Strippable Multi-Layer Printing Blanket for Flexo
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Solution Overview
Problem
The production of printing forms for flexographic and letterpress printing is complex due to the need for multiple work steps, dynamic material rigidity requiring adjusted contact pressure, low ink transfer, and errors during mounting of photopolymer sheets, which also limits design flexibility and increases costs due to the requirement for various formats.
Innovation Solution
A multi-layer sheet material where the first layer can be easily peeled off from further layers, using an elastomeric material with a lower separation resistance intermediate layer to simplify the creation of non-image areas and reduce contamination, allowing for efficient removal of non-image areas and improved surface smoothness, thereby reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photopolymer print layer is used with laser engraving to form raised print elements, then printing relief can be engraved into the printed layer, but the production process becomes very complex with multiple work steps and requires adjustment of contact pressure at different printing speeds
Solution Approach 1:
The printing form is divided into multiple functional layers: a print layer for ink transfer, a reinforcement layer for structural support, and optionally a compressible layer for pressure distribution. This segmentation allows each layer to be optimized independently, simplifying the overall production process while maintaining printing precision.
Solution Approach 2:
The print layer is pre-vulcanized before mounting on the printing cylinder, creating a dimensionally stable component that maintains consistent contact pressure across different printing speeds. This preliminary vulcanization eliminates the need for dynamic pressure adjustments during operation.
2Manufacturing precision
If photopolymer print layer is used, then laser engraving can create printing relief, but ink transfer is low and errors occur during mounting of the exposed photopolymer sheet
Solution Approach 1:
The print layer is vulcanized in advance before mounting, ensuring dimensional stability and preventing deformation during the mounting process. This preliminary vulcanization eliminates mounting errors and ensures consistent ink transfer performance.
Solution Approach 2:
The printing form uses a composite structure combining a vulcanized print layer with a reinforcement layer. This composite design provides both the flexibility needed for ink transfer and the structural stability required for reliable mounting and consistent performance.
3Ease of manufacture
If photopolymer sheets are produced in roll goods format, then delivery and mounting is simplified, but design flexibility is limited and different formats must be stocked
Solution Approach 1:
The printing form is segmented into a print layer and reinforcement layer that can be produced separately in standardized roll formats. This allows the core components to be manufactured efficiently in rolls while still enabling custom design configurations when assembled.
Solution Approach 2:
The standardized roll goods format serves multiple purposes: it simplifies delivery and storage, enables efficient mounting on printing cylinders, and maintains design flexibility through the modular layer structure that can be configured for different printing applications.
4Productivity
If complete vulcanization of the printing layer is performed, then laser engraving and washing out of non-irradiated areas is eliminated, but the areas to form indentations must be removed completely by laser or mechanical processing
Solution Approach 1:
The printing form is segmented into a print layer and reinforcement layer with controlled adhesion. This allows the non-image areas of the print layer to be easily separated from the reinforcement layer, providing a quick method to create indentations without time-consuming laser or mechanical removal of large areas.
Solution Approach 2:
Instead of removing material to create indentations, the invention inverts the approach by using selective separation: the print layer is kept intact in image areas and separated in non-image areas, creating the printing template through separation rather than 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
This approach simplifies the production of printing forms by allowing easy separation of non-image areas, reducing contamination, and improving surface smoothness, leading to faster and more cost-effective production with enhanced reproducibility and accuracy.
Implementation Method 1
the material of the printed layer is irradiated by means of laser light at the points which will later form the printed elements or image points... Irradiation, for example with actinic light, results in full-surface crosslinking (vulcanization) of this printed layer
Implementation Method 2
the intermediate layer has a lower separation resistance T than the first layer... the first layer (10) can be pulled off or stripped from the at least one further layer (30, 40)
Data Source
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AI summary
The present invention relates to a multi-layered structure form (1) for use as printing blanket or printing plate for relief printing, in particular flexo printing, comprising a first layer (10) having a vulcanizate on the basis of at least one elastomer, and at least an additional layer (30, 40). The first layer (10) can be stripped off (strippable) from the additional layer (30, 40).