Polymeric Gravure Printing Form with Multifunctional Urethane
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Solution Overview
Problem
Conventional metal gravure printing forms are expensive, time-consuming, and environmentally harmful due to electroplating and etching processes, and polymer-based alternatives face challenges in meeting requirements for coatability, curability, engravability, solvent resistance, and mechanical wear resistance for long print runs while being easy to remove.
Innovation Solution
A process involving a curable composition of multifunctional urethane with ethylenically unsaturated groups and an initiator, applied to a substrate and cured using radiation or heat, followed by engraving, which forms a hard layer suitable for gravure printing with improved solvent and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal layers (copper and chrome) are used for gravure printing forms, then durability and engravability are improved, but manufacturing cost and environmental harm increase due to electroplating and etching processes
Solution Approach 1:
The patent removes the harmful electroplating and etching processes from the manufacturing workflow, extracting only the essential function of creating a durable printing surface. This is achieved by applying a polymeric composition directly to the gravure cylinder, eliminating the need for copper and chrome metal layers and their associated hazardous waste generation
Solution Approach 2:
The patent changes the fundamental material parameter from metal-based (copper/chrome) to polymeric-based composition. This parameter change maintains the essential function of durability and engravability while eliminating environmental harm, as the polymeric composition cures to form a durable surface that can be engraved without requiring harmful metal plating processes
2Ease of manufacture
If polymeric composition is used to replace metal layers, then environmental friendliness and cost are improved, but coatability, curability, and engravability must be optimized to meet strict tolerances
Solution Approach 1:
The patent optimizes the polymeric composition parameters including reactive group equivalent weight (200-500 g/equivalent), viscosity (50-2000 cP), and crosslink density to achieve the desired balance of coatability, curability, and engravability. These parameter adjustments ensure the composition forms a uniform layer that cures properly and can be engraved to strict tolerances
Solution Approach 2:
The patent employs a composite polymeric composition containing multifunctional urethane acrylates, reactive diluents, and photoinitiators that work together to achieve the required performance characteristics. This composite formulation provides the necessary coatability, curability, and mechanical properties for successful gravure printing application
3Manufacturing precision
If the surface layer is made hard for defined print cell structure, then engravability is improved, but solvent resistance and mechanical wear resistance must be maintained
Solution Approach 1:
The patent carefully controls the crosslink density and hardness parameters of the cured polymeric layer to achieve the optimal balance between engravability and durability. The composition is formulated to cure to a hardness that allows precise cell definition during engraving while simultaneously providing adequate solvent resistance and mechanical wear resistance for long print runs
Solution Approach 2:
The patent uses a composite polymeric system with multifunctional urethane acrylates and reactive diluents that provides both the hardness needed for defined print cell structure and the chemical resistance required for durability. The synergistic combination of these components achieves both engravability and long-term reliability
4Duration of action of stationary object
If the polymeric layer is designed for long print runs (100,000+ impressions), then durability is improved, but ease of removal for reuse is reduced
Solution Approach 1:
The patent creates a dynamically adjustable system where the polymeric layer's adhesion properties can be modified after curing. The layer is designed to be removable through controlled methods such as heating or chemical treatment, allowing it to transition from a strongly adhered state during printing to a removable state for reuse, thus achieving both long durability and ease of removal
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 process enables the production of a polymer-based gravure printing form that is cost-effective, environmentally friendly, and meets the necessary performance criteria for high-quality printing with long print runs, including excellent solvent and mechanical resistance, and can be easily removed for reuse.
Implementation Method 1
exposing the layer of the curable composition to actinic radiation or heat to form a cured layer
Data Source
Figure 1
AI summary
The invention pertains to a printing form and a process for preparing a polymeric printing form from a curable composition that includes a multifunctional urethane in a specified reactive group equivalent weight range, and an initiator. The process includes coating the curable composition onto a supporting substrate, such as a print cylinder, to form a layer, curing the layer with heat or by exposure to actinic radiation, and engraving the resulting cured layer to form at least one printing cell in the cured layer. The process prepares novel polymeric printing forms, particularly novel polymeric gravure printing forms, having a cured polymer-based composition layer that is engravable, resistant to solvent inks, and capable of printing gravure-quality images. The present invention shortens the time to prepare gravure printing cylinders and removes the need for and disposal of toxic heavy metals such as copper and chrome associated with conventional gravure print cylinder preparation.