Abstract:
A method of producing a relief image printing element from a photocurable printing blank. The method includes the steps of a) providing a photocurable printing blank, the photocurable printing blank comprising (i) a backing or support layer; and (ii) one or more photocurable layers disposed on the backing or support layer. The one or more photocurable layers comprise a photocurable composition comprising (1) a binder; (2) one or more monomers; (3) a photoinitiator; and (4) an additive. The one or more photocurable layers are selectively imaged by exposing the layers to actinic radiation to selectively crosslink and cure portions of the one or more photocurable layers, and then developed to remove uncured portions of the one or more photocurable layers and reveal the relief image therein. The relief image comprises a plurality of relief printing dots, including relief printing dots that have a rounded top and relief printing dots that have a flat top.
Abstract:
A method of processing a flexographic printing blank to produce a relief image printing element capable of printing cleanly. The method comprises the steps of: (a) providing a flexographic printing blank comprising: (i) a support layer; (ii) at least one photocurable layer disposed on the support layer, and (iii) a laser ablatable mask layer disposed on the at least one photocurable layer. The at least one photocurable layer comprises a photocurable composition comprising: (1) at least one ethylenically unsaturated monomer; (2) at least one silicone monomer or oligomer; (3) at least one binder or oligomer; and (4) a photoinitiator. The laser ablatable mask layer is laser ablated to create an in situ negative in the laser ablatable mask layer. Thereafter, a barrier layer is disposed on the laser ablatable mask layer. The at least one photocurable layer is exposed to actinic radiation through the barrier layer and the laser ablatable mask layer.
Abstract:
An apparatus for thermally processing a relief image printing element and a method of using the same are described. The printing element comprises at least one photopolymer layer and is selectively exposed to actinic radiation to crosslink portions of the at least one photopolymer layer. The apparatus comprises: (a) means for supporting the printing element; (b) heating means for melting or softening non-crosslinked portions of the at least one photopolymer layer; (c) at least one rotatable roll that is capable of bringing a blotting material into contact with the at least one photopolymer layer to remove the melted or softened non-crosslinked portions of the at least one photopolymer layer,; and (d) an element arranged adjacent to the at least one rotatable roll for removing non-crosslinked photopolymer remaining on a surface of the at least one rotatable roll after step c). The apparatus may alternatively be operated without a blotting material.
Abstract:
An apparatus for transferring a relief image printing blank between stations of a printing element manufacturing process and a method of using the same is described. The apparatus comprises a cylindrical mandrel for supporting the relief image printing element which includes means for securing the relief image printing blank to the mandrel. The mandrel is capable of transferring the relief image printing blank into and/or out of various stations of the printing element manufacturing process.
Abstract:
An apparatus for laminating a laminating film to a substrate and a method of using the same is described. The apparatus comprises a) a heated laminating roller and a second roller, wherein said heated laminating roller and said second roller are opposably mounted and form a nip therebetween for receiving the substrate to be laminated; b) a drive mechanism for rotating the heated laminating roller and second roller; c) a laminating film supply roller adapted to support a ran of laminating film and supply the laminating film over an outer surface of the heated laminating roller and into the nip, and d) a splitter bar positioned at a suitable location between the laminating film supply roller and the heated laminating roller and in contact with the laminating film supplied from the supply roller.
Abstract:
A method of tailoring the shape of a plurality of relief dots created in a photosensitive printing blank during a digital platemaking process is provided. The photosensitive printing blank comprises a laser ablatable mask layer disposed on at least one phoiocisrahle layer which is mountab!e on a printing sleeve. The method comprises the steps of (1) placing a barrier layer on top of the laser ablatable mask layer; (2) laser ablating the laser ablatable mask layer to create an in situ negative in the laser ablatable layer; (3) exposing the at least one photocurable layer to actinic radiation through the in situ negative; (4) removing the barrier layer; and (5) developing the imaged and exposed photosensitive printing blank to reveal the relief image therein, the relief image comprising the plurality of relief dots. The presence of the barrier layer produces printing dots having desired geometric characteristics.
Abstract:
A method of making a relief image printing element having a relief pattern, the method comprising the steps of: a) selectively ablating the masking layer to create an overall image in the masking layer, such that the overall image comprises a sub-image, comprising a pattern of cells, in it; b) applying an oxygen barrier layer on top of the masking layer; c) exposing the printing element to actinic radiation through the oxygen barrier layer and the masking layer to selectively crosslink: and cure the at least one photocurable layer, thereby creating the relief image therein and a textured surface on the printing element; and d) developing the printing blank by removing the barrier layer and the uncured portions of the photocmable layer to reveal the relief image.
Abstract:
A method of controlling surface roughness of a flexographic printing element during thermal processing is provided. An imaged and exposed relief image printing element is thermally developed to remove the portions of at least one layer of photopoiymer that are not crosslinked and cured by a) heating the at least one layer of photopoiymer to a sufficient temperature to soften uncured portions of the at least one layer of photopoiymer; b) causing contact between the at least one layer of photopoiymer and a blotting material, wherein when the blotting material contacts the at least one layer of photopoiymer, the softened uncured photopoiymer portions of the at least one layer of photopoiymer are absorbed into the blotting material; and c) separating the blotting material from the at least one layer of photopoiymer. Thereafter, a smooth material is inserted between the surface of the at least one layer of photopoiymer and the blotting material, in the alternative, after the flexographic printing element is removed from the thermal processor, a polymeric film is laminated onto the relief image printing element using heat and pressure. Based thereon, the average surface roughness of the relief surface of the- flexographic printing element can be reduced.
Abstract:
A method of preparing a photosensitive printing blank, the method comprising the steps of: a) coating a slip film onto a coversheet and drying the slip film; and depositing at least one layer of photosensitive material on top of the slip film coated coversheet and laminating a substrate layer to the exposed surface of the photosensitive material. The slip film comprises: i) a polymer selected from the group consisting of polystyrene and polyvinylpyrrolidone; ii) optionally, an additive. The slip film at least substantially eliminates the formation of hot spots during an analog plate making process.
Abstract:
A photocurable printing blank comprises a backing layer having a photocurable layer disposed thereon, a barrier layer disposed on the photocurable layer, and a laser ablatable mask layer disposed on top of the barrier layer. The method includes the steps of (1 ) imaging the at least one photo curable layer by ablating the laser ablatable mask layer to create the relief pattern on the photocurable printing blank; (2) exposing the printing blank to actinic radiation through the barrier layer and mask layer to selectively crosslink portions of the photocurable layer, thereby creating the relief pattern; (3) developing the printing blank to remove the barrier layer, the laser ablated mask layer and uncured portions of the photo curable layer and reveal the relief pattern. The method can also be used with an analog platemaking process that uses a negative instead of an ablatable mask layer.