Flexographic Printing Plate Imaging to Reduce Trailing Edge Voids
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Solution Overview
Problem
Flexographic printing often results in trailing edge voids or pinholes in solid printed surfaces due to the lifting of the printing plate from the substrate, which existing methods have not adequately addressed.
Innovation Solution
The method involves applying different micro-screen opening sizes and laser light intensities in edge and center regions of the printing plate, using a flexographic printing plate with a photopolymer mask layer, to minimize voids by optimizing ink transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flexographic printing is used with uniform micro-screen openings, then the printing process is simple and fast, but trailing edge voids appear in solid printed surfaces
Solution Approach 1:
The patent applies different micro-screen opening sizes in different regions of the printing plate. Specifically, edge regions have smaller micro-screen openings while center regions have larger openings. This local differentiation ensures that trailing edge voids are prevented without unnecessarily complicating the center region printing, thus improving print quality while maintaining reasonable process complexity.
2Manufacturing precision
If smaller micro-screen openings are used in edge regions to reduce voids, then trailing edge voids are minimized, but ink transfer efficiency may be reduced
Solution Approach 1:
The patent optimizes ink transfer by matching micro-screen opening sizes to local requirements. Edge regions with smaller openings receive appropriate ink amounts for their specific needs, while center regions with larger openings receive more ink to maintain transfer efficiency. This regional optimization ensures both edge quality and overall ink transfer efficiency.
3Manufacturing precision
If different laser light intensities are applied to create varied micro-screen openings, then precise control over opening sizes is achieved, but the imaging process becomes more complex
Solution Approach 1:
The patent utilizes laser light intensity as a controllable parameter to precisely determine micro-screen opening sizes. By adjusting the laser light intensity during imaging, different opening sizes are created in different regions. This parameter-based control achieves precise manufacturing while using an established technology (laser imaging) to minimize additional process complexity.
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 effectively reduces voids at the trailing edges of printed surfaces by enhancing ink transfer and maintaining optimal print quality without visible structures.
Implementation Method 1
the mask layer has a solid rendition or linework mask region corresponding to each solid rendition or linework print region. The method comprises providing mask micro-screen openings in an edge region of the solid rendition or linework mask region that have a different size than micro-screen openings in a center region of the solid rendition or linework mask region
Implementation Method 2
The flexographic printing plate comprises a photopolymer cured through openings in a mask layer of the plate formed by an imager
Data Source
AI summary
Methods, systems, and non-transitory memory media embodying computer readable instructions for minimizing voids in front of a trailing edge of a solid rendition or linework print region printed using a photocurable flexographic printing plate having a printing surface corresponding to information in an image file. At least one solid rendition or linework image region corresponding to the solid rendition or linework print region has a pattern of “on” and “off” single pixels that correspond to openings formed by an imager in a mask layer of the plate. Micro-screen openings in an edge region of the solid rendition or linework mask region are imaged with a different size than micro-screen openings in a center region of the solid rendition or linework mask region.