Optimization of uv curing

Abstract

A system and method of preparing a reinforced flexoplate comprising a base support structure and a printing surface. The method includes controlling the curing conditions of the reinforced flexoplate, thereby controlling the properties of the flexoplate such as floor thickness, printing and base support pattern cross-sectional geometry, repeatability of printed features during the printing process, and durability of the reinforced flexoplate during the printing process.

What is claimed is: 
     
         1 . A method of forming a flexoplate comprising:
 disposing a first mask on a first surface of a flexoblank, wherein the flexoblank comprises a second surface opposite the first surface, wherein the first surface comprises a backing;   curing the first surface to form a floor on the first surface using ultraviolet (UV) radiation with wavelengths between 250 nm-600 nm and a curing dosage from 0.3 J/cm 2  to 1.0 J/cm 2 ;   curing the second surface to form a printing pattern on the second surface using UV light at a dosage between 5 J/cm 2  and 25 J/cm 2 , wherein the printing pattern comprises a first plurality of lines; and   curing, the second surface to form a base support structure, wherein the base support structure comprises a second plurality of lines.   
     
     
         2 . The method of  claim 1 , wherein curing the second surface comprises curing each line of the first and the second pluralities of lines to form a cross section, and wherein the cross-section of each line of the first and the second pluralities of lines is one of a square, a rectangle, a triangle, a half-circle, and a trapezoid, or combinations thereof. 
     
     
         3 . The method of  claim 1 , wherein curing the second surface to begin to form the printing pattern comprises using a second mask sized between 10-1000 times the size of the printing pattern. 
     
     
         4 . The method of  claim 1 , wherein curing the second surface to further form the base support structure comprises using a third mask that is within 10% of the size of the printing pattern. 
     
     
         5 . The method of  claim 1 , wherein curing the second surface comprises curing each line of the first and the second pluralities of lines to form a cross section, and wherein the cross-section of each line of the first and the second pluralities of lines is a trapezoid comprising a tip formed by a first angled side and a second angled side, and a tip-to-floor depth. 
     
     
         6 . The method of  claim 5 , wherein a sidewall angle is formed between the intersection of the first angled side of the cross-section of each line of the plurality of lines and the top of the tip of the line for each line of the plurality of lines. 
     
     
         7 . The method of  claim 6 , wherein the sidewall angle is between 30°-50°. 
     
     
         8 . The method of  claim 6 , wherein the printing pattern comprises a plurality of lines, and wherein a sidewall angle of a line the plurality of lines is between 20°-70°. 
     
     
         9 . The method of  claim 1 , wherein a valley is formed in between each pair of adjacent lines of the second plurality of lines. 
     
     
         10 . The method of  claim 1 , wherein curing the first surface is prior to curing the second surface. 
     
     
         11 . The method of  claim 1 , wherein curing the first surface is subsequent to curing the second surface. 
     
     
         12 . The method of  claim 11 , further comprising curing the first surface again subsequent to curing the second surface. 
     
     
         13 . A flexoplate comprising:
 a raised print pattern disposed on a floor,   wherein the raised print pattern comprises a first plurality of lines,   wherein a base support structure is disposed on the floor and comprises a second plurality of lines,   wherein each of the first plurality of lines is disposed in an alternating fashion with each line of the second plurality of lines.   
     
     
         14 . The flexoplate of  claim 13 , wherein the second plurality of lines is not in contact with the first plurality of lines. 
     
     
         15 . The flexoplate of  claim 13 , wherein at least a portion of each of the second plurality of lines is in contact with at least part of a line of the first plurality of lines. 
     
     
         16 . The flexoplate of  claim 13 , wherein the floor comprises an elastomer or a photopolymer disposed on a polyethylene terephthalate film. 
     
     
         17 . The flexoplate of  claim 13 , wherein the cross section of each of the first and second plurality of lines is a trapezoid comprising a tip formed by the intersection of a first angled side and a second angled side, a sidewall angle, and a tip-to-floor depth, wherein the sidewall angle is the angle formed between the intersection of the first angled side of the cross-section of each line of the plurality of lines and the top of the tip of each line of the plurality of lines. 
     
     
         18 . The flexoplate of  claim 17 , wherein the sidewall angle is between 30°-50°.