Note: Descriptions are shown in the official language in which they were submitted.
1038692
This i8 a division of application Serial No. 222,238
filed March 17~ 1975.
This invention relates to a method and apparatus for making
a printing plate from a porous substrate.
It has previously been proposed to produce a printing plate by
selectively collapfiing the open cell structure of a thermoplastic plate
to provide relief (depression oE non-printing areas), and thereby to
define the non-depreased portions necessary for performing a printing
operation.
It is an ob~ect of this invention to carry out the foregoing
basic method in a more effective manner and at lower cost.
It iB a further obiect of the invention to achieve a more
complete collapse of the cell structure in the areaa ~here relief i8
desired, and to better define the planar difference between the raised
and relief portions of the plate.
I will first summarize the basic invention and then I will
explain certain inventive improvement~ that may be applied to the basic
invention.
A low-energy ab~orbing thermoplastic printing plate, having
an open-cell structure, has energy absorbing material selectlvely
applied to thofie areas of its surface where relief (depression of non-
printing areas) is desired. The plate 18 then exposed to infra-red
energy to collapse the cells in said areas and provide relief in the
plate.
Alternatively, the plate may have high energy absorbing
characteristicfi if the portions thereof to which said material is
applied are thereby given low energy absorbing characteristic~.
Accordingly there is provided in accordance with the present
invention a method of making an open-cell thermoplastic plate into a
printing plate comprising
bringing a coating material into contact with a surface of the
plate,
causing said material to adhere to the plate only in selected
areas, whereby to form coated and uncoated areas of the plate, to
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thereby create a printing configuration and change the absorptivity of
said selected areas to radiant energy,
and applying radiant energy to said plate to cause the coated and
uncoated areas of the surface to be heated differentially, relieving
one of ~aid areas to create a printing configuration on said surface.
There is also provided in accordance with the present invention
an apparatus for making a printing plate from an open-cell type of
thermoplastic plate comprising
mean6 for selectively applying a coating to the surface of said
plate to form thereby a replica of the printing configuration desired
on the surface of the plate,
means for heating said plate to a temperature just below the
temperature at which the thermoplastic radically changes viscosity,
and
meana for e~posing the heated plate to infra-red radiation to
collapse the structure under said coating without collapsing the
structure not covered by the coating.
~aving thus de8cribed the basic concept of the invention, I
will now describe several inventive improvements which may be applied
to the basic concept:
The thermoplastic printing plate, at the fitart of the process,
may be polypropylene, nylon, or other similar material.
~ithin the scope of the ba~ic invention described above, the
said "material" may be selectively applied to the plate in any suitable
way. Two such ways, each of which is an improvement upon the basic
concept, will now be described. First, a cover sheet applied to the
plate may have "material" in the form of a coating which, when exposed
to radiant energy directed through the cover sheet, is transferred to
the plate. Secondly, the cover sheet may include the "material" and
will transfer it to the plate when the cover sheet is impressed with a
mechanical force (such as when one draws on a sheet of carbon paper or
causes the type bar of a typewriter to strike the ribbon to effect a
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transfer of an image~, Preferably the transfer of the "material" to
the plate should be an "impact" type of transfer, A typical and suit-
able impact transfer method will now be described.
According to a further improvement, the radiation transparent cover
she~t on the plate 18 polyethylene terephthalate (sold under the trade mark
Mylar by ~.I. du Pont de Nemours & Co.) and this cover sheet has a coating
of an energy absorbing material such as carbon and nitrocellulose, in
contact with one surface of the plate. The coating is maintained in intimate
contact with the plate in any suitable way, such as by applying a vacuum
to the opposlte surface of the porous open celled plate. A beam, of
suitable radiation and power~ such as from a laser, then traverses those
areas of the plate where relief i8 desired and transfers a portion of the
coating to the surface of the plate.
The Mylar layer is then removed, leaving a pattern of coating
material that has been transferred to the surface of the plate. The
plate can then be glven an infra-red eYposure, to selectlvely collapse
ant seal the areas where rellef is desired, thereby providng shallow
rellef in the order of 0.0003 to 0.01 i~ches.
Another improvement upon the invention includes a second treatment
of the plste with infra-red energy to achieve a more complete collapse
of the cells in the areas of relief. If a cooling fluid, such as air,
is passed through the plate during thl~ second treatment, it will
selectively cool the printing areas, assisting in the prevention of cell
collapse of those areas. Since the cells have at least partially collapsed
and become sealed in the areas where relief is desired, the cooling fluid
will not keep these cells cool, and they will be heated to a degree
necessary to achieve the desired relief.
Another improvement is that either or both of the treatments of
the plate with infra-red energy is preferably carried out after the
plate has been raised to a temperature just below that at which the plate
material undergoes a radical change of viscosity. Following such a
preheating of the plate, the infra-red energy falling on the deposited
~038692
energy-absorbing coating on the~surface of the plate adds energy to those
areas of said surface on which some of the coating has been deposited.
This energy causes the structure under said areas to collapse, thus
resulting in a relief of the surface in those areas.
Either or both of the infra-red treatments may be improved by
using feed-back. This may be accomplished by having an infra-red source
that scans the surface of the plate and supplies energy to it. The
reflectivlty of the surface is continuously determined as the scanning
proceeds, and the infra-red source intensity is increased in those areas
where the reflectivity is low (areas where deep relief in the surface i8
desired) and the source intensity is reduced in those areas where the
reflectivity is high (areas where shallow relief is desired).
A further improvement results by filtering out, from the infra-
red rays applied to the plate, those wavelengths to which the plate
(without treatment with energy absorbing material) has maximum absorptlon.
This still further enhanceR the thermal contrast between the areas of the
plate wlth the energy absorbing coating and the areas without the coating.
The present tivisional application is directed to the method of
increasing the relief existing in an interconnected open-celled thermo-
plastic plate, which rellef was achleved by at least partlal sealing of the
open-cell struct~re of the plate, comprising pAssing a coollng fluid through
the remaining interconnected open-cell structure, and heatin8 the plate to
effect further collapse of the cells.
The invention is illustrated by way of example with reference to
the accompanying drawings wherein:
Figure 1 iQ a side view of Step I of the process;
Figure 2 is a perspective view of Step II of the process;
Figure 3 is a side view of Step III of the process;
Figure 4 i8 a side view of one optional form of Step IV of the process;
Figure 4A is a first alternate form for carrying out Step rv of
the process;
Figure 4B i9 a second alternate form for carrying out Step rv of the
process;
Figure 5 is a side view of apparatus for carrying out Step V
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of the process. (This step is optional, but its inclusion is an
improvement~;
Figure 5A is a greatly enlarged view of a portion of plate 10
of Figure 5;
Figure 6A illustrates Step VI and shows how the resulting plate
may be inked for letterpress or letterset printing;
Figure 6B illustraees a modified form of Step VI and shows
how the plate may be inked for screen printing; and
Figure 7 illustrates modified apparatus for carrying out
Steps IV and/or V.
The plate 10, after the processing hereinafter described,
becomes the printing plate. At the start, this is a plate fabricated
of polypropylene, nylon, or other thermoplaatic material. Preferably
the plate 10 should exhibit a sharp transition between its solid and
its semi-solid Ytates as its temperature rises. This characteristic
is exhibited by polypropylene between 150 and 180C. If the msterial
has the desired sharp transition, and is preheated to a temperature
~ust below that at ~hich the plate becomes semi-solid, a further sur-
face temperature rise of several degrees Centigrade, resulting from
exposure to infra-red rays, will ca~se structural collapse in the
plate and cauae the portions of the plate exposed to the infra-red
energy to sink below the surface of the plate by 0.0003 inch or more.
In other ~ords, the plate material should have a high "melt index".
The melt index is sufficiently "high" for the purpose of this invention
if it is greater than 3.
It is also preferable that plate 10 have an interconnected
open-cell structure, to permit transpiration cooling. This can be
easily achieved by preparing the plate in accordance wlth the
instructions specified in lines 57 et seq., of column 3, of my ~.S.
Patent No. 3,779,779 entitled "Radiation Etchable Plate", issued
December 18, 1973.
In the first step of the method, a radiation transparent
cover sheet 11 of polyethylene terephthalate ~sold under the trade
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name Nylsr~, haYing an energy absorbing coating 12, $Uch a~ a mixture
of carbon and nitrocellulose, on its underside, is placed in intimate
contac~ with the upper side of plate 10. Thu6 the carbon and nitro-
cellulo~e coating is in direct contact with the upper surface of plate
10..
The afore~aid intimate contact may be maintained in any suit-
able way, such as by applying a vacuum to the underside of open-celled
plate 10, or by applying electro~tatic charge(s) to one or both of plate
10 and/or cover sheet 11.
In ~tep IT, the plate 10, with its cover sheet 11, is next
exposet to a very fine laaer beam of infra-red energy, ~hlch is scanned
across the plste and modulated as necessary to tranfifer the information
to be printed to plate 10. This is done ln accordance with Figure 2
of my prior ~.S. Patent No. 3,739,088, granted June 12, 1973, and
entitled "Printing Plate Productlon Method and Apparatu ". Figure 2
of that patent i8 reproduced here (as Plgure 2~ except that in the
present drawlng the cover sheet 11, bearing energy absorbing coating
12 thereon, is superimposed on plate 10.
In the apparatus illustrated in Figure 2, the pa6te-up lS and
2~ plate 10 are supported in curved conditlon concentrically relative to
the axis of an elongated rotatlng double scanning assembly 18. The
lasers 16 and 17 are carried at Qpposlte ends of assembly 18 for their
beams to be deflected by rotating angular mirrors 19 and 20 through
focusing lenses 21 and 22 to impinge respectively on the paste-up 15
and the plate 10.
AB indicated by thearrows 24a and 24, the mirror and len~
is rotated by a drive mechanism 23 and is simultaneously moved axially
by suitable translational drive means such as a linear induction motor
80 that the beams from lasers 16 and 17 scan along a spiral path. The
entire scanning assembly is suitably mounted on an air bearing member.
The beam from the laser 16 as focussed on the paste-up 15 by
the lens 21 is reflected back to a detector 25 which converts the
103869Z
reflected light of the bea~ into electric signals ~hose inten~ities are
proportional to the intensity of the reflected light received. The
detector 25 is suitably a photomultiplier, or photodiode, and is
connected to actuate a modulator 34. The modulator 34 is connected to
modulate the intensity of the beam from the laser 17 in a binary man-
ner corresponding to the signals received from the detector 25 for
reproducing a template on the plate 10 corresponding to the material
represented on the paste-up 15 as described above.
The laser 16 is suitably a neon heli~m laser which has an
operating wavelength of 0.6328 microns, and the lens 21 is selected
to focus the beam from laser 16 into a spot of about 0.001 inch dia-
meter on the paste-up 15.
~hen the beam from laser 17 passes through lens 22 and im-
pinges on transparent cover sheet 11, a portion of the energy absorbing
carbon and nitrocellulose coating 12 is transferred to the plate 10,
where it forms a pattern, normally as a negative of the material to
be printed, afi will appear.
My prior U.S. Patent 3,816,659, for l'Scanning Apparatus",
issued June 11, 1974, contains suggestions that may be helpful in
constructing the apparatu shown in Figure 2 of the present application.
The polypropylene plate 10 is formulated to exhibit minimum
infra-red absorption. However, where the laser beam has transferred
carbon and nitrocellulose to the plate, the absorption of infra-red
energy will be much greater. Thus, in response to the infra-red heat-
ing steps described below, the energy absorbing portions of the plate
will be heated more than the untreated portions of the plate.
The vacuum previously described in connection with Step I
may be continued during Steps II and III.
Step III consists merely of peeling cover sheet 11 from plate
10, as shown in Figure 3. This leaves that portion 12a of coating 12
ch ~as transferred to plate 10 intact on that plate.
Instead of employing a polypropylene plate 10 with minimum
~1038692
infra-red absorption, and a coating of carbon and nitrocellulose to
increase the absorption, the reverse may be done. That is, one may
fabricate a polypropylene plate 10 ~ith maximum absorption and a coat-
ing 12 that will reduce the absorption of the plate 10 in the areas to
which the coating is transferred. In event such a reversal is employed,
the ~riting step should also be reversed so that transfer of the coat-
ing occurs in the areas which will receive ink and print the desired
text, insteat of in the areas of relief (non-printing areas~.
Furthermore, instead of using a carbon and nitrocellulose
coating 12 and a laser beam, various other energy absorbing coatings
and methods of transferring the same may be employed. Transfer to the
plate 10 may be accomplished in any suitable way, including any suit-
able mechanical method. For example, the pressure transfer of a carbon
coating from carbon paper, or of heat-absorbing ink from a typewriter
ribbon, may be used. Furthermore, suitable thin metallic foils may be
used as energy reflecting material, and methods of transferring quch
metallic foils to other objects may be used to transfer such thin
metallic foils to plate 10. Other suitable coatings and transfer tech-
niques are described in U.S. Patent No. 3,745,586, issued July 10, 1973
to Robert S. Braudy for "Laser Writi~g", U.S. Patent No. 3,787,210,
issued January 22, 1974 to Donald Lee Roberts for "Laser Recording
Technique Using Combustible Blow-Off", and Woodward, IBM Technical
Disclosure Bulletin Vol. 9, No. 11, April 1967, page 1592. Preferably
the transfer of the coating to the plate should be by an impact method,
several of whlch methods have been referred to above.
Step IV comprises directing infra-red or other suitable radi-
ant energy onto the imaged surface of plate 10. The time of application,
and the intensity of this energy, are carefully selected so that the
areas of the surface of plate 10 to which carbon and nitrocellulose 12a
have been selectively transferred change viscosity. Consequently, the
open-cell structure under such areas collapses, causing the surface in
such areas to sink below the surface of the printing areas, which remain
103869~
solid since the tempe~ature to which they are heated is lower. To
facilitate this, the plate ~ay be pre-heated in an oven or by trans-
piration methods to a temperature just below the thermoplastic transition
temperature, 90 that the lnfra-red heating step may then be of short
duration. This limits the conduction process in the plate, and is there-
fore a desirable result since heat conduction in the plate, when part of
the plate has reached a semi-solid atate, reduces the resolution of the
resulting printing plate.
I will next describe three ways that the infra-red heating step,
just referred to, may be carried out:
1. As shown ln Figure 4, the upper side of plate 10 may be exposed
to an infra-red source 30 which heats the entire upper surface of plate
10 simultaneously.
2. As shown in Figure 4A, the plate 10 may be held in oven 31 until
it achieve~ a temperature ~ust below the transition temperature. It is
then moved to the right under the elongated heater such as sold under the
trade mark Calrod (or other electric heater in the form of a long rod).
The heater 32 may have a suitable reflector 32R to concentrate its heating
power along a very limited but ~traight segment of plate 10. As a given
segment of plate 10 passes under heater rod 32, that portion of the segment
having the carbon and nitrocellulose coating transferred thereto is heated
more, by the absorption of energy. This collapses the structure of the
plate under the coated areas of that segment.
If plate 10 has the necessary ~harp transition from a solid to a
semi-solid state, and the other desired characteristics explained above,
and if the heater 32 emits suitable energy toward the plate 10, a cell
collapse, sufficient to cause the surface of plate 10 to sink about
0.0003 to 0.01 inches in the areas to which carbon has been transferred,
will occur as a result of an exposure to the infra-red rays for about
one second. The preferred speed of plate 10 past the infra-red heater 32
will give the plate an exposure for about one second.
3. As shown in Figure 4B, the preferred way of heating the
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plate is by a controlled beam of infra-red energy, such a9 the beam of
a tungsten halogen lamp (such as sold by General Electric under the trade
mark Quartzline, Type DYS, rated at 600 watts and 120 volts), that scans
the surface of plate 10, Energy reflected by the surface of plate 10
operates detector 71 to provide the input to control apparatus 72, which
controls radiant source 70 to lncrease the beam intensity incident upon
those areas where the plate surface has a large heat absorptivity due to
the transferred coating 12 and to decrease the intensity where the plate
surface is uncoated and has a low heat absorptivity. Apparatus for
determining the surface reflectivity and for controlling the beam is shown
in Cra~g U. S. Patent 2,342,025, issued July 8, 1958, entitled "Photo-
graphic Method", and in Folse U. S. Patent 3,036,497, issued May 29, 1962,
entitled "Photographic Dodging Apparatus".
Step V of the process, shown in Figure 5, is an improvement,
and will now be described. After Steps I through III have been completed,
the plate 10 i8 passed under Calrod heater 32. The infra-red energy from
rod 32 passes through filter 33, which may be made of the same material
as the plate 10. The filter 33 ls therefore particularly absorbent to
the ratiant energy which has optlmum heating effect on those portions
of plate 10 which have had no part of the carbon and nitrocellulose
coating 12 transferred thereto. This enhances the differential heatlng
effect between the coated portions o~ the surface of plate 10 (the portions
to whlch some of said coating 12 has been transferred) and the uncoated
portions of said surface, resulting in a more complete collapse of the
cell structure under the coated portions. This step will not, however,
create any collapse of the cell structure of those areas to which no
part of the coating 12 was transferred.
As shown in Figure 7, the filter plate 33 is rotated by motor
34 past the outlet of cold air 35. Hence, any heat from the radiant
energy source 32 (directed through filter plate 33 at plate 10) which
has been absorbed by filter plate 33 is dissipated without significantly
elevating the temperature of the filter plate 33.
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If a vacuum i~ applied to the underside of plate 10 during
Step V, air will be induced to flow through the open cells in the
surface of plate 1~, that is, through the cells in the areas to which
no part of coating 12 was transferred. Since the other surface cells
have at least partially collapsed, the air flow through them will be
wholly or partially impaired. The transpiration cooling therefore
enhance~ the local temperature differences. It does not interfere with
collap~e of cells in the areas to which some of the coating 12 was trans-
ferred, and may, in fact, enhance the cell collapse as a result of the
presaure gradient created. On the other hand, air does flow through
those portions of the upper surface of plate 10 ~here there haa been
no collapse of the cell structure, thus keeping those portions cool
and free from collapse.
Instead of applying a vacuum to the lower side of the plate,
to generate the above-mentioned air flow, any ~uitable ~ir pressure
differential may be applied acrofi~ the plate.
Figure 5A is a greatly enlarged sectional vlew of Figure 5.
It ia noted that the upper surface of the plate 10 has printing portions
50 and areas of relief Sl. The cells 52 in the printing portions SO
have not collapsed and are interconnected wlth the open cells 53 in
the body of the plate. The cells 54, ~ust beneath each area of relief,
have, however, collapsed and are at least partly sealed against trans-
mission of air therethrough.
If the process is carried out as aforesaid, a printing plate
fiuitable for letterpress or letterfiet ~ork is produced and may be inked
by a roller 80, as shown in Step VI, Figure 6A.
For screen pr:inting (Figure 6B), the ink may be forced through
the plate from the side which does not contact the paper to the printing
side. The ink will travel through the non-collapsed portion of the
cell structure to the raised printing portions on the plate and will
thus wet those portions with ink. Ink will not, however, pass through
those relieved portions of the plate where the structure has been sealed.
103B692
If the starting plate 10 of Figure 1 is composed of urethane
rubber (e.g " a product of B.F. Goodrich Co. designated 58105 and sold
under the trade mark Estane) the end product (after Steps I to V) will
be su~table for flexographic printing and may be inked as shown in
Figure 6A.
