Cylindrical Flexo Printing Element Liquid Melt Deposition

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Solution Overview

Problem

Current methods for producing cylindrical flexographic printing elements, such as photopolymerizable flexographic printing plates, face challenges in achieving high surface quality without subsequent machining and are costly due to complex and time-consuming processes like calendering, which can introduce air bubbles and particulate material, limiting their effectiveness.

Innovation Solution

A method involving a cylindrical sleeve with a relief-forming layer applied using an apparatus that includes a mounting means, drive unit, and application means for areal application of a relief-forming material in liquid melt form, ensuring at least two complete rotations to coat multiple layers spirally, thereby avoiding the need for subsequent machining and minimizing defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods like calendering are used to produce cylindrical flexographic printing elements, then the printing elements can be manufactured, but air bubbles and particulate material are introduced, degrading surface quality

Engineering Contradiction:

Improvesurface qualityVSAvoidair bubbles and particulate material

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent removes the calendering step from the manufacturing process entirely. Instead of using calendering to apply and smooth the photopolymer layer, the invention uses a die to directly extrude the material onto the cylindrical support in a controlled manner, eliminating the source of air bubbles and particulate contamination that calendering introduces

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical calendering system with a die-based extrusion system. The die directly forms the photopolymer layer as it is deposited, eliminating the need for subsequent mechanical smoothing operations that can trap air and introduce contaminants

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If calendering and grinding operations are used to achieve high surface quality, then printing elements with acceptable surface finish can be produced, but production time increases significantly

Engineering Contradiction:

Improvesurface finishVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent performs the surface finishing action during the deposition process itself. The die extrudes the photopolymer material in a controlled manner that inherently produces a smooth surface, eliminating the need for subsequent grinding or polishing operations that would otherwise be required

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent enables continuous production by eliminating discrete machining steps. The die extrusion process continuously deposits and forms the photopolymer layer in one uninterrupted operation, whereas conventional methods require stopping for calendering, grinding, and polishing operations

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If complex processes like calendering and multiple machining steps are employed, then printing elements can achieve required tolerances, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvedimensional tolerancesVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent removes multiple complex machining steps from the manufacturing process. By using a die to directly extrude and form the photopolymer layer, the invention eliminates calendering, grinding, and polishing operations, significantly simplifying the overall manufacturing process while maintaining dimensional tolerances

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the fundamental approach from mechanical deformation (calendering) and material removal (grinding) to direct controlled deposition. The die extrusion process allows precise control of layer thickness and surface quality through extrusion parameters, achieving required tolerances with a simpler 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 method produces defect-free, high-quality cylindrical flexographic printing elements with precise tolerances and outstanding surface finish, eliminating the need for grinding or polishing and reducing production time and costs.

Implementation Method 1

areal application of a relief-forming material in liquid melt form to the cylindrical sleeve (3), with a layer of the relief-forming material forming on the cylindrical sleeve (3)

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS10953648B2Method for producing cylindrical flexo printing elements

Publication Date: 2021.03.23 XSYS GERMANY GMBH

AI summary

Methods for producing cylindrical flexographic printing elements, the cylindrical flexographic printing elements having a relief-forming layer, and the relief-forming layer being produced by successive application of a plurality of layers of a relief-forming material in liquid melt form, preferably of a photopolymerizable material in liquid melt form, to a rotating cylindrical sleeve in a continuous process.