Water-Dilutable Photopolymer Layer for Solvent-Free Flexographic Imaging
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Solution Overview
Problem
Flexographic printing plates require lengthy solvent-based development processes that are time-consuming and produce toxic by-products, and water-soluble photopolymer layers offer poor chemical resistance and image integrity.
Innovation Solution
A photopolymerizable layer comprising a photopolymerization initiator and a water-dilutable but not water-soluble monomer, which allows for aqueous development without organic solvents, enabling fast development times and improved chemical resistance while maintaining high image integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent-based development is used, then image integrity and chemical resistance are improved, but development time increases and toxic by-products are produced
Solution Approach 1:
The patent changes the chemical parameter of the monomer from water-soluble to water-dilutable but not water-soluble. This parameter change enables the photopolymer layer to be developed quickly with aqueous solutions while maintaining the chemical resistance and image integrity typically associated with solvent-based systems. The specific parameter change is the water-dilutability of the monomer, which allows controlled interaction with aqueous developers.
Solution Approach 2:
The patent converts the potential harm of water-soluble monomers (poor chemical resistance) into a benefit by selecting water-dilutable but not water-soluble monomers. These monomers can be diluted with water for easy development but remain resistant to water-based chemicals during printing, thus converting the apparent disadvantage of water compatibility into an advantage for both development and printing performance.
2Productivity
If water-soluble photopolymer layers are used, then development time is reduced and environmental friendliness is improved, but chemical resistance and image integrity deteriorate
Solution Approach 1:
The patent changes the solubility parameter of the monomer from water-soluble to water-dilutable but not water-soluble. This parameter change enables the material to interact with water-based developers for fast development while maintaining sufficient hydrophobicity to resist water-based chemicals during the printing process, thus achieving both fast development and good chemical resistance.
Solution Approach 2:
The patent applies different properties to different aspects of the monomer's behavior: it is water-dilutable during development (allowing fast aqueous processing) but water-resistant during printing (maintaining chemical resistance). This local differentiation of properties resolves the contradiction between development speed and chemical resistance.
3Object-generated harmful factors
If water-dilutable monomers are used, then environmental friendliness and development speed are improved, but monomer selection constraints increase
Solution Approach 1:
The patent specifies a particular parameter range for the monomer: water-dilutable but not water-soluble. This parameter specification narrows the selection criteria but enables the use of environmentally friendly aqueous developers. The constraint is justified by the significant benefit of eliminating toxic organic solvent by-products while maintaining printing performance.
Data Source
AI summary
Flexographic printing members amenable to aqueous (or organic) development do not exhibit the deleterious effects on printing performance characteristic of some conventional alternatives. Embodiments of the invention utilize a photopolymerizable layer comprising, consisting of, or consisting essentially of a photopolymerization initiator and a water-dilutable (but not water-soluble) monomer.