Reconfigurable Relief Surface Using Microvalves
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Solution Overview
Problem
Flexographic and gravure printing methods are inefficient for low-volume printing due to the high cost and time required for patterning traditional master plates, which are not easily reusable, making them unsuitable for short runs of different prints.
Innovation Solution
A reusable printing plate with a flexible surface and an intermediate layer of flow paths controlled by an electric field, using a pressurizable/depressurizable fluid to create and modify relief patterns, allowing for rapid reconfiguration of the printing surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional master plates are used for flexography or gravure printing, then print quality and speed are improved, but the cost and time for patterning master plates increases significantly for low-volume printing
Solution Approach 1:
The printing plate uses a flexible substrate with an intermediate layer containing microvalves that can dynamically change state between open and closed positions based on applied voltage. This dynamic control allows the relief pattern to be reconfigured rapidly without replacing the entire master plate, eliminating the time-consuming patterning process while maintaining printing capability.
Solution Approach 2:
The invention changes the physical state of the intermediate layer material through voltage application. When voltage is applied, the material transitions from a compliant state (allowing microvalves to open) to a rigid state (maintaining microvalve position), enabling rapid pattern reconfiguration and eliminating traditional master plate fabrication time.
2Manufacturing precision
If traditional master plates are used for flexography or gravure printing, then print quality is improved, but the cost of manufacturing master plates cannot be justified for low-volume printing
Solution Approach 1:
The dynamic microvalve system allows a single inexpensive plate to be reconfigured for different printing jobs, replacing the need for multiple expensive custom-master plates. This eliminates the high manufacturing cost barrier for low-volume printing while maintaining print quality through precise microvalve control.
Solution Approach 2:
The printing plate is designed to perform multiple functions: it can be reconfigured to print different patterns and images by simply changing the voltage pattern applied to the intermediate layer. This universal plate replaces the need for multiple specialized master plates, significantly reducing manufacturing costs for low-volume diverse printing.
3Productivity
If traditional master plates are used, then high-speed printing is achieved, but the plates cannot be easily re-imaged or re-used
Solution Approach 1:
The microvalves transition dynamically between open and closed states based on applied voltage, allowing the same physical plate to be rapidly reconfigured for different printing tasks. This maintains high printing speed while enabling unlimited reuse and reconfiguration, unlike traditional static master plates.
4Adaptability or versatility
If electrostatic or electromagnetic techniques are used to adjust the print surface, then reusability is improved, but device complexity and difficulty of implementation increase
Solution Approach 1:
The invention replaces complex electromagnetic coils and magnetic field generation systems with a simpler electrostatic actuation system using voltage-controlled dielectric material. This substitution maintains plate reusability and reconfigurability while significantly reducing device complexity and ease of implementation.
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 rapid and cost-effective creation of relief patterns on the printing surface, allowing for efficient low-volume printing by reusing the plate and reducing the need for expensive master plates, while maintaining print quality.
Implementation Method 1
The intermediate layer includes a dielectric material that expands or contracts in response to an applied electric field pattern
Implementation Method 2
The fluid flows through open flow paths in the intermediate layer to produce a relief pattern in the flexible printing surface
Data Source
AI summary
A structure and method of using a reusable master printing plate is described. In one embodiment, the method uses an electric field to control a series of microvalves. The microvalves control a fluid flow that raises or lowers selected regions on a flexible printing surface to create a desired relief pattern. After creating the relief pattern, the pattern is fixed and used for printing. After completion of printing, the relief pattern is removed from the master printing plate and the printing plate may be reused by applying a new pattern.