UV LED Finishing for Flexographic Plates
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Solution Overview
Problem
Current finishing methods for flexographic digital printing plates using neon lamps are inefficient due to unpredictable light intensity and deterioration, requiring specialized personnel and leading to potential human errors and high production waste.
Innovation Solution
A method and device utilizing a plurality of UV-A LEDs and UV-C LEDs with controlled exposure, allowing for predictable and controllable finishing, eliminating the need for specialized personnel and reducing production waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If neon lamps are used for finishing, then the finishing treatment can be performed, but the light intensity becomes unpredictable and the lamps deteriorate, requiring specialized personnel and leading to production waste
Solution Approach 1:
The patent changes the light source from neon lamps to LED lamps, fundamentally altering the parameters of light intensity stability, lifespan, and controllability. LEDs provide consistent, predictable light intensity without the deterioration issues of neon lamps, eliminating the need for specialized personnel monitoring and adjustment.
2Manufacturing precision
If static finishing is performed, then the process is simple, but the surface finish consistency is poor
Solution Approach 1:
The patent introduces dynamic elements to the finishing process by implementing a conveyor system that moves plates through the LED finishing chamber. This dynamic approach ensures uniform exposure of all plate surfaces to the LED light sources, achieving consistent surface finish while maintaining process simplicity through automated motion control.
3Productivity
If conventional UV lamps are used for exposure, then the process is established, but the exposure time varies and requires manual adjustment
Solution Approach 1:
The patent implements feedback control by using sensors to monitor the actual light intensity from LEDs and automatically adjusting the exposure parameters. The system receives feedback on plate position and light intensity, dynamically adjusting exposure time and intensity to optimize the finishing process without manual intervention, thereby improving both productivity and ease of operation.
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 a consistent and optimal surface finish for flexographic plates, enhancing print quality while reducing costs and operational complexities.
Implementation Method 1
providing a plurality of UV-A LEDs and a plurality of UV-C LEDs
Implementation Method 2
Exposure of the plate to light causes polymerization of only those parts of the plate located at portions of the mask that are permeable to light, thereby forming the image to be printed in relief on the photopolymer
Implementation Method 3
moving the plate being processed or the plurality of UV-A LEDs and the plurality of UV-C LEDs along a feed direction, with a such a speed that the entire surface to be treated is radiated by the LEDs for a prefixed time
Data Source
Figure 1~2
Figure 3~4
AI summary
There are described a method and a device for finishing flexographic digital printing plates. The finishing device comprises: - an exposure chamber (5) hermetic to UV rays, wherein radiating of the plate (1) to be treated is carried out; - a plurality of UV-A LEDs and a plurality of UV-C LEDs, said LEDs being placed inside the exposure chamber so that that their radiating surface faces the surface of the plate to be treated and being suitable for radiating the plate to be treated; - means for relative movement between the plate being processed, said plurality of UV-A LEDs and said plurality of UV-C LEDs, suitable for moving the plate being processed or the plurality of UV-A LEDs and the plurality of UV-C LEDs along a feed direction (x).