Textured Imaging Blanket for Variable Data Lithography
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Solution Overview
Problem
Offset inks with high viscosity and tacky nature are difficult to manipulate in variable printing systems, as they have high surface adhesion forces relative to electrostatic forces, making them unsuitable for nozzle-based inkjet systems and requiring surface texturing methods that are not optimized for retaining dampening fluid effectively.
Innovation Solution
A method of forming an imaging blanket with a desired texture pattern using photolithographically patternable materials, where the blanket is removably secured to an image forming member, involving deposition, exposure, etching, and curing of a curable liquid polymer to create a template surface with specific texture features that optimize dampening fluid retention and ink transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If offset inks are used in variable printing systems, then high quality printing with low cost ink is achieved, but the high viscosity and high surface adhesion forces make them difficult to manipulate in nozzle-based inkjet systems
Solution Approach 1:
The patent replaces the mechanical nozzle-based inkjet system with an electrostatic-based ink transfer system. Instead of mechanically propelling high-viscosity offset ink through nozzles, the system uses electrostatic forces to attract and transfer toner particles onto the imaging blanket, which then transfers the image to the substrate. This substitution of the delivery mechanism resolves the contradiction by enabling ink-like quality printing without the manipulative difficulties of high-viscosity inks.
Solution Approach 2:
The patent changes the physical parameters of the marking material from liquid offset ink to dry or liquid toner particles with tailored surface chemistry. This parameter change reduces surface adhesion forces relative to electrostatic forces, enabling effective manipulation in variable printing systems while maintaining high color pigment content for quality printing.
2Quantity of substance
If offset inks are used, then high color pigment content and low cost are achieved, but very high surface adhesion forces relative to electrostatic forces make them very difficult to manipulate onto or off of a surface using electrostatics
Solution Approach 1:
The patent changes the surface chemistry parameters of the marking material to create toner particles with low surface adhesion forces. By tailoring the surface chemistry and using special surface additives, the system reduces the adhesion forces relative to electrostatic forces, enabling effective electrostatic manipulation while maintaining high color pigment content for cost-effective, high-quality printing.
Solution Approach 2:
The patent uses composite toner particles with tailored surface chemistry and special surface additives to achieve the desired balance between color pigment content and surface adhesion properties. These composite materials enable both high printing quality and effective electrostatic manipulation in variable printing systems.
3Reliability
If a textured surface is created on the imaging blanket, then dampening fluid retention is improved, but the surface texture must be optimized for both fluid retention and ink transfer
Solution Approach 1:
The patent applies local quality by creating specific micro-scale surface features (peaks and valleys) with controlled dimensions and distributions on the imaging blanket surface. These localized structural characteristics are optimized to provide both dampening fluid retention in the valleys and effective ink transfer from the peaks, resolving the contradiction between fluid retention and ink transfer requirements.
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 textured imaging blanket effectively retains a thin dampening fluid layer and allows for selective ink transfer, enabling high-quality variable data printing by optimizing surface roughness and oleophobicity, improving fluid retention and ink acceptance.
Implementation Method 1
exposing the photolithographically patternable material to a desired exposure pattern
Implementation Method 2
curing the liquid polymer to thereby form the imaging blanket
Implementation Method 3
The textured surface of the imaging blanket retains a relatively thin layer of dampening fluid
Implementation Method 4
the quality and color gamut of the inks used... these inks, which typically have very high color pigment content
Implementation Method 5
The hydrophobic regions repel dampening fluid and accept ink
Implementation Method 6
image regions formed of hydrophobic and oleophilic material
Data Source
AI summary
Forming an imaging blanket for a printing apparatus includes depositing a patternable material over a substrate, etching the patternable material according to a desired exposure pattern, hardening the etched patternable material to thereby form a template surface comprising a desired template pattern of texture features, depositing a layer of curable liquid polymer over and in physical contact with the template surface, curing the liquid polymer to thereby form the imaging blanket, and removing the imaging blanket from the template surface to thereby expose a patterned imaging surface of the imaging blanket. The image blanket may thereby be provided with a desired texture surface, for example comprised of individual molded image blanket features, such as recesses or pillars, of a desired cross-sectional shape. The image blanket is configured for and may be disposed on an image forming member of a variable data lithography system.