Cylindrical Photosensitive Element Lamination Process
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Solution Overview
Problem
Existing methods for forming cylindrically-shaped photosensitive elements are time-consuming and prone to defects such as bubbles, which can lead to ink-transfer issues and poor print quality due to air entrapment and non-uniformities in the photopolymer layer.
Innovation Solution
A process involving a cylindrically-shaped support with a compliant outer surface, where a photosensitive layer is laminated and sealed using a laminating roll to form a continuous, seamless layer without the need for adhesives, reducing the risk of bubbles and enabling quick production of high-quality printing forms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the photopolymerizable layer is heated after wrapping to join the edges together to form a seamless cylindrical element, then the cylindrical printing element can be formed, but the process takes extended periods of time
Solution Approach 1:
The photopolymerizable layer is pre-heated to a temperature sufficient to effect attachment before contacting the cylindrical support. This preliminary heating action allows the layer to become tacky and bond immediately upon contact, eliminating the need for extended heating after wrapping and significantly reducing production time
2Shape
If the photopolymerizable layer is heated to join the edges, then the seamless cylindrical element can be formed, but bubbles and air entrapment occur leading to defects
Solution Approach 1:
The photopolymerizable layer is pre-heated before contact to activate adhesion, allowing it to bond smoothly to the cylindrical support without trapping air bubbles. The layer becomes tacky in advance, ensuring uniform contact and eliminating defects that would compromise print quality
Solution Approach 2:
The temperature of the photopolymerizable layer is changed to a specific range (above glass transition temperature but below melting point) to optimize its adhesive properties. This parameter change makes the layer tacky and bondable without causing excessive flow or bubble formation, ensuring reliable print quality
3Stability of the object's composition
If adhesive material or tape is used to attach the photopolymerizable layer to the support, then the layer can be secured, but potential for defects and non-uniformities increases
Solution Approach 1:
The photopolymerizable layer attaches to the cylindrical support through its own inherent adhesive properties when heated to the appropriate temperature. No external adhesive materials or tapes are needed, eliminating the potential for defects associated with additional bonding materials and ensuring uniform attachment across the entire surface
4Shape
If the photopolymerizable layer is heated to a temperature to join the edges, then the cylindrical form can be formed, but the process is time-consuming
Solution Approach 1:
The photopolymerizable layer is pre-heated to attachment temperature before contact with the cylindrical support. This preliminary action ensures immediate bonding upon contact, allowing rapid formation of the cylindrical structure without extended heating periods, thereby significantly improving production efficiency
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 process significantly reduces production time to minutes, eliminates defects like bubbles, and ensures uniformity and adhesion of the photosensitive layer, resulting in improved print quality and increased operational efficiency.
Implementation Method 1
wherein the roll (11) is selected from a shaft, a drum or a mandrel and wherein the outer surface (21) of the roll (11) is compliant
Implementation Method 2
heating the photosensitive layer (20), or the support (12), or both the photosensitive layer (20) and the support (12)
Implementation Method 3
Upon imagewise exposure to actinic radiation, polymerization, and hence, insolubilization of the photopolymerizable layer occurs in the exposed areas
Data Source
Figure 1~3
AI summary
The invention provides a process for making a cylindrically-shaped photosensitive element for use as a printing form. The process includes supporting an interior surface of a cylindrically-shaped support on a roll having an outer surface that is compliant; contacting a photosensitive layer to an exterior surface of the cylindrically-shaped support by wrapping the photosensitive layer around the support to bring a second end of the layer adjacent a first end of the layer; laminating the photosensitive layer to the support and sealing the ends together to form a continuous layer on the support; and heating the photosensitive layer, or the support, or both the photosensitive layer and the support.