Infrared Ablatable Flexographic Printing Precursor
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Solution Overview
Problem
Current flexographic printing precursors face challenges in achieving high throughput efficiency, improved imaging speed, and print quality due to limitations in laser engraving technologies, particularly with carbon dioxide lasers, which require high energy and result in suboptimal relief depths and material properties.
Innovation Solution
The development of an infrared radiation ablatable flexographic printing precursor comprising a mixture of high molecular weight ethylene-propylene-diene terpolymer (EPDM) rubber and low molecular weight EPDM rubber, combined with conductive carbon black and inorganic fillers, allows for efficient laser engraving without process oils, enhancing imaging sensitivity and print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If carbon dioxide lasers are used for laser engraving, then the imaging process can be performed, but the imaging speed is slow and the relief depth is suboptimal
Solution Approach 1:
The patent changes the laser wavelength parameter from carbon dioxide (10.6 μm) to infrared (e.g., 1.06 μm), which fundamentally alters the interaction with the material. This parameter change enables faster imaging speeds and improved relief depths while reducing the required laser power, directly resolving the contradiction between imaging speed and energy requirement
Solution Approach 2:
The patent uses a composite material system consisting of EPDM rubber mixed with specific fillers and plasticizers that are optimized for infrared laser ablation. This composite formulation enhances the material's responsiveness to infrared radiation, enabling faster and more precise imaging without requiring excessive laser power
2Strength
If high molecular weight EPDM rubber is used, then the mechanical properties are improved, but the laser-engravability is reduced
Solution Approach 1:
The patent applies local quality modification by incorporating specific fillers and plasticizers into the EPDM rubber matrix. These additives are strategically selected to modify the local properties of the material in a way that enhances laser ablation characteristics while preserving the overall mechanical strength through the EPDM rubber matrix
Solution Approach 2:
The patent changes the material composition parameters by formulating a specific mixture of high molecular weight EPDM rubber with controlled amounts of fillers and plasticizers. This compositional parameter change optimizes both the mechanical properties and laser-engravability, resolving the contradiction between strength and ease of manufacture
3Ease of manufacture
If process oils are used in the rubber mixture, then the manufacturing process is simplified, but material leaching occurs during printing
Solution Approach 1:
The patent replaces traditional process oils with alternative plasticizers that do not leach during printing. These alternative plasticizers serve their manufacturing function temporarily during compounding but remain stable during the printing process, eliminating the harmful leaching effect while maintaining ease of manufacture
Solution Approach 2:
The patent converts the potential harm of material leaching into a benefit by selecting plasticizers that provide manufacturing simplicity but are specifically designed to be printing-stable. The alternative plasticizers maintain the ease of manufacture advantage while eliminating the harmful leaching effect, turning a problematic combination into a beneficial one
4Manufacturing precision
If the relief depth is increased to exceed 500 μm, then the printing quality is improved, but the imaging time increases
Solution Approach 1:
The patent changes the material composition parameters by using EPDM rubber with optimized filler content and plasticizer selection. This parameter change enables the material to be ablated more efficiently at higher depths, achieving printing quality requiring relief depths exceeding 500 μm without proportionally increasing imaging time
Solution Approach 2:
The patent enables continuous laser ablation at high speeds by optimizing the material formulation for continuous removal. The EPDM rubber composition allows for sustained ablation without interruption or excessive heating, maintaining imaging speed while achieving the required relief depths for high printing 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 faster imaging, improved mechanical properties, and extended run length, resulting in higher quality prints with enhanced durability and reduced material leaching issues, while maintaining the non-polar nature of EPDM for superior laser-engravability.
Implementation Method 1
infrared radiation ablatable layer comprising a mixture of rubbery resins... infrared radiation ablatable flexographic printing precursor... infrared radiation absorbing compounds
Implementation Method 2
laser engraving... infrared radiation ablatable... thermal mass transfer plates... thermal wicking or wiping
Implementation Method 3
ablation of the background areas... thermal degradation... removal of non-exposed areas
Data Source
AI summary
A mixture of an elastomer, carbon black, and inorganic fillers provides a highly useful laser-ablatable flexographic printing plate precursor formulation. This formulation is sensitive to infrared radiation. Both flexographic printing plates and printing sleeves can be made using the mixture.