Printing Plate UV Curing Flat Round Top Structures
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Solution Overview
Problem
Conventional printing plates with pure flat top structures struggle to balance ink transfer for line work and screened areas, leading to excessive ink transfer in highlight regions, limiting the gray scale range and requiring separate plates for different features.
Innovation Solution
A method and apparatus that image and cure printing plates with both flat tops and round tops using varying UV exposure parameters, including different intensities and repetition periods, allowing for the production of both feature types on the same plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pure flat top structures are used on printing plates, then ink transfer volume is improved for line work and solid areas, but ink transfer becomes excessive in highlight regions with low percentage screen dot areas
Solution Approach 1:
The patent applies different top structures (flat top vs. round top) to different regions of the printing plate based on the local requirements. Line work and solid areas receive flat top structures for maximum ink transfer, while highlight regions with low screen dot percentages receive round top structures to control ink transfer. This local differentiation resolves the contradiction by allowing each region to have the optimal structure for its specific function.
Solution Approach 2:
The patent segments the printing plate into different feature types (line work, solid areas, screened areas) and applies different curing parameters to each segment. By dividing the plate treatment into distinct zones with different top structures, the system achieves both high ink transfer where needed and controlled ink transfer in highlight areas, thus resolving the contradiction between quantity of ink transfer and gray scale precision.
2Manufacturing precision
If pure round top structures are used on printing plates, then gray scale range is improved for screened areas, but ink transfer volume is reduced for line work and solid areas
Solution Approach 1:
The patent applies different top structures (flat top vs. round top) to different regions of the printing plate based on the local requirements. Line work and solid areas receive flat top structures for maximum ink transfer, while highlight regions with low screen dot percentages receive round top structures to control ink transfer. This local differentiation resolves the contradiction by allowing each region to have the optimal structure for its specific function.
3Manufacturing precision
If separate plates are used for line work and screened areas, then printing quality is improved for each feature type, but device complexity and production time increase
Solution Approach 1:
The patent merges the functionality of multiple separate plates into a single printing plate by applying different top structures to different regions of the same plate. Through selective curing with varying UV exposure parameters, the system creates both flat top and round top features on one plate, eliminating the need for separate plates for line work and screened areas while maintaining the printing quality of both feature types.
Solution Approach 2:
The patent makes a single printing plate universal by enabling it to perform multiple functions that previously required separate plates. By incorporating both flat top structures (for line work and solid areas) and round top structures (for screened areas and highlights) on the same plate, the system achieves multi-functionality, allowing one plate to handle diverse printing requirements without compromising quality.
4Adaptability or versatility
If selective imaging with different UV exposure parameters is applied, then both flat top and round top features are produced on the same plate, but process complexity increases
Solution Approach 1:
The patent introduces dynamic control of UV exposure parameters during the curing process. By varying the UV exposure energy and duration in different regions of the plate, the system dynamically adjusts the curing conditions to produce either flat top or round top features as needed. This dynamic parameter adjustment enables versatile feature production on a single plate while managing process complexity through controlled variability.
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
Enables the creation of printing plates with both flat tops and round tops on the same plate, improving ink transfer and gray scale range without the need for separate plates, enhancing printing quality and efficiency.
Implementation Method 1
curing the printing plate with a light source to a first set of features with a first UV exposure and to a second set of features with a second UV exposure
Data Source
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AI summary
A method of imaging a printing plate and curing the printing plate made of or having photocurable material that includes an ablatable mask. In one embodiment, the method comprises imaging the ablatable mask with a first portion of imaging data to produce a partially imaged uncured plate. Imaging data includes the first portion and a second portion of imaging data. The method includes curing the partially imaged uncured plate using UV with a first set of parameters to produce a partially cured plate with a partially ablated mask thereon, the curing arranged for producing flat tops, imaging the partially ablated mask on the partially cured plate with the second portion of imaging data to produce a totally imaged partially cured plate, and curing the totally imaged partially cured plate with a second set of one or more curing parameters to produce a totally cured plate to produce round tops.