Flexographic Printing Element Textured Surface Ink Density

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Solution Overview

Problem

Flexographic printing faces challenges in achieving uniform ink transfer and high solid ink density, particularly in solid areas, leading to issues like uneven ink distribution and halo effects, which affect the quality of printed images.

Innovation Solution

A method involving a relief image printing element with a photocurable layer and a laser ablatable masking layer, where an oxygen barrier layer is applied to limit oxygen diffusion during exposure, and a sub-image pattern is used to create a textured surface with cells, enhancing ink retention and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional flexographic printing plates are used with smooth surfaces, then the printing process is simple, but the solid ink density is low and ink transfer is uneven

Engineering Contradiction:

Improvesolid ink densityVSAvoidplate structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The printing plate surface is segmented into micro-scale cells arranged in a sub-image pattern, dividing the continuous surface into discrete ink-receiving units that improve ink distribution and retention, thereby increasing solid ink density

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The printing plate incorporates a cellular structure with micro-pores that enhance ink capillary action and retention, allowing for better ink transfer to the substrate and improved solid ink density without compromising the overall plate integrity

Inventive Principle:

Principle #31Porous materials

2Manufacturing precision

If conventional printing plates without oxygen barrier are used, then the exposure process is simple, but oxygen diffusion during exposure reduces curing efficiency and print quality

Engineering Contradiction:

Improvecuring uniformityVSAvoidlayer structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

An oxygen barrier layer is introduced as an intermediary between the exposure source and the photocurable layer, blocking oxygen diffusion during exposure and preventing oxygen inhibition of the curing reaction, thereby improving curing uniformity and print quality

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The oxygen barrier layer creates an inert environment during the exposure process by preventing atmospheric oxygen from reaching the photocurable layer, ensuring complete and uniform curing without oxygen-related defects

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Manufacturing precision

If smooth surface printing plates are used, then the manufacturing process is simple, but halo effects occur and color uniformity is poor

Engineering Contradiction:

Improvecolor uniformityVSAvoidplate fabrication complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The surface is divided into a cellular sub-image pattern that distributes ink more evenly across the printing area, eliminating halo effects and improving color uniformity through controlled ink placement in each cell

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The surface topology is changed from smooth to cellular with specific depth and dimensional parameters optimized for ink retention and transfer, fundamentally altering the ink interaction characteristics to achieve uniform color distribution

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 improves the achievable solid ink density and uniformity, reducing halo effects and increasing the quality of printed images by creating a textured surface that anchors ink effectively, resulting in higher density and better color uniformity.

Implementation Method 1

an oxygen barrier layer is applied to limit oxygen diffusion during exposure

Methodology Applied

Scientific EffectOxygen diffusion: Diffusion

Implementation Method 2

exposing the printing element to actinic radiation through the barrier layer and the masking layer to selectively crosslink and cure the at least one photocurable layer

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 3

selectively ablating the masking layer to create an overall image in the masking layer

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentEP2732339B1Method for improving print performance of flexographic printing elements

Publication Date: 2016.04.20 MACDERMID PRINTING SOLUTIONS LLC

AI summary

A method of making a relief image printing element having a relief pattern, the method comprising the steps of: a) selectively ablating the masking layer to create an overall image in the masking layer, such that the overall image comprises a sub-image, comprising a pattern of cells, in it; b) applying an oxygen barrier layer on top of the masking layer; c) exposing the printing element to actinic radiation through the oxygen barrier layer and the masking layer to selectively crosslink: and cure the at least one photocurable layer, thereby creating the relief image therein and a textured surface on the printing element; and d) developing the printing blank by removing the barrier layer and the uncured portions of the photocmable layer to reveal the relief image.