Abstract: A method of making a relief image printing element from a photosensitive printing blank is described. The photosensitive printing blank comprises a laser ablatable mask layer disposed on at least one photocurable layer and the laser ablatable mask layer is selectively laser ablated to create an in situ mask and uncover portions of the at least one photocurable layer. The method includes a) pushing the photosensitive printing blank through a nip formed by a textured roller and a backing roller, wherein the textured roller contacts the in situ mask and the uncovered portions of the at least one photocurable layer; and b) exposing the at least one photocurable layer to at least one source of actinic radiation through the in situ mask to selectively cross link and cure the portions of the at least one photocurable layer not covered by the in situ mask. A defined topographical pattern is transferred from the textured surface of the roller to the at least one photocurable layer.

Abstract: A photosensitive printing blank having is described. The photosensitive printing blank comprises at least one photocurable layer that is capable of being selectively crosslinked and cured upon exposure to actinic radiation at a desired wavelength region comprising (a) at least one elastomeric binder, (b) at least one ethylenically unsaturated monomer, (c) a photoinitiator having a favorable absorption profile in the desired wavelength region used for exposing the at least one photocurable layer to actinic radiation, and (d) a dye, wherein the dye exhibits a suitable percent transmission as measured with a UV spectrophotometer at the desired wavelength region used for exposing the at least one photocurable layer to actinic radiation, and optionally an infrared ablatable layer disposed on the at least one photocurable layer. A method of making a relief image printing element from the photosensitive printing blank is also described.

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: A method of tailoring the shape of a plurality of relief printing dots created in a photosensitive printing blank during a platemaking process including the steps of: (a) selectively exposing at least one photocurable layer to a source of actinic radiation to selectively crosslink and cure the at least one photocurable layer; and (b) developing the exposed at least one photocurable layer to reveal the relief image therein, said relief image comprising the plurality of relief printing dots. The source of actinic radiation comprises a source of UV light in the UV-A range and a source of light in the UV-C range. The at least one photocurable layer is simultaneously exposed to the source of UV light in the UV-A range and the source of UV light in the UV-C range to produce printing dots having at least one desired geometric characteristic.

Abstract: An apparatus for laminating a 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; b) a drive mechanism for rotating the heated laminating roller and second roller; c) a film supply roller adapted to support a roll of film and supply the film over an outer surface of the heated laminating roller and into the nip, wherein the film is contactable with a top surface of the substrate at a point where the substrate advances through the nip; and d) a splitter bar in contact with the film supplied from the supply roller, wherein the position of the splitter bar controls a wrap angle between the film and the heated laminating roller.

Abstract: A method of thermally developing a photocurable printing blank to produce a relief pattern comprising a plurality of relief dots. The photocurable printing blank comprises a backing layer having at least one photocurable layer disposed thereon and a laser ablatable mask layer disposed on top of the at least one photocurable layer.

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: 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 photopolymer that are not crosslinked and cured by a) heating the at least one layer of photopolymer to a sufficient temperature to soften uncured portions of the at least one layer of photopolymer; b) causing contact between the at least one layer of photopolymer and a blotting material, wherein when the blotting material contacts the at least one layer of photopolymer, the softened uncured photopolymer portions of the at least one layer of photopolymer are absorbed into the blotting material; and c) separating the blotting material from the at least one layer of photopolymer. Thereafter, a smooth material is inserted between the surface of the at least one layer of photopolymer and the blotting material.

Abstract: A method of developing a photocurable printing blank to produce a relief pattern comprising a plurality of relief dots. The photocurable printing blank comprises a backing layer having at least one photocurable layer disposed thereon, a barrier layer disposed on the at least one photocurable layer, and a laser ablatable mask layer disposed on top of the barrier layer.

Abstract: The photosensitive printing element of the invention comprises a hollow cylindrical support layer (2), at least one layer of photopolymerizable material (3), and a masking layer (4). Portions of the masking layer are removed by laser radiation. The layer of photopolymerizable material (3) is then exposed to actinic radiation through the hollow cylindrical support layer (2) to create a floor layer of polymerized material. Next, the sleeve is exposed to actinic radiation to polymerize portions of the layer of photopolymerizable material (3) revealed during removal of the masking layer (4). The photosensitive printing element is then developed to remove the masking layer (4) and unpolymerized portions of the layer of photopolymerizable material (3) to create the relief image.

Abstract: Laser imageable flexographic printing elements, including printing plates and printing sleeves and methods of making the laser imageable flexographic printing elements using a collapsible cross-linkable material comprising a curable elastomer, a material that absorbs laser radiation at a selected wavelength, and microspheres are disclosed. A laser is used to collapse and melt the collapsible cross-linkable material to form a relief image on the printing element. The printing element is thereafter cured by face exposure to crosslink and cure the formed relief image. The invention addresses a market need for eliminating chemical processing of printing elements, thus going from printing element to press much more quickly and using an environmentally friendly process.