Liquid Platemaking Viscosity Reduction for Resin Reclamation
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Solution Overview
Problem
The existing methods for producing flexographic printing plates from liquid photopolymer resins are inefficient in reclaiming uncured resin, leading to material waste and increased costs due to the need for water or solvent washing in the reclamation step.
Innovation Solution
A method that involves selectively exposing the liquid photopolymer to actinic radiation to create a relief image, followed by heating the uncured portions to reduce viscosity, and then removing them without washing with water or solvent, using an absorbent fabric or blotting to reclaim the uncured resin for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If water or solvent washing is used to remove uncured resin, then the uncured resin can be effectively removed, but material waste increases and processing costs increase
Solution Approach 1:
The patent changes the physical parameter of temperature to facilitate resin removal. By heating the printing plate to elevated temperatures (e.g., 50-150°C), the uncured resin becomes more fluid and easier to remove mechanically through blotting or absorption, eliminating the need for water or solvent washing and reducing material waste
Solution Approach 2:
The patent replaces the chemical washing mechanism (water or solvent-based removal) with a thermal-mechanical approach. Heating the plate modifies the resin properties, and then mechanical blotting or absorption methods remove the uncured resin, substituting a simpler, more efficient process that avoids material waste
2Productivity
If heating is applied to reduce viscosity of uncured resin, then resin removal efficiency improves, but energy consumption increases
Solution Approach 1:
The patent utilizes temperature as a controllable parameter to optimize resin removal. By adjusting the heating temperature to the appropriate range, the uncured resin achieves optimal fluidity for easy removal, maximizing reclamation efficiency while minimizing unnecessary energy consumption through precise temperature control
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 process enhances the reclamation of liquid photopolymer, reducing material waste and costs by allowing for the efficient recycling of uncured resin without the need for solvent or water washing, resulting in higher quality and consistent printing plates.
Implementation Method 1
Upon exposure to actinic radiation, the liquid photopolymer resin polymerizes and changes from a liquid state to a solid state to form the raised relief image
Implementation Method 2
heating the relief printing element to decrease the viscosity of the uncured portions of the layer of liquid photopolymer
Data Source
AI summary
A method of making a relief printing element in a liquid photopolymer platemaking process is described. The method comprises the steps of: (a) selectively exposing the liquid photopolymer to actinic radiation through a negative to crosslink and cure portions of the liquid photopolymer; and (b) reclaiming uncured portions of the liquid photopolymer to be reused in the platemaking process. The step of reclaiming uncured portions of the liquid photopolymer comprises (i) heating the printing element to decrease the viscosity of the uncured liquid photopolymer; and (ii) removing uncured liquid photopolymer from the surface of the relief image printing element so that recovery of uncured liquid photopolymer from the surface of the relief image printing element is enhanced.