Flexo Master Angle Adjustment for Uniform Line Widths

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Solution Overview

Problem

Conventional flexographic printing systems face issues with non-uniform line widths and line spacing due to inefficient ink transfer from anilox rolls to flexo masters and subsequently to substrates, leading to irregular conductivity and performance deviations from design parameters.

Innovation Solution

The method involves a flexographic printing system with a flexo master having printing patterns disposed at an adjusted angle relative to the directional printing axis, which enhances ink transfer uniformity from the anilox roll to the substrate, allowing for the formation of fine lines with consistent line widths and spacings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional flexographic printing is used, then printing process simplicity is maintained, but line width uniformity deteriorates

Engineering Contradiction:

Improveline width uniformityVSAvoidprinting system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies parameter changes by adjusting the angle at which printing patterns are disposed on the flexo master relative to the directional printing axis. This angular parameter modification enables uniform ink transfer and consistent line widths without requiring fundamental changes to the flexographic printing system architecture.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If ink transfer from anilox roll to flexo master is improved, then ink distribution uniformity improves, but ink transfer efficiency deteriorates

Engineering Contradiction:

Improveink distribution uniformityVSAvoidink transfer efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent modifies the angular parameter of printing pattern disposition to optimize the interaction between the anilox roll and flexo master surfaces. This angular adjustment enables simultaneous achievement of uniform ink distribution and efficient ink transfer by optimizing the contact geometry during the printing process.

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

This approach enables the printing of high-resolution lines with uniform line widths and spacings, minimizing variations and improving conductivity and performance by ensuring even ink distribution and compression between the anilox roll, flexo master, and substrate.

Implementation Method 1

transferring ink from the anilox roll to the flexo master

Methodology Applied

Scientific EffectInk transfer:

Implementation Method 2

transferring ink from the flexo master to the substrate

Methodology Applied

Scientific EffectInk transfer:

Implementation Method 3

compression between the anilox roll, flexo master, and substrate

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS9132622B2Method of printing uniform line widths with angle effect

Publication Date: 2015.09.15 FUTURE TECH CAPITAL LLC

AI summary

A method of printing uniform line widths with angle effect includes transferring ink to a flexo master comprising printing patterns disposed at an adjusted angle relative to a directional printing axis and transferring ink from the flexo master to a substrate. A flexographic printing system includes an ink roll, an anilox roll, a plate cylinder, a flexo master, and an impression cylinder. The flexo master is disposed on a plate cylinder. The flexo master includes printing patterns disposed at an adjusted angle relative to a directional printing axis.