Oxygen Barrier Membrane Lamination for Flexographic Printing Plates
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Solution Overview
Problem
Flexographic printing plates face difficulties in maintaining small graphic elements like fine dots and lines due to the nature of the platemaking process, which results in issues such as dot removal and damage during printing, and the curing process is inhibited by molecular oxygen in photocurable resin compositions.
Innovation Solution
A method of laminating an oxygen barrier membrane to the printing plate using heat and pressure, with a splitter bar controlling the tension and wrap angle of the laminating film to minimize wrinkles and waves, and an oxygen barrier membrane that limits oxygen diffusion and imparts desired geometric characteristics to the printing dots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional lamination process is used to apply the oxygen barrier membrane to the printing plate, then the membrane can be laminated to the plate surface, but wrinkles and waves form in the membrane during lamination, reducing the quality of the laminated product
Solution Approach 1:
The patent applies preliminary action by pre-tensioning the oxygen barrier membrane on a tensioning roller before it reaches the lamination zone. This pre-tensioning prevents wrinkles and waves from forming during the subsequent lamination process, ensuring high lamination quality without requiring complex real-time control mechanisms.
Solution Approach 2:
The patent utilizes parameter changes by controlling the wrap angle of the membrane around the tensioning roller to be at least 125 degrees. This specific angular parameter, combined with heat and pressure application, optimizes the tension distribution and lamination quality while maintaining a relatively simple process configuration.
2Manufacturing precision
If the wrap angle between the laminating film and heated laminating roller is less than 125 degrees, then the lamination process is simpler, but wrinkles and waves form in the laminating film
Solution Approach 1:
The tensioning roller with a wrap angle of at least 125 degrees applies preliminary tension to the film before lamination, preventing wrinkles and waves from forming during the process. This preliminary action ensures film smoothness without requiring multiple correction passes or extended processing time.
3Reliability
If molecular oxygen is present in the photocurable resin composition, then the resin can be easily applied and handled, but the curing process is inhibited, reducing printing quality
Solution Approach 1:
The patent converts the harmful effect of oxygen (which inhibits curing) into a beneficial function by using an oxygen barrier membrane. This membrane selectively blocks oxygen from reaching the photocurable resin during lamination and printing, ensuring complete curing while maintaining the ease of handling the resin composition during application.
Solution Approach 2:
The patent employs a composite structure consisting of the printing plate, photocurable resin composition, and oxygen barrier membrane. This composite system combines materials with different properties: the membrane provides oxygen barrier functionality while the resin provides printing functionality, achieving both easy handling and complete curing.
4Manufacturing precision
If the laminating film tension is not controlled, then the lamination process is simpler to operate, but the geometric characteristics of printing dots are compromised
Solution Approach 1:
The tensioning roller applies preliminary and controlled tension to the laminating film before it reaches the lamination zone. This pre-established tension control ensures that the geometric characteristics of printing dots are maintained without requiring complex real-time adjustment mechanisms during operation.
Solution Approach 2:
The patent utilizes the wrap angle parameter (at least 125 degrees) as a fixed geometric parameter to control film tension. By optimizing this angular parameter, the system achieves precise control over dot geometric characteristics while maintaining operational simplicity through a straightforward mechanical configuration.
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 method improves the quality of the laminated product by ensuring wrinkle-free lamination, controlling tension, and enhancing the geometric characteristics of printing dots, leading to superior printing performance by reducing oxygen inhibition and maintaining dot integrity during the printing process.
Implementation Method 1
an oxygen barrier membrane that limits oxygen diffusion
Implementation Method 2
A method of laminating an oxygen barrier membrane to the printing plate using heat and pressure
Implementation Method 3
with a splitter bar controlling the tension and wrap angle of the laminating film
Data Source
AI summary
An apparatus for laminating a film to a substrate and a method of using the same is described. The apparatus comprises a) a heated laminating roller and a second roller, wherein said heated laminating roller and said second roller are opposably mounted and form a nip; b) a drive mechanism for rotating the heated laminating roller and second roller; c) a film supply roller adapted to support a roll of film and supply the film over an outer surface of the heated laminating roller and into the nip, wherein the film is contactable with a top surface of the substrate at a point where the substrate advances through the nip; and d) a splitter bar in contact with the film supplied from the supply roller, wherein the position of the splitter bar controls a wrap angle between the film and the heated laminating roller.