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 reel-to-reel printing processes, as standard plates lack the necessary resolution and are mechanically fragile, limiting their ability to print at micron scales effectively.

Innovation Solution

A bi-layer printing plate construction with a thermo- or photo-crosslinkable elastomeric floor layer and a thin photo-imageable elastomeric layer, where one layer contains hydrophobic fluoroalkyl side groups and the other hydrophilic hydroxyl side groups, optimizing mechanical properties and resolution by allowing differential wetting with hydrophilic or hydrophobic inks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If standard elastomeric printing plates are used, then mechanical durability is maintained, but high resolution printing capability is lost due to large relief feature depths

Engineering Contradiction:

Improveprinting resolutionVSAvoidrelief feature depth

Core Design Contradiction:

Manufacturing precisionVSLength of moving object

Solution Approach 1:

The printing plate is divided into two distinct layers: a support layer providing mechanical durability and a thin imaging layer (1-10 microns) enabling high resolution printing. This segmentation allows each layer to be optimized for its specific function, resolving the contradiction between mechanical strength and printing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the printing plate have different properties: the support layer has high mechanical strength while the imaging layer has thin dimensions for high resolution. This local differentiation of properties allows the plate to simultaneously achieve both mechanical durability and high resolution printing capability.

Inventive Principle:

Principle #3Local quality

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 reel-to-reel processes

Engineering Contradiction:

Improveprinting resolutionVSAvoidmechanical durability

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The printing plate uses a composite structure combining a mechanically robust support layer with a thin elastomeric imaging layer. This composite material approach allows the plate to achieve high resolution printing like PDMS while maintaining the mechanical durability needed for reel-to-reel processes.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If single-layer elastomeric plates are used, then manufacturing simplicity is maintained, but differential wetting capability for selective inking is lost

Engineering Contradiction:

Improveselective inking capabilityVSAvoidplate structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The imaging layer is chemically modified with specific side groups (hydrophobic fluoroalkyl or hydrophilic hydroxyl) to create differential wetting properties in different regions. This local chemical differentiation enables selective inking capability while maintaining a relatively simple two-layer structure.

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If unmodified elastomeric polymers are used, then ease of manufacture is maintained, but high resolution printing capability is limited due to large relief feature depths

Engineering Contradiction:

Improveprinting resolutionVSAvoidplate fabrication

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The elastomeric polymer is chemically modified by introducing specific side groups (fluoroalkyl or hydroxyl) that enable photoimageability and differential wetting. This chemical parameter change allows the material to achieve high resolution printing capability while remaining manufacturable through standard coating and curing processes.

Inventive Principle:

Principle #35Parameter changes

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 design enhances mechanical durability and achieves high resolution printing by optimizing each layer's properties, enabling selective inking and maintaining inter-layer adhesion, thus overcoming the limitations of standard plates in high-resolution printing applications.

Implementation Method 1

coating the composition onto a substrate and UV irradiating the coating to a depth sufficient to crosslink the elastomeric polymer

Methodology Applied

Scientific EffectPhoto polymerization: Photopolymerisation

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

Methodology Applied

Scientific EffectWetting: Wetting

Data Source

PatentUS8877428B2High resolution, solvent resistant, thin elastomeric printing plates

Publication Date: 2014.11.04 DUPONT ELECTRONICS INC

AI summary

The present invention relates to a printing element comprising at least one polymer layer on a substrate which has photoimageable constituents and a chemically functionalized polymer to make the polymer layer either more hydrophobic or hydrophilic. In one embodiment of the present invention, 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.