HK1005495B

HK1005495B - Improved stencil or mask for applying solder to circuit boards and support frame therefor

Info

Publication number: HK1005495B
Application number: HK98104552.5A
Authority: HK
Inventors: Godfrey Williams David
Original assignee: Alpha Fry Limited
Priority date: 1992-06-03
Filing date: 1993-05-19
Publication date: 1999-01-08

Description

The present invention relates to an improved stencil or mask for use in applying solder paste on to circuit boards and to a support frame therefor.

It is known to produce electric circuit boards with solder connections for components, such as integrated circuit chips, to apply a solder paste to the circuit board by means very similar to screen printing. In one such non printing arrangement, a solder stencil or mask comprises a thin but still relatively, stiff sheet of stainless steel or brass in which fine lines or apertures for the passage of solder paste have been formed, for example, by etching or laser cutting. The metal sheet is bonded to and supported by a thin peripherally surrounding flexible perforate sheet, of polypropylene or like, which in turn is bonded at its edges to a rectangular rigid metal frame. Such known arrangement is expensive and time-consuming to produce - particularly in view of the curing time necessary for the bonding of the adhesive. Additionally, the mesh and mask are not removably replaceable on the rectangular support frame without destruction of the mesh.

More recently it has been proposed in WO 92/08616 to provide a rigid rectangular support frame wherein on two opposite sides and extending along a substantial part of the length thereof there are mechanical coupling means for interconnection with opposite sides of a metal printing stencil or mask with one mechanical coupling means being mounted on displaceable support means which are displaceable to tension the sheet when connected between the coupling means by suitable hydraulic pneumatic or spring or mechanical tension devices as will be apparent to persons skilled in the art and well known. The mechanical coupling means includes two metal strips which underlie the normally lowermost surface of the mask sheet when in the operative position of the printing frame and mask and are coupled to the mask sheet long two opposite edges my means of a plurality of apertures in each strip at relatively large spacing and secured by screws, rivets or the like. Whilst such arrangement is suitable for relatively small circuit boards, it does have the disadvantage of not permitting circuit boards of large area to be printed because of the projection of the opposite side strips of the mechanical coupling means beneath the lowermost surface of the mask. Additionally, the arrangement produces a very rigid mask when tensioned which may not allow for slight irregularities in the circuit boards which were tolerated by the first abovementioned arrangement.

Prior specification SU1299-822-A of Omsk Poly relates to an apparatus for "silk screen printing" where the screen is of a fabric or mesh and printing ink is applied to soak through the portions of the fabric or mesh.

It is known, e.g. from DE-A-3 227 433, to provide an improved solder stencil or mask which may be readily mechanically connected with a mask or supporting and printing frame such that the mechanical coupling means do not project below the lowermost surface of the mask in its operative position and to provide a mask which is readily detachably connectable to the support frame.

It is an object of the present invention to provide a solder stencil mask which has opposite sides modified so as to be more flexible than the main body of the sheets from which the mask is formed so as to be deflectable without kinking or other deformation or possibly consequential permanent deformation in the mechanical coupling with the support frame.

The invention provides an apparatus for enabling stencilling processes to be performed in accordance with claims 1, 5, 31 and 42 ; an apparatus for supporting a stencil or mask in accordance with claim 8 ; a stencil or mask in accordance with claims 22 to 24 and 33 ; a demountable stencil in accordance with claim 36 and the use of a stencil in an apparatus, in accordance with claim 44.

According to the present invention there is provided a solder stencil or mask having opposite side regions adapted or modified by being apertured or of reduced thickness so as to be more flexible than the main body of the sheet from which the mask is formed so as to enable the opposite side regions to be bent without kinking or other deformation in the mechanical coupling with a support frame and subsequent tensioning.

Still further according to the present invention there is provided an improved stencil or mask comprising a sheet of material more flexible than known mask sheets or having at least two opposite edges adapted to be more flexible than the main body of the sheet material to enable the opposite edges to be flexed out of plane of the main sheet of material for connection to tensioning means by interengaging means sufficiently closely spaced apart along the length of said edges to avoid or minimise any irregularity or distortion in the main body of the sheet.

Preferably the stencil or mask comprises a rectangular sheet, preferably of metal, which in two opposite edges have a plurality of parallel slots extending from each edge towards the other edge by an amount sufficient to make the edge sufficiently flexible as mentioned and sufficiently closely spaced to avoid or minimise any distortion in the main body of the sheet upon tensioning. The slots in opposite edges will preferably be aligned to avoid or minimise distortion.

Instead of slots or other apertures, other interengaging means may be provided on opposite edges of the sheet, for example, fingers or tines shaped to be interengageable with cooperating interengaging means of support means of the support frame for the stencil or mask as will be described hereinafter.

Also according to the present invention there is provided apparatus for supporting a stencil or mask of sheet material, comprising a support frame having two spaced apart parallel support members interengageable with opposite edges of the stencil or mask with at least one of said support members being displaceable so as to tension said sheet or mask of sheet material between said support members and wherein the main body of the mask in which apertures are provided for the passage of solder paste, lies in a plane when tensioned, characterised by the feature that interengagable or interengaging means are provided on the support members and on the stencil or mask such that when the mask is interengaged with the support members and in the tensioned condition, the interengaging means do not project beneath the lowermost surface of the main body of the sheet material of the mask in the normal position of use.

Still further according to the present invention support apparatus for a stencil or mask of sheet material and such as already described, comprises a support frame having two spaced apart parallel support members interengageable with opposite edges of the stencil or mask with at least one of said support members being displaceable so as tension said sheet or mask of sheet material between said support members and wherein the main body of the mask in which apertures are provided for the passage of solder paste, lies in a plane when tensioned, characterised by the feature that interengagable or interengaging means are provided on the support members and on the stencil or mask such that when the mask is interengaged with the support members and in the tensioned condition, the interengaging means do not project beneath the lowermost surface of the main body of the sheet material of the mask in the normal position of use.

The support members have two lowermost surfaces proximate each other which may be planar and in the tensioned position lie in the same plane and lead in opposite and outward directions into an adjacent surface, preferably curved and possibly arcuate, which extends upwardly and away from the plane in which the normally lowermost planar surface lies in use such that the opposite edges of the mask sheet when interengaged with the support members and tensioned abut against said planar and said adjacent surface. Alternatively, the lowermost adjacent surfaces of the support members are each curved and extend from the plane of the upper surface of the mask in the position of use upwardly and away therefrom to the interengaging means. Preferably the opposite edges of the mask which are of increased flexibility or which are adapted to be of increased flexibility by said interengaging means, extend over said adjacent surface and preferably at least along a portion and along preferably half said planar surfaces.

The support members together with the interengaging means thereof which may be in the form of interdigitating shaped tines, will be displaceable, possibly by rotary movement, so as to displace the interengaging means i.e. the mechanical coupling parts out of and above the lowermost plane of the tensioned mask sheet.

It has been found that when the apparatus of the invention including the stencil or mask of sheet material is tensioned between the support members, that the support members will bow or flex inwardly and such may give rise to irregularities or inaccuracies.

To compensate for the possible bending of the support member or members caused by the pressure thereon in the operative position, it is proposed in a further embodiment that compensation means be provided in that the interengaging means on at least one support member are disposed, preferably by being arranged in an arc or curve, so that when tensioned the mask is not distorted in any way. Alternatively the supporting means may have a slight enlargement extending in an opposite direction to the bowing effect in use to compensate therefor. Alternatively the edges of the mask sheet may have a corresponding enlargement or shaped thickening as compensation means.

Preferably, however, the bowing compensation means comprises insertion means locatable between at least one edge of the stencil sheet and at least one support member and shaped and dimensioned such as to or assemble so as to fill in the space resulting from bowing as occurs in use to compensate for such and prevent or minimize any distortion of the sheet as would otherwise occur. Preferably, the insertion means comprises at least one shim or preferably a plurality of shims of different length arranged between the stencil sheet and each support member with the shorter shims being located adjacent each support member and the longer shims being located more adjacent each sheet - the shims being preferably centred on the support member and preferably located by having apertures through which the interengaging means (preferably teeth of the comb-like member) extend.

Alternatively, the bowing compensation means for each cross piece may comprise resilient means carried by each said support or each support member and which act on said stencil or mask when tensioned along the width thereof to compensate for any bowing effect.

Alternatively, bracing members may be located between the support members to either prevent bowing thereof or be extensible under pressure when the sheet is tensioned to remove the bowing or flexing effect.

In its broadest aspect, the present invention provides a stencil and support therefor which are interengageable, and preferably detachably so, such that the interengaging means do not project beneath the lowermost planar surface of the stencil in its operative position and such is preferably achieved by displacing edge regions of the stencil sheet where interengaging is effected upwardly out of said lowermost plane although such may be achieved by interengaging means which engage with the upper surface or projections (e.g. upwardly projecting tangs) therefrom of said planar stencil sheet.

According to a further aspect of the invention there is provided an improved stencil or mask comprising a sheet of material having at least one side which has a reinforcing or stiffening means extending therealong to reduce any sagging of the sheet as would otherwise exist in its position of use.

Preferably although not essentially, the mask sheet will be such as described and/or illustrated herein and the stiffening means are provided along the opposite unsupported edges/sides of the sheets which extend between the supporting means and preferably comprise L-shaped or flat rigid bars secured to and extending along the normally upper surface of the sheet.

It will be appreciated that the various features together or separately also considerably improve the accuracy of the printing operation and the resultant circuit boards.

The invention will be described further, by way of example, with reference to the accompanying drawings, in which:-

Fig. 1 is a plan view of a preferred embodiment of a symmetrical stencil or mask of thin metal sheet material wherein the opposite identical edge portions each have a plurality of identical slots aligned with respect to the slots on the opposite side and of lengths such as to provide first interengaging means and the required flexibility at the edge portions to fit around curved portions of support members of the support frame;
Fig. 2 is an example of a preferred embodiment of one of two second interengaging means cooperable with such means of the mask - one of each of such means being mountable on opposite support members and having plurality of fingers extending therefrom interengagable with the slots of the sheet member;
Fig. 3 is a schematic plan view from above of a support apparatus and mask connected thereto;
Fig. 4 is a schematic enlarged section on the line X-X of Fig. 3 illustrating the mounting of the mask sheet on the interengaging means of the support members of the support frame;
Fig. 5 is a schematic inverted plan view of an alternative and preferred embodiment of the invention and including flexing or bowing compensation means.
Fig. 6 is an enlarged fragmentary cross-section through a modified support member of the apparatus of Fig. 5 and illustrating an uppermost bowing compensation means;
Fig. 7 is a plan view of a single shim member suitable for use as a flexing or bowing compensation means;
Fig. 7A is a schematic illustration of a disposition of a four shim arrangement on one cross piece;
Fig. 8 is a sectional view through a stencil or mask sheet having lateral stiffening means and forming a separate inventive development;
Fig. 9 is a perspective view of a preferred embodiment of an apparatus according to the invention upstanding on one end and including a tensioned stencil or mask;
Fig. 10 is a fragmentary perspective view of one end of the frame having the end of a mask located thereon and illustrating the flexing edge region of the mask; and
Fig. 11 is a plan view of an alternative compensation means for compensating flexing or bowing of the support frame cross pieces.

Fig. 1 illustrates the embodiment of a solder stencil or mask 1 for use in a support apparatus 2 (not shown) and for printing solder paste on an electric circuit board which is subsequently to be heated to form the necessary circuits.

The mask 1 is made of a thin sheet of metal, such as stainless steel or brass and comprises a main portion 3 in which the necessary lines or other apertures 4 (not shown in Fig. 1) are formed by etching or laser cutting or the like (not shown) and through which solder paste passes on to a circuit board 5 when placed beneath.

Opposite identical edges of the sheet 1 have identical interengaging means 6 and 7 which are provided in the form of a row of closely spaced, narrow parallel slits or slots 6,7 which extend over sufficient length as to make the end edges 8,9 of the metal sheet more flexible than in the main body portion 3 to enable the edges to be bent out of the plane in which the main body 3 lies in the tensioned condition.

The slots 6,7 are parallel and also aligned with the identical slots 7,6 on the opposite edge 9,8.

Fig. 2 illustrates one of two interengaging members 10 with each being identical and securable to a support member 11,12 as will be described later and has a plurality of interengaging projections 13 extending from an edge thereof which are shaped and dimensioned and spaced so as to fit into the slots 6,7 of the edges 8,9 of the mask sheet 1 and be displaceable towards the outermost edge 8',9' so as to abut the ends of the slots and cause the edges of the sheet to be bent slightly out of the plane in which the main body 3 of the sheet 1 lies. Four apertures 14 are provided for securement of the interengaging members 10 on support member 11,12.

The spacing and dimensioning of the slots 6,7 at the end of the sheet 1 (other apertures or even projections may be provided) are such as to achieve flexing without permanent deformation and also such as to ensure an even tensioning without distortion of the main sheet 1.

Figs. 3 and 4 illustrate a support frame 15 having first support member 11 at one edge for carrying interengaging member 10 and second support member 12 which is displaceably mounted in the frame and displaceable by suitable known means such as hydraulic rams or locking lever means (not shown) to provide tension of the sheet. The first member 11 may be fixed against lateral displacement but rotatably displaceable and securable. Either member 11,12 may be rotary to achieve displacement of projections 13 out of the plane in which the main portion 3 lies. Preferably, however, one support member forms an end cross-piece of frame 15 and is fixed in position whilst the other support member also forms an end cross-piece of the frame parallel to said other end cross-piece and is pivotally mounted on the end of the side pieces and displaceable by means of a lever acting through a locking linkage similar to such used in Mole grip tools (possibly a locking toggle type lever linkage) so as to displace said support member and lock such in the tensioning position.

The shape of the bottom of each support member 11,12 is preferably identical but oppositely facing and has a planar or flat portion 16 leading from a perpendicular face 17 and outwardly and smoothly into a curved surface 18 against which edge portions 8,9 are tensioned.

Interengaging means or comb-like members 10 as shown in Fig. 2 are bolted to support members 11,12 and second support member. The lower surfaces of each support member 11,12 comprises a flat planar portion 16 leading from an upwardly extending portion 17' with said planar portions 16 lying in the same plane and each planar portion 16 extends smoothly into a curved portion 18 which leads upwardly and away from said plane.

The mask 1 has one edge portion 8 positioned on the first interengaging member 10 with the projections 13 thereof extending into the slots 6 and the other edge portion 9 is located on the second interengaging member 10 with the projections thereof located in the slots 7 thereof and the second support member 12 is displaceable by displacement means (not shown) such as a hydraulic or pneumatic means or spring means arranged so as to achieve even and parallel displacement of the support member 12 relative to member 11 to tension the sheet member 1 and hold such in position during the printing operation. Solder paste (not shown) is applied from above the top surface of the mask between the support members and flows through apertures 4 formed therein to a circuit board 5 located underneath to achieve accurate deposition on the board which is subsequently heat treated or the like. It will be appreciated that if the circuit board is of such size as to extend under the support members 11,12 no adverse affect is produced because the interengaging means 13,6,7 is located out of the plane in which the lowermost surface of the main body 3 of the mask sheet 1 lies and out of the plane in which the uppermost surface of the circuit boards lies which is normally the same plane.

Both of the support members 11,12 may be arranged to execute rotary movement and such rotary movement may even effect the necessary tensioning.

It is preferred that the length of the slots 6,7 in each edge of the mask sheet 1 is such to extend from the interengaging means 13 downwardly to at least half the width of the lowermost planar surface 16 of the support members.

It is important that the edges 8,9 of the sheet 1 are made sufficiently flexible, for example, by slotting or other aperturing or even thinning so as to enable flexing without distortion, and that the interengaging means not be at widely spaced points such as would cause a distortion but should be very closely spaced to ensure an even distribution of pressure over the whole width of each edge when the tensioning is applied. In this manner it is thus possible to avoid the transmission of any tensioning distortions to the main body of the mask.

It is even envisaged that the slots or like extend beyond the lowermost surface of the support members such will give sufficient flexibility to the mask to accommodate uneven circuit boards.

Fig. 5 illustrates an alternative and preferred embodiment of the invention which comprises a rectangular support frame 19 of hollow box metal section having a first support member or cross-piece 20 which is fixed relative to side frame members 21 and a second support member or cross piece 22 which interconnects the opposite ends of side members 21 and is rotatable relative thereto.

The cross-pieces 20, 22 are of similar construction apart from their mounting within frame 19 and each include interengaging members 10 having a plurality of interconnection members or teeth 13. Fig. 6 is a section in the line A-A of Fig. 5 and rotated through 180° (to correspond to the disposition of Fig. 4 which shows an alternative part arrangement). Each cross-piece 20, 22 is in two parts and comprises a main box section 23 of aluminium and a clamping plate 24 of aluminium whose lower surface 25 is a continuous curve between edge points 25' and 25" and flat/planar surface 23' on box section 23 is tangential to point 25". The steel comb-like interengaging member 10 is sandwiched between plate 24 and box section 23 and secured by screws 26 (only one shown). Location or dowel pins 27 are provided between the cross-piece sections which also increase the stiffness of the structure. A plurality, four by way of example, of compensation means for the flexing of each of the cross-pieces are provided in the form of shims 28-31 and located in position between surface 25 and mask sheet 1 having apertures therein located over the teeth of member 10. The mask sheet 1 is located so that the teeth 13 extend through the slots 6, 7 thereof and rotation of cross-piece 22 by levers 29 which operate a lever linkage somewhat in the manner of a Mole wrench or locking toggle lever arrangement (not shown) located in the box section of sides 21 and operable to rotate the teeth 13 of cross-piece 22 away from those of cross-piece 20 and thus tension the mask sheet 1 in the position of use. The cross-piece 22 is temporarily located in the tensioned position in use with the levers 29 being positioned in recesses in the side frames 21. The cross-piece may be released by moving levers 29 in the opposite direction to rotate teeth 13 thereof in the opposite direction to enable sheet 1 to be removed.

Compensation shims 28-31 of different length are centrally disposed stepwise on each cross-piece 20, 22 with the shortest 31 being in the centre and most adjacent surface 24 and the longest and outmost abutted by sheet 1. The holes 32 in the shims receive the teeth 13.

Fig 8 is a sectional view through a mask sheet having stiffening means provided on opposite lateral sides on the normally upper surface and may form a modification or improvement of the present invention or an adaption to existing mask screens and constitutes an invention in its own right.

In Fig. 8 two rigid, L-shaped and oppositely facing aluminium extrusions are bonded by a double sided adhesive strip or other means to the opposite lateral upper edges of a mask sheet 1 to provide reinforcement and to prevent sagging of the sheet in operation and/or to facilitate handling or act as protection means. A flat strip or bar may even be provided. Other alternative reinforcing or strengthening means may be provided along the edge and such as to provide improved efficiency and performance in operation. The reinforcement or strengthening may be incorporated in the stencil or mask of the present invention described herein or may alternatively adapt existing screening masks.

Figs. 9 and 10 illustrate a preferred embodiment of the apparatus according to the invention very similar to that of Figs. 5 and 6 but being inverted and with the mask 1 being tensioned. Accordingly, the same reference numerals are applied as in Figs. 5 and 6 and the description in respect thereof generally applies to this embodiment also except insofar as the bowing compensation means is concerned - see Fig. 11.

Fig. 11 is a plan view of an alternative tensioning device or bowing compensation means in the form of a flat spring plate 34 which replaces shims 28-31 of Fig. 6. Spring plate 34 is of resilient metal and is to be located between box section 23 and clamping plate 24 shown in Fig. 6 and specifically between each comb-like interengaging member 10 and plate 24 with its spring portion 35 extending beyond the edge of plate 24 to abut mask sheet 1. Plate 34 has a generally rectangular mounting portion 36 having nine main mounting apertures 37 through which securing screws 26 extend and has nine smaller apertures 38 through which location pins 27 extend.

The spring portion 35 comprises a front, abutting portion 36 connected to the main body and mounting portion by a plurality of flat generally U-shaped spring arm portions 39 which resiliently bend when a load is applied to front portion 36. In a preferred arrangement front portion 36 is in fact formed as a plurality of sections by very thin dividing cuts 37 being formed along the length.

In use, when the mask is tensioned on the projections 13 and not abutting the main body of the interengaging members at the root of the projections 13, the front portion 36 of the spring plate 34 abuts the strips defining the slots 6, 7 in the edge region of mask 1 and are pressed inwards against the action of spring arm portions 29. Since bowing or flexing of the frame cross pieces 20, 22 occurs to a greater extent towards the middle thereof, the spring arm portions 29 towards the centre may push the associated parts of abutting portion 36 into greater contact with mask 1 or to exert greater pressure thereon to compensate for the bowing of the cross piece and avoid or minimize any irregularities.

A keeper 40 is provided on each cross piece 20, 22 to facilitate the mounting of the mask 1 on the projections 10 and comprises a strip 41 (only shown in part in Fig. 11) which extends along the length of the cross piece and has a mounting arm 42 portion extending at right angles therefrom at each end (only one end shown in Fig. 11). A spring step portion 42' is provided in each arm 42. The keeper 40 is displaceably mounted on each cross piece adjacent the sides of mask 1 and may be extended to permit the slotted end region of mask 1 to be located over projections 10 and then retracted to abut mask 1 on the upper side of projections 10 to retain the mask 1 in position on projections 10 whilst tensioning is effected or whilst the other end of mask 1 is connected to the other projections 10 of the other cross piece.

In Figs. 9 and 10 a central larger locating projection 13' is provided on each interengaging means 10 and over which a larger slot 6', 7' of mask 1 is locatable for achieving desired alignment.

It will be appreciated that many modifications of embodiments may be effected without departing from the scope of the present invention. For example, instead of slots or other apertures closely spaced in two opposite edges of the sheet of the mask, a plurality of projections may be provided shaped so as to interengage with shaped apertures on interengaging means 10 on the support members 11, 12. Alternatively, the edge regions may be formed with reduced thickness to facilitate bending or flexing in the required region.

Claims

Apparatus for enabling stencilling processes to be performed, comprising a stencil (1) of sheet material and support (2,10;20-22) therefor with said stencil having at least two opposite side regions (8,9) adapted to be more flexible than the main body of the stencil; said stencil and said support (2,10;20-22) being detachably interengageable by interengaging means such that the side regions (8,9) of the stencil are flexed or bent so that the interengaging means (6,7,10,13) of the support do not project beneath the lowermost planar surface of the stencil in its operative position.
Apparatus as claimed in claim 1, in which the stencil is flexed against curved surfaces and tensioned on the support by rotary displacement of at least one support member (11,12;20,22).
Apparatus as claimed in claim 1 or 2, in which the at least two opposite side regions are adapted by being of reduced thickness or are adapted by having a plurality of apertures (6,7) in each side region (8,9), said apertures also functioning as the means for interengaging with the support, said apertures being sufficiently closely spaced apart along the length of said side regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet when tensioned.
Apparatus as claimed in any of claims 1 to 3, in which the opposite side regions (8,9) of the stencil are each adapted to be more flexible by the provision of a plurality of closely spaced, elongate narrow slots (6,7).
Apparatus for enabling stencilling processes to be performed, comprising a stencil (1) and a support frame (2,10;20,21,22) having two spaced apart parallel support members (11,12;20,22) detachably interengageable with apertures (6,7) in opposite side regions (8,9) of the stencil (1) forming interengaging means with at least one of said support members (11,12;20,22) being displaceably mounted in the frame (2,10;20-22) and displaceable so as to tension said stencil (1) between said support members (11,12;20,22), characterised by the feature that
each of the support members has interengaging means (13) extending therefrom in the form of a plurality of closely spaced comb-like teeth (13); that

said at least one support member (11,12;20,22) is rotatably mounted in said support frame and reversibly displaceable from a stencil mounting/dismounting position to a stencil-tensioning position; and that

said stencil (1) is a thin sheet of metal and having at least two opposite side regions adapted to be more flexible than the main body by the apertures in each side region (8,9) being elongate slots (6,7) similarly closely spaced and aligned with the slots forming the apertures in the opposite side region and receive said comb-like teeth (13); said stencil (1) and support members (11,12;20,22) are located such that when the stencil is mounted on the support members, said at least two opposite side regions (8,9) of the stencil (1) are flexed or bent over the support members (11,22;20,22) and the interengaging means (10,13) of the support members do not project beneath the lowermost planar surface of the stencil in its operative position.
Apparatus as claimed in claim 5, in which each opposite side region (8,9) has a larger central slot (6'7') for aligning the screen on the support members.
Apparatus as claimed in any of claims 1 to 6 in which the stencil has at least one side which has a reinforcing or stiffening means (33) extending therealong to reduce any sagging of the sheet as would otherwise exist in its position of use and/or facilitate handling or to act as protection means.
Apparatus for supporting a stencil or mask (1) of sheet material for use as part of the apparatus as claimed in any of claims 1 to 7, comprising a support frame (2,10;20,21,22) having two spaced apart parallel support members (11,12;20,22) interengageable by interengaging means (13) with interconnection means of opposite side regions (8,9) of the stencil or mask with at least one of said support members (22) being displaceable into a tensioning position (Figs. 9 and 10) so as, in use, to tension said stencil or mask (1) of sheet material between said support members (11,12;20,22), characterised by the feature that said at least one displaceable support member (11,22) has a bending surface for bending the side regions of the stencil which are adapted to be more flexible than the mainbody of the stencil and when in its tensioning position (Figs. 9, 10), the interengaging means (10,13) of the support members (11,12;20,22) do not project beneath the lowermost stencil-supporting surfaces (16) of the support members (20,22) in the normal position of use of the apparatus and that said interengaging means of each support member lie in a plane which subtends an obtuse angle with the adjacent bending surface of the support member.
Apparatus as claimed in claim 8, in which the support members (11,12;20,22) have two lowermost surfaces (16) proximate each other and in the tensioning position of the support members lie in the same plane and lead in opposite and outward directions into an adjacent surface (18) which extends upwardly and away from the plane in which the normally lowermost surfaces (16) lie in use such that the opposite side regions (8,9) of the mask sheet (1) when interengaged with the support members (11,12;20,22) and tensioned, abut against said lowermost surfaces (16) and said adjacent surfaces (18).
Apparatus as claimed in claim 8, in which two support members (11,12;20,22) are provided and have two lowermost adjacent surfaces proximate each other which are each curved and extend from the plane of the upper surface of the mask (1) in the position of use upwardly and away therefrom to the interengaging means (10, 13).
Apparatus as claimed in claim 9, in which said adjacent surface (18) is curved.
Apparatus as claimed in any of claims 8 to 11, in combination with a stencil, in which the opposite side regions (8,9) of the stencil (1) which are of increased flexibility or which are adapted to be of increased flexibility by said interengaging means, extend over said adjacent surface (18).
Apparatus as claimed in any of claims 8 to 12 in combination with a stencil, wherein the stencil is as claimed in any of claims 22 to 30 or 33-35 or 43.
Apparatus as claimed in any of claims 8 to 13, in which the support member or members (11,12;20,22) together with the interengaging means (10,13) thereof are displaceable, so as to displace the interengaging means (13) out of and above the lowermost plane of the stencil supporting surfaces (16) for the tensioned stencil (1).
Apparatus as claimed in claim 14, in which the support member (22) or members is or are displaceable by rotary movement.
Apparatus as claimed in any of claims 8 to 15 in combination with a stencil, in which the stencil (1) is adapted to be more flexible in its side regions (8,9) by the provision of a plurality of parallel slots (6,7) and the interengaging means (10) of the support members (11,12;20,22) are interdigitating projections (13).
Apparatus as claimed in any of claims 1 to 16, in which to compensate for the possible bending of the support or the support member or members (11,12;20,22) caused by the pressure thereon in the operative position, compensation means are provided either by (a) the interengaging means on at least one support member being disposed, preferably by arranged in an arc or curve, so that when tensioned, the mask or stencil is not distorted in any way; or (b) the support or support members, which support the stencil having a slight enlargement extending in an opposite direction to the bowing effect in use to compensate therefore; or (c) the edges of the mask sheet having a corresponding enlargement or shaped thickening as compensation means; or (d) insertion means (28-31) locatable between at least one edge (8',9') of the stencil sheet (1) and at least one support member (20,22) and shaped and dimensioned such as to, or assemblable so as to, fill in the space resulting from bowing as occurs in use to compensate for such and prevent or minimise any distortion of the sheet as would otherwise occur; or (e) bracing members being located between the support members to either prevent bowing thereof or be extensible under pressure when the sheet is tensioned to remove the bowing of flexing effect.
Apparatus as claimed in any of claims 1 to 16, in which compensation means (34) are provided to compensate for possible bending of the support or support members (20,22) and each comprise resilient means (35) carried by each said support (20,22) or each support member (20,22) and which act on said stencil or mask (17) when tensioned along the width thereof to compensate for any bowing effect.
Apparatus as claimed in claim 18, in which said resilient means (34) comprises a flat spring plate (34) having a mounting portion (36,37) a plurality of spring arms (39) extending therefrom and connected to or running into a mask abutting portion (36).
Apparatus as claimed in claim 19, in which said abutting portion (36) is divided into a plurality of discrete parts.
Apparatus as claimed in any of claims 1 to 20, in which each support or support member of the support frame, or the side of the frame, has a displaceable keeper bar (40-42) thereon which once the mask is located on the support or support member or support frame is displaceable to hold the mask in position until tensioning is commenced.
A stencil or mask (1) for use as part of the apparatus claimed in any of claims 1 to 21 or claims 31 or 32 or 42 of sheet material having opposite side regions (8,9) adapted or modified by being apertured (6,7) or of reduced thickness so as to be more flexible than the main body (3) of the sheet from which the mask is formed and so as to enable the opposite side regions (8,9) to be bent along said regions without kinking or other deformation during tensioning.
A stencil or mask (1) for use as part of the apparatus claimed in any of claims 1 to 21 or claims 31 or 32 or 42 for enabling solder paste to be applied onto circuit boards (5) comprising a sheet of material having at least two opposite side regions (8,9) adapted to be more flexible than the main body (3) of the sheet material (1) so as to enable the opposite side regions to be bent along said regions without kinking or other deformation during tensioning and, for connection to tensioning means (2;20-22), interengaging means (6,7) sufficiently closely spaced apart along the length of said side regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet when tensioned.
A stencil or mask (1) for use as part of the apparatus claimed in any of claims 1 to 21 or claims 31 or 32 or 42 for enabling solder paste to be applied onto circuit boards (5), comprising a sheet (1) of material having at least two opposite side regions (8,9) adapted to be more flexible than the main body (3) of the sheet material to enable the opposite side regions (8,9) to be flexed out of plane of the main sheet (1) of material and, for connection to tensioning means (2;20-22), interconnection means (6,7) sufficiently closely spaced apart along the length of said side regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet (1).
A stencil as claimed in any one of claims 22, 23 or 24, in which the opposite side regions (8,9) or edges are adapted to be more flexible than the main body (3) by having a plurality of apertures (6,7) in the region where flexing is required.
A stencil as claimed in claim 25, in which the sheet (1) is a rectangular sheet having in two opposite edges (8',9') a plurality of parallel slots (6,7) extending from each edge (8',9') towards the other edge (9',8') by an amount (8,9) sufficient to make the side regions (8,9) sufficiently flexible and said slots (6,7) being sufficiently closely spaced to avoid or minimise any distortion in the main body (1) of the sheet upon tensioning.
A stencil as claimed in claim 26, in which the slots (6,7) in opposite side regions are aligned to avoid or minimise distortion.
A stencil as claimed in any of claims 22 to 27 in which at least one side of the sheet (1) of material (3) has a reinforcing or stiffening means (33) extending therealong to reduce any sagging of the sheet (1) as would otherwise exist in its position of use.
A stencil as claimed in claim 28, in which the stiffening means (33) are provided, along the opposite unsupported edges or sides of the main body of the sheets (1) which in use extend between the support means of the stencil support apparatus.
A stencil as claimed in claim 29, in which the stiffening means each comprise an L-shapecl (33) or flat rigid bar secured to and extending along the normally upper surface (3) of the sheet (1).
Apparatus for enabling stencilling processes to be performed, comprising a stencil (1) of sheet metal and support (2,10;20,22) therefor with said stencil having two opposite side regions (8,9) made more flexible than the main body of the sheet to enable flexing without distortion; said stencil and said support (2,10;20-22) being detachably interengageable such that the side regions (8,9) of the stencil are flexed or bent against the support (2,10;20-22) and interengaging means (2,6,10,13) do not project beneath the lowermost planar surface of the stencil in its operative position.
Apparatus as claimed in claim 31, in which the stencil has a plurality of apertures (6,7) in each side region (8,9) as the means for interengaging with the support; said apertures being closely spaced apart along the length of said slide regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet when tensioned.
A stencil or mask (1) of sheet material for use as part of the apparatus claimed in any of claims 1 to 21 or claims 31 or 32 or 42 having opposite side regions (8, 9) made more flexible than the material of the sheet to enable flexing without irregularity or distortion and, for connection to tensioning means (2;20-22), interengaging means (6,7) provided by a plurality of apertures (6,7) sufficiently closely spaced apart along the length of said side regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet when tensioned.
A stencil as claimed in claim 33, in which the interengaging means include a larger central aperture provided in each side region for aligning the stencil on a support.
A stencil as claimed in claim 33 or 34 in which the interengaging means comprise a plurality of closely spaced, elongate parallel slots (6,7) provided in each side region (8,9) and over the whole of the length of each side region (8,9), with said slots being aligned with the slots in the opposite side region (8,9).
A demountable stencil (1) of thin sheet metal mounted on or mountable on a support and tensioning frame including interengaging means (6,7) in two opposite side regions (8,9) of the stencil for connection to tensioning means (2;20-22) of the frame, said interengaging means each comprising a plurality of closely spaced, elongate parallel slots (6,7) provided in each opposite side region (8,9) of the stencil to receive the comb-like projections (13) of one of the support members of the support and tensioning frame and with said slots being provided over the whole of the length of each side region (8,9) and to adapt such to be more flexible than the main body of the sheet with said slots being aligned with the slots in the opposite side region (8,9), said apertures (6,7) being sufficiently closely spaced apart along the length of said side regions (8,9) to avoid or minimise any irregularity or distortion in the main body (3) of the sheet when tensioned; and wherein a larger central aperture is provided in each side region for aligning the stencil on the frame; said stencil being sufficiently flexible to enable said opposite side regions to be flexed over surfaces, preferably curved surfaces, of the support members of the tensioning frame without or with minimal irregularity on tensioning and out of the lowermost planar surface of the stencil in its operative position.
A demountable stencil as claimed in claim 36 mounted on a support frame and such that the projections of the support members extend freely in cantilever manner from inwardly of the curve, through said slots so that the free ends of the projections of the two supports point in opposite directions.
Apparatus as claimed in one or more of claims 1 to 21 or claim 31 or 32 in combination with a thin sheet metal stencil, in which the interengaging means of the support members (11,12;20,22) each comprise a plurality of closely spaced projections (13) which lie in a plane and extend from the support members in cantilever manner and are mounted such that when the stencil is mounted thereon, the projections extend through the closely spaced apertures in opposite side regions (8,9) of the stencil with the free ends of the projections projecting outwardly beyond the stencil, to thereby, retain the stencil thereon, and wherein the normally downwardly facing surfaces of the outermost opposite side regions of the stencil in the operative position of use of the apparatus each extend from their associated support member and subtend an acute angle with the plane in which the projections lie in the tensioning position.
Apparatus as claimed in claim 38, in which, in the tensioning position, the projections of opposite supports lie in the same plane and the projections extend in opposite directions.
Apparatus as claimed in any of claims 1 to 21 or any of claims 31, 32, 38 or 39, in which one of the support members (20) is fixed and the other support member (22) is rotatably mounted and displaceable by operating levers (29) which act through a lever linkage, for example, in the manner of a Mole wrench or locking toggle lever arrangement, to displace the displaceable support member (22) such that the projections move into apertures (6,7) of the stencil and are rotated into the tensioning position whereat the lever linkage releasably holds the displaceable support (20) in such position.
Apparatus as claimed in claim 4, in which there is provided a larger aligning slot (6',7') aligned with a larger aligning slot (7',6') in the opposite side region for aligning the stencil on the support members (20,22).
Apparatus for enabling stencilling processes to be performed, comprising a stencil of thin sheet metal and support therefor which are detachably interengageable by means of closely spaced projections on opposite sides of the support engaging in abutting relationship in closely spaced apertures, preferably elongate slots, in opposite side regions of the stencil, and interengageable such that the stencil, in the tensioned position, is flexed or bent so that the interconnection means do not project beneath the lowermost planar surface of the stencil in its operative position.
A stencil as claimed in any of claims 23, 24 or 25, in which the opposite side regions (8,9) are adapted to be more flexible than the main body by having a plurality of elongate, closely spaced, narrow slots provided over the length of two opposite sides of the stencil.
The use of a stencil of thin sheet metal as claimed in any one of claims 22 to 30 or in any of claims 33 to 35 or 36 or 37 or 43 in an apparatus for enabling stencilling processes to be performed as claimed in any of claims 1 to 21 or claim 31 or 32 or 38 or 42, wherein the stencil is detachably located on the supports (2,10;20-22) of the apparatus with the projections forming the inter-engaging means of the supports (2,10;20-22) being inserted through apertures forming the inter-engaging means of the stencil, and wherein at least one support is displaced causing the opposite side regions of the stencil to be bent over support surfaces of the supports when the stencil is in the tensioned condition, so that the inter-engaging means do not project beneath the lowermost planar surface of the stencil in its operative position.
A stencil or mask (1) as claimed in any one of claims 22 to 30, 33 to 35 and 43 made of a thin sheet of metal.
A stencil or mask (1) as claimed in claim 45 made of stainless steel or brass.