Flexographic Mask Layer Patterning with Subpixel Radiation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for creating flexographic printing plates require manipulation of image files to generate surface screening patterns, which is time-consuming and inefficient, and do not allow for a fine gradation of surface screening without increasing file size.
Innovation Solution
A method for applying a pattern on a mask layer by treating it with electromagnetic radiation to create areas with altered physical properties, where the area sizes are smaller than the pixel sizes, allowing for direct adjacent pixel treatment without overlapping, thus eliminating the need for image file manipulation and enabling finer gradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If image file manipulation is used to generate surface screening patterns, then surface screening resolution can be achieved, but processing time increases and file size increases
Solution Approach 1:
The invention extracts the surface screening pattern generation step from the image file manipulation process. Instead of manipulating the entire image file to create screening patterns, the method applies a separate screening pattern directly to the mask layer using electromagnetic radiation, thereby eliminating the time-consuming file manipulation while achieving the desired surface screening resolution
Solution Approach 2:
The invention segments the printing plate creation process into distinct steps: image acquisition, mask layer treatment with electromagnetic radiation, and pattern application. By separating the surface screening pattern application from the image file processing, the method achieves efficient processing without increasing file size or processing time
2Manufacturing precision
If image file manipulation is used to generate surface screening patterns, then surface screening resolution can be achieved, but file size increases
Solution Approach 1:
The invention extracts the surface screening pattern generation from the image file. The screening pattern is applied directly to the mask layer using electromagnetic radiation, eliminating the need to store and manipulate enlarged image files, thereby reducing file size while maintaining surface screening resolution
Solution Approach 2:
Instead of manipulating the original image file to create screening patterns, the method creates a separate screening pattern representation and applies it to the mask layer. This copying approach allows the screening pattern to be applied without increasing the original image file size
3Manufacturing precision
If beam size is made smaller than pixel size to achieve finer gradation, then surface screening resolution improves, but treatment complexity increases
Solution Approach 1:
The invention changes the beam size parameter to be smaller than the pixel size, enabling finer gradation and higher surface screening resolution. This parameter change allows adjacent pixels to be treated without overlapping, achieving precise control over the screening pattern while maintaining manageable treatment complexity through automated 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 approach reduces processing time and file size while achieving improved printing quality with higher surface screening resolution without manipulating the image file, resulting in efficient and effective printing of solid and halftone regions.
Implementation Method 1
treating it with electromagnetic radiation to create areas with altered physical properties
Data Source
AI summary
A method for applying a pattern on a mask layer includes obtaining an image file representing pixels with a first pixel size in a first direction parallel to an edge of the pixel, and a second pixel size in a second direction perpendicular to the first direction, where the first and second pixel size are the same or different, treating the mask layer such that a plurality of areas with altered physical properties are created in the mask layer, the plurality of areas corresponding to a plurality of pixels of the image file, where the treatment is done such that a first and/or a second area size of an area of said plurality of areas, seen in said first and/or said second direction, is smaller than the first and/or second pixel size, respectively.