Laminating Apparatus and Method of Using the Same

Abstract

An apparatus for laminating a film to a substrate and a method of using the same is described. The apparatus comprises a) a heated laminating roller and a second roller, wherein said heated laminating roller and said second roller are opposably mounted and form a nip; b) a drive mechanism for rotating the heated laminating roller and second roller; c) a film supply roller adapted to support a roll of film and supply the film over an outer surface of the heated laminating roller and into the nip, wherein the film is contactable with a top surface of the substrate at a point where the substrate advances through the nip; and d) a splitter bar in contact with the film supplied from the supply roller, wherein the position of the splitter bar controls a wrap angle between the film and the heated laminating roller.

Description

FIELD OF THE INVENTION[0001]The present invention relates generally to a laminating apparatus and a method of using the same.BACKGROUND OF THE INVENTION[0002]Flexography is a method of printing that is commonly used for high-volume runs. Flexography is employed for printing on a variety of substrates such as paper, paperboard stock, corrugated board, films, foils and laminates. Newspapers and grocery bags are prominent examples. Coarse surfaces and stretch films can be economically printed only by means of flexography. Flexographic printing plates are relief plates with image elements raised above open areas. Generally, the plate is somewhat soft, and flexible enough to wrap around a printing cylinder, and durable enough to print over a million copies. Such plates offer a number of advantages to the printer, based chiefly on their durability and the ease with which they can be made.[0003]A typical flexographic printing plate as delivered by its manufacturer is a multilayered article...

AI Technical Summary

Benefits of technology

The solution improves the quality of the laminated product by ensuring wrinkle-free lamination, maintaining dot integrity, and enhancing the geometric characteristics of printing dots, such as planarity and edge sharpness, leading to superior printing performance.

Problems solved by technology

It is very difficult to print small graphic elements such as fine dots, lines and even text using flexographic printing plates while maintaining open reverse text and shadows.

Maintaining small dots on flexographic plates can be very difficult due to the nature of the platemaking process.

The smallest of these dots are prone to being removed during processing, which means no ink is transferred to these areas during printing (the dot is not “held” on plate and / or on press).

Alternatively, if the dot survives processing they are susceptible to damage on press.

For example small dots often fold over and / or partially break off during printing causing either excess ink or no ink to be transferred.

In some instances, however, the quality of the laminate has been affected by the existences of wrinkles and / or waves in the laminate barrier layer film during lamination.

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