Flexographic Roller Recess and Tape for High-Resolution Conductive Patterns

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Solution Overview

Problem

Flexographic printing faces challenges in producing high-resolution conducting patterns with intricate geometries, particularly in assembling and controlling the printing of microscopic patterns with existing flexographic systems.

Innovation Solution

The use of a printer roller with a recess and a tape of specific thickness and hardness, combined with a flexoplate having a pattern of lines, allows for precise adherence and printing of high-resolution conductive patterns through a high-resolution pattern printing module, including an ink source and an anilox roll, followed by plating to form conductive patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional flexographic printing systems are used, then the printing process is simple and easy to operate, but the manufacturing precision of microscopic patterns with intricate geometries deteriorates

Engineering Contradiction:

Improveprinting resolution of microscopic patternsVSAvoidflexographic printing system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The printing system is segmented into distinct functional modules: a printer roller with a recess, a specifically configured tape (separated from traditional mounting tape), a flexoplate, an ink source, and an anilox roll. This segmentation allows each component to be optimized independently for high-resolution printing while maintaining overall system functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A tape with specific properties (thickness between 250-750 μm, density 10-25 lb/in², hardness about 20 on Shore A scale) is introduced as an intermediary element between the printer roller and the flexoplate. This tape acts as a mediator that enables precise control of the flexoplate's positioning and pressure distribution, thereby achieving high-resolution printing of microscopic patterns with intricate geometries.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the tape thickness is increased to improve adherence, then the adherence strength improves, but the printing precision deteriorates due to excessive cushioning

Engineering Contradiction:

Improveadherence strength of tapeVSAvoidline width control and edge sharpness

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The tape parameters are precisely controlled within specific ranges: thickness between 250-750 μm (with optimal range 300-500 μm), density 10-25 lb/in², and hardness about 20 on Shore A scale. These parameter specifications ensure the tape provides sufficient adherence strength while maintaining appropriate cushioning properties for high-resolution printing, preventing both insufficient bonding and excessive pressure distribution.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the recess depth is increased to accommodate thicker tape, then the adherence and cushioning improve, but the device complexity increases

Engineering Contradiction:

Improveflexoplate adherence and pressure distributionVSAvoidprinter roller structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The recess is pre-configured in the printer roller with a depth specifically designed to accommodate the tape thickness (within +/−10% of recess depth). This preliminary structural preparation ensures that when the tape is installed, it achieves the optimal thickness match for both adherence and pressure distribution, eliminating the need for complex adjustable mechanisms while maintaining high printing reliability.

Inventive Principle:

Principle #10Preliminary action

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 method enables the production of uniform, high-resolution conductive patterns with controlled line widths and edge shapes, overcoming the limitations of existing flexographic systems in printing intricate geometries.

Implementation Method 1

adhering the flexoplate to the printer roller comprises disposing adhesive on at least one of the flexoplate or the printer roller

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS9156242B2Flexographic printing using flexographic printing roll configurations

Publication Date: 2015.10.13 EASTMAN KODAK CO

AI summary

In a flexographic printing system, both the process parameters and equipment setup and configuration may play a role in producing the desired printed pattern. One component of the equipment setup is the printer roller assembly which may comprise a roller and a flexoplate as well as tape. The properties of the flexoplate and the tape as well as the relative dimensions of each in the assembly may affect the geometry and quality of the transferred pattern, as well as the ability of the system to produce a pattern on a repeatable, consistent basis.