Resin Intaglio Plate Cell Uniformity for Stable Ink Transfer
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Solution Overview
Problem
Conventional resin gravure plates face issues with variation in cell volume and ink transfer stability, particularly in highlight regions, and are inadequate for small-lot and high-mix production, with environmental concerns due to metal waste liquids.
Innovation Solution
A printing intaglio plate with a resin layer having specific Shore A hardness (30-90 degrees), surface free energy (10-35 mN/m), and coefficient of variation in cell volume (0.200 or less), formed using a laser to create cells with controlled dimensions, enhancing ink transfer stability and deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a conventional resin gravure plate is used, then the plate can be produced without metal waste liquids, but the ink transfer stability in highlight regions deteriorates and cell volume variation increases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Shore A hardness (30-90 degrees) and surface free energy (10-35 mN/m) of the resin layer to achieve both environmental benefits and improved ink transfer stability. This parameter optimization resolves the contradiction between using resin plates for environmental reasons and maintaining printing quality.
Solution Approach 2:
The patent uses laser engraving to create precise cell patterns on the resin plate, copying the functional structure needed for ink transfer while eliminating the need for metal plates. This allows resin plates to replicate the performance characteristics of metal plates without the associated environmental harm.
2Object-generated harmful factors
If a conventional resin gravure plate is used, then the plate can be produced without metal waste liquids, but the ink deposition in solid regions is insufficient
Solution Approach 1:
The patent controls the coefficient of variation in cell volume to 0.200 or less through precise laser engraving parameters, ensuring uniform ink deposition across solid regions. This parameter control enables resin plates to achieve manufacturing precision comparable to metal plates while maintaining environmental advantages.
3Object-generated harmful factors
If laser engraving is used to form cells in resin plates, then metal waste liquids are eliminated, but cell volume variation increases
Solution Approach 1:
The patent replaces traditional mechanical cell formation methods with laser engraving technology, eliminating the need for metal plates and chemical etching processes that generate waste liquids. The laser parameters are precisely controlled to maintain cell volume uniformity within 0.200 coefficient of variation.
Solution Approach 2:
The patent optimizes laser engraving parameters including pulse width, energy density, and scanning speed to achieve consistent cell dimensions. By controlling these parameters, the patent achieves coefficient of variation in cell volume of 0.200 or less, resolving the precision issue while maintaining environmental benefits.
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 achieves stable ink transfer in highlight regions and improved ink deposition in solid regions, supporting small-lot and high-mix production while reducing environmental impact by minimizing metal waste.
Implementation Method 1
a processing step of forming a depressed portion in the resin layer with a laser
Implementation Method 2
Inks can be stored in depressed portions thus formed, and transferred to objects
Data Source
AI summary
A printing intaglio plate including a resin layer constituting a plate surface, in which a Shore A hardness of the resin layer is 30 degrees or more and 90 degrees or less, a surface free energy of the resin layer is 10 mN/m or more and 35 mN/m or less, and the resin layer includes a cell on the plate surface and a coefficient of variation in cell volume of the cell, for printing at the same ink concentration, is 0.2 or less.