Flexographic Printing Mask Film for Faster UV Exposure
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Solution Overview
Problem
Existing flexographic printing masks have optical properties that hinder efficient processing of relief-forming layers, leading to longer processing times and reduced economic efficiency.
Innovation Solution
A mask element for flexographic printing comprising a transparent polymeric carrier sheet with a non-crosslinked nitrocellulose barrier layer and a thermally-ablatable imaging layer containing carbon black and an IR dye, optimized for improved optical density and ablation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional photosensitive mask materials are used, then the mask can form relief images, but the optical properties are inefficient and processing time is extended
Solution Approach 1:
The patent changes the optical parameters of the mask by incorporating infrared-absorbing materials (carbon black and IR dye) that selectively absorb infrared radiation from the UV lamp. This parameter change enables the mask to efficiently block unwanted wavelengths while transmitting useful UV wavelengths, thereby reducing exposure time and improving processing speed without sacrificing image formation quality
Solution Approach 2:
The mask uses a composite material system consisting of a transparent polymeric carrier sheet, a nitrocellulose barrier layer, and an imaging layer containing carbon black and IR dye in a thermally-ablatable polymeric binder. This composite structure combines materials with complementary optical properties to achieve both high optical density for image formation and selective wavelength transmission for reduced exposure time
2Ease of manufacture
If traditional mask materials with less efficient optical properties are used, then the mask can be manufactured, but energy consumption increases
Solution Approach 1:
The patent modifies the optical absorption parameters of the mask material to selectively absorb infrared radiation while transmitting UV radiation. This parameter optimization ensures that the mask efficiently utilizes the energy spectrum, reducing wasted energy absorption and lowering overall energy consumption during the photopolymerization process while maintaining ease of manufacture through conventional coating and curing 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 improved mask achieves shorter UV exposure times and reduced energy consumption, enhancing productivity and economic efficiency in flexographic printing by allowing faster photopolymerization of relief-forming layers.
Implementation Method 1
an infrared-absorbing material (e.g., carbon black, an IR dye, or a combination thereof) in an amount and of a particle size distribution that provides an optical density of at least 3.5 at 400 nm
Implementation Method 2
a thermally-ablatable polymeric binder
Implementation Method 3
The mask can then be removed and the uncured regions on the relief-forming material can be removed using a development process
Implementation Method 4
Photosensitive relief-forming materials having a relief-forming material or photosensitive layer are known in the art
Data Source
AI summary
A mask element for flexographic printing is provided. The mask element can be used for preparing a mask that has a mask image. The mask element can include: a transparent polymeric carrier sheet; a barrier layer on the transparent polymeric carrier sheet, wherein the barrier layer comprises non-crosslinked nitrocellulose; and an imaging layer on the barrier layer, wherein the imaging layer includes a non-silver halide thermally-ablatable material comprising non-crosslinked nitrocellulose, carbon black, and an infrared (IR) dye. In some aspects, the mask element further includes a transparent overcoat layer on the imaging layer. The mask can include: imaged regions in the imaging layer, wherein the imaged regions have optical apertures that are substantially devoid of the carbon black and non-crosslinked nitrocellulose thereof; and non-imaged regions in the imaging layer, wherein the non-imaged regions have the non-crosslinked nitrocellulose, carbon black, and infrared dye.