Imaging Blanket Surface Texturing for Variable Printing Ink Control

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Solution Overview

Problem

Offset inks with high viscosity and tacky nature are difficult to manipulate in variable printing systems, such as nozzle-based inkjet systems, due to high surface adhesion forces, and existing lithographic and offset printing methods are not suitable for high-speed variable printing without replacing print cylinders or imaging plates.

Innovation Solution

The development of an imaging blanket with a native elastomeric polymer etching process to create an ultra-fine surface texture that retains a thin dampening fluid layer and is conformable for ink transfer, using methods like dry or wet etching to achieve a surface roughness of 0.5 to 1.5 microns, allowing for improved ink separation and fluid retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If offset inks are used in variable printing systems, then high quality printing with low cost ink is achieved, but the high viscosity and surface adhesion forces make the ink difficult to manipulate in nozzle-based inkjet systems

Engineering Contradiction:

Improveprinting qualityVSAvoidink manipulability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces traditional mechanical ink transfer methods with electrostatic forces. The imaging plate uses electrostatic charging to attract and transfer offset ink particles, substituting mechanical manipulation with electrical field control. This allows high-viscosity offset inks to be effectively handled in variable printing systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent modifies the surface properties of the imaging plate through electrostatic charging, changing the electrical parameter of the surface to create strong attractive forces for ink particles. This parameter change enables control over high-viscosity inks that cannot be manipulated by conventional mechanical means.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional lithographic plates are used for long print runs, then high quality printing is achieved, but the plates cannot accommodate variable printing without removal and replacement

Engineering Contradiction:

Improveprinting qualityVSAvoidvariable printing capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent introduces a programmable electrostatic imaging plate that can dynamically change its charging pattern through electronic control. This allows the plate to adapt to different printing requirements and variable data without physical replacement, combining the quality of traditional lithography with the flexibility of digital printing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The electrostatically charged imaging plate serves as an intermediary between the digital variable data and the offset ink transfer process. It translates electronic patterns into electrostatic fields that selectively attract ink particles, enabling variable printing while maintaining offset printing quality.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If offset inks with high surface adhesion forces are used, then high quality printing is achieved, but the inks are very difficult to manipulate onto or off of a surface using electrostatics

Engineering Contradiction:

Improveprinting qualityVSAvoidsurface adhesion force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent applies local quality by creating localized electrostatic charge regions on the imaging plate that correspond precisely to the desired print pattern. This localized charging creates strong electrostatic forces only where needed, enabling selective ink transfer despite the high surface adhesion forces of offset inks.

Inventive Principle:

Principle #3Local quality

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 solution enables the imaging blanket to effectively retain a thin dampening fluid layer and facilitate ink transfer, addressing the limitations of existing methods by enhancing surface roughness and oleophobicity, thus enabling high-speed variable printing with improved printing quality and reliability.

Implementation Method 1

an imaging surface having a periodic surface roughness, Ra, of substantially between 0.5 and 1.5 microns

Methodology Applied

Scientific EffectSurface roughness retention:

Implementation Method 2

using methods like dry or wet etching with specific etch processes

Methodology Applied

Scientific EffectDry etching:

Implementation Method 3

using methods like dry or wet etching with specific etch processes

Methodology Applied

Scientific EffectWet etching:

Data Source

PatentUS9126452B2Ultra-fine textured digital lithographic imaging plate and method of manufacture

Publication Date: 2015.09.08 GENESEE VALLEY INNOVATIONS LLC

AI summary

A method of forming an imaging blanket for a printing apparatus comprises preparing a support structure (e.g., mold) for receipt of a polymer blanket compound, introducing the polymer blanket compound in liquid state over the support structure, curing the polymer blanket compound to produce an imaging blanket, releasing the imaging blanket from the support structure, and etching a surface of the imaging blanket to form a texture pattern therein, the surface forming an imaging surface of said imaging blanket. An imaging surface providing desirable dampening fluid retention is provided. Wet etch, dry etch or a combination of both may be used. The polymer may be a silicone compound, may include 3 percent by weight granular material.