Apparatus and method for producing a relief carrier

Abstract

An apparatus for generating a relief carrier using a solidifiable material (M), the apparatus comprising: a support structure (100) configured to provide a substantially cylindrical support surface, the support surface can be formed by a substrate intended to become part of the relief carrier to be generated, or by a cylindrical support not intended to become part of the relief carrier to be generated; a container (200) for the solidifiable material, the container having a wall (210) arranged substantially parallel to an axis (A) of the support structure; movement means (300) for moving the support structure relative to the wall so that a rear area (Z1, Z2) of the support surface faces the wall during movement, the movement including at least a rotation around the axis (A); and irradiation means (400) for irradiating a predetermined area between the support surface and the wall through the wall.

Description

[Technical field]

[0001] The field of the invention is that of apparatus and methods for producing relief carriers such as relief plates or sleeves, more particularly printing plates or printing sleeves, using solidifiable materials. Particular embodiments relate to the field of producing image relief plates or sleeves for printing. [Background technology]

[0002] Flexography or letterpress printing is a technique commonly used for high volume printing. A flexographic or letterpress printing plate is a relief plate in which image elements protrude above non-image elements to produce an image on a recording medium such as paper, cardboard, film, foil, laminate, etc. Flexographic or letterpress printing plates are usually flexible enough to be wrapped around a printing cylinder. Also, cylindrical printing plates or sleeves can be used.

[0003] There are various methods for making flexographic printing plates. According to the conventional method, flexographic printing plates are made from a multi-layer substrate including a backing layer and one or more photohardenable layers. These photohardenable layers are imaged by exposure to electromagnetic radiation through a mask layer containing image information, or by direct and selective exposure to light, for example by scanning the plate to transfer the image information, to obtain a relief plate. Summary of the Invention [Problem to be solved by the invention]

[0004] According to another known method, the printing plate is manufactured using additive manufacturing or 3D printing manufacturing methods. In such methods, the construction of each layer can be carried out layer by layer by solidifying the material, for example by photocurable polymer resin using UV light radiation or by melt deposition. Successive layers can be formed additively on top of the growing layer structure. Another improved method can use a continuous liquid interface printing method. Such a continuous process uses a reservoir of solidifiable material with a bottom that is transparent to radiation capable of solidifying the solidifiable material. The carrier substrate, which is the substrate on which the relief structure is built, is initially in direct contact with the solidifiable material. Subsequently, after polymerization has taken place, the substrate is moved away from the bottom of the reservoir and new liquid material fills the gaps. The formation of the solidified material on the surface of the substrate is a continuous process, the solidified material being constantly in contact with the solidifiable material in the reservoir until the formation of the printing plate is completed. Such a continuous liquid interface printing method can avoid the problem of cleavage lines that occurs in stepwise methods. It can also reduce the time taken to create the printing plate compared to traditional methods. However, when using such methods, the solidified material may adhere to the bottom wall of the container, leading to the destruction of the formed structure. Also, the supply of fresh solidifiable material to the gap formed between the growing substrate and the bottom wall may be slow and difficult, especially if the viscosity of the solidifiable material is too high. This limits the achievable speed of the manufacturing process and the quality of the resulting printing plate.

[0005] Furthermore, most additive processes are performed in a planar configuration: in printing applications, the relief-bearing plate must be mounted on a printing cylinder, which imposes mechanical stresses on the relief surface through bending, which can reduce mechanical stability and shorten the printing length.

[0006] It is an object of embodiments of the present invention to provide an apparatus and method for producing a relief carrier using a solidifiable material that is faster and more reliable than known apparatus and methods. More specifically, it is desirable to be able to produce a relief carrier or structure, in particular a printing plate or printing sleeve, using a solidifiable material in a faster and more reliable manner. Furthermore, it is desirable to provide a method and apparatus that works well with viscous solidifiable materials. [Means for solving the problem]

[0007] According to a first aspect of the invention, an apparatus for generating a relief carrier using a solidifiable material is provided. The apparatus comprises a support structure, a container, a moving means and an irradiation means. The support structure is configured to provide a substantially cylindrical support surface, which may be formed by a substrate intended to be part of the generated relief carrier or by a cylindrical support not intended to be part of the relief carrier. In other words, the support structure may be a support structure intended to be used with a substrate, or a support structure intended to be used without a substrate placed thereon, or a support structure that can be used with or without a substrate. The container is configured to receive the solidifiable material. The container has a wall arranged substantially parallel to the axis of the support structure, the support surface being at a determined distance of the wall. The moving means is configured to move the support structure relative to the wall such that during the movement, a rear area of ​​the support surface faces the wall. The movement includes at least a rotation around the axis (A) of the support structure. The support structure moves relative to the wall, which means that the support structure moves, the wall moves, or both the support structure and the wall move. The irradiation means is configured to emit irradiation through the wall in a predetermined area between the support structure and the wall to solidify the solidifiable material on the support surface, the wall being configured to allow said irradiation to pass through the wall.

[0008] By providing a cylindrical support surface, either a cylindrical surface of the substrate placed on the support structure or a cylindrical surface of the support structure itself, the solidifiable material in the container can reach the predetermined area to be irradiated more easily compared to known solutions in which the substrate is placed on a plate. Indeed, when the support structure rotates about its axis, the solidified material moves away from the predetermined area to be irradiated and new solidifiable material can flow towards the predetermined area from the immediately adjacent areas where there is a lot of solidifiable material, due to its cylindrical shape. Also, due to the rotation of the support structure, new material that is attached to the surface upstream of the predetermined area can be drawn into the predetermined area. In this way, new material can be easily drawn into the predetermined area and irradiated, even if it is a viscous material. The speed of its flow does not limit the speed of the moving means, and therefore the solidifiable material used may be more viscous than in the prior art, while still achieving good results. The support structure may be substantially cylindrical, or it may be configured to receive a cylindrical carrier, such as a hollow cylinder or a sleeve. The substrate may be, for example, a flat flexible plate or sheet or film disposed around a support structure or a cylindrical sleeve or sleeve section. If a cylindrical carrier, such as a cylindrical sleeve, is used, the support structure may, but need not, be cylindrical.

[0009] According to an exemplary embodiment, the moving means are configured to make it possible to provide the solidified material over substantially 360° on the support surface. Typically, this means that the support structure rotates around its axis one or more times over 10° to 360°. The device can usually rotate over 360°, but the rotation can also be performed over an angle of 10° to 360°, preferably 45° to 360°, more preferably 90° to 360°, most preferably 180° to 360°, most preferably 270° to 360°, most preferably less than 360°. The rotation may start at one end of the container, but a partial rotation can also be started at any point of the container. In this way, one or more layers can be formed over the entire support surface or a part of it.

[0010] In a preferred embodiment, the support surface represents a complete cylinder. For example, in an embodiment in which a substrate is used, the substrate may be a sleeve-like substrate that forms a complete cylinder. In a preferred embodiment, the support structure includes a drum to which the flexible substrate can be secured. Alternatively, a drum may be used with the substrate. In other embodiments, the support structure may include two cones configured to be inserted into either end of the sleeve-like substrate so that the cylindrical substrate can be clamped and rotated.

[0011] According to an exemplary embodiment, the moving means is configured to move the axis of the support structure parallel to the wall of the container while rotating the support structure around the axis. In that way, as a layer of solidified material is formed on the support surface, the support surface can be more or less "rolled" onto the newly solidifiable material. As seen in the given area where irradiation is taking place, the direction of rotation of the support structure is preferably opposite to the direction of movement of the support structure relative to the wall of the container. In other words, the support structure is moved relative to the wall of the container in a direction away from the side of the support structure on which the layer is formed.

[0012] According to a further developed embodiment, the moving means are configured to translate and rotate the support structure relative to the wall such that for each rotation angle of the support structure, the support structure is translated relative to the wall over a distance within 20% of π multiplied by the outer diameter d of the support surface divided by 360 (π*d / 360), preferably within 10% of said value. In other words, the movement performed by the support structure is such that the support surface rolls on an imaginary surface. In this way, disturbance or agitation of the solidifiable material in the container is limited, the forces removing the solidified material from the wall are low due to the limited adhesion area, and the peeling occurs gently and gradually, resulting in a proper formation of the solidified layer on the support surface. It is noted that the translation speed can be adjusted in function of the thickness of the substrate (if a substrate is used) and / or in function of the number of layers formed on the support surface, in order to compensate for the increased diameter.

[0013] According to an exemplary embodiment, the moving means is configured to move the support structure and / or to move the container. More specifically, the support structure can be moved parallel to the wall of the container and / or the container can be moved so that the wall of the container moves parallel to the axis of the support structure. An advantage of moving the support structure is that the device can be more compact. An advantage of moving the container is that both the support structure and the illumination means can remain fixed. However, it is also possible to couple the support structure and the illumination means and move them together relative to the container. In such an embodiment, the device can comprise an illumination moving means configured to move the illumination area of ​​the illumination means relative to the wall in synchronization with the support structure. The illumination means can also be moved parallel to the wall of the container. In addition, the movement of the illumination area of ​​the illumination means can be performed by moving the illumination area generated by the light source, for example by a moving mirror, by activation of selected LEDs of the LED array, or by a moving beam or a combination thereof.

[0014] According to a preferred embodiment, the device further comprises an adjustment means configured to change the distance between the wall and the support structure. In this way, the distance between the wall and the support structure can be changed after a first layer of solidified material is grown on the support surface or on the previous layer, so as to form a new gap between the surface of the last layer and the wall. Thereafter, a second layer can be grown on the first layer. By repeating these procedures, a relief structure with multiple layers can be grown.

[0015] According to an exemplary embodiment, the device further comprises a controller configured to control the moving means and the illumination means such that adjacent longitudinal zones behind the support surface are illuminated. These longitudinal zones extend parallel to the axis of the support structure. For example, the illumination means may be configured to illuminate a longitudinal zone having a width between 0.1 and 20 mm. Depending on the type of illumination means used, this may correspond to 1 to 2000 lines of illumination elements. For example, one line of elements may consist of a line of LEDs, or 20 to 100 laser lines may form the illumination area. It is noted that this is merely an example, and other widths and different numbers of lines may also be used in embodiments of the invention.

[0016] Preferably, the movement of the support structure (translation and / or rotation) and the illumination means is a more or less continuous process, in the sense that the support structure is continuously moved while the illumination means is continuously and selectively illuminated. However, it is also possible to provide a controller configured to control the movement means and the illumination means such that the movement and illumination are performed in stages. The segments or regions of these stages may be partially overlapping or adjacent to each other.

[0017] In a typical embodiment, the controller is configured to control the moving means, the adjusting means and the irradiating means such that one or more layers of solidified material are formed on the support surface. Preferably, at least one of said one or more layers covers more than 90°, more preferably more than 180°, and most preferably substantially 360°. In other words, preferably, the one or more layers are formed on a majority of the support surface.

[0018] More preferably, the controller is configured to control the moving means, the adjusting means and the illuminating means such that during one or more rotations of the support structure, for example over 360°, at least one full layer of solidified material forms on the support surface to form a bed, and during one or more subsequent rotations, for example over 360°, at least one image layer of structured solidified material is formed on the bed. In other words, a relief structure can be formed by forming one or more layers on the support surface. Such a method allows the production of relief structures with good image quality and at an improved speed. When working without a substrate, the bed is formed first. However, when using a substrate, the bed can also be omitted.

[0019] According to a preferred embodiment, the controller is configured to control the moving means, the adjusting means and the irradiation means in such a way that at least one structured layer of solidified material is formed during one or more rotations of the support structure through up to 360°. By repeating this movement, a three-dimensional relief is realized.

[0020] According to a preferred embodiment, the moving means is configured to move the support structure in a forward direction from an initial position to an end position relative to the wall while the support structure rotates, and then in a backward direction from the end position back to the initial position. It is also possible to move the support structure further away from the wall of the container, move the support structure backwards with or without rotation, and repeat the formation of the next layer in the forward direction. Irradiation can be stopped or continued during the backward movement. If irradiation is continued while moving the support structure in the backward direction, the support structure also rotates when it is being moved in the backward direction. Further time savings can be achieved by irradiating when the support structure moves in both the forward and backward directions. If structures have to be built on some areas of the support surface, the rotation and exposure can be limited to those areas, while during rotation without exposure, the rotation speed can be increased and the light source can be switched off to save time and / or energy.

[0021] According to an exemplary embodiment, the wall is the bottom wall of the container, preferably a flat bottom wall. Such a container is simple, robust and allows good alignment with the axis of the support structure. However, it is also possible to include a container with a curved wall, for example a bottom wall portion with a cylindrical section arranged parallel to the axis of the support structure. In a possible embodiment, the bottom wall of the container has an upwardly curved cylindrical section facing a downwardly curved cylindrical section of the support structure, the axis of which is parallel to the axis of the cylindrical section of the bottom wall. By using such opposing cylindrical sections (see also the embodiment of FIG. 3), the new solidifiable material can easily flow towards the area to be irradiated. The irradiation means is preferably arranged centrally below the cylindrical bottom wall section, so that the area in which the gap between the support structure and the bottom wall is minimal is irradiated. According to another possible embodiment, the container can be formed as a cylinder or partial cylinder with an axis parallel to the axis of the support structure, where the axis of the container and the axis of the support structure are arranged at a distance from each other and the diameter of the cylindrical container is larger than the diameter of the completely built structure (support structure with any substrate and built layers). The use of a closed cylinder can be advantageous to keep the system dust-free and to prevent evaporation of volatile substances from the container. A container formed as an open or partial cylinder facilitates the loading of any substrate and the removal of the generated relief carrier. The irradiation means are arranged to irradiate the area where the gap between the support structure and the container is minimal (see also the embodiment of FIG. 4). In order to limit the disturbance of the solidifiable material in the container, both the support structure and the container can be rotated in the same direction, for example at more or less the same speed. Also, in such an embodiment, the solidified material on the support surface can be gradually removed from the bottom wall of the container, while the new solidifiable material flows towards the irradiated area. In this setting, the amount of solidifiable material in the container can be significantly reduced.

[0022] In a possible embodiment, the wall is provided on the inside surface of the container with an anti-adhesion layer configured to limit adhesion to the solidified material. This further improves the loosening of the solidified layer from the wall of the container when the support structure is moved. Such a layer is preferably a film or coating with low surface energy, for example a fluorine- or silicon-containing material such as Teflon or silicone or organosilicon.

[0023] In another embodiment, the wall and / or part of the wall is transparent to electromagnetic radiation and / or inhibitors. Transparency to electromagnetic radiation is an important property of the wall, typically more than 50%, preferably more than 60%, more preferably more than 70%, most preferably more than 80% in the wavelength range used for irradiation. The electromagnetic wave can be, for example, any of the following: broadband electromagnetic wave, narrowband electromagnetic wave, monochromatic electromagnetic wave, large area electromagnetic wave, for example with a lamp, selective electromagnetic wave, for example irradiated by a laser, wave emitted along the entire axial length of the drum or part of the axial length of the drum, continuous or pulsed electromagnetic wave, high or low energy electromagnetic wave, UV to IR electromagnetic wave. The wavelength of the electromagnetic wave can be in the range of 200 to 20000 nm, preferably in the range of 250 to 15000 nm, more preferably in the range of 300 to 11000 nm, most preferably in the range of 350 to 11000 nm. The total power of the electromagnetic radiation may range from low enough to cause a chemical reaction to high values ​​causing rapid heating of the material, for example in the range of 0.1 mW to 2000 W, preferably 1 mW to 1000 W, more preferably 5 mW to 7500 W, and most preferably 1 W to 200 W.

[0024] The transparency of the inhibitors can be achieved by layers or membranes, which allow the inhibitors of the solidification reaction to diffuse through them and prevent solidification close to the wall. In this way, adhesion to the wall is prevented and the forces required to lift the solidified material are reduced. One of the most commonly used solidification reactions is radical polymerization and / or crosslinking, which are inhibited by oxygen. Thus, layers with a high oxygen diffusion coefficient or porous layers can be used to reduce the forces required to loosen the solidified layer from the wall of the container. Such layers with high oxygen diffusion coefficients are, for example, silicones, fluorinated polymers, LD-PE, natural and artificial rubbers.

[0025] In a preferred embodiment, the illumination means comprises one or more illumination elements arranged in one or more lines parallel to the axis of the cylinder. Typically, ten or more lines may be provided. The illumination means may comprise any one of the following or a combination thereof: UV illumination means (e.g. multiple UV LEDs), LED arrays, infrared illumination means, laser means, scanning means, projection means, liquid crystal displays, active matrix (O) LED displays. The projection means may for example comprise multiple digital micromirrors projecting a radiation beam onto the support surface. When using a liquid crystal display, one line at a time of the liquid crystal display may be switched on while the support structure is moving. More generally, illumination means may be provided that can illuminate only a small elongated zone or illumination means that can illuminate a wide zone covering the distance over which the support structure is moved (e.g. liquid crystal displays). In the latter case, there is no need to move the illumination means.

[0026] It is preferable to be able to control the illumination means so that the intensity of small increments of the linear illumination area can be changed or switched off to transition the image information. There are several ways to achieve this, which depend greatly on the illumination means employed. In the case of an LED array, the intensity of a single LED can be controlled or switched off. In the case of a light source such as a display, a single pixel can be controlled or switched off. In the case of a projection system employing movable micromirrors, the mirrors can be controlled to illuminate only selected areas. In the case of a scanning laser beam, the laser can be controlled or switched off. It is also clear that the controller controlling the moving and adjusting means can control the illumination means not only in terms of movement and speed, but also in terms of intensity, beam shape and / or diameter and position of illumination.

[0027] Preferably, the determined distance between the support surface and the wall is less than 1 cm. More preferably, the support surface and the wall are shaped such that, viewed in the direction of movement, a gap is formed that narrows towards the predetermined irradiation area. Preferably, the predetermined irradiation area is such that the solidified material extends from the support surface to the wall to obtain a suitable layer.

[0028] According to a second aspect of the present invention, there is provided a method for producing a relief carrier, more preferably a printing plate or printing sleeve, using a solidifiable material, the method comprising the steps of: - providing a substantially cylindrical support surface, which may be formed by a substrate intended to be part of the generated relief carrier or by a cylindrical support not intended to be part of the generated relief carrier; disposing said substantially cylindrical support surface at least partially within the solidifiable material in the container at a distance to a wall of the container such that the wall is parallel to an axis of the substantially cylindrical support surface; moving the support surface relative to the wall such that during the movement a trailing area of ​​the support surface faces the wall; and solidifying the solidifiable material in a predetermined area between the support surface and the wall by irradiating through the wall.

[0029] Preferred embodiments of the method are disclosed in the enclosed claims. The technical values ​​stated above in relation to the device apply mutatis mutandis to the method. Also, the features of the device can be combined with the features of the method and vice versa.

[0030] According to an exemplary embodiment, additional layers can be applied / laminate on the formed and structured solidified material. By applying additional layers on top of the formed relief structures, devices containing isolated and / or connected channels and spaces can be created. The additional layers can be made rigid enough not to sink into the formed channels, or the additional layers can be used flexible layers and care can be taken not to sink into the channels, for example by filling the channels with a fluid or gas. Optionally, the channels can be filled with other materials and fluids. Such devices can be used as microfluidic devices (e.g. for microanalysis or high throughput screening), as microreactors, as optical devices (e.g. as forehetic cells as described in WO2004 / 015491), as light control elements (e.g. as described in WO2003 / 062900) or as photonic crystals. Additional layers can be applied in a post-processing step. The above devices can be designed to be rigid or elastic. Flexible devices are preferred, especially when they are used on and / or within the human body and / or in fabrics and / or clothing.

[0031] In a preferred embodiment, the solidifiable material is a viscous photosensitive coating material. The viscosity according to DIN 1342-2 may be higher than 400 mPa·s, more preferably higher than 500 mPa·s, even more preferably higher than 700 mPa·s, and most preferably higher than 1000 mPa·s. Examples of solidifiable materials that can be used in embodiments of the present invention are viscous photosensitive compositions that solidify or harden by chemical reactions resulting in polymerization and / or crosslinking. Such reactions can be radical, cationic or anionic polymerization and crosslinking. Other means of crosslinking are condensation or addition reactions, for example the formation of esters, ethers, urethanes or amides. Such compositions may contain initiators and / or catalysts, triggered by electromagnetic radiation. Such initiators or catalysts may be photoinitiator systems with one or more components that form radicals, acids or bases, which in turn initiate or catalyze the reactions that result in polymerization or crosslinking. The required functional groups can be attached to low molecular weight monomers, oligomers, or polymers. Furthermore, the composition may contain additional components such as binders, fillers, colorants, stabilizers, surfactants, inhibitors, modifiers and other additives, which may or may not have functional groups used in the solidification reaction. Depending on the components used, flexible and / or rigid materials can be obtained after solidification and post-treatment are completed.

[0032] The method is not limited to the use of one solidifiable material. By changing the solidifiable material in the container or by replacing the container with at least another one containing a different solidifiable material, it is possible to create layers made of different materials. In this way, a multi-layer relief using at least two different materials can be obtained. Each layer can differ in color, their mechanical, chemical or physical properties.

[0033] In embodiments of the invention in which a substrate is used, the substrate may be, for example, a flat flexible plate or sheet or film or a cylindrical sleeve or sleeve section. Suitable sleeves may, for example, comprise layers of polyester, polyacrylate, polyurethane or epoxy resin, which are usually reinforced with woven or non-woven fibers or fiber mats. The fibers may be selected from polymeric fibers (made of polyester, polyamide, polyaramid, polyimide, polyethylene, polypropylene), glass fibers or carbon fibers. Preferably, glass fibers are used. Suitable dimensionally stable support layers, for example flexible plates, films or sheets, are usually 50 to 1000 micrometers thick. The material of the support layer may, for example, comprise plastics such as polyesters, such as polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyurethane or polycarbonate. Particularly suitable is a PET film having a thickness of 100 to 200 micrometers.

[0034] Preferably, the predetermined area in which the settable material is set is bounded by a support surface and a wall in order to obtain a proper depiction of the set layer.

[0035] According to another aspect, the present invention relates to the use of a relief carrier or a relief structure, preferably manufactured according to any one of the embodiments disclosed above, as a flexographic printing plate or sleeve, a letterpress printing plate or sleeve, a tampon printing plate or sleeve, an intaglio printing plate or sleeve, a microfluidic device, a microreactor, a forehetic cell, a photonic crystal and an optical device.

[0036] According to another aspect of the invention, there is provided a relief carrier having a base layer and a relief layer, the relief layer being formed as a stepped profile of solidified material, the stepped profile having a step height of less than 0.5 millimeters, preferably less than 300 micrometers.

[0037] Such a relief carrier has the advantage that the relief area is stable and narrower at the top than at the bottom, and the use of steps allows accurate and well-aligned relief structures to be obtained.

[0038] The total height or thickness of the relief layer to be constructed may be in the range of 0.1 μm to 10000 μm, preferably in the range of 1 μm to 7000 μm, more preferably in the range of 100 μm to 5000 μm, and most preferably in the range of 100 μm to 3000 μm.

[0039] Preferably, the stepped profile comprises a plurality of relief areas, at least one of which has an upper landing and at least one continuous step between the base layer and the upper landing. When the relief carrier is used for printing purposes, the upper landing can precisely define the image to be printed, while the step can ensure sufficient stability and flexibility of the relief area during printing. As explained above in connection with the embodiments of the method and the device, the upper landing can have a curved surface, since the relief layer can be built up by forming a plurality of cylindrical layers on a cylindrical support surface.

[0040] By applying and solidifying the layer creating the steps in a curved form, the surface layer of the relief carrier is not mechanically stressed when mounted cylindrically as it is on the support structure, which is an added advantage over prior art relief structures which are produced flat and then bent for mounting on, for example, a printing cylinder.

[0041] According to an exemplary embodiment, the upper landing is substantially surrounded by at least one continuous step. This further improves the stability of the relief area. However, in other embodiments, it may be sufficient to provide a continuous step at certain ends of the upper landing, but not at all ends of the upper landing. In some cases, it may be sufficient to have a step only on one side of the landing, or no steps on all sides. For example, steps may be provided parallel to the axially extending edge of the support structure, while no steps are provided at the edge perpendicular to the axial direction of the support structure. These steps may be used to mechanically stabilize the relief structure in one or several directions where stabilization is required by subsequent applications.

[0042] Preferably, each series of steps comprises at least two steps, preferably at least three steps, more preferably at least five steps. It is noted that each step may comprise one or more layers of solidified material, i.e. each step may be developed through one or more passes of the irradiation means. The step dimensions and / or shapes for adjacent steps of a series of steps may be the same or different. Optionally, if the relief carrier is intended to be used for printing, the step dimensions and / or shapes may be determined based on the image to be printed.

[0043] The step width may be the same for all steps, or the step width may be different such that the step width closer to the substrate is larger than the step width closer to the landing, or vice versa. The step width from bottom to top or from top to bottom may vary linearly, polynomially, logarithmically, or exponentially. The step width may be in the range of 1 μm to 5000 μm, preferably in the range of 10 μm to 3000 μm, more preferably in the range of 10 μm to 1000 μm, and most preferably in the range of 10 μm to 500 μm.

[0044] According to an exemplary embodiment, the relief carrier is a relief sleeve with a cylindrical base layer. However, in other embodiments, the relief carrier can be a relief cylinder segment or a flexible relief plate. Preferably, the stepped profile is provided over more than 20°, preferably over more than 90°, more preferably over more than 180°, even more preferably over more than 270° and most preferably over substantially more than 360° of the outer surface of the relief carrier. In this way, the carrier can be optimally used. When using the relief carrier for printing, the skilled person understands that the relief area, i.e. the stepped profile, depends on the image to be printed, and that certain areas of the relief carrier corresponding to the non-printed areas can be empty of any relief structure.

[0045] Preferably, the relief carrier has a maximum thickness of less than 20 mm, preferably less than 10 mm, more preferably less than 7 mm. In this way, the relief carrier can be sufficiently stable while not being too rigid.

[0046] The total height or thickness of the relief layer built up on the base layer may be in the range of 0.1 μm to 10000 μm, preferably in the range of 1 μm to 7000 μm, more preferably in the range of 100 μm to 5000 μm, and most preferably in the range of 100 μm to 3000 μm.

[0047] Preferably, the steps of the stepped profile are delimited by riser walls oriented within 20° of the radial direction of the cylindrical support surface on which the relief area is formed, preferably within 10° of the radial direction. Even more preferably, the steps of the stepped profile are delimited by walls oriented substantially radially. It should be noted that the relief carrier may be cylindrical, in which case the radial direction corresponds to the radial direction of the cylinder. Alternatively, the relief carrier is a flexible plate attached to a cylindrical surface, and the radial direction corresponds to the radial direction of the cylindrical surface.

[0048] According to yet another aspect of the present invention, there is provided a method for generating a relief carrier, more preferably a printing plate or printing sleeve, using a solidifiable material based on image data, the method comprising: providing a substantially cylindrical support surface, which may be formed by a substrate intended to be part of the generated relief carrier or by a cylindrical support not intended to be part of the generated relief carrier; determining a stepped structure including a plurality of relief areas based on the image data; applying a plurality of layers of a solidifiable material onto a substantially cylindrical support surface to obtain a stepped structure on said support surface.

[0049] Preferably, the stepped structure is determined such that at least one relief area has an upper landing and at least one continuous step between the base layer and the upper landing. The base layer may correspond to a substrate and / or one or more layers of solidified material. If a substrate is used, the one or more layers of solidified material are optional. If no substrate is used, the base layer may be formed by one or more layers of solidified material.

[0050] The preferred features given below for a relief carrier with a stepped profile may also be present in the determined stepped structure. More specifically, the number and / or the size and / or the shape of the steps of the relief area may be determined based on the image data.

[0051] Furthermore, any method step defined above in relation to the method embodiments may be used in the method according to the last aspect.

[0052] The accompanying drawings are used to illustrate presently preferred, non-limiting, exemplary embodiments of the device of the present invention. The above and other advantages of the features and objects of the present invention will become more apparent and the invention will be better understood from the following detailed description, read in conjunction with the accompanying drawings. [Brief description of the drawings]

[0053] [Figure 1] 1A, 1B and 1C show a first exemplary embodiment of a method in which the container is fixed while the support structure and the irradiation means are moved. [Diagram 2] 2A, 2B, 2C and 2D show a second exemplary embodiment of the method in which the support structure is only rotated while the container is being translated. [Diagram 3] FIG. 3 illustrates a third exemplary embodiment of an apparatus for disposing solidified material on a substrate or cylindrical carrier. [Figure 4] FIG. 4 illustrates a fourth exemplary embodiment of an apparatus for disposing solidified material on a substrate or cylindrical carrier. [Diagram 5] FIG. 5 shows a schematic perspective view of an exemplary embodiment of an apparatus for disposing solidified material on a substrate or on a cylindrical carrier. [Figure 6] FIG. 6 is a schematic cross-sectional view of an exemplary embodiment of a produced relief carrier. [Figure 7] FIG. 7 is a more detailed schematic cross-sectional view of a relief area of ​​the relief carrier of FIG. [Figure 8] 8A, 8B, and 8C respectively show a top view, a cross section along line BB in FIG. 8A, and a cross section along line CC in FIG. 8A of an exemplary embodiment of a relief area. [Figure 9] 9A, 9B, and 9C respectively show a top view, a cross section along line BB in FIG. 9A, and a cross section along line CC in FIG. 9A of an exemplary embodiment of a relief area. [Figure 10] 10A and 10B respectively show a top view and a cross-sectional view along line BB of FIG. 10A of an exemplary embodiment of a relief area. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] FIG. 1A shows a schematic representation of an apparatus for arranging a solidifiable material M on a cylindrical support surface S. The apparatus comprises a support structure in the form of a drum 100 to which a substrate can be fixed. In another embodiment, the cylindrical drum 100 itself forms the support surface on which the relief carrier is constructed, without the use of a substrate. The apparatus further comprises a container 200 containing the solidifiable material M, movement means (not shown) configured to move the drum 100 parallel to the bottom wall 210 of the container 200, adjustment means (not shown) configured to adjust the distance t between the drum 100 and the bottom wall 210, and irradiation means 400. The container 200 has a bottom wall 210 and a side wall 220. The bottom wall 210 is arranged parallel to the axis A of the drum 100. The drum 100 is arranged in the container such that the support surface S is at a determined distance t of the bottom wall 210. It is noted that the irradiation means 400 is configured to emit irradiation through the bottom wall 210 in a predefined area between the drum 100 and the bottom wall 210 to solidify the solidifiable material in that area so that it adheres to the support surface S in that area. The bottom wall 210 is configured to allow the irradiation to pass through the bottom wall 210. The adjustment means (not shown) for adjusting the distance t may be configured to move the container 200 vertically and / or the drum 100 vertically. If the container 200 is moved, the irradiation means may have to be adjusted as well.

[0055] In the following figure descriptions, when reference is made to a support surface S, this may be the surface of a flat substrate or sleeve placed on the drum 100, or it may be the surface of the drum 100 itself. In yet another embodiment, the support structure is not a drum and does not have a cylindrical support surface, but is a mounting system suitable for a cylindrical substrate. For example, the mounting system may include two cones.

[0056] The moving means (not shown) are configured to translate the drum 100 in a forward direction F parallel to the bottom wall 210 and to rotate the drum 100 in a rotation direction R about its axis A. FIG. 1A shows the drum 100 in an initial position on the right side of the container 200. FIG. 1B shows an intermediate position approximately in the middle of the container 200. The point P on the support surface S illuminated in the initial position of FIG. 1A is located at the top of the drum 100 in the position of FIG. 1B. FIG. 1B further shows that a layer L of solidified material has been formed on the support surface S over substantially 180°. The drum 100 is further rotated and translated in a forward direction F towards the left side of the container 200 (see FIG. 1C). The position shown in FIG. 1C corresponds to the end position of the drum 100. In this position, a circumferential layer L of solidified material has been formed on the support surface S and may extend over a large part of the support surface, for example over substantially 360°. Now, a second layer can be formed on the circumferential layer L on the support surface S by moving the drum 100 in a backward direction B while rotating the drum 100 in the opposite direction of rotation R. In the embodiment of Figs. 1A-1C, the irradiation means 400 move synchronously with the drum 100. However, it is also possible to provide irradiation means that extend along a distance Dp between the initial position of Fig. 1A and the end position of Fig. 1C. In such an embodiment, the switching on of the line of the irradiation means 400 can be synchronized with the translation movement of the drum 100.

[0057] In a possible embodiment, during one or more initial rotations of the support surface S over 10° to 360° in the forward / backward direction F / B, at least one circumferential layer of solidified material may be formed on the support surface S to form the bed. During one or more subsequent rotations over 10° to 360° in the forward / backward direction F / B, at least one structured layer of solidified material may be formed on the bed to form the relief structure.

[0058] In a preferred embodiment, the distance Dp between the initial position and the end position is approximately equal to the circumference of the drum 100, i.e. Dp=π*d, where d can be the outer diameter of the entire drum 100, including the substrate (if present) and any added layers. In other words, the drum 100 is rolled on an imaginary plane with a distance t of the bottom wall 210 from the initial position shown in FIG. 1A to the end position shown in FIG. 1C. Preferably, both the rotation speed of the drum 100 and the translation speed in the forward / backward direction F / B are constant, and the axis A is translated relative to the bottom wall 210 over a distance within 10% of π*d / 360 for every degree of rotation of the drum 100 around the axis A.

[0059] A person skilled in the art will understand that instead of moving the drum 100 and the irradiation means 400 in a forward / backward direction F / B, it is also possible to move the container 200 in a forward / backward direction B / F.

[0060] 2A, 2B, 2C and 2D show a second exemplary embodiment of the device comprising a drum 100 arranged in a container 200. The irradiation means 400 emits irradiation through the bottom wall 210 of the container 200 in a similar manner as described above in connection with the embodiment of FIGS. 1A-1C. In the embodiment of FIGS. 2A-2D, the container 200 is moved between an initial position shown in FIG. 2A and an end position shown in FIG. 2B. In this embodiment, the drum 100 does not rotate through 360° between the initial position and the end position, but through a smaller angle α, as shown in FIG. 2B. Note that the point P has moved through an angle α from the initial position in FIG. 2A to the second position in FIG. 2B. While the container 200 is moving in a forward direction F from the initial position to the end position, the drum 100 rotates in a rotational direction R, and the irradiation means 400 irradiates a predetermined area between the drum 100 and the bottom wall 210. In this way, a layer L of solidified material is formed on the support surface S. This layer L extends over an angle α in the end position shown in Figure 2B. The container 200 is then moved in a backward direction B from the end position of Figure 2B to the initial position (see Figure 2C). Now the container 200 is again transferred in a forward direction F and the drum 100 is rotated in a rotational direction R such that a further segment of the support surface S is covered with solidified material (see layer L in Figure 2D, which extends over an angle equal to 2*α). In the embodiment of Figures 2A-2C, no irradiation is performed during the backward movement of the container 200.

[0061] A person skilled in the art will understand that instead of moving the container 200 in the embodiment of Figures 2A-2D, it is also possible to move the drum 100 and the irradiation means 400 in a forward / backward direction F / B.

[0062] Figures 3 and 4 show two further exemplary embodiments of an apparatus for placing a solidified material on a support surface, with the same reference numbers referring to the same or similar components. In the embodiment of Figure 3, the apparatus comprises a drum 100 on which a substrate can be fixed, a container 200 containing a solidifiable material M, a moving means (not shown) configured to rotate the drum 100, an adjusting means (not shown) configured to adjust the distance between the drum 100 and a bottom wall 210 of the container 200, and an irradiation means 400. The container 200 has a bottom wall 210 and a side wall 220. The bottom wall 210 has an upwardly curved wall portion, here a bottom wall portion 215 with a cylindrical section arranged parallel to the axis A of the support structure, such that a gap is created between the cylindrical section 215 and the support surface S. Preferably, the irradiation means 400 is positioned to irradiate the area between the axis A″ of the cylindrical section and the axis A of the drum, where the gap is minimal. The upwardly curved cylindrical section 215 faces the downwardly curved cylindrical section of the support surface S. By using such opposed cylindrical sections 215, 100, the freshly solidifiable material can easily flow towards the area to be irradiated. The irradiation means 400 is preferably positioned centrally below the cylindrical bottom wall section 215, such that the area with the minimum distance between the drum 100 and the bottom wall 210 is irradiated.

[0063] In the embodiment of FIG. 4, the container 200 is formed as a cylinder or partial cylinder with an axis A' parallel to the axis A of the support structure, here the drum 100. However, the support structure can also include a clamping structure for clamping a cylindrical carrier with an axis A that is parallel to the axis A' of the container 200. The axes A, A' of the container 200 and the drum 100 are arranged at a distance from each other and the diameter of the cylindrical container 200 is larger than the diameter of the complete built structure (drum 100, any substrate, built layers). The container 200 can be a closed cylinder (shown in dotted lines), which can be advantageous to keep the system dust-free and to avoid evaporation of volatile substances from the container 200. However, the container 200 can also be formed as an open, or partial cylinder, which facilitates the loading of any substrate and the removal of the generated relief carrier. The irradiation means 400 are configured to irradiate the area where the gap between the drum 100 and the container 200 is the smallest. In this configuration, the amount of solidifiable material in the container can be significantly reduced. Both the drum 100 and the container 200 can be rotated (see arrows R and R'). For example, to limit disturbance of the solidifiable material in the container, the drum 100 and the container 200 can be rotated in the same direction. However, for other purposes, it can also be envisaged to rotate the container 200 in the opposite direction. In yet other embodiments, the container 200 can be stationary. In yet another embodiment, the drum 100 and / or the container can be stationary during exposure while the irradiation means moves on an orbit around the container. With a set of LED arrays arranged around the container, it is also possible to move the irradiation area by switching the LEDs on and off. In a subsequent step, the drum is rotated to bring further areas of the drum into contact with the solidifiable material, which is then exposed by moving the irradiation means.

[0064] In the embodiment of Figures 3 and 4, solidified material on support surface S may be gradually displaced away from the bottom wall of container 200 while newly solidifiable material flows towards the irradiated area.

[0065] FIG. 5 shows a schematic representation of an apparatus for placing a solidified material on a support surface. The apparatus comprises a container 200, a drum 100, a moving means 300, an irradiating means 400, an adjusting means 600 and a controller 500. The controller 500 is configured to control the moving means 300, the irradiating means 400 and the adjusting means 600 as shown by the dotted lines in FIG. 5. The irradiating means 400 can be coupled to the moving means 300 such that the irradiating means moves synchronously with the translation of the axis A of the drum 100. In the embodiment shown in FIG. 5, the drum 100 comprises a shaft arranged in a bearing block. The moving means is configured to move the bearing block along a guide means extending in a direction perpendicular to the axis A of the drum 100 and parallel to the bottom wall 210 of the container 200. The adjusting means 600 is configured to adjust the distance between the drum 100 and the bottom wall 210 of the container 200. The adjustment means may be configured to vertically move the axis A of the drum 100 and / or to move the container 200. When the container 200 is moved vertically, this combines with an adjustment of the illumination means 400 such that the illumination area is adjusted accordingly.

[0066] FIG. 6 is a cross-sectional view of a relief carrier 1000 having a base layer 1100 and a relief layer 1200. The relief layer 1200 is formed as a stepped profile of solidified material. The stepped profile is composed of a plurality of relief areas 1250, 1250', 1250'', 1250'''. Preferably, the base layer 1100 is a cylindrical base layer. The cylindrical base layer 1100 can subscribe the entire circumference so that a relief sleeve is formed or it can extend over less than 360°. The base layer 1100 can at least partially correspond to the substrate in embodiments where a substrate is used. In other embodiments where no substrate is used, the base layer 1100 can be a layer formed using a solidifiable material. The stepped profile can be provided over more than 10°, preferably over more than 90°, more preferably over more than 180°, even more preferably over more than 270° and most preferably over substantially 360° of the outer surface of the relief carrier 1000.

[0067] FIG. 7 shows one relief area 1250 in detail. The relief area 1250 has an upper landing 1251 and at least one continuous step 1252 between the base layer 1100 and the upper landing 1251. The upper landing 1251 can be a curved surface, for example a cylindrical surface concentric with the cylindrical base layer 1100. Each continuous step 1252 can include multiple steps, preferably at least three steps, more preferably at least five steps. In the illustrated example, for simplicity, the continuous step includes only three steps 1252, but one skilled in the art will understand that many more steps can be provided. The continuous step 1252 can extend all the way from the base layer 1100 to the upper landing, as shown in FIG. 7. However, as shown in FIG. 6, when adjacent relief areas 1250', 1250'', 1250''' are located near each other, the continuous steps of relief area 1250'' may not extend completely into base layer 1100 and may merge with the continuous steps of the adjacent relief area 1250', 1250'''.

[0068] A step may correspond to a single layer L built up during one pass of the irradiation means, but also to several layers L built up during successive passes of the irradiation means. FIG. 7 further shows some dimensions of the step 1252. Preferably, the height hs of the stepped profile step 1252 is smaller than 0.5 millimeters, more preferably smaller than 300 micrometers. The height hs may also be smaller than 200 micrometers or smaller than 100 micrometers. The base layer 1100 may have a thickness hb, for example, between 0.5 and 3 mm. The relief carrier 1000 may have a maximum thickness ht smaller than 10 mm, preferably smaller than 7 mm. The stepped profile step 1252 is delimited by riser walls 1253, 1253'. The riser walls 1253' are oriented at an angle α of less than 20° from the radial direction R, preferably less than 10° from the radial direction R. Preferably, the riser walls 1253 are substantially oriented radially. The widths w1, w2 of the steps 1252 may vary depending, for example, on the desired "steepness" of the series of steps. For example, if two adjacent relief areas 1250 are to be located close to each other, the width w2 of an upper step may be relatively small, while one or more lower steps may have a width w1 that is greater than width w2.

[0069] In a possible embodiment, the upper landing 1251 is substantially surrounded by at least one continuous step. In the embodiment of Figures 8A, 8B, 8C, the upper landing 1251 has a substantially polygonal shape, and at each end of the polygonal upper landing 1251 a continuous step 1252, 1252' is provided (see also the cross section along the line BB shown in Figure 8B and along the line CC shown in Figure 8C). The direction of the line CC may correspond to the axial direction A of the support structure. In the illustrated example, the shape of the upper landing 1251 is rectangular, but the skilled person will understand that the upper landing 1251 may have any shape, for example depending on the image that needs to be printed.

[0070] In another possible embodiment, the upper landing 1251 is not completely surrounded by at least one continuous step. In the embodiment of Figures 9A, 9B, 9C, the upper landing 1251 has a substantially polygonal shape, with two continuous steps 1252 on opposite sides of the polygonal upper landing 1251 (see also the cross section along line BB shown in Figure 9B). The direction of line CC may correspond to the axial direction A of the support structure. In the illustrated example, the shape of the upper landing 1251 is rectangular, but those skilled in the art will understand that the upper landing 1251 may have any shape, for example depending on the image that needs to be printed.

[0071] In yet another possible embodiment, the upper landing 1251 is circular or rounded. In the embodiment of Figures 10A and 10B, the upper landing 1251 has a substantially circular shape, with a circular continuous step 1252 provided around the upper landing 1251 (see also the cross section along line BB shown in Figure 10B). Naturally, other regular or irregular shapes of the upper landing and its surrounding steps are possible, so that in general the contours of the different layers are similar to the shapes of the landings, but they may also be different.

[0072] Due to the application and solidification of the layer in a curved form, the surface layer of the relief carrier is mechanically unstressed compared to prior art relief structures which are manufactured in a planar configuration and bent for mounting on a cylinder.

[0073] Furthermore, providing steps in the relief area provides additional stability to the relief area 1250. This may be particularly useful for relief areas 1250 with a small upper landing 1251. In more advanced embodiments, the stepped profile is determined in function of the image to be printed, and the number and / or size and / or shape of the steps may be adjusted in function of the image to be printed. For example, for large relief areas, fewer steps may be provided, while for small relief areas, more steps may be provided.

[0074] Those skilled in the art will readily recognize that the steps of the various methods described above may be performed by a programmed computer. Some embodiments herein are also intended to cover program storage devices, such as digital data storage media that are machine or computer readable and that encode a machine-executable or computer-executable program of instructions, the instructions performing some or all of the steps of the methods described above. The embodiments are also intended to cover computers programmed to perform the steps of the methods described above.

[0075] The functions of the various elements shown in the figures, including the functional block labeled "controller," may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. If provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared.

[0076] While the principles of the present invention have been described above with reference to specific embodiments, it should be understood that this description is made only by way of example and not as a limitation on the scope of protection determined by the appended claims.

Claims

1. 1. An apparatus for producing a relief carrier using a solidifiable material (M), said apparatus comprising: a support structure (100) configured to provide a substantially cylindrical support surface, said support surface may be formed by a substrate intended to become part of the relief carrier to be generated or by a cylindrical support not intended to become part of the relief carrier to be generated; a container (200) for receiving said solidifiable material, said container having a wall (210) arranged substantially parallel to the axis (A) of said support structure, said support surface being at a determined distance (t) of said wall; - movement means (300) configured to move said support structure relative to said wall so that a rear area (Z1, Z2) of said support surface faces said wall during the movement, said movement including at least a rotation about an axis (A); - irradiation means (400) configured to emit radiation through the wall in a predetermined area between the support surface and the wall, so as to solidify the solidifiable material on the support surface, the wall being configured so that the radiation passes through the wall.

2. The apparatus of claim 1 , wherein the support structure (100) is configured to receive a substrate in the form of a plate or sleeve that forms the support surface.

3. 3. Apparatus according to claim 1 or 2, wherein the movement means is configured to enable solidified material to be applied over substantially 360° of the support surface.

4. An apparatus according to any one of claims 1 to 3, wherein the support surface describes a complete cylinder.

5. 5. The apparatus according to claim 1, wherein the moving means is configured to move the support structure relative to the wall of the container such that the axis (A) of the support structure is moved parallel to the wall while rotating the support structure about the axis (A) of the support structure.

6. 6. The apparatus of claim 1, wherein the moving means is configured to translate and rotate the support structure relative to the wall such that for each degree of rotation of the support structure, the support structure is translated relative to the wall over a distance within 10% of a value calculated as π multiplied by an outer diameter (d) of the support surface divided by 360 (π*d / 360).

7. Apparatus according to any one of the preceding claims, wherein the movement means is configured to translate the support structure and / or to translate the container.

8. The apparatus according to any one of claims 1 to 7, further comprising an illumination moving means configured to move an illumination area of ​​the illumination means relative to the wall in synchronism with the support structure.

9. An apparatus according to any one of the preceding claims, further comprising an adjustment means configured to vary the distance between the wall and the support structure.

10. 9. The apparatus of claim 8, further comprising a controller configured to control the moving means, the illumination moving means, and the illumination means to illuminate adjacent longitudinal zones behind the support surface, the longitudinal zones extending parallel to an axis of the support structure.

11. 11. The apparatus of claim 10, wherein the controller is configured to control the moving means, the adjusting means configured to vary the distance between the wall and the support structure, and the irradiating means such that one or more layers of solidified material are formed on the support surface.

12. 12. The apparatus of claim 10 or 11, wherein the controller is configured to control the moving means, the adjusting means configured to vary the distance between the wall and the support structure, and the irradiation means so that during one or more rotations of the support structure, at least one circumferential layer of solidified material is formed on the support surface to form a bed, and during one or more subsequent rotations, at least one imaging layer of structured and solidified material is formed on the bed.

13. 12. The apparatus of claim 10 or 11, wherein the controller is configured to control the moving means, the adjusting means configured to vary the distance between the wall and the support structure, and the irradiation means such that at least one structured layer of solidified material is formed during one or more rotations of the support structure.

14. 14. Apparatus according to any one of claims 1 to 13, wherein the moving means is configured to translate the support structure relative to the wall in a forward direction from an initial position to an end position and then in a backward direction from the end position to the initial position while the support structure is rotated.

15. An apparatus according to any one of the preceding claims, wherein the wall is a bottom wall of the container.

16. Apparatus according to any one of the preceding claims, wherein the walls are provided on an inner surface of the vessel with an anti-adhesion coating configured to limit adhesion to solidified material.

17. An apparatus according to any one of the preceding claims, wherein the wall is transparent to electromagnetic radiation and / or the inhibitor can pass through the wall.

18. Apparatus according to any one of the preceding claims, wherein the illumination means comprises one or more illumination elements arranged in one or more lines parallel to the axis of the support structure.

19. 19. Apparatus according to any one of the preceding claims, wherein the illumination means comprises any one or combination of: UV illumination means, infrared illumination means, laser means, scanning means, projection means, LED array, liquid crystal display, active matrix (O) LED display.

20. 20. The apparatus of any one of claims 1 to 19, wherein the support surface is at a determined distance (t) of the wall, the distance being less than 1 cm, and / or the support surface and the wall are shaped such that a gap is formed which narrows towards a predetermined illumination area when viewed in the direction of movement.

21. 1. A method for producing a relief carrier using a solidifiable material, comprising: providing a substantially cylindrical support surface, said support surface may be formed by a substrate intended to become part of the relief carrier to be generated or by a cylindrical support not intended to become part of the relief carrier to be generated; - placing said substantially cylindrical support surface at least partially in the solidifiable material in a container at a distance of a wall of said container, said wall being parallel to the axis of said substantially cylindrical support surface; - moving the support surface relative to the wall so that during the movement a rear area of ​​the support surface faces the wall; - solidifying the solidifiable material in a predetermined area between the support surface and the wall by irradiation through the wall, The method, wherein the moving at least includes a rotation of the support surface about the axis.

22. 22. The method of claim 21, wherein the moving and solidifying steps are performed to provide solidified material over substantially 360 degrees of the support surface.

23. 23. The method of claim 21 or 22, wherein the step of moving comprises moving the axis parallel to the wall while rotating the support surface about the axis.

24. A method according to any one of claims 21 to 23, wherein the solidifiable material is a viscous photosensitive coating material.

25. 25. The method of any one of claims 21 to 24, wherein during one or more initial rotations of the support surface through 360°, at least one circumferential layer of solidified material is formed on the support surface to form a bed, and during one or more subsequent rotations, at least one imaging layer of structured and solidified material is formed on the bed to form a relief structure.

26. 26. The method of claim 25, wherein during one or more initial rotations of the support surface, at least one imaging layer of structured and solidified material is formed on the floor to form a relief structure.

27. 27. The method of any one of claims 21 to 26, wherein the moving step comprises translating and rotating the support surface relative to the wall such that for each degree of rotation of the support surface about the axis, the axis is translated relative to the wall over a distance within 10% of a value calculated as π multiplied by an outer diameter (d) of the support surface divided by 360 (π*d / 360).

28. A method according to any one of claims 21 to 27, wherein the moving step comprises translating the support surface and / or translating the container.

29. A method according to any one of claims 21 to 28, further comprising increasing the distance between the wall and the support surface after the layer of solidified material has been formed.

30. The method according to any one of claims 21 to 29, further comprising controlling the moving and irradiating steps such that an adjacent longitudinal zone behind the support surface is irradiated.

31. The method of any one of claims 21 to 30, further comprising controlling the moving and irradiating steps such that the support surface is treated multiple times.

32. 32. The method of claim 31, wherein the controlling step moves the support surface in a forward direction from an initial position to an end position while the support surface rotates, and then moves the support surface in a reverse direction from the end position to the initial position.

33. 33. The method according to any one of claims 21 to 32, wherein the irradiating step is performed with one or more irradiation elements arranged in one or more lines parallel to the axis of the substantially cylindrical support surface.

34. The method according to any one of claims 21 to 33, wherein the viscosity of the settable material according to DIN 1342 is higher than 400 mPa*s.

35. The method further comprising: - removing the produced relief carrier from the container; performing any one or more of the following post-treatments: removing unsolidified material, washing, post-exposure, post-treatment with chemicals, heating, grinding, adding at least one additional layer or a combination thereof; The method of any one of claims 21 to 34, further comprising:

36. A method according to any one of claims 21 to 35, further comprising applying or laminating a further layer onto the formed relief carrier to form channels.

37. A method according to any one of claims 21 to 36, wherein the predetermined area in which the settable material is set is delimited by the support surface and the wall.

Images