Photosensitive Flexographic Plate Mask Layer
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Solution Overview
Problem
Conventional flexographic printing plates with heat sensitive mask layers face challenges in achieving high light blocking effect and durability while maintaining a thin film thickness, as they either become brittle with increased carbon black density or require high energy for abrasion, leading to wrinkles and reduced durability.
Innovation Solution
The use of a butyral resin and polyamide containing polar groups as dispersion binders for carbon black in the heat sensitive mask layer improves dispersing properties, achieving a high light blocking effect with enhanced durability and reduced energy requirements for abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heat sensitive mask layer is made thinner to improve abrasion efficiency, then the light blocking effect decreases, but the layer becomes more susceptible to wrinkles and has reduced durability
Solution Approach 1:
The invention changes the chemical composition parameters of the binder resin, specifically using a polyamide resin with polar groups (carboxyl, hydroxyl, or amine groups) to improve carbon black dispersion. This parameter change allows achieving high optical density with thinner layers, resolving the contradiction between layer thickness and durability
Solution Approach 2:
The invention creates a composite heat sensitive mask layer combining carbon black with a specific polyamide binder resin containing polar groups. This composite material achieves superior dispersion and optical density at reduced thickness, maintaining durability while improving abrasion efficiency
2Reliability
If the carbon black density is increased to improve light blocking effect, then the optical density increases, but the layer becomes brittle and durability decreases
Solution Approach 1:
The invention changes the binder resin parameters to a polyamide with polar groups that specifically improves carbon black dispersion. This parameter change allows achieving high optical density through better dispersion rather than increased carbon black density, preventing brittleness and maintaining durability
Solution Approach 2:
The invention improves the local dispersion quality of carbon black within the binder matrix. The polyamide resin with polar groups creates localized regions of enhanced dispersion, allowing high optical density without uniform increases in carbon black concentration that would cause brittleness
3Reliability
If a nylon resin is used as binder to improve durability, then the layer durability improves, but the carbon black dispersing state becomes undesirable requiring increased layer thickness
Solution Approach 1:
The invention changes the binder resin from nylon to a polyamide containing polar groups (carboxyl, hydroxyl, or amine groups). This parameter change simultaneously improves carbon black dispersion and maintains durability, eliminating the need to increase layer thickness to achieve desired optical density
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 solution allows for a photosensitive flexographic printing original plate with a heat sensitive mask layer that maintains high light blocking effect and durability even at a thin thickness, reducing the risk of wrinkles and energy consumption during the abrasion process.
Implementation Method 1
the dispersing property for carbon black of a heat sensitive mask layer
Implementation Method 2
an infra-red ray sensitive layer (a heat sensitive mask layer) that is opaque to chemical rays and by evaporating this infra-red ray sensitive layer by using an infrared laser
Implementation Method 3
by evaporating this infra-red ray sensitive layer by using an infrared laser, an image mask is formed
Data Source
AI summary
The present invention provides a photosensitive flexographic printing original plate provided with a heat sensitive mask layer having high light blocking effect and durability yet prepared as a thin film. A photosensitive flexographic printing original plate including at least (A) a supporting member, (B) a photosensitive resin layer, (C) a protective layer and (D) a heat sensitive mask layer that are successively laminated, wherein the heat sensitive mask layer (D) contains carbon black and as a dispersion binder therefor, a butyral resin as well as polyamide containing polar group selected from the group consisting of polyamide containing a tertiary amine group, polyamide containing a quaternary ammonium salt group, polyamide containing an ether group and polyamide containing a sulfonic group.