Herringbone Microstructure Printing Plate for Uniform Ink Transfer
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Solution Overview
Problem
Existing micro-structure patterns in flexographic printing plates exhibit limitations in ink distribution, including orientation dependency, pattern repetition size, imaging defects, and compatibility with halftone screening, leading to issues such as pinholes, moiré patterns, and tonal jumps.
Innovation Solution
The introduction of a herringbone microstructure pattern with alternating diagonal orientations and specific pixel configurations, optimized for rotation symmetry, small pattern repetition size, and compatibility with halftone screening, applied through methods like laser ablation or embossing, to enhance ink transfer and reduce imaging defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional flat or porous surface structure is used on flexographic printing plates, then the plate material is easy to manufacture and process, but the plate shows poor resistance to scratching, scuffing, and chemical degradation
Solution Approach 1:
The patent applies asymmetry by using a herringbone microstructure pattern instead of traditional flat or uniformly porous surfaces. This asymmetric geometric arrangement creates interlocking features that mechanically resist scratching and scuffing while maintaining manufacturability through standard photopolymerization processes.
Solution Approach 2:
The herringbone pattern incorporates curved and angled surfaces rather than flat planes. These curved geometric features distribute mechanical stresses more effectively and provide better resistance to chemical degradation while maintaining ease of manufacture through photopolymerization.
2Reliability
If the surface of the printing plate is made harder to resist scratching, then resistance to mechanical damage improves, but the plate becomes less compliant and flexible during mounting and operation
Solution Approach 1:
The herringbone microstructure creates local variations in surface properties. The raised ridges provide hardness and scratch resistance where needed, while the valleys and overall plate structure maintain compliance and flexibility. This local differentiation allows simultaneous achievement of both hardness and flexibility.
Solution Approach 2:
The surface is segmented into a herringbone pattern of ridges and valleys. This segmentation allows different regions to perform different functions - the ridges provide mechanical strength and scratch resistance, while the overall segmented structure maintains flexibility and compliance for mounting operations.
3Manufacturing precision
If conventional plate materials are used without special surface treatment, then the plates are easy to manufacture, but they exhibit inconsistent ink transfer and poor image quality
Solution Approach 1:
The herringbone microstructure is incorporated into the plate material itself during photopolymerization, before the plate is mounted or used. This preliminary structuring ensures consistent ink transfer and high image quality from the first use, eliminating the need for subsequent surface treatments or adjustments.
Solution Approach 2:
The invention changes the surface parameter from flat or uniformly porous to a structured herringbone pattern. This parameter change in surface topology improves ink transfer consistency and image quality while maintaining compatibility with standard photopolymerization manufacturing processes.
Data Source
Figure 1A~1F
Figure 1G~1H
Figure 2A~2C
AI summary
A printing plate includes a defined image area having a microstructure pattern. The microstructure pattern is defined by a plurality of rows each having a plurality of diagonal oriented elevated line segments having orientations alternating between a positive angle in one row and a negative angle in an adjacent row, wherein each line segment has a first end aligned with a middle portion of and spaced apart from a first line of a first adjacent row and a second end aligned with a middle portion of and spaced apart from a second line of a second adjacent row. Processes, computer readable media programmed with instructions for performing the processes, and tools for making the printing plate are also described.