Thermal Contact Imaging Roll for Digital Lithography
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Solution Overview
Problem
High power laser-based digital lithographic ink printing systems are costly due to the high latent heat of vaporization of water-based fountain solutions, requiring substantial power for imaging, which is expensive to manufacture and limits process speed.
Innovation Solution
Thermal contact imaging systems using an imaging roll with external and internal heating elements to heat the roll surface above the fountain solution boiling point, allowing for selective cooling by ejecting a solution to create a thermal latent image, reducing the need for high power light sources and enabling efficient ink image formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high power infrared laser is used for imaging, then water-based fountain solution can be vaporized, but manufacturing cost becomes prohibitively expensive
Solution Approach 1:
The patent replaces the optical laser system with a thermal contact imaging system using heated rollers. Instead of using high-power infrared lasers to vaporize fountain solution, the system uses thermally conductive rollers heated to controlled temperatures to transfer heat directly to the fountain solution through contact, achieving vaporization at much lower energy input and eliminating expensive laser infrastructure
Solution Approach 2:
The patent changes the fundamental imaging parameter from optical energy (laser) to thermal energy (heated rollers). By controlling the temperature of the imaging rollers and the duration of contact, the system achieves selective vaporization of fountain solution without requiring the high power levels needed by laser systems, thereby reducing both energy consumption and manufacturing cost
2Productivity
If high power laser is used to evaporate water-based fountain solution, then imaging is achieved, but system complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex optical systems (lasers, mirrors, lenses, synchronization electronics) with simple thermal contact systems (heated rollers, temperature control). This substitution maintains high process speed through direct thermal transfer while dramatically reducing system complexity and eliminating the need for precise optical alignment and high-power electrical infrastructure
Solution Approach 2:
The imaging system is segmented into multiple independent heated rollers that can be controlled individually. Each roller can be temperature-controlled and independently activated, allowing selective imaging without the need for complex laser modulation systems. This segmentation simplifies control while maintaining productivity
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 reduces manufacturing costs and allows for high-speed operation with water-based fountain solutions, eliminating the need for expensive infrared laser systems and minimizing power requirements, while maintaining efficient ink image transfer.
Implementation Method 1
at least one external heating element configured to heat the imaging roll surface to a first temperature
Implementation Method 2
an imaging roll and a drop ejecting system configured to eject a solution onto a surface of the imaging roll for selectively cooling the surface of the imaging roll
Implementation Method 3
the drop ejecting system configured to eject the solution at ambient temperature or otherwise a temperature sufficient to locally cool the imaging roll surface
Implementation Method 4
their high latent heat of vaporization of water necessitates prohibitively large amounts of power to be applied during an imaging step
Implementation Method 5
the imaging roll and the imaging plate forming an imaging nip with the imaging roll of the imaging apparatus
Implementation Method 6
transfer thermal energy from the imaging roll surface regions to a fountain solution film formed on an imaging plate for selectively removing fountain solution
Data Source
AI summary
An imager apparatus useful for a digital lithographic printing system includes imaging roll configured to be heated to a first temperature. The imager apparatus may include one or more heating elements for heating the imaging roll to the first temperature within one revolution. The imaging roll may be about the same width as an imaging plate in a cross-process direction, the imaging plate and the imaging roll being configurable for forming an imaging nip in a digital lithographic ink printing system. The imager apparatus may include a solution ejecting mechanism such as a printhead for ejecting fountain solution or water at ambient temperature onto a surface of the imaging roll according digital image data.