Low Density Foam PSA Tape for Flexographic Plate Mounting
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Solution Overview
Problem
Current pressure-sensitive adhesive (PSA) tapes used in flexographic printing applications lack adequate plate edge lifting resistance, especially on ink residue-contaminated plates, and do not allow for easy repositioning and clean removability without damaging the printing plates.
Innovation Solution
The development of PSA tapes with a foam layer density of 0.32 g/cm³ or less, featuring a polymer component with a peel force of at least 0.055 Newtons per cm, and a lifting resistance of less than 3.0 mm/48 hours, along with a primer and crosslinking agent, to provide enhanced adhesion and removability on both clean and ink-coated surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional PSA tapes with high density foam backings are used, then initial adhesion strength is improved, but plate edge lifting resistance deteriorates and clean removability is lost
Solution Approach 1:
The patent applies parameter changes by reducing foam density from conventional high density to 0.32 g/cm³ or less, and by controlling gel swell parameters (5-150%, preferably 10-50%). This transforms the adhesive system from rigid high-strength bonding to a more compliant system that maintains adhesion while enabling clean removability and edge lifting resistance.
Solution Approach 2:
The patent uses composite materials by combining low density foam substrate with specific polymer adhesives containing crosslinking agents. This creates a multi-layer composite structure where the foam provides compliance and the crosslinked adhesive provides controlled bonding strength, achieving both adhesion and clean removability simultaneously.
2Reliability
If PSA tapes with strong adhesion are used, then plate mounting stability is improved, but plate edge lifting resistance deteriorates
Solution Approach 1:
The patent changes physical parameters by controlling gel swell within 5-150% (preferably 10-50%) and foam density at 0.32 g/cm³ or less. These parameter changes create an adhesive system that provides sufficient mounting stability through controlled adhesion while preventing edge lifting through appropriate compliance and stress distribution.
3Ease of operation
If PSA tapes are designed for easy removability, then plate repositioning ease is improved, but adhesion durability deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling gel swell (5-150%, preferably 10-50%) and incorporating crosslinking agents. This creates a time-dependent adhesion profile where the adhesive maintains strong bonding during operational periods but allows clean removal and repositioning when needed, achieving both durability and repositioning ease.
4Ease of operation
If low density foam substrates are used, then clean removability is improved, but structural support deteriorates
Solution Approach 1:
The patent uses composite materials by combining low density foam (0.32 g/cm³ or less) with crosslinked polymer adhesives. The foam substrate provides compliance and enables clean removability, while the crosslinked adhesive network provides the necessary structural support and bonding strength, achieving both clean removability and structural integrity.
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
These PSA tapes offer improved removability and damage-free recovery of printing plates, maintaining adhesion over time and resisting plate edge lifting, even after prolonged use or extended storage, while allowing for easy repositioning and cleaning.
Implementation Method 1
the polymer component further comprises a crosslinking agent
Implementation Method 2
Pressure sensitive adhesives are useful in a variety of applications
Data Source
Figure 1~2
AI summary
There is provided adhesive tapes for mounting flexographic printing plates having a foam substrate and two adhesive layers on either side of the foam substrate, where the adhesive layers may include a polymer component obtainable by free-radical polymerization: a) 50 wt% or greater linear or branched acrylic esters having 2 or more carbon atoms in the alkyl radical, b) 22.5 wt% to 46.5 wt% linear, cyclic or branched acrylic esters having 1 to 20 carbon atoms in the alkyl radical, and c) greater than 3.5 wt% to 27.5 wt% of highly polar vinyl substituted monomers, where the polymer component has a glass transition temperature value of between -22 °C and -7°C according to the Fox method and based on measurement of the homopolymers of the monomers in (a), (b), and (c) by modulated DSC, and further wherein the polymer component has a solubility parameter between 9.58 (cal/cm2) 1/2 and 9.99 (cal/cm2) 1/2 according to the Fedors method. In a preferred embodiment, the linear or branched acrylic esters in (a) are selected from at least one of isooctyl acrylate, 2-ethylhexyl acrylate, n-butyl acrylate, ethyl acrylate, and combinations thereof; wherein the linear or branched acrylic esters in (b) is isobornyl acrylate; and wherein the highly polar vinyl-substituted monomers in (c) is acrylic acid.