Bi-layer elastomeric printing plates for high resolution
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Solution Overview
Problem
Current printing technologies face challenges in achieving high resolution and mechanical durability for elastomeric printing plates, particularly in large-scale reel-to-reel printing processes, as existing materials are either mechanically fragile or unsuitable for high-resolution applications.
Innovation Solution
A bi-layer printing plate design featuring a thermo- or photo-crosslinkable elastomeric floor layer and a thin photo-imageable elastomeric layer with chemically modified polymers, optimized for differential inking with hydrophilic or hydrophobic inks, utilizing semi-interpenetrating polymer networks (SIPNs) to enhance mechanical properties and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unmodified elastomeric polymers are used for printing plates, then mechanical durability is improved, but relief feature depths become very large precluding high resolution printing
Solution Approach 1:
The printing plate is divided into a multilayered structure with different elastomeric polymer layers, each having different hardness and relief feature depths. The top layer has smaller relief features for high resolution printing, while the bottom layer has larger relief features for mechanical durability and conformal contact.
Solution Approach 2:
Different regions of the printing plate have different properties - the top layer has softer, smaller relief features optimized for high resolution, while the bottom layer has harder, larger relief features optimized for durability. This local differentiation allows each layer to perform its specific function optimally.
2Manufacturing precision
If PDMS elastomeric stamps are used for high resolution printing, then printing resolution is improved, but mechanical fragility increases making them unsuitable for large scale reel-to-reel printing
Solution Approach 1:
The printing plate is segmented into multiple layers where the top PDMS layer provides high resolution printing capability while the bottom layer provides mechanical durability. This segmentation allows the fragile high-resolution layer to be supported by a robust base layer.
Solution Approach 2:
The invention uses composite elastomeric polymer materials with different properties in each layer. The top layer uses PDMS or similar soft elastomers for high resolution, while the bottom layer uses harder elastomeric polymers for mechanical strength, creating a composite structure that combines both benefits.
3Strength
If standard elastomeric printing plates are used, then mechanical durability is maintained, but compatibility with hydrophilic inks is reduced
Solution Approach 1:
The surface properties of the printing plate are locally modified to create hydrophobic regions that are compatible with hydrophilic inks. The chemically modified polymers with fluoroalkyl or hydroxyl side groups create differential wetting patterns that enable selective inking while maintaining the overall mechanical durability of the elastomeric structure.
Solution Approach 2:
The chemical composition of the polymer is changed by adding side groups (fluoroalkyl or hydroxyl) that alter the surface energy and wettability properties. This parameter change enables the elastomeric polymer to become compatible with hydrophilic inks while retaining its mechanical properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bi-layer plate achieves high resolution printing with improved mechanical durability, enabling selective inking and compatibility with hydrophilic or hydrophobic inks, addressing the limitations of existing materials in high-resolution and large-scale printing applications.
Implementation Method 1
the polymer is photoimageable and has been chemically modified to contain either hydrophobic fluoroalkyl side groups or hydrophilic hydroxyl side groups to provide differential wetting with hydrophilic inks
Implementation Method 2
the polymer is photoimageable and has been chemically modified to contain either hydrophobic fluoroalkyl side groups or hydrophilic hydroxyl side groups to provide differential wetting with hydrophilic inks
Implementation Method 3
chemically modified to contain either hydrophobic fluoroalkyl side groups or hydrophilic hydroxyl side groups to provide differential wetting with hydrophilic inks
Implementation Method 4
the polymer layer comprises an elastomeric block copolymer... that has been chemically modified... along with separate photoimaging constituents
Data Source
AI summary
The present invention relates to a printing element having at least one polymer layer which has photoimageable constituents and a chemically functionalized polymer to make the polymer layer either more hydrophobic or hydrophilic. In one embodiment, the printing element comprises two adjacent polymer layers on a substrate in which the photoimaged layer comprises a polymer chemically modified with hydrophobic fluoroalkyl side groups to provide differential wetting with hydrophilic inks.