Flexo Printing Plate Adhesive Foam Structure
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Solution Overview
Problem
Conventional pre-assembled structures for flexographic printing of corrugated cardboard require a rigid double-sided adhesive and foam covering the entire base, which can lead to suboptimal printing quality and increased pressure on the cardboard, potentially causing fiber breakage and inefficient foam usage.
Innovation Solution
A pre-assembled structure with adhesive foam directly between the printing plate and the polyester base, eliminating the need for a rigid adhesive and reducing foam coverage to only the printing surfaces, allowing direct cushioning and improved ink distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid double-sided adhesive layer is used to join the photopolymer plate and support base, then the structural stability is improved, but the printing quality deteriorates due to increased pressure on the corrugated cardboard
Solution Approach 1:
The patent removes the rigid double-sided adhesive layer from the pre-assembled structure, extracting the harmful element that caused excessive pressure on the corrugated cardboard. The foam layer is left in direct contact with the photopolymer plate, providing both adhesion and pressure distribution without the intermediate rigid layer.
Solution Approach 2:
The patent uses a composite structure where the foam layer serves dual functions: as the adhesive bonding the photopolymer plate to the support base, and as a pressure-distributing cushioning layer. This composite approach eliminates the need for a separate rigid adhesive layer while improving printing quality.
2Reliability
If the foam layer covers the entire support base, then the adhesion between plate and base is improved, but the material consumption and carbon footprint increase
Solution Approach 1:
The patent applies the foam layer locally only where adhesion is needed - specifically on the support base within the printing area boundaries - rather than covering the entire base. This localized application maintains sufficient adhesion for the printing process while significantly reducing foam material consumption and associated carbon footprint.
3Object-affected harmful factors
If the foam layer is soft and cushioning, then the cardboard fiber breakage is reduced, but the printing pressure distribution becomes insufficient
Solution Approach 1:
The patent optimizes the foam layer parameters including density, thickness, and durometer to achieve the right balance between softness for cushioning and firmness for pressure distribution. The foam is formulated to be compliant enough to prevent fiber breakage on irregular corrugated surfaces while maintaining sufficient rigidity to distribute printing pressure evenly across the printing area.
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
Enhances printing quality by reducing pressure on corrugated cardboard, optimizing foam usage, and minimizing material consumption, resulting in improved print results and a reduced carbon footprint.
Implementation Method 1
the foam layer of the support base, which is usually polyester, is incorporated at the bottom thereof, that is, without being in direct contact with the photopolymer plate
Implementation Method 2
adhesive foam incorporated directly between the printing plant and the polyester of the base
Data Source
Figure 1-A~1-B
Figure 2-A~2-B
AI summary
Pre-assembled structure for flexographic printing on shaped corrugated cardboard that is fixed to the printing plate, improving the printed quality and reducing the pressure required for the cardboard to be covered by the ink, and comprising a photopolymer plate (2) on which the motif to be printed is engraved, consisting in turn of a photopolymer layer (3) incorporated on a first polyester sheet (4); a support base (5) which is fixed to the plate (2) and which, in turn, comprises a second polyester sheet (6); and a padded foam (7), characterised in that the padded foam (7), which is not part of the support base (5) but is an independent element, is incorporated sandwiched between the first polyester sheet (4) of the photopolymer plate (2) and the polyester sheet (6) of the support base (5), such that said foam (7) is directly in contact with said photopolymer plate (2).