Tangential Flexographic Plate Mounting Device Eliminates Air Bubbles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing flexographic plate mounting machines face challenges in eliminating air bubbles and preventing detachments between plates with double-sided tape and flexible supports, especially with thick or differently thick plates, leading to quality issues and increased costs due to ineffective mechanical systems for bubble removal and residual tension causing curvature deformations.
Innovation Solution
A tangential flexographic plate mounting device without tension, featuring a frame with a rotatable cylindrical support and an applicator roller that applies the plate with double-sided tape to a flexible support, allowing a tension-free coupling by gravity or pressure, ensuring the plate assumes an opposite curvature to the cylindrical support, thus avoiding air bubbles and detachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical pressure systems are used to eliminate air bubbles during plate mounting, then air bubble removal is improved, but device complexity and cost increase
Solution Approach 1:
The invention extracts and eliminates the complex mechanical pressure system from the plate mounting device. Instead of using pneumatic or mechanical pressure rollers to remove air bubbles, the design relies on the natural adhesion properties of the double-sided tape and the flexibility of the support material to achieve bubble-free mounting without additional pressure-generating components.
Solution Approach 2:
The mounting system performs self-service by utilizing the inherent properties of the materials involved. The double-sided tape automatically adheres the plate to the flexible support, and the flexibility of the support material naturally accommodates and expels air bubbles during the mounting process, eliminating the need for external pressure systems.
2Reliability
If mechanical pressure systems are used to eliminate air bubbles, then air bubble removal is improved, but manufacturing cost increases
Solution Approach 1:
The invention removes the expensive mechanical pressure system from the plate mounting device. By relying on the natural adhesion and flexibility properties of the materials, the design eliminates the need for costly pneumatic components, pressure rollers, and associated control systems, thereby reducing manufacturing costs.
Solution Approach 2:
The invention employs simple, inexpensive materials such as double-sided tape and flexible support materials that can be easily replaced. This approach replaces expensive, complex mechanical pressure systems with low-cost consumable materials that achieve the same functional result of bubble-free mounting.
3Ease of operation
If plates are mounted on cylindrical supports, then mounting is enabled, but permanent curvature deformation occurs
Solution Approach 1:
The invention segments the mounting process into two distinct phases: first, mounting the plate on a flexible support material that can accommodate curvature; second, transferring the assembled plate-support combination to the cylindrical drum. This segmentation allows the flexible support to absorb the curvature deformation during mounting while the final cylindrical mounting occurs after the plate is already secured to the flexible base.
Solution Approach 2:
The invention inverts the traditional mounting sequence by first attaching the plate to a flexible support material and then transferring the combined assembly to the cylindrical drum. This reversal ensures that the plate is secured in a tension-free state on the flexible support before encountering the cylindrical curvature, preventing permanent deformation of the plate itself.
4Ease of operation
If the flexible support is removed from the cylindrical support, then plate detachment occurs, but storage and handling become possible
Solution Approach 1:
The invention segments the system into a flexible support layer with mounted plate and a rigid cylindrical support structure. The flexible support maintains continuous adhesion to the cylindrical support throughout the printing process, while the plate remains securely attached to the flexible support. This segmentation allows the entire assembly to be removed from the cylindrical support for storage or handling without causing plate detachment, as the plate's adhesion to the flexible support remains intact.
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 solution enables a bubble-free, stress-free assembly of flexographic plates on flexible supports, improving printing quality, reducing costs by eliminating the need for pressure devices, and allowing easier handling and storage of plates without residual curvature, effective for both thick and large plates.
Implementation Method 1
a tangential flexographic plate mounting device without tension on a flexible support S, comprising a frame 2 and a rigid cylindrical support 3 rotatably coupled with said frame 2, said cylindrical support 3 comprising an outer surface 3a on which it is possible to apply at least a flexible support S... a flexographic plate 5, provided with double-sided tape 4, is fixable on said flexible support S
Implementation Method 2
an applicator roller 101 for the application of the plate 5, provided with double-sided tape 4, on the flexible support S... In said operative position, the applicator roller 101 is in rolling contact with the plate 5
Implementation Method 3
In said operative position, the applicator roller 101 is in rolling contact with the plate 5 by the action of gravity or pressure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A tangential flexographic plate mounting device (100) without tension on a flexible support (S), comprising a frame (2) and a rigid cylindrical support (3) rotatably coupled with said frame (2), said cylindrical support (3) comprising an outer surface (3a) on which it is possible to apply at least a flexible support (S), on which in turn a flexographic plate (5), complete with double-sided tape (4), is fixable. The device comprises an applicator roller (101) of the plate (5), complete with double-sided tape (4), on the flexible support (S), mobile between an inactive position and an operative application position of said plate (5) complete with double-sided tape (4) on said flexible support (S) from an end edge (10,10a) thereof or from the middle portion (M) thereof, in such operative position and during application the plate (5) being wrapped around at least a portion of the outer cylindrical surface (101a) of said application roller (101), in order to assume, during application, an opposite curvature to that of said cylindrical support (3).