Flexo-Plate Maker Using Segmented Photopolymerization
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Solution Overview
Problem
Current methods for creating flexographic print masters are inefficient, lack precision in defining relief features, and generate excessive dust and debris, leading to poor print quality due to the complexity of mechanical manufacturing and layer control.
Innovation Solution
A flexo-platemaker system with a vat for curable liquids, featuring a transparent bottom and illumination systems for precise curing, including a matrix of addressable pixels and a scanning light beam, allows for the creation of flexographic print masters with optimized mechanical characteristics and reduced dust production by controlling the physical properties of each layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional photopolymerization method with mask layer is used, then image features can be formed on print master, but the process requires extensive processing steps and offers little control over the slope of image features
Solution Approach 1:
The patent segments the image features into multiple layers (first image relief layer and second image relief layer) with different functions. The first layer captures major image features with controlled slopes, while the second layer adds fine details. This segmentation allows independent optimization of each layer's slope characteristics, solving the control problem without requiring complex multi-step processing.
Solution Approach 2:
The patent performs preliminary action by pre-defining the slope characteristics of image features in the first image relief layer before adding the second layer. The slope control is established in advance during the formation of the first layer, which then serves as a foundation for the second layer. This preliminary slope definition simplifies the overall process by eliminating the need for complex real-time slope adjustment mechanisms.
2Manufacturing precision
If inkjet printing system is used to build up flexographic print master layer by layer, then slope control is theoretically possible, but it is difficult to control the exact shape and thickness of layers due to surface tension effects and spherical shape of droplets
Solution Approach 1:
The patent replaces the mechanical inkjet droplet deposition system with a photopolymerization-based layer formation system. Instead of relying on mechanical control of droplet shape and placement, the invention uses light-induced polymerization to form layers with precise shape and thickness control. The photopolymerization process allows for exact layer geometry definition through mask patterns, eliminating the harmful surface tension effects and spherical droplet shapes inherent in inkjet systems.
Solution Approach 2:
The patent changes the fundamental parameter of layer formation from mechanical droplet deposition to photopolymerization. By switching from a mechanical system (inkjet) to a chemical-optical system (photopolymerization), the invention achieves precise control over layer shape and thickness. The photopolymerization process allows layers to be formed with exact geometric definitions from masks, completely avoiding the unevenness problems caused by inkjet droplet physics.
3Manufacturing precision
If additive three-dimensional print processes use inkjet to create flexographic print master, then layers can be deposited, but it is difficult to achieve that the image features in the top image layer are in a single plane
Solution Approach 1:
The patent segments the image relief structure into two separate layers (first and second image relief layers) deposited on the elastomeric floor. Each layer is formed through controlled photopolymerization processes that ensure planarity. The first layer establishes a planar foundation, and the second layer is deposited to achieve the final planar top surface. This segmentation allows each layer to be optimized for planarity independently, solving the problem of achieving a single-plane top image layer.
Solution Approach 2:
The patent replaces the inkjet-based additive manufacturing system with a photopolymerization-based system. Instead of using mechanical droplet deposition that struggles with planarity control, the invention uses light-induced polymerization with mask patterns to form each layer. This substitution enables precise control over layer geometry and ensures that the top image layer achieves a single-plane configuration, eliminating the planarity problems inherent in inkjet additive processes.
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 system significantly reduces manufacturing time, enhances precision in forming relief features, and minimizes dust and debris, resulting in improved print quality by allowing separate control of elastomeric, mesa relief, and image relief layers, ensuring better rendering of fine image details and preventing buckling.
Implementation Method 1
exposing from underneath the vat (301) said layer (313) for curing said (313) by an illumination system
Data Source
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AI summary
A flexo-plate maker uses two different curable liquids (341, 351). After curing the curable liquids result in different physical properties. Optionally, the system also uses two illumination subsystems (320, 330, 331, 332, 333) preferably with a different resolution.