WO2002006900A2 - Procede et systeme de stratification d'une plaque d'impression integree - Google Patents

Procede et systeme de stratification d'une plaque d'impression integree Download PDF

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Publication number
WO2002006900A2
WO2002006900A2 PCT/US2001/022644 US0122644W WO0206900A2 WO 2002006900 A2 WO2002006900 A2 WO 2002006900A2 US 0122644 W US0122644 W US 0122644W WO 0206900 A2 WO0206900 A2 WO 0206900A2
Authority
WO
WIPO (PCT)
Prior art keywords
foam
photopolymer
layer
sheet
material guide
Prior art date
Application number
PCT/US2001/022644
Other languages
English (en)
Inventor
Gerald W. Mounsey
Eric S. Speas
Original Assignee
Conversion Technology Graphics Ltd.
Rubber Light
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Conversion Technology Graphics Ltd., Rubber Light filed Critical Conversion Technology Graphics Ltd.
Priority to AU2001277909A priority Critical patent/AU2001277909A1/en
Publication of WO2002006900A2 publication Critical patent/WO2002006900A2/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B39/00—Layout of apparatus or plants, e.g. modular laminating systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N1/00—Printing plates or foils; Materials therefor
    • B41N1/12—Printing plates or foils; Materials therefor non-metallic other than stone, e.g. printing plates or foils comprising inorganic materials in an organic matrix
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N3/00—Preparing for use and conserving printing surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N6/00—Mounting boards; Sleeves Make-ready devices, e.g. underlays, overlays; Attaching by chemical means, e.g. vulcanising
    • B41N6/02—Chemical means for fastening printing formes on mounting boards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0831—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using UV radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1858—Handling of layers or the laminate using vacuum

Definitions

  • the invention relates to the printing industry. More specifically, this invention relates to the field of laminating plates for flexographic relief and offset printing.
  • the majority of printing with relief plates is accomplished by first creating an image on a plate and next mounting that plate to a foam tape for printing.
  • the initial step in the process is placing a photosensitive photopolymer sheet on a vacuum table.
  • a mylar substrate covers the photopolymer surface that is not adjacent to the vacuum table, the back surface.
  • the mylar substrate stabilizes the photopolymer by resisting shape changes.
  • This back surface covered by a mylar substrate is exposed to ultra violet (UV) light for a few seconds creating a base for the photopolymer.
  • UV ultra violet
  • the customer receives this back-exposed photopolymer sheet and mylar combination and places it so that the front surface, opposite the back-exposed surface, faces a UV light source.
  • a plastic membrane material, kreen is then rolled over the front surface of the photopolymer and a negative of an image is placed over the sheet and kreen. The kreen provides intimate contact between the photopolymer sheet and the negative.
  • this four-layered composite is exposed to UV light and the desired image is formed on the front surface of the photopolymer.
  • a wash-out process uses solvents or water to remove the excess, unexposed photopolymer from the sheet. Then the plate is dried to remove any solvent or water the plate may have absorbed during the wash-out process.
  • the next step is a post-exposure to UV light that cures the entire plate bringing it to the proper degree of hardness for printing.
  • the last step of the plate's manufacture is mounting the plate onto a foam base to be used in a printing press. Mounting the plate onto a foam tape is necessary to absorb the shock the printing press exerts on the plate during the printing process.
  • An alternative design for relief plates starts with a sheet of photopolymer between two protective polyester sheets.
  • the next layer of the plate is a closed cell foam that is smooth without skin.
  • the last layer is a dimensionally stable support layer such as a polyester film or a thin metal backing.
  • the photopolymer is back-exposed and then the back protective polyester sheet is removed leaving the front protective sheet.
  • the foam and support layer are laminated into one piece.
  • a film adhesive is used to laminate the exposed surface of the foam to the back-exposed surface of the photopolymer sheet.
  • the foam is covered by a silicone coated polyester release film that must be pulled off the foam before lamination to the photopolymer layer.
  • the photopolymer is manually brought into contact with the foam and backing layer. This labor intensive process requires multiple laborers to hold the two sheets, lay down one edge to another and press the layers as they are lowered into contact. Additionally, the removed release film is a waste product.
  • the present invention is a laminating system and method that allow a layered plate to be manufactured by mechanically laminating a back-exposed photopolymer sheet to a pre-laminated layer of foam and stable backing.
  • a photopolymer sheet is conveyed into a light chamber where it is briefly exposed to UV light. This back-exposure creates a base for the photopolymer.
  • the sheet moves to the laminating station where the photopolymer is laminated to the pre-laminated foam and stable backing combination using a hot melt spray adhesive. After the three layers have been laminated together, the laminate is taken to the cutting table, where it is shaped to the necessary size.
  • the production line has tracks, a cart, an ultraviolet light chamber, an infra red lamp, a laminating station and a cutting table.
  • the cart conveys the photopolymer sheet along the track during the process.
  • This three-layer design for a printing plate provides better quality printed images and eases the customer's work by eliminating the need for laminating before use. Additionally, the polyurethane, ester based foam used in the above process is a micro cellular, open cell design, which allows for better compression recovery rates and longer life to the plate.
  • the design of the apparatus allows for laminating without the need for manual labor such as smoothing and pressing; the lamination is accomplished by the system so that human contact is not required.
  • the only manual work involved is the feeding of the foam and stable backing together into the nip roll down the material guide.
  • the feeding of the foam and stable backing together may be automated, with mechanical feeders supplying the foam and backing into the nip roll.
  • the automatic application of the hot melt adhesive without the necessity of contact between the layers until they reach the nip roll, allows for a more cost-effective and better controlled lamination process.
  • a printing plate may be manufactured and customer-ready through a mechanical process that avoids steps seen in conventional plate manufacturing.
  • One object of the present invention is to eliminate the labor intensive processes and reduce costs associated with manual laminating.
  • Another object of the present invention is to increase the quality of printed images.
  • a further object of the present invention is to produce more durable printing plates by adding a protected layer of compressible foam within the plate that absorbs the mechanical shock imposed by the printing process.
  • Fig. 1 is a cross section of the integrated printing plate of the present invention
  • Fig. 2 is a side perspective view of the apparatus, including the cart;
  • Fig. 3 is a view similar to Fig. 2, but depicts the cart's progression down the track of the present invention
  • Fig. 4 is a side perspective view of the lamination station of the present invention.
  • Fig. 5 is a view similar to Fig. 4, but depicts a break-away view of lamination of the photopolymer sheet to the pre-laminated foam and stable backing combination of the present invention
  • Fig. 6 is a plan view of the material guide of the present invention, taken along the lines 6-6 of Fig. 2.
  • the apparatus of the present invention is described in relation to the lamination of a photopolymer sheet layer to a foam and support backing combination to create an integrated printing plate.
  • the dimensionally stable backing may be composed of mylar or a thin metal. The backing is not limited to these materials, but the backing must prevent dimensional distortion of the image.
  • the foam and dimensionally stable backing are laminated to one another before reaching the present apparatus where the two layers are laminated to the photopolymer sheet.
  • the process lamination of foam and dimensionally stable backing is accomplished with a slot die coater.
  • Fig. 1 shows integrated printing plate 10, having three separate layers which are laminated together.
  • one side of foam layer 12 is laminated to support layer 15.
  • photopolymer sheet 16 is laminated to the other side of foam layer 14.
  • Printing plate 10 is comprised of one three-layered sheet secured by two independent layers of adhesive.
  • Fig. 2 shows transfer cart 18 on which photopolymer sheet 16 is placed. Photopolymer sheet 16 is secured to the exposed surface of transfer cart 18 with a hermetic seal created by vacuum bed 19. After photopolymer sheet 16 is on transfer cart 18, sheet 16 is conveyed along track 20 into UV light chamber 22.
  • Fig. 3 illustrates the progression of cart 18 into UV light chamber 22. While in UV light chamber 22, photopolymer sheet 16 is exposed to UV light emanating from a plurality of UV lamps 24 for five to sixty seconds. The surface exposed becomes the back surface and creates a base for photopolymer sheet 16. After this back-exposure, transfer cart 18 conveys photopolymer sheet 16 down track 20 to laminating station 26, shown in greater detail in Fig. 4.
  • Fig. 4 shows in-line spray head 28 located before and beneath material guide 30.
  • In-line spray head 28 has multiple spray tips 32 that coat photopolymer sheet 16 with a hot melt spray adhesive.
  • Infra red light 34 is located along the interior surface of material guide 30 to maintain the adhesive's sealant qualities.
  • Material guide 30 is comprised of guides 31 and of slots 39 (best shown in Fig. 6) for adjusting material guide 30 to accommodate pre-laminated foam stable support combinations of varied widths.
  • An operator feeds the pre-laminated foam layer 14 and dimensionally stable support layer 15 down material guide 30 and against nip roll 40. It is contemplated that this feeding process could be automated.
  • Nip roll 40 may be adjusted as needed, depending upon the height of transfer cart 18.
  • Fig. 5 depicts the pre-laminated foam layer 14 and dimensionally stable support layer 15 being fed into nip roll 40, and being pressed into contact with adhesive coated photopolymer sheet 16, which is still secured by vacuum to transfer cart 18.
  • the foam layer 15 is laminated to photopolymer sheet 16 at the back-exposed surface of photopolymer sheet 16.
  • the pre-laminated foam layer 14 and stable support layer 15 may be manually fed into nip roll 40, or alternatively, a mechanical feeder may direct pre-laminated foam layer 14 and stable support layer 15 into nip roll 40.
  • Transfer cart 18 carries the integrated printing plate 10 to cutting table 42 to be sized to customer specifications.
  • the foam layer is comprised of a micro cellular, open cell, polyurethane, ester based foam. This foam's qualities allow for the best recovery rate after compression, which in turn provide the plate with the greatest protection from the mechanical stress of the printing process. Additionally, certain qualities advance the foam's compatibility with various imaging processes.
  • Foam An open cell, micro cellular, ester-based foam was cut into 1 inch by 1 inch (2.54 cm by 2.54 cm) squares.
  • the open cell, ester based, polyurethane foam provides unexpected results, namely dramatic increases in compressibility compared to conventional foams.
  • the recovery rate for a foam is calculated by dividing the foam's thickness 20 minutes after the final compression by the foam's original thickness before any compression.
  • the recovery rate for the open cell, ester based, polyurethane foam is 98%.
  • the above results reveal that the open cell, polyurethane foam is extremely stable over compression.
  • the first compression to 75% of the foam's thickness required 19.8 pounds (9.9811 kg.) of pressure.
  • the final compression to 75% of the foam's thickness after four previous compressions required 19.3 pounds (8.7543 kg.) of pressure.
  • the customer benefits from the convenience of an integrated plate.
  • the product of the apparatus is a plate that is ready for face-exposure by a customer.
  • the customer does not need to laminate the product further, nor does he need to mount the plate onto a foam tape, as a foam layer is already secured within the plate.
  • the customer may now take the unexposed plate and create a relief plate using a negative as in conventional practice.
  • face-exposure the integrated plate is washed-out, dried and post exposed as any other plate would be. During the wash-out process, solvents that carry away the unexposed photopolymer are washed over the plate. The foam within the plate does not deteriorate when washed by these solvents.
  • the foam is compatible with the wash-out process because it is ester based and therefore solvent resistant.
  • the foam layer further works with thermal radiation, a process that accomplishes the same purpose as the wash-out process. Thermal radiation uses brief exposure to heat to remove the unexposed photopolymer that remains on the plate after the image is created.
  • thermal radiation uses brief exposure to heat to remove the unexposed photopolymer that remains on the plate after the image is created.
  • the present invention produces a plate that is compatible with computer controlled digital imaging.
  • the mechanical application of hot melt spray adhesive and lamination has advantages over manual lamination with release film adhesives. This mechanical process reduces the number of laborers required to apply an adhesive and allows a better quality application.
  • Manual lamination using release liner adhesive requires multiple laborers to bring together two layers by hand and press them into place before being sent through a nip roll.
  • the present invention provides an automatic application of a spray adhesive that does not require manual removal of a film. Eliminating film adhesives in lieu of spray adhesives reduces the cost of lamination because spray adhesives require fewer laborers to be applied.
  • Use of three laborers to apply release liner adhesives may prevent release liners' adoption in the industry.
  • the use of film adhesives produces a wasted release film that adds cost by necessitating disposal.
  • the present system utilizes only one laborer during the lamination step and does not yield extra waste products.
  • the present invention also provides a better quality lamination through the mechanical process in which all contact between the two layers is carried out by a machine.
  • the present invention provides a more controlled process that is less susceptible to human error. This cost-effective system allows for regulated lamination that saves customers steps, time and money.
  • track 20 is about thirty-six and a half feet (11.1252 m.) in length and two feet (0.6096 m.) in width.
  • Transfer cart 18 has a rectangular surface and dimensions of about seven feet (2.1336 m.) in length and three feet and eight inches (1.1156 m.) in width. Alternatively, other shapes and dimensions may be used to accomplish the objectives of the present invention.
  • the photopolymer sheet when vacuum sealed to the surface of transfer cart 18 is conveyed at a height of about three feet (0.9144 m.) from the ground.
  • UV light chamber 22 is a frame with dimensions of about ten feet (3.0480 m.) in height, five feet and two inches (1.5748 m.) in width and seven feet and five inches (2.2860 m.) in depth. Alternatively, other shapes and dimensions may be used to expose transfer cart 18 to UV light.
  • the UV lamps 24 are located on crosspieces parallel to track 20 at a height of four feet and ten inches (1.4732 m.) from the ground. UV lights of varying number may be positioned in other formations within UV light chamber 22.
  • the exemplary embodiment of the present invention reveals one in-line spray head 28 with multiple spray tips 32.
  • multiple in-line spray heads 28 may be positioned beneath material guide 30.
  • Material guide 30 of the exemplary embodiment has a height of about two feet and eight inches (0.8128 m.), a length of about two feet and seven inches (0.7874 m.) and width of about three feet and eight inches (1.1176 m.).
  • Material guide 30 is comprised of slots 39 for adjusting material guide 30 for accommodating sheets of varied widths.
  • Nip roll 40 is adjustable in height so that it may correspond with the height of transfer cart 18, creating the proper opening for laminating the photopolymer and foam combination.
  • cutting table 42 has a rectangular surface and dimensions of about three feet in height (0.9144 m.), four feet and eleven inches (1.4986 m.) in width and six feet in depth (1.8288 m.). In the alternative, other shapes and dimensions may be used to accomplish the objectives of cutting table 42.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention porte sur un système et sur un procédé de stratification d'une plaque d'impression multicouche (10). Au cours d'une étape séparée, une couche de mousse à alvéoles ouvertes, microcellulaires, à base ester (14) est stratifiée sur un support stable du point de vue des dimensions (15). Dans la première station de l'appareil, le dos d'une feuille photopolymère (16) est exposé à une lumière ultraviolette. Puis, la feuille photopolymère (16) est acheminée vers une station de stratification (26) où sa surface dorsale exposée est recouverte par pulvérisation d'un adhésif thermofusible. Après revêtement, la feuille photopolymère (16) est transportée vers un cylindre exprimeur (40) où elle est pressée et stratifiée sur la couche de mousse (14) et une combinaison de renfort stable (38). La couche de mousse (14) absorbe le choc de la presse d'impression, ce qui permet d'obtenir des clichés en relief plus durables. Le processus de stratification automatisé est bien contrôlé et est économique du fait qu'il ne requiert qu'une main-d'oeuvre humaine pour amener la mousse (14) et le matériau de renfort stable (15) dans le cylindre exprimeur (40). Il est toutefois envisager d'automatiser l'alimentation de la mousse et du matériau de renfort stable dans le cylindre exprimeur. On peut ainsi obtenir une plaque durable pourvue d'une couche de mousse (14) entre le photopolymère (16) et le support (15), cette plaque pouvant être envoyée à un client devant réaliser un processus d'imagerie sans qu'elle ait besoin de subir une stratification supplémentaire ou une exposition dorsale.
PCT/US2001/022644 2000-07-18 2001-07-18 Procede et systeme de stratification d'une plaque d'impression integree WO2002006900A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001277909A AU2001277909A1 (en) 2000-07-18 2001-07-18 Integrated printing plate lamination system and method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US21925300P 2000-07-18 2000-07-18
US60/219,253 2000-07-18

Publications (1)

Publication Number Publication Date
WO2002006900A2 true WO2002006900A2 (fr) 2002-01-24

Family

ID=22818518

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/022644 WO2002006900A2 (fr) 2000-07-18 2001-07-18 Procede et systeme de stratification d'une plaque d'impression integree

Country Status (2)

Country Link
AU (1) AU2001277909A1 (fr)
WO (1) WO2002006900A2 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1332871A3 (fr) * 2002-01-31 2004-08-18 Celfa AG Plaque d'impression composée de plusieurs couches séparables
WO2017031174A1 (fr) 2015-08-20 2017-02-23 Macdermid Printing Solutions, Llc Feuille de support et son procédé d'utilisation
EP3375604A1 (fr) * 2017-03-17 2018-09-19 The Boeing Company Stratifiés décoratifs ayant une couche de mousse à cellules ouvertes
GB2624783A (en) * 2023-11-03 2024-05-29 Vesey Uk Ltd Method and apparatus for applying ornamentation to a garment

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1332871A3 (fr) * 2002-01-31 2004-08-18 Celfa AG Plaque d'impression composée de plusieurs couches séparables
WO2017031174A1 (fr) 2015-08-20 2017-02-23 Macdermid Printing Solutions, Llc Feuille de support et son procédé d'utilisation
EP3375604A1 (fr) * 2017-03-17 2018-09-19 The Boeing Company Stratifiés décoratifs ayant une couche de mousse à cellules ouvertes
US10967605B2 (en) 2017-03-17 2021-04-06 The Boeing Company Decorative laminates having an open-cell foam layer
GB2624783A (en) * 2023-11-03 2024-05-29 Vesey Uk Ltd Method and apparatus for applying ornamentation to a garment

Also Published As

Publication number Publication date
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