Flexographic Printing Laminated Sleeves with Spliced Support Layers
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Solution Overview
Problem
Current laminated sleeves in flexographic printing face issues such as heavy weight, susceptibility to deformation, high cost, complex manufacturing processes, and limited material selection, which restrict their thickness and production efficiency.
Innovation Solution
A laminated sleeve with a spliced support layer structure is manufactured by cutting plate material into strips and arranging them isoperimetrically between inner and outer reinforcement layers, using lightweight and high-strength materials like PMI, PVC, or polyurethane, and coating with epoxy resin to form a laminated structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional polyurethane foam rotation casting is used for the support layer, then the sleeve provides necessary support, but the production equipment investment is large, energy consumption is high, and production line area is large
Solution Approach 1:
The support layer is divided into multiple independent support strips that are spliced together, replacing the traditional monolithic foam structure. This segmentation allows for simpler manufacturing processes, reduced energy consumption, and flexible assembly while maintaining the necessary support capability.
Solution Approach 2:
The invention changes the manufacturing parameters from high-energy foam rotation casting to low-energy strip cutting and splicing processes. The support layer thickness and material properties can be adjusted by selecting appropriate strip dimensions and materials, achieving the same support effect with lower energy input.
2Strength
If rubber wrapping followed by high temperature vulcanizing is used, then the support layer is formed, but the product becomes heavy, thermal expansion causes deformation, and production costs increase
Solution Approach 1:
The invention uses lightweight strip materials that can be easily replaced if needed, avoiding the need for heavy rubber vulcanization processes. The strip structure provides sufficient support without the weight penalty of traditional rubber-based solutions.
Solution Approach 2:
The support layer combines lightweight strips with reinforcement layers to create a composite structure that achieves the necessary strength without relying on heavy materials. The composite approach allows for optimized weight-strength ratios compared to traditional homogeneous rubber structures.
3Strength
If honeycomb panel wrapping is used, then the support layer strength is enhanced, but the manufacturing difficulty and cost increase significantly
Solution Approach 1:
The support layer is segmented into standard strips that can be cut from plate material using conventional equipment, replacing the complex honeycomb panel wrapping process. This segmentation simplifies manufacturing while maintaining structural strength through the spliced configuration.
Solution Approach 2:
The invention uses simple, easily manufacturable strip components that can be produced with basic cutting tools, avoiding the high-cost honeycomb panel manufacturing process. The simplicity of the strip structure reduces both manufacturing difficulty and cost.
4Length of stationary object
If multiple layers are wrapped to increase support layer thickness, then the thickness requirement is met, but the production efficiency decreases
Solution Approach 1:
The support strips are pre-cut to the required thickness and length before assembly, allowing for rapid installation without the need for multiple wrapping layers during production. This preliminary preparation of components enables faster assembly and higher production efficiency.
Solution Approach 2:
The support layer is constructed from discrete strips that can be quickly spliced together to achieve the required thickness, replacing the time-consuming process of wrapping multiple layers. The segmented approach allows for modular assembly that maintains production efficiency while meeting thickness requirements.
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 method allows for a lightweight, flexible, and cost-effective production of laminated sleeves with adjustable thickness, reduced thermal expansion, and enhanced structural strength, improving fatigue resistance and reducing energy consumption.
Implementation Method 1
arranging the support strips in an isoperimetric manner around a central axis of the laminated sleeve and between an inner reinforcement layer and an outer reinforcement layer to form a support layer
Implementation Method 2
coating with epoxy resin to form a laminated structure
Data Source
AI summary
A laminated sleeve includes: a basic sleeve, an elastic layer, an inner reinforcement layer, a support layer, an outer reinforcement layer and a surface layer which are sequentially arranged in that order from inside to outside. A manufacturing method includes: cutting a plate material into support strips of the same size, arranging the support strips around a central axis of the sleeve to cover the inner reinforcement layer annularly to obtain the support layer, wrapping the outer reinforcement layer around the support layer, and obtaining the laminated sleeve after surface processing. The manufacturing method greatly expands the wide range of material choices for the support layer and allows for flexible adjustment of the outer diameter size of the product. The support layer of the laminated sleeve made by the disclosure can be made of general rigid solid materials with low density, high strength, and minimal deformation.