Method and apparatus for preparing a screen printing screen

1. A method of preparing a screen for a screen printing machine, comprising the steps of:

a) entering a design into a computer;

b) separating the design into individual color silhouettes, each silhouette representing a color and an individual screen;

c) coating individual pre-stretched screens with an ultra-violet light sensitive emulsion;

d) loading each pre-stretched, emulsion coated screen into a digital printing machine having both a digital printer and a source of ultra-violet light connected to the digital printing machine;

e) moving one of the screen and the digital printer relative to the other while digitally printing a silhouette on each emulsion coated screen with an ultra-violet light blocking agent while a distance between the digital printer and screen is maintained at less than approximately about 1½ millimeters;

f) moving one of the screen and the ultra-violet light source relative to the other while exposing each printed-upon emulsion coated screen to the ultra-violet light source while a distance between the light source and screen is maintained at less than 1 inch;

g) removing each exposed screen from the digital printing machine wherein the digital printing machine has a housing that substantially prevents light from entering therein and the exposed screen is removed from the housing of the digital printer;

h) processing each removed exposed screen chemically or by power spraying; and,

i) drying each screen mechanically, electronically, or naturally.

2. The method of claim 1 wherein the source of ultra-violet light operates on a wavelength wherein the ultra-violet light sensitive emulsion solidifies upon exposure thereto and the ultra-violet light blocking agent remains at least substantially flowable.

3. The method of claim 2 wherein the digitally printing step and the exposing step are carried out in a housing that substantially prevents ambient light from entering therein.

4. The method of claim 3 wherein a means for providing relative movement between each pre-stretched screen and a print head on the digital printer further provides relative movement between each pre-stretched screen and the source of ultra-violet light.

5. The method of claim 4 further comprising the step of ensuring each screen is registered in the housing.

6. A method of preparing a screen for a screen printing machine comprising the steps of:

providing a digital printing machine comprising:

a reservoir for holding a supply of an ultra-violet light blocking agent;

an applicator in fluid communication with the reservoir;

a screen bed in operative alignment with the applicator and in a housing that substantially prevents light from entering therein; and

a source of ultra-violet light in operative alignment with the screen bed;

receiving a digitally encoded design with the digital printing machine;

loading a pre-stretched screen having an ultra-violet light sensitive emulsion coating a surface thereof onto the screen bed;

providing a first relative movement between the screen bed and the applicator while the screen is on the screen bed;

applying a quantity of the ultra-violet light blocking agent to the ultra-violet light sensitive emulsion coating during the providing the first relative movement step while maintaining a distance between the applicator and the emulsion coating of approximately less than 1½ millimeters;

providing a second relative movement between the screen bed and the source of ultra-violet light while the screen is on the screen bed and subsequent to the ultra-violet light blocking agent application to the ultra-violet light sensitive emulsion coating; and

exposing the ultra-violet light sensitive coating and the ultra-violet light blocking agent to the source of ultra-violet light during the second relative movement step while maintaining a distance between the light source and the screen of approximately less than 1 inch.

7. The method of claim 6 wherein the exposing step is performed until a first portion of the ultra-violet light sensitive coating is substantially solidified and a second portion of the ultra-violet light sensitive coating beneath the ultra-violet light blocking agent and the ultra-violet light blocking agent remain at least substantially flowable.

8. The method of claim 7 wherein the exposing step is performed continuously as the pre-stretched screen traverses on the screen bed.

9. The method of claim 6 wherein the source of ultra-violet light comprises a narrow band of light emitting diodes and wherein the exposing step includes exposing only narrow portions of the pre-stretched screen continuously until a desired area of the surface of the pre-stretched screen is exposed during the second relative movement.

10. The method of claim 6 wherein the source of ultra-violet light operates on a wavelength wherein a first region of a layer of the ultra-violet light sensitive emulsion on the pre-stretched screen solidifies when exposed thereto and wherein a second region of the layer of the ultra-violet light sensitive emulsion masked by the ultra-violet light locking agent remains substantially flowable when exposed thereto.

11. The method of claim 10 wherein the exposure step is performed in less than one minute.

12. The method of claim 10 wherein the distance between the light source and the screen is less than one-eighth of an inch.

13. The method of claim 10 wherein the wavelength is between 360 and 400 nanometers.

14. The method of claim 6 further comprising the step of:

rinsing the pre-stretched screen with a pressurized fluid subsequent to the exposing step exposed screen wherein a portion of the ultra-violet light sensitive emulsion that was exposed to the source of ultra-violet light remains on the pre-stretched screen and a portion of the ultra-violet light sensitive emulsion beneath the ultra-violet light blocking agent is removed by the rinsing step.