105. While frame member 105 is depicted in FIG. 3A as rectangular, it is to be understood that the shape of the frame member 105 can vary as appropriate to suit any given substrate 110. For instance, a frame member 105 having a perimeter shape that substantially corresponds to the shape of the substrate 110 can be used. The frame member 105 can thus have one or more linear and/or curvilinear edges, as desired to approximate the shape of the substrate 110. The frame member 105 may have any desired height, but in some embodiments, the height may be chosen such that the substrate 110 as positioned in the recess does not rise more than halfway up the height of the frame member 105. As noted above, the figures are not necessarily drawn to scale.

[0029] The substrate 110 can be chosen from substrates of varying compositions, sizes, and shapes. For example, the substrate 110 may comprise a glass, ceramic, glass-ceramic, polymeric, metal, and/or plastic material. Exemplary substrates 110 can include, but are not limited to, glass sheets, glass articles, plastic sheets, molded plastic parts, metal sheets, metal parts, ceramic sheets, ceramic bodies, glass-glass laminates, glass-polymer laminates, and polymer-polymer laminates, to name a few.

[0030] As depicted in FIG. 3A, the substrate 110 can have an irregular perimeter shape, but other shapes are also possible, including regular shapes such as rectangles, squares, and so forth, or any other irregular shape. In various embodiments, the substrate can be a 3D substrate, e.g., comprising at least one non-planar major surface having at least one radius of curvature, as shown in FIG. 3B. A cross-section of a 3D substrate taken from one major surface to another major surface may be non-linear, e.g., having at least one radius of curvature along at least one axis.

[0031] The substrate 110 may have any shape or thickness suitable for printing. For instance, a thickness of the substrate 110 can range from about 0.1 mm to about 5 mm or more, depending, e.g., on the flexibility of the substrate material. For instance, the substrate may have a thickness ranging from about 0.3 mm to about 4 mm, from about 0.5 mm to about 3 mm, from about 1 mm to about 2.5 mm, or from about 1.5 mm to about 2 mm, including all ranges and subranges therebetween. A three-dimensional substrate 110 may have a single radius of curvature or multiple radii, such as two, three, four, five, or more radii. The radius of curvature may, in some embodiments, be about 500 mm or greater, such as greater than about 600 mm, greater than about 700 mm, greater than about 800 mm, greater than about 900 mm, or greater than about 1000 mm, including all ranges and subranges therebetween. In other embodiments, the radius of curvature may be less than about 500 mm, such as less than about 400 mm, less than about 300 mm, less than about 200 mm, or less than about 100 mm, including all ranges and subranges therebetween.

[0032] As depicted in FIG. 3A, one or more sealing panels 120 can be positioned around a perimeter of the substrate 110. As better seen in FIG. 3B, the sealing panel(s) 120, in some embodiments, can cover a gap 121 between an edge 11 1 of the substrate 110, and an interior edge of the recess 106. In various embodiments, the sealing panel(s) 120 can extend from an interior edge of the frame member 105 to the substrate edge 111 , thereby forming a cavity 122 that can be evacuated by drawing a vacuum through orifices 102. In FIG. 3A, the sealing panels 120 are depicted as four overlapping rectangular flaps (as shown by the dashed lines), but the sealing panels can have any shape or orientation as appropriate to create a cavity 122 for promoting a vacuum seal between the substrate 110 and the base member 100. The sealing panels can also extend from the interior edge of the recess (or frame member) to any distance appropriate for forming the desired vacuum configuration. Exemplary sealing panels include, but are not limited to, vacuum flaps or platens.

[0033] FIG. 3B illustrates a cross-section, as taken along the dotted line in FIG. 3A, of the substrate 110 positioned in the fixturing member 200. The recess 106 in the fixturing member 200 is visible in the cross-sectional view and, in the depicted embodiment, the recess 106 is formed by the frame member 105 and the base member 100, which are coupled together by way of one or more sealing gaskets 107. Suitable materials for the sealing gasket 107 can include, but are not limited to, polymeric materials, such as polyurethane foam and other like

compressible materials. Non-limiting exemplary dimensions for the sealing gasket can include a width of less than about 30 mm, such as ranging from about 5 mm to about 25 mm, from about 10 mm to about 20 mm, or from about 12 mm to about 15 mm, including all ranges and subranges therebetween, although other gasket widths can also be used to maintain a vacuum seal. In some embodiments, the gasket may have a thickness of less than about 2 mm, such as less than about 1 mm, less than about 0.5 mm, less than about 0.25 mm, or less than about 0.1 mm, e.g., ranging from about 0.1 mm to about 2 mm, including all ranges and subranges

therebetween.

[0034] The substrate 110 can be positioned in the recess 106, optionally with the assistance of one or more locators on the base member (not depicted) and/or one or more locators 104' on the frame member. The substrate 110 can be positioned with a first major surface 112 in contact with the base member 100 and an opposing second major surface 1 13 facing upward or outward for printing. The substrate thickness discussed above can thus refer to the distance between the first and second major surfaces 112, 113 of the substrate 110. In some embodiments, the second major surface is the surface on which a pattern is to be printed.

[0035] As positioned in the recess 106, a gap 121 may exist between the substrate 110 and the interior edge of the recess 106. The gap 121 can be defined as a distance between an edge 111 of the substrate 1 10 and the interior edge of the recess 106. As shown in the depicted embodiment, the interior edge of the recess can correspond to the interior edge of the frame member 105. The gap 121 can extend around a perimeter of the substrate 110, although the gap length may not remain constant around the perimeter. In some instances, the gap 121 can range from about 0.1 mm to about 1 mm, such as from about 0.2 mm to about 0.9 mm, from about 0.3 mm to about 0.8 mm, from about 0.4 mm to about 0.7 mm, or from about 0.5 mm to about 0.6 mm, including all ranges and subranges therebetween. The gap 121 can be varied and/or maintained, in some embodiments, using one or more locators 104' as depicted in FIG. 3B.

[0036] Sealing panels 120 can be used to cover the gap 121 along the perimeter of the substrate 110 and to create a cavity 122 along one or more edges of the substrate 110. In certain embodiments, the sealing panel(s) 120 can comprise at least one feature, such as a surface contour, designed to mate with the edge of the recess, e.g., the top of the frame member 105, to form a vacuum seal. The cavity 122 can thus be defined by the interior edge of the recess 106 (or frame member 105), the base member 100, the substrate 110, and the sealing panel 120.

[0037] Upon application of negative pressure, such as by drawing a vacuum through orifice(s) 102, the cavity 122 can be evacuated and the substrate 110 may become vacuum sealed to the base member 100, as discussed in more detail with reference to FIGS. 4-5. Because the at least one cavity 122 is relatively small, e.g., the gap between the substrate edge 111 and the frame member 105 is relatively small (< 1 mm), the volume of air that is evacuated by the vacuum is also small, such that the negative pressure generated by the vacuum can provide enough force to flex and/or bend the substrate 110 and conform it to the predetermined contour of the fixturing surface.

[0038] For ease of illustration, FIGS. 4A-B depict only base member 100 and do not depict a frame member, although such a frame member can be combined with the base member 100 to form a fixturing member as disclosed herein. For instance, base member 100 can include one or more contact surface contours, such as one or more grooves 108, which can correspond to contour(s) on a contact surface of the frame member (not depicted). In certain embodiments, all or a portion of a frame member can fit into groove 108, optionally in an interlocked configuration. Of course, different shapes and configurations are possible, including a frame member comprising recessed features, such as grooves, that can mate with a corresponding raised feature on the base member 100, or vice versa. The raised and recessed features can have any contour, including curvilinear and flat profiles. In additional embodiments, a slide mechanism with mechanical stops may also be used to affix a frame member to the base member 100 in an accurate and/or repeatable manner. Each mechanism disclosed herein can be used alone or in conjunction with one or more sealing gaskets 107, as depicted in FIGS. 4A-B.

[0039] FIG. 4A depicts a substrate 110 having a concave shape and a fixturing surface 101 having a predetermined contour. FIG. 4A depicts the initial orientation of the substrate 110 prior to drawing a vacuum through orifices 102. In the depicted embodiment, the substrate 110 has an initial non-planar (concave) shape and the predetermined contour is also non-planar (concave), but with a shape different from that of the substrate 110. However, this embodiment is non-limiting and the initial substrate shape and predetermined contour of the fixturing surface may have any shape, including a planar shape and different degrees and/or variations of convex and/or concave curvature, and combinations thereof, including complex shapes with one or more portions that may be concave, convex, and/or planar. It should also be appreciated that while FIG. 4A depicts a substrate 110 with first and second major surfaces 1 12, 113 having the same curvature, it is also possible to perform the methods disclosed herein using substrates with first and second major surfaces having different curvatures. For example, the first major surface may be more or less planar than the second major surface, or vice versa.

[0040] FIG. 4B depicts the fixtured orientation of the substrate 110 after application of a vacuum through orifices 102 (as illustrated by the downward arrows). By applying negative pressure to the first major surface 112 of the substrate 110, the substrate can be conformed to the predetermined contour of the fixturing surface 101. The first major surface 112 can thus conform to the predetermined contour of the fixturing surface 101 and the second major surface 113 can have a contour desired for subsequent printing. The configuration depicted in FIGS. 4A-B may be advantageous for printing on substrates having the same general shape, but with slight variations. By conforming the substrates to the same predetermined contour, printing may be carried out in an accurate and/or repeatable fashion despite any minor variations that may occur due to manufacturing, processing, storing, transporting, gravity, etc. According to various embodiments, the second major surface 113 may be substantially planar upon application of negative pressure to the first major surface 112. [0041] In non-limiting embodiments, one or more retention components, such as retention gaskets 107', can be employed to promote a vacuum seal between the substrate 110 and the base member 100. For instance, the first major surface 112 of the substrate 110 may contact the retention gasket 107' before, during, and/or after application of negative pressure and the retention gasket 107' can promote formation of a vacuum seal that can be maintained, e.g., after the sealing panels (not illustrated) and/or frame member (not illustrated) are removed. Retention gasket(s) 107' can have any suitable dimension and/or composition, including those discussed above with respect to sealing gaskets 107.

[0042] FIGS. 5A-B also depict only the base member 100 and do not depict a frame member, although such a frame member can be combined with the base member to form a fixturing member as disclosed herein. However, in some embodiments, a frame member may not be present. For instance, the base member 100 can comprise a recess 106 into which the substrate 110 can be positioned. In the case of a substrate 110 with convex curvature, such as the substrate illustrated in FIGS. 5A-B, the use of a framing member and/or sealing panels may not be necessary if the radius of curvature of the substrate 110 is relatively large (e.g., the largest distance between the substrate and the base member is relatively small, such as < 5 mm). In such instances, the substrate 110 may form a cavity 122 with the base member 100 that is small enough to be evacuated to apply sufficient negative pressure to the first major surface of the substrate 110. Retention gaskets 107' may also be used to promote a vacuum seal between the substrate 110 and the base member 100. One or more locators 104, such as retractable location pins, may be provided on the base member 100 to position the substrate 110 as desired for printing.

[0043] FIG. 5A depicts the initial orientation of the substrate 110 prior to drawing a vacuum through orifices 102. In the depicted embodiment, the substrate 110 has an initial non-planar (convex) shape and the predetermined contour of the fixturing surface 101 is planar. However, this embodiment is non-limiting and the initial substrate shape and predetermined contour of the fixturing surface may have any shape, including a planar shape and different degrees and/or variations of convex and/or concave curvature, and combinations thereof, including complex shapes with one or more portions that may be concave, convex, and/or planar. As mentioned above with respect to FIGS. 4A-B, the substrate 110 can comprise first and second major surfaces that have the same or different curvature.

[0044] FIG. 5B depicts the fixtured orientation of the substrate 110 after drawing a vacuum through orifices 102 (as illustrated by the downward arrows) to evacuate cavity 122 and conform the substrate 110 to the predetermined contour of the fixturing surface 101. In some embodiments, as illustrated in FIG. 5B, the recess (not labeled) may have a height corresponding approximately to the height or thickness of the substrate in its fixtured orientation. As shown in FIG. 5B, the substrate 110 is fully flattened and the recess has a height corresponding to the thickness of the flattened substrate. According to other embodiments, the substrate may not be fully flattened and the height of the recess may correspond to a height of the substrate. According to non-limiting embodiments, the height of the recess may be within about 250 μηι of the height or thickness of the substrate in its fixtured orientation, such as ranging from 0 μηι to about 250 μηι, from about 50 μηι to about 200 μηι, or from about 100 μηι to about 150 μηι, including all ranges and subranges therebetween.

[0045] As shown in FIGS. 6A-B, the apparatuses disclosed herein may comprise one or more printing components for printing a pattern on the substrate 110. Exemplary printing components include, but are not limited to, rigid or flexible applicators, which may be straight-edged or pressure-controlled, monolithic or segmented. An exemplary applicator 130 is illustrated in FIGS. 6A-B, but other applicators such as brushes, spatulas, pads, plungers, inkjet heads, or the like, of varying shapes and sizes, are also contemplated and within the scope of the disclosure.

[0046] According to various embodiments, the applicator can be a squeegee, which can comprise any material, such as rubber materials,

polyurethanes, and the like. The applicator can be a single unit, such as a single squeegee, or can comprise segmented units, such as two or more adjacent or non- adjacent squeegees.

[0047] The applicator 130 shown in FIGS. 6A-B can, in some

embodiments, be used alone or in combination with one or more auxiliary components (not illustrated), such as screens, membranes, or other like

components. In non-limiting exemplary embodiments, a framed screen can be chosen from those disclosed in U.S. Patent Publication No. 2017/0217151 , entitled SCREEN PRINTING APPARATUS AND METHODS, filed by Applicant on July 31 , 2015, 2014, which is incorporated herein by reference in its entirety.

[0048] Additional printing components can include a printing medium, as well as components for dispensing and/or distributing such a medium. An exemplary printing medium can comprise one or more coloring agents, such as pigments, dyes, and the like. The printing medium can be a liquid, gel, sol-gel, solid, or semi-solid and can optionally comprise at least one solvent, such as water, or any other suitable solvent. In certain embodiments, the printing medium can be chosen from inks of various colors and shades. In other embodiments, the printing medium can be chosen from non-pigmented mediums, such as clear lacquers or protective coatings, to name a few. The printing medium can be chosen from colored, opaque, translucent, or transparent mediums and may serve a functional and/or decorative purpose.

[0049] In certain embodiments, such as the embodiment depicted in FIG. 6A, the fixturing surface 101 may have regions 101' of extended contour, that extend a predetermined distance beyond a dimension, e.g., length, of the substrate 110 in the fixtured orientation. For example, the extended contour region 101' may provide a location for the applicator to mechanically reside before and/or after printing, e.g. , print start and print end locations. In additional embodiments, the applicator 130 can have one or more dimensions, such as a length, that is longer than that of the substrate 110.

[0050] As shown in FIG. 6A, the extended contour regions 101 ' may allow the entire applicator 130 to conform to the predetermined contour of the fixturing surface 101 and/or to ensure proper contact between the applicator 130 and the substrate 110 during printing. For instance, portion(s) of the applicator 130

extending beyond the length of the substrate 110 can conform to the extended contour regions 101'. As shown in FIG. 6B, if the fixturing surface 101 does not comprise extended contour regions, the applicator 130 may not be able to fully conform to the shape of the fixturing surface 101 , such that spaces 132 are formed between the applicator 130 and the substrate 110. Such spaces 132 can

undesirably result in missing print on the substrate 1 10 due to the outer edges of the applicator 130 taking the shape of the non-contoured region(s) of base member 100. Downward pressure on the applicator 130 in the non-contoured region can cause an upward pressure along the remainder of the applicator 130 that can reduce the likelihood that the applicator 130 will contact the substrate 110 during printing.

However, depending on the applicator used, a base without extended contour regions 101' can also be employed in some non-limiting embodiments.

Methods

[0051] Disclosed herein are methods for printing on a surface of a substrate, the methods comprising positioning a substrate comprising a first major surface and an opposing second major surface in a recess of a fixturing member, wherein the first major surface is at least partially in contact with a fixturing surface having a predetermined contour; placing at least one sealing panel over at least one interior edge of the recess to cover a gap between a perimeter of the substrate and an interior edge of the recess; applying negative pressure to the first major surface of the substrate to conform the first major surface to the predetermined contour of the fixturing surface; and printing on the opposing second major surface of the substrate.

[0052] The methods disclosed herein can be used in combination with any of the apparatuses disclosed above or depicted in any of FIGS. 1 -6. The methods disclosed herein can be used to print or decorate substrates, such as three- dimensional substrates comprising at least one non-planar surface. Decorating or printing as disclosed herein can be used to describe the application of a coating, which can be functional and/or aesthetic, of any solid or liquid material, onto a substrate surface.

[0053] According to exemplary embodiments, the methods disclosed herein can comprise positioning a base member in a desired location, such as on a vacuum table or any other location where a vacuum component can be deployed. In some embodiments, if a frame member is utilized, the frame member can be positioned on the base member and these components can be attached, affixed, engaged or otherwise mated together to form a fixturing member comprising a recess. A substrate having an initial shape can be placed in the recess of the fixturing member, e.g., with a first major surface in contact with a fixturing surface of the base member. At least one sealing panel, such as a vacuum panel or platen, can be placed over at least one interior edge of the recess to cover a gap between a perimeter of the substrate and the interior edge of the recess. [0054] Negative pressure may then be applied to the first major surface of the substrate, e.g., by drawing a vacuum through one or more orifices present in the base member. The negative pressure may be sufficient to conform the first major surface to a predetermined contour of the fixturing surface to achieve a fixtured orientation. The predetermined contour may comprise a convex, concave, or planar curvature, or a complex curvature comprising any combination thereof. In some embodiments, the frame member (if present) and/or sealing panel(s) may be removed, and the negative pressure on the first major surface may be sufficient to retain the fixtured orientation of the substrate.

[0055] The fixtured substrate can then be optionally transported to a printing location, where a second major surface of the substrate can be printed. Alternatively, the vacuum and printing components may be in the same location such that the substrate can be fixtured and subsequently printed without a relocation step. In various embodiments, the second major surface of the substrate may be cleaned after fixturing but before printing. Alternatively, or additionally, the second major surface may be cleaned before fixturing. The substrate can be printed using any method available in the art including, but not limited to, screen printing, pad printing, inkjet printing, off-set printing, and so forth. After printing, the negative pressure on the first major surface of the substrate can be disengaged and the printed substrate removed from the fixturing member. Upon release from the fixturing member, the printed substrate can return to its initial shape.

[0056] Various additional steps can also be performed after printing such as, for example, drying the printing medium to remove one or more solvents, curing the printing medium, and/or cleaning the substrate, to name a few. According to various embodiments, the printed pattern can be corrected and/or adjusted using the methods disclosed, e.g., in U.S. Patent Publication No. 20170217152, entitled METHODS FOR SCREEN PRINTING THREE-DIMENSIONAL SUBSTRATES AND PREDICTING IMAGE DISTORTION, filed by Applicant on July 31 , 2015, which is incorporated herein by reference in its entirety.

[0057] In various embodiments, the apparatuses disclosed herein may be configured for use in a printing method that is partially or fully mechanized and/or automated. For instance, one or more steps described above may be carried out by a machine or robot, which can eliminate the need for manual alignment by a human operator. Because the accuracy and/or repeatability of the methods can be improved via locators and/or by full or partial automation, the substrate can be fixtured and subsequently printed with a location accuracy of about 500 μηι or less, such as about 250 μηι or less, about 200 μηι or less, or about 100 μηι or less, e.g., ranging from about 50 μηι to about 500 μηι, including all ranges and subranges therebetween.

[0058] The methods disclosed herein may also be used to process multiple substrates at one time or in sequence. For example, several fixturing members may be employed in the methods disclosed herein and these fixturing members may have the same or different fixturing surface contours. Several substrates may thus be pre- fixtured off-line and subsequently printed or the substrates may be fixtured and printed in sequence on-line.

[0059] The disclosed methods may have the additional advantage of little or no mechanical contact and/or pressure application, e.g., air bearing pressure, to the surface of the substrate to be printed, e.g., the second major surface. Reduced contact can result in reduced contamination from mechanical parts or dust and/or particulates from applied air pressure. In some embodiments, the apparatus may contact the second major surface of the substrate, but may not contact the portions of the substrate that are to be printed. Additionally, during removal from the apparatus, the printed portions of the substrate may not be contacted. According to various embodiments, the second major surface of the substrate may be cleaned after fixturing to remove any potential contaminants prior to printing.

[0060] Additional advantages of the disclosed methods can include the ability to fixture numerous substrates in an accurate and/or repeatable manner, which can compensate for shape and/or size variability due to manufacturing or other processing discrepancies. Further, in the case of screen printing, partially flattening a curved surface of a substrate can reduce the off-contact distance between the screen and the substrate, which can reduce print distortion. Fully flattening a curved surface of a substrate can also allow for traditional 2D printing and decoration techniques that may not otherwise be applicable to 3D substrates.

[0061] Aspect (1) pertains to a method for printing on a surface of a substrate, the method comprising the steps of: (a) positioning a substrate comprising a first major surface and an opposing second major surface in a recess of a fixturing member, wherein the first major surface is at least partially in contact with a fixturing surface having a predetermined contour;

(b) placing at least one sealing panel over at least one interior edge of the recess to cover a gap between a perimeter of the substrate and an interior edge of the recess;

(c) applying negative pressure to the first major surface of the substrate to conform the first major surface to the predetermined contour of the fixturing surface; and

(d) printing on the opposing second major surface of the substrate.

[0062] Aspect (2) pertains to the method of Aspect (1), wherein positioning the substrate in a recess of the fixturing member comprises placing a frame member in contact with a base member and placing the substrate on the base member within a perimeter of the frame member, the base member and frame member together defining the recess in the fixturing member.

[0063] Aspect (3) pertains to the method of Aspect (1) or Aspect (2), further comprising removing the frame member and the at least one sealing panel prior to printing on the second major surface.

[0064] Aspect (4) pertains to the method of any one of Aspects (1) through

(3) , wherein applying a negative pressure comprises drawing a vacuum through at least one orifice in the fixturing member.

[0065] Aspect (5) pertains to the method of any one of Aspects (1) through

(4) , wherein the substrate comprises at least one of a glass, ceramic, glass-ceramic, metal, plastic, or polymeric material.

[0066] Aspect (6) pertains to the method of any one of Aspects (1) through

(5) , wherein the substrate comprises a three-dimensional substrate having at least one non-planar surface with at least one radius of curvature.

[0067] Aspect (7) pertains to the method of any one of Aspects (1) through

(6) , wherein the substrate has a thickness extending between the first major surface and the opposing second major surface ranging from about 0.1 mm to about 5 mm. [0068] Aspect (8) pertains to the method of any one of Aspects (1) through (7), wherein the first major surface has an initial non-planar shape and the predetermined contour is substantially planar.

[0069] Aspect (9) pertains to the method of Aspect (8), wherein the opposing second major surface is substantially planar during printing.

[0070] Aspect (10) pertains to the method of any one of Aspects (1) through (9), wherein the predetermined contour has a non-planar shape different from an initial shape of the first major surface.

[0071] Aspect (11) pertains to the method of Aspect (10), wherein the fixturing surface comprises at least one extended contour extending a predetermined distance beyond at least one edge of the substrate positioned in the recess.

[0072] Aspect (12) pertains to the method of any one of Aspects (1) through (11), wherein the at least one gap has a width ranging from about 0.1 mm to about 1 mm.

[0073] Aspect (13) pertains to the method of any one of Aspects (1) through (12), wherein printing on the opposing second major surface comprises screen printing.

[0074] Aspect (14) pertains to the method of any one of Aspects (1) through (13), wherein the opposing second major surface of the substrate is not mechanically contacted by the fixturing member prior to printing on the opposing second major surface.

[0075] Aspect (15) pertains to an apparatus for printing on a surface of a substrate, the apparatus comprising:

a fixturing member comprising:

a base member comprising a fixturing surface having a predetermined contour and at least one orifice extending through a thickness of the base member; and

a frame member attached to the base member, the frame member comprising an interior edge defining a recess;

at least one sealing panel attached to the interior edge of the frame member and configured to cover at least one gap between a perimeter of a substrate positioned in the recess and the interior edge of the frame member; at least one vacuum component configured to apply negative pressure to a first major surface of the substrate through the at least one orifice; and

at least one printing component for printing on an opposing second major surface of the substrate.

[0076] Aspect (16) pertains to the apparatus of Aspect (15), wherein the fixturing member comprises at least one sealing component for sealing the frame member to the base member, wherein the sealing component is chosen from sealing gaskets, mechanically interlocking parts, and matching contact surface contours.

[0077] Aspect (17) pertains to the apparatus of Aspect (15) or Aspect (16), wherein the frame member is detachable from the base member, and wherein the vacuum component is configured to maintain negative pressure on the first major surface upon detachment of the frame member.

[0078] Aspect (18) pertains to the apparatus of Aspect (17), wherein the fixturing surface further comprises a retention component for retaining the first major surface in the predetermined contour upon detachment of the frame member.

[0079] Aspect (19) pertains to the apparatus of any one of Aspects (15) through (18), wherein the predetermined contour is non-planar or substantially planar.

[0080] Aspect (20) pertains to the apparatus of any one of Aspects (15) through (19), wherein the printing component comprises a screen and a squeegee. It will be appreciated that the various disclosed embodiments may involve particular features, elements or steps that are described in connection with that particular embodiment. It will also be appreciated that a particular feature, element or step, although described in relation to one particular embodiment, may be interchanged or combined with alternate embodiments in various non-illustrated combinations or permutations.

[0081] It is also to be understood that, as used herein the terms "the," "a," or "an," mean "at least one," and should not be limited to "only one" unless explicitly indicated to the contrary. Thus, for example, reference to "a component" includes examples having two or more such components unless the context clearly indicates otherwise. Likewise, a "plurality" is intended to denote "more than one."

[0082] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, examples include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0083] The terms "substantial," "substantially," and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a "substantially planar" surface is intended to denote an object that is planar or approximately planar. Moreover, as defined herein, "substantially similar" and "substantially identical" are intended to denote that two values or objects are equal or approximately equal.

[0084] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.

[0085] While various features, elements or steps of particular

embodiments may be disclosed using the transitional phrase "comprising," it is to be understood that alternative embodiments, including those that may be described using the transitional phrases "consisting" or "consisting essentially of," are implied. Thus, for example, implied alternative embodiments to a method that comprises A+B+C include embodiments where a method consists of A+B+C and embodiments where a method consists essentially of A+B+C.

[0086] It will be apparent to those skilled in the art that various

modifications and variations can be made to the present disclosure without departing from the spirit and scope of the disclosure. Since modifications combinations, subcombinations and variations of the disclosed embodiments incorporating the spirit and substance of the disclosure may occur to persons skilled in the art, the disclosure should be construed to include everything within the scope of the appended claims and their equivalents.

Claims

WHAT IS CLAIMED IS:

1. A method for printing on a surface of a substrate, the method comprising the steps of:

(a) positioning a substrate comprising a first major surface and an opposing second major surface in a recess of a fixturing member, wherein the first major surface is at least partially in contact with a fixturing surface having a predetermined contour;

(d) printing on the opposing second major surface of the substrate.

2. The method of claim 1 , wherein positioning the substrate in a recess of the fixturing member comprises placing a frame member in contact with a base member and placing the substrate on the base member within a perimeter of the frame member, the base member and frame member together defining the recess in the fixturing member.

3. The method of claim 1 or claim 2, further comprising removing the frame member and the at least one sealing panel prior to printing on the second major surface.

4. The method of any one of the preceding claims, wherein applying a negative pressure comprises drawing a vacuum through at least one orifice in the fixturing member.

5. The method of any one of the preceding claims, wherein the substrate comprises at least one of a glass, ceramic, glass-ceramic, metal, plastic, or polymeric material.

6. The method of any one of the preceding claims, wherein the substrate comprises a three-dimensional substrate having at least one non-planar surface with at least one radius of curvature.

7. The method of any one of the preceding claims, wherein the substrate has a thickness extending between the first major surface and the opposing second major surface ranging from about 0.1 mm to about 5 mm.

8. The method of any one of the preceding claims, wherein the first major surface has an initial non-planar shape and the predetermined contour is substantially planar.

9. The method of claim 8, wherein the opposing second major surface is substantially planar during printing.

10. The method of any one of the preceding claims, wherein the predetermined contour has a non-planar shape different from an initial shape of the first major surface.

11 . The method of claim 10, wherein the fixturing surface comprises at least one extended contour extending a predetermined distance beyond at least one edge of the substrate positioned in the recess.

12. The method of any one of the preceding claims, wherein the at least one gap has a width ranging from about 0.1 mm to about 1 mm.

13. The method of any one of the preceding claims, wherein printing on the opposing second major surface comprises screen printing.

14. The method of any one of the preceding claims, wherein the opposing second major surface of the substrate is not mechanically contacted by the fixturing member prior to printing on the opposing second major surface.

15. An apparatus for printing on a surface of a substrate, the apparatus comprising:

a fixturing member comprising:

at least one sealing panel attached to the interior edge of the frame member and configured to cover at least one gap between a perimeter of a substrate positioned in the recess and the interior edge of the frame member;

at least one vacuum component configured to apply negative pressure to a first major surface of the substrate through the at least one orifice; and

16. The apparatus of claim 15, wherein the fixturing member comprises at least one sealing component for sealing the frame member to the base member, wherein the sealing component is chosen from sealing gaskets, mechanically interlocking parts, and matching contact surface contours.

17. The apparatus of claim 15 or claim 16, wherein the frame member is detachable from the base member, and wherein the vacuum component is configured to maintain negative pressure on the first major surface upon detachment of the frame member.

18. The apparatus of any one of claims 15-17, wherein the fixturing surface further comprises a retention component for retaining the first major surface in the predetermined contour upon detachment of the frame member.

19. The apparatus of any one of claims 15-18, wherein the predetermined contour is non-planar or substantially planar.

20. The apparatus of any one of claims 15-19, wherein the printing component comprises a screen and a squeegee.