CORRELATION BETWEEN THE LAMS AND PRINTING AREA ON THE FLEXOGRAPHIC PRINTING PLATE

7th lnternational Symposium of lnformation and Graphic Arts Technology,

CORRELATION BETWEEN THE LAMS AND PRINTING ELEMENT AREAON THE FLEXOGRAPHIC PRINTING PLATE

Tamara TOMASEGOVIC, SanJa MAHOVIC PoLJAEEK, Tomislav CIGULA,Miroslav GOJO & Diana MlLetC

University of Zagreb Faculty of Graphic Arts

Abstract: Production of a flexographic printing plate inctudes a number of procedures which have to bemade in order to form a printing plate with optimal functional properties. One of the procedure which wasobserued in this paper is the application of the bump curves to the LAMS-based flexographic printing ptate.The aim of the paper was to define and characterize the changes in the dimensions of printing elements onthe printing plate compared to dimenslons of openings on LAMS when different bump curves were apptied.Resu/fs have shown that combination of the oxygen influence and the contraction of the photopolymermaterial resu/fs with the decreased coverage values on the printing plate compared to LAMS values in thewhole reproduction area. This indicates that the type of the bump curve in the LAMS-based flexographicworkflow should be applied in conjunction with the changes which occur in the photopotymer material.

Keywords: flexography, photopolymer, LAMS, bump curue.

1 INTRODUCTION

Flexographic printing plates are used in packaging industry, newspaper reproduction and in printedelectronics productlon as well. They are applicable for printing on a wide range of printing substrates and arecharacterised by a geometrical difference between printing and nonprinting areas and a flexible materialwhich is elastically deformed for each imprint [1-2]. Flexographic printing plates are mainly made fromphotosensitive monomers and a number of additives, such as photo initiators and plasticizers, to obtain highlevel of their quality [3-4]. When exposed to UV radiation, photo polymerization occurs and exposed parts ofthe plate become insoluble in defined processing solution.

ln the last decade a great improvement has been made in digitalization of the plate making procedure and inthe usage of newly formed materials which increased the quality of the printing plates and made the platemaking procedure ecologically friendlier. One of the most present prlnting plates making procedure is basedon the LAMS (laser ablated mask) technology [5-6]. LAMS is a type of the graphene layerwhich is placed onthe top of the photopolymer material. ln the printing plate production process, LAMS has to be removed fromthe image area of the photopolymer material by means of the laser ablation. After removal of LAMS, imageelements will be formed by exposure of the photopolymer material through the openings in LAMS to UVAwavelengths. Exposure initiates the photopolymerization process in order to form the relief (image elements)on the printing plate. The exposed area of the printing plate becomes insoluble in the developing solution. lnthe Figure 1 one can see the phases of the printing plates making procedure.

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ln the first step, exposure of the back side of the plate has been performed in order to form a basis layer(Figure 1.a). Ablation of the LAMS follows the back-exposure and forms a mask of the image which will be

Session 81 Printing, Print Qual ty, Postpress 43

7th lnternational Symposium of lnformation and Graphic Arts Technology,5-6 June 2014, Liubljana, Slovenia

reproduced (Figure 1.b). Due to main-exposure image elements have been formed in the polymer material(Figure 1.c) and by chemical and mechanical developing (Figure 1.d), non exposed areas are removedforming non-image areas of the plate. Drying and after-exposure (UV-A, UV-C) improve the mechanicalproperties of polymer (Figure 1.e and 1.f).

Printing plate workflow, besides above mentioned parameters, depends on a number of printing parameterswhich should be controlled and standardized in the reproduction process. For example, the properties of theprinting substrate and printing ink should be characterised and possible deformations of printing plate duringthe printing should be defined and predict as well [7-8]. Therefore, adjustments of the printing plate makingprocess must be performed to compensate limitations in the workflow, in order to achieve an optimal qualityof the imprint [9-11]. Corrections can be made by modifying and adjustment of a digital file which will betransferred to the printing plate by correction of two factors: the dot gain on imprints by compensation curveand the reproduction of highlights by usage a bump-up curve. Their purpose is to decrease the middle tonevalues and to increase the low coverage values on the printing plate, respectively [6]. Besides printingparameters, in the printing plate workflow, the shape and formation of prlnting elements on the printing plateis influenced by several parameters. They should be taken into consideration as well, when the digitalcorrection is made. The parameters that should be controlled are:- undercopying, which is caused by the dispersion and diffraction of the UV radiation, resulting with photo-chemical reaction under the area covered with LAMS. This can result with increased coverage value on theprinting plate and/or filling in of the nonprinting surfaces, especially in the high coverage value area [12].- the contraction of the photopolymer as a result of the photochemical reaction causes decrease of theprinting element's dimensions in the whole coverage value range.- properties of the photopolymer material are connected to the material composition, polymerizationmechanism and the degree of the polymerization. This properties influence the reproducibility of the finedetails, too.- the influence of the oxygen on the photopolymer material is significant as well [13]. Oxygen causes theoxidation and degradation of the photopolymer material, resulting with incompletely formed printing elementsof the insufficient height. The degradation is mostly expressed in the low coverage area. Therefore, smallprinting elements should be "bumped up" in order to ensure their stability and reproducibility in the printingprocess. Also, the dimension of the smallest printing element on the printing plate should be adjusted to theanilox roller cell in order to achieve the correct transfer of the tone values in the reproduction process.

2 EXPERIMENTAL

The aim of this paper was to define and characterize the changes which happened in transferring theinformation from a digital file on the LAMS mask and from LAMS openings to the printing plate. It was madeby measuring of dimensions of printing elements on the printing plate compared to dimensions of openingson LAMS when different bump curves were applied.2.1 Preparation of samplesFor this research, five different bump curves were applied to the LAMS-based flexographic printing plate.The differences between bump curves applied can be seen in Table 1.

Table 1. Coverage values on the printing plate and size of openings on LAMS for different bump curves

The image transferred to the samples was a control wedge with fields of coverage values from 1Yo to 100%with step of 10% coverage value between the fields. Additionally, fields in highlights and shadows had asmaller step: values of 1, 3, 5, 8, 10, 15,92,94, 96 and 98 % were represented on the control wedge inorder to examine the transfer of the low and high coverage values from LAMS to the printing plate in detail.Ten samples were prepared: five samples of the photopolymer material with LAMS removed from the imagearea, and five corresponding samples of the finished printing plate. The aim of the paper was to define andcharacterize the changes in the dimensions of printing elements on the printing plate compared to

Session 81 - Printlng, Prlnt QuaLity, Postpress 44

7th lnternational Symposium of lnformation and Graphic Arts Technology,p--,S;,lH.lE;91 1,.liybljnna, slp,ypntg

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dimensions opened on LAMS when different bump curves are applied. Also, the aim of the research was todefine the significance of particular parameters on the changes in dimensions of the printing elements.The type of photopolymer material used was solvent-washable, SBS copolymer-based. Samples of finishedprinting plates were processed in standard conditions proposed by the printing plate manufacturer.

2.2 Measurement methodology

ln order to monitor the formation of the printing elements and the relation of the openings on LAMS andcorresponding printing element sizes, the areas of the openings on LAMS and the areis of the printingelements on the printing plate were measured. Olympus Metallurgical Microscope BXS1 was used forcapturing images of LAMS openings and printing elements [14]. Olympus BXS1 is a microscope with theability of capturing images under magnification up to 1500x, with program support for image adjustment andanalysis. lt enables the calculation of the coverage values on the printing plate and the imprinis, as well asthe measurement of the printing element's area and diameter. After measuring the areas of the openings onLAMS and printing element areas, the correlation coefficient was calculated foi each bump curve.

3 RESULTS AND DISCUSSION

After capturing the images of areas opened on LAMS and corresponding printing elements, their area wasmeasured in order to characterize the transfer of the coverage values from LAMS to the printing plate. lnFigures 2 and 3 one can see the differences in sizes of areas opened on LAMS and printing elJments forsamples with applied bump curve 2BU. lt is visible that the printing elements formed on printing plate havesmaller area than the openings on LAMS. This is especially expressed in the low coverage arealFigures 2.aand 3.a), where the influence of the oxygen has a major impact on the formation of the printing elemLnts.

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Figure 2: Areas opened on LAMS for a) 5o/o, b) 50% and c) 96% nominal coverage value for sample 2BU

Figure 3: Printing elements for a) 5o/o, b) 50% and c) 96% nominal coverage value on sample 2BU

Figures 4 and 5 represent the areas opened on LAMS and formed printing elements for sample 108U,respectively. lt is visible that the influence of the bump curve is major in the low coverage area (Figures 4.aand 5.a), as itwas visible in Figures 2.aand 3.a. The difference in the areas of the printing elements of 5%nominal coverage value on sample 2BU and 1OBU is cca. 900 pm2.

Undercopying as an influence factor for the printing element formation is visible when observing Figures 3.cand 5.c. The edges of the printing elements are not correctly formed and sharp. The non printing areas startto fill in the printing elements because of the photochemical reaction under the area covered with LAMS.

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Session B1 -- Printing, Print Ouatity, Postpress 45

7th lnternational Symposium of Information and Graphic Arts Technology,5-6 June 2014, Ljubljana, Slovenia

c) .IFigure 4: Areas opened on LAMS for a) 5%, b) 50% and c) 96% nominal coverage value for sample 1OBU

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Figure 5: Printing elements for a) 5%, b) 50% and c) 96% nominal coverage value on sample 1oBU

Results of the measurements of the area opened on LAMS and the corresponding area of printing elementsfrom 0% lo 70o/o coverage value can be seen in Figures 6.a and 6.b. ln Figure 6.a it is visible that thedifferences in openings on LAMS are most signiflcant in the low coverage areas for different bump curvesapplied. The difference in the areas opened on LAMS for 1% nominal coverage value between the 1OBU and2BU sample is cca. 1300 pm2. These differences in low coverage areas confirm that all bump curves wereapplied correctly. With the increase of the coverage value, the differences between the areas opened onLAMS for different bump curves applied decrease. When observing Figure 6.b, one can notice the slmilartrend of coverage value transfer as in the Figure 6.a. The application of the bump curve 10BU results withlarger areas of printing elements than the application of lower bump curves. This differences are distinct inthe coverage area under 50%, which was expected due to the type of the bump curves applied. Microscopicimages of the LAMS and printing elements (Figures 2 to 5) showed the noticeable differences between theareas of interest on LAMS and printing plate. When observing higher coverage areas on the finished printingplate samples, the undercopying was visible.

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ln Flgure 7.a one can see the comparison between the areas of the LAMS layer remained on the printingplate when different bump curves were applied. The steps between the higher percentage of coverage on

Session 81 - Prrnt nel, Pr nt CL.ralrty, Posl.press 46

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7th lnternational Symposium of lnformation and Graphic Arts Technology,5-6 June 2014, Liubliana, Slovenia

Gorresponding author:

Tamara TOMASEGOVIC, Mag.ing. techn.graph.University of Zagreb Faculty of Graphic ArtsGetaldi6eva 2Croatia, 10000 Zagreb,phone: +385 1 2371 080 (248) e-mail: [email protected], http://wnnrv.qrf.unizg.hr

Go-author(s):

Sanja MAHOVIC POLJAeEK, Ass.prof.dr.sc.University of Zagreb Faculty of Graphic ArtsGetaldi6eva 2Croatia, '10000 Zagrebphone: +385 12371 080 (129) e-mail: [email protected], http://wwr,v.qrf.unizo.hr

Tomislav CIGULA, Dr.sc.University of Zagreb Faculty of Graphic ArtsGetaldiceva 2Croatia, 10000 Zagrebphone: +385 1 2371 080 (248) e-mail: [email protected], http:i/www.qrf.unizq.hr

Miroslav GOJO, Prof,dr.sc.University of Zagreb Faculty of Graphic ArtsGetaldi6eva 2Croatia, '10000 Zagrebphone: +385 1 2371 080 (245) e-mail: [email protected], http://www.qrf.unizq.hr

Diana MlLelC, Prof.dr.sc.University of Zagreb Faculty of Graphic ArtsGetaldi6eva 2

Croatia, 10000 Zagrebphone: +385 1 2371 080 (250) e-mail: [email protected], http://www.orf.unizo.hr

Session B1 Printinq, Print OuaLity, Posrpress 49