Mask Element Precursor LTHC Layer Adhesion
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Solution Overview
Problem
Current mask element precursors in flexographic printing face challenges in achieving efficient adhesion and intimate contact with relief-forming precursors during imaging, leading to potential interlayer adhesion failures and poorer imaging quality.
Innovation Solution
An imageable material comprising a transparent polymeric carrier sheet with a non-ablatable light-to-heat converting (LTHC) layer and a non-silver halide thermally-ablatable imaging layer, which enhances adhesion and imaging properties by converting infrared radiation into heat, improving interlayer contact and vacuum draw-down processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mask element precursors are used, then the imaging process can be completed, but interlayer adhesion fails and imaging quality deteriorates
Solution Approach 1:
A light-to-heat converting layer is introduced as an intermediary between the mask element precursor and the relief-forming precursor. This layer converts incident light into heat, creating thermal energy that enhances adhesion between the layers during the imaging process, thereby resolving the interlayer adhesion failure while maintaining imaging quality
Solution Approach 2:
The patent changes the energy conversion parameter by introducing a light-to-heat converting layer that transforms optical energy into thermal energy. This parameter change enables improved thermal interaction between layers, enhancing adhesion and preventing contamination during the imaging process
2Manufacturing precision
If vacuum draw-down is used to achieve intimate contact, then contact quality improves, but the process complexity increases
Solution Approach 1:
The patent replaces the mechanical vacuum draw-down system with a light-driven thermal mechanism. The light-to-heat converting layer absorbs incident light and generates heat, which thermally facilitates intimate contact between the mask element precursor and relief-forming precursor, eliminating the need for complex vacuum equipment while achieving superior contact quality
3Reliability
If lamination process is used to bond layers, then adhesion improves, but contamination between layers increases
Solution Approach 1:
The light-to-heat converting layer serves as a protective intermediary between the mask element precursor and relief-forming precursor. During lamination, this layer facilitates thermal bonding while its properties prevent direct contamination between layers, allowing adhesion to improve without increasing contamination risk
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 solution provides improved interlayer adhesion and reduced contamination, resulting in better imaging quality and minimized artifacts by ensuring complete optical contact and effective removal of mask elements during the relief image formation process.
Implementation Method 1
a non-ablatable light-to-heat converting (LTHC) layer disposed directly on the transparent polymeric carrier sheet, the LTHC layer having an average dry thickness of at least 1 μm and up to and including 5 μm, and comprising: (i) a first infrared radiation absorbing material
Implementation Method 2
the IL comprising a second infrared radiation absorbing material and a UV-light absorbing material dispersed within one or more thermally-ablatable polymeric binder materials
Implementation Method 3
a first infrared radiation absorbing material in an amount of at least 0.1 weight % and up to and including 5 weight %
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
An imageable material can be used to form a mask element that in turn is useful for providing relief images such as in flexographic printing plates. The imageable material has, in order: (a) a transparent polymeric carrier sheet; (b) a non- ablatable light-to-heat converting having an average dry thickness of 1-5 μm and comprising: (i) an infrared radiation absorbing material at 0.1-5 weight %; (ii) a thermally crosslinked organic polymeric binder material; and (iii) non-thermally ablatable particles having an average particle size of 0.1-20 μm in an amount of 0.2- 10 weight %; and (c) a non-silver halide thermally-ablatable imaging layer (IL) disposed on the LTHC layer, the IL comprising a second infrared radiation absorbing material and a UV-light absorbing material dispersed within one or more thermally- ablatable polymeric binder materials.