UV LED Exposure for Uniform Flexo Plate Curing
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Solution Overview
Problem
Conventional fluorescent light sources in flexographic printing systems suffer from inconsistent light output, requiring frequent bulb replacements and posing environmental hazards, which affects the consistency and quality of cured printing plates.
Innovation Solution
Employing UV LED light tubes in an exposure system for flexographic printing, allowing precise control over wavelength and intensity, and using a controller to individually modulate each tube's output, ensuring uniform exposure across the printing surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If fluorescent light sources are used in the exposure system, then the system can provide sufficient light intensity for curing, but the light output becomes inconsistent over time requiring frequent bulb replacements and affecting curing quality
Solution Approach 1:
The patent transitions from fluorescent light sources to LED light sources, fundamentally changing the illumination parameter. LEDs provide consistent light output intensity over their operational lifespan without the degradation issues of fluorescent bulbs, eliminating the need for frequent replacements and maintaining reliable curing quality throughout the system's service life.
2Illumination intensity
If fluorescent bulbs are used frequently, then sufficient illumination is maintained, but environmental hazards increase due to mercury content and disposal requirements
Solution Approach 1:
The patent eliminates the harmful mercury-containing fluorescent bulbs and replaces them with environmentally friendly LED light sources. This substitution removes the environmental hazard while maintaining sufficient illumination intensity for curing, converting a harmful lighting system into a beneficial one that protects the environment.
3Reliability
If conventional fluorescent exposure systems are used, then curing can be performed, but exposure time varies due to bulb intensity degradation affecting productivity
Solution Approach 1:
The patent changes the light source parameter from fluorescent to LED, which maintains consistent intensity output. This consistency allows for optimized and standardized exposure times, improving productivity by eliminating the need to adjust exposure times due to bulb degradation while maintaining reliable curing consistency throughout the system's operational life.
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 UV LED system provides consistent and high-quality flexographic printing plates with reduced exposure time, eliminating the need for frequent bulb replacements and reducing environmental impact.
Implementation Method 1
The liquid photopolymer is typically a material that is both fluid when uncured and hardens upon exposure to selective wavelengths of actinic radiation. Upon exposure to actinic radiation, the liquid photopolymer resin polymerizes and changes from a liquid state to a solid state to form a raised relief image.
Data Source
AI summary
A method of exposing a layer of liquid photopolymer resin to actinic radiation from a UV light source to crosslink and cure the layer of liquid photopolymer resin. The liquid photopolymer resin is capable of being selectively crosslinked and cured upon exposure to actinic radiation at a desired wavelength. The exposure unit includes a plurality of UV LED light tubes arranged at a distance from a surface of the layer of liquid photopolymer resin.