Imaging Blanket Barrier Layer Prevents Sulfur Diffusion

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Solution Overview

Problem

Conventional lithographic and offset printing techniques are not capable of true high-speed variable printing, where the image changes from impression to impression, as they require removing and replacing print cylinders and imaging plates, limiting their ability to accommodate variable data printing.

Innovation Solution

An imaging blanket with a base comprising an elastic polymer and sulfur, a barrier layer, and a surface layer comprising an elastomer and a platinum catalyst is used in a variable data lithography system, which includes a fountain solution subsystem, patterning subsystem, inking subsystem, and image transfer subsystem to enable variable data printing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If NBR rubber carcass with sulfur crosslinker is used as substrate for imaging blanket, then manufacturing cost is reduced and ease of manufacture is improved, but sulfur diffusion occurs which harms the surface layer cross-linking effectiveness

Engineering Contradiction:

Improveease of manufactureVSAvoidsulfur diffusion

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

A barrier layer is introduced between the sulfur-containing NBR rubber base and the surface layer to prevent sulfur diffusion. This intermediary layer blocks the harmful sulfur from migrating into the surface layer while allowing the inexpensive NBR base to be used, thus resolving the contradiction between manufacturing cost and sulfur diffusion prevention.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The imaging blanket is divided into distinct functional layers: a sulfur-containing NBR rubber base layer and a separate surface layer with platinum catalyst cross-linking. The barrier layer segments these two layers, preventing harmful interaction while allowing each layer to perform its intended function independently.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If conventional lithographic printing techniques are used, then structural integrity of printing components is maintained, but adaptability to variable data printing is lost and productivity is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidadaptability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The imaging blanket incorporates a surface layer with platinum catalyst that enables dynamic reconfiguration of the printing surface. This allows the system to switch between different printing modes (conventional and variable data) without replacing the entire printing component, thus maintaining structural integrity while gaining adaptability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The imaging blanket is designed to perform multiple functions: it can operate in conventional lithographic mode and also support variable data printing with fountain solution patterning. The multi-functional surface layer enables a single component to replace what would traditionally require multiple specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Quantity of substance

If sulfur-containing elastic polymer base is used in imaging blanket, then manufacturing cost is reduced, but sulfur diffusion into surface layer occurs which deteriorates cross-linking effectiveness and reliability

Engineering Contradiction:

Improvemanufacturing costVSAvoidreliability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The barrier layer serves as an intermediary that physically blocks sulfur diffusion from the inexpensive NBR base to the surface layer. This allows the system to use cost-effective sulfur-containing materials in the base while maintaining the reliability of the surface layer cross-linking process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The sulfur that would normally be a harmful contaminant is contained within the base layer where it serves its intended purpose as a crosslinker for the NBR rubber, providing structural integrity. The barrier layer prevents this same sulfur from harming the surface layer, thus converting a potential harm into a beneficial structural function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 system allows for high-speed variable printing by maintaining the structural integrity of the imaging blanket, preventing sulfur diffusion and ensuring effective cross-linking of the surface layer, thereby enabling efficient ink transfer and image reproduction with high transfer efficiencies exceeding 95%.

Implementation Method 1

a barrier layer on the base; a surface layer on the barrier layer

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion Barrier

Implementation Method 2

The surface layer comprises an elastomer and a platinum catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS12122178B2Imaging blanket and variable data lithography system employing the imaging blanket

Publication Date: 2024.10.22 GENESEE VALLEY INNOVATIONS LLC

AI summary

An imaging blanket comprises a base comprising an elastic polymer and sulfur. A barrier layer is on the base and a surface layer is on the barrier layer. The surface layer comprises an elastomer and a platinum catalyst.