Printable Laminates for Flexo Plates, Methods of Making, and Methods of Using

Abstract

Negatives and laminates containing negatives for exposing liquid photopolymers in UV flexographic plate making are created by printing opaque images directly onto the protective or release cover films used in plate making processes. Combining negatives and cover films in this way eliminates two layers and two interfaces in the exposure process, reducing cost and improving quality.

1 . A method of making a laminate, comprising the steps of:
 (a) obtaining an first image sheet having a first surface and a second surface;
 the first surface being compatible with inks; 
   (b) obtaining a backing sheet having a third surface and a fourth surface;
 the third surface being liquid photopolymer compatible; 
 the fourth surface being at least partially coated with an adhesive coating which adheres more strongly to the fourth surface than the second surface; 
   (c) applying the second surface of the image sheet to the adhesive coating; and   (d) printing a first image on the first surface.   
     
     
         2 . The method of  claim 1 , further comprising the steps of:
 (e) obtaining a second image sheet having a fifth surface and a sixth surface;
 the fifth surface being compatible with inks; 
   (f) printing a second image on the fifth surface;   (g) placing said first image on the bottom glass of a UV exposure device;   (h) casting a layer of liquid photopolymer on top of the sixth surface;   (i) placing said third surface in contact with the upper surface of the liquid photopolymer layer; and   (j) placing the top glass of the UV exposure device in contact with the second image.   
     
     
         3 . The method of  claim 2 , in which:
 step (g) is placing said sixth surface on the bottom glass of said UV exposure device; and   step (h) is casting said layer of liquid photopolymer on top of said first image.   
     
     
         4 . The method of  claim 1 , wherein:
 said first surface is compatible with solvent-based inks.   
     
     
         5 . The method of  claim 2 , in which:
 said first surface is compatible with solvent-based inks; and   said fifth surface is compatible with solvent-based inks.   
     
     
         6 . The method of  claim 5 , in which:
 step (g) is placing said sixth surface on the bottom glass of said UV exposure device; and   step (h) is casting said layer of liquid photopolymer on top of said first image.   
     
     
         7 . A method of making a laminate, comprising the steps of:
 (a) obtaining an image sheet having a first surface and a second surface;
 the first surface being comprised of a microporous coating; 
   (b) obtaining a backing sheet having a third surface and a fourth surface;
 the third surface being liquid photopolymer compatible; 
 the fourth surface having an adhesive coating which adheres more strongly to the fourth surface than to the second surface; 
   (c) applying the second surface to the adhesive coating; and   (d) printing a first image on the first surface.   
     
     
         8 . The method of  claim 7 , in which:
 said microporous coating is receptive to either:   (1) solvent-based inks; or   (2) water-based inks.   
     
     
         9 . The method of  claim 7 , further comprising the steps of:
 (e) obtaining a second image sheet having a fifth surface and a sixth surface;
 the fifth surface being comprised of a microporous coating; 
   (f) printing a second image on the fifth surface;   (g) placing said first image on the bottom glass of a UV exposure device;   (h) casting a layer of liquid photopolymer on top of the sixth surface;   (i) placing said third surface in contact with the upper surface of the liquid photopolymer layer; and   (j) placing the top glass of the UV exposure device in contact with the second image.   
     
     
         10 . The method of  claim 9 , in which:
 step (g) is placing said sixth surface on the bottom glass of said UV exposure device; and   step (h) is casting said layer of liquid photopolymer on top of said first image.   
     
     
         11 . The method of  claim 9 , in which:
 said microporous coating is receptive to either:   (1) solvent-based inks; or   (2) water-based inks.   
     
     
         12 . The method of  claim 10 , in which:
 said microporous coating is receptive to either:   (1) solvent-based inks; or   (2) water-based inks.   
     
     
         13 . A method of making a laminate, comprising the steps of:
 (a) obtaining a first release liner having on one side a first polymer-based surface, and a first ink-receptive surface on the other side, which is either:
 (1) polymer-based; or 
 (2) a microporous coating; 
   (b) obtaining a backing sheet with a photopolymer-compatible surface on one side of the backing sheet and a first adhesive coating on at least a portion of the other side of the backing sheet;   (c) placing the one side of the first release liner against the first adhesive coating; and   (d) printing a first image on the first ink-receptive surface.   
     
     
         14 . The method of  claim 13 , further comprising the steps of:
 (e) obtaining a second release liner having one side a second polymer-based surface, and a second ink-receptive surface on the other side, which is either:
 (1) polymer-based; or 
 (2) a microporous coating; 
   (f) printing a second image on the second inkjet-receptive surface;   (g) placing said first image on the bottom glass of a UV exposure device;   (h) casting a layer of liquid photopolymer on top of said one side of said first release liner;   (i) placing the second polymer-based surface in contact with the upper surface of the liquid photopolymer layer; and   (j) placing the top glass of the UV exposure device in contact with the second image.   
     
     
         15 . The method of  claim 14 , in which:
 step (g) is placing said one side of said first release liner on the bottom glass of a UV exposure device; and   step (h) is casting said layer of liquid photopolymer on top of said first image.