Relief Image Mask Element Adhesion via Spacer Layer
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Solution Overview
Problem
Existing methods for making mask elements in the flexographic industry face challenges in achieving efficient production, improving interlayer adhesion, and ensuring intimate contact between the mask element and the relief-forming precursor during imaging, particularly in lamination and vacuum draw-down processes, which can lead to poorer imaging quality and contamination.
Innovation Solution
A method involving a non-ablatable light-to-heat converting (LTHC) layer with specific components such as infrared radiation absorbing materials, thermally crosslinked organic polymeric binders, and non-thermally ablatable particles, combined with a non-silver halide thermally-ablatable imaging layer, to enhance the adhesion and contact between the mask element and the relief-forming precursor, facilitating better imaging and reducing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lamination process is used to place the mask element in contact with the relief-forming precursor, then the mask element can be positioned on the precursor, but interlayer adhesion is insufficient and intimate contact is not achieved
Solution Approach 1:
A spacer layer is introduced between the mask element and the relief-forming precursor to facilitate intimate contact during imaging. The spacer layer acts as an intermediary that ensures proper positioning and contact while allowing the mask element to be easily positioned and removed without creating permanent adhesion bonds.
Solution Approach 2:
The surface energy parameters of the spacer layer are specifically controlled to be higher than both the mask element and relief-forming precursor surfaces. This parameter change enables the spacer layer to form strong temporary bonds with both surfaces, ensuring intimate contact during imaging while allowing easy separation afterward.
2Reliability
If vacuum draw-down is used to improve contact between mask element and relief-forming precursor, then drawing can be achieved, but adhesion remains insufficient and contact is not intimate
Solution Approach 1:
The spacer layer serves as a mediator that enables vacuum draw-down to function effectively. It transmits the vacuum force uniformly across its surface, drawing the mask element into intimate contact with the relief-forming precursor while maintaining the ability to separate the layers after imaging.
Solution Approach 2:
The surface energy parameters of the spacer layer are optimized to respond effectively to vacuum forces during draw-down. This parameter change allows the spacer layer to transmit vacuum pressure efficiently, achieving intimate contact between the mask element and precursor while maintaining operational ease.
3Manufacturing precision
If conventional mask element precursors are used, then the imaging process can be completed, but imaging quality is poor due to insufficient contact and adhesion
Solution Approach 1:
The spacer layer acts as a consistent intermediary that ensures uniform and reliable contact between the mask element and relief-forming precursor throughout the imaging process. This mediator eliminates contact inconsistencies that degrade imaging quality, providing stable and repeatable imaging results.
Solution Approach 2:
The surface energy parameters of the spacer layer are specifically adjusted to optimize contact consistency during imaging. This parameter change ensures that the spacer layer maintains uniform contact pressure and alignment throughout the imaging process, directly improving imaging quality and reliability.
4Ease of manufacture
If the mask element is removed after imaging, then the relief-forming precursor can be processed, but contamination may occur during removal
Solution Approach 1:
The spacer layer serves as a temporary intermediary that facilitates clean separation between the mask element and relief-forming precursor. It enables the mask element to be easily removed without creating adhesion bonds that would cause contamination, while still ensuring intimate contact during the imaging process.
Solution Approach 2:
The spacer layer is designed with specific surface energy parameters that create temporary bonds strong enough to maintain contact during imaging but weak enough to allow easy separation afterward. This beforehand design prevents contamination by ensuring the mask element can be cleanly removed without leaving residues or causing damage to the relief-forming precursor.
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 solution improves interlayer adhesion and intimate contact, minimizing artifacts and contamination, and allows for more efficient imaging processes by effectively converting infrared radiation into heat for complete ablation of the imaging layer, leading to higher quality relief images.
Implementation Method 1
a first infrared radiation absorbing material in an amount of at least 0.1 weight % and up to and including 5 weight %
Implementation Method 2
a non-ablatable light-to-heat converting (LTHC) layer... converting infrared radiation into heat
Implementation Method 3
a thermally crosslinked organic polymeric binder material
Implementation Method 4
a non-silver halide thermally-ablatable imaging layer (IL)... UV-light absorbing material
Implementation Method 5
vacuum draw-down of the mask element to the relief-forming precursor
Data Source
AI summary
A relief image is prepared by: A) imaging an imageable material to form a mask element; B) exposing a relief-forming precursor through the mask element; C) removing the mask element; and D) developing the imaged relief-forming precursor. The imageable material has, in order: (a) a transparent polymeric carrier sheet; (b) a non-ablatable light-to-heat converting having an average dry thickness of 1-5 μm and comprising: (i) an infrared radiation absorbing material at 0.1-5 weight %; (ii) a thermally crosslinked organic polymeric binder material; and (iii) non-thermally ablatable particles having an average particle size of 0.1-20 μm in an amount of 0.2-10 weight %; and (c) a non-silver halide thermally-ablatable imaging layer (IL) disposed on the LTHC layer, the IL comprising a second infrared radiation absorbing material and a UV-light absorbing material dispersed within one or more thermally-ablatable polymeric binder materials. The imageable material can be included in a relief image-forming assembly.