Systems and methods for optimization of parameters for exposing flexographic photopolymer plates

A method for determining exposure parameters for curing a selected photopolymer plate having a predetermined photopolymer type and a predetermined plate thickness over multiple exposure steps, the method comprising the steps of:

• (a) disposing a sample of photopolymer material in a target area, the sample having the predetermined photopolymer type and the predetermined plate thickness, the target area having a first dimension and second dimension;
• (b) providing a first exposure unit comprising a light source comprising a plurality of LEDs arranged in an array coextensive with the first dimension;
• (c) causing relative movement between the light source and the target area along the second dimension;
• (d) causing different units of the sample to receive different amounts of total energy exposure, different amounts of exposure energy per exposure step, or a combination thereof;
• (e) visually evaluating each sample unit against a reference plate having the predetermined photopolymer type and the predetermined plate thickness to identify a sample unit embodying a minimum acceptable total exposure energy and a maximum acceptable exposure energy per exposure step;
• and
• wherein the plurality of criteria for visually assessing the sample against the reference plate for determining the minimum total exposure energy comprise criteria for determining a minimum stable dot size.

A method for determining exposure parameters for curing a selected photopolymer plate having a predetermined photopolymer type and a predetermined plate thickness over multiple exposure steps, the method comprising the steps of:

• (a) disposing a sample of photopolymer material in a target area, the sample having the predetermined photopolymer type and the predetermined plate thickness, the target area having a first dimension and second dimension;
• (b) providing a first exposure unit comprising a light source comprising a plurality of LEDs arranged in an array coextensive with the first dimension;
• (c) causing relative movement between the light source and the target area along the second dimension;
• (d) causing different units of the sample to receive different amounts of total energy exposure, different amounts of exposure energy per exposure step, or a combination thereof;
• (e) visually evaluating each sample unit against a reference plate having the predetermined photopolymer type and the predetermined plate thickness to identify a sample unit embodying a minimum acceptable total exposure energy and a maximum acceptable exposure energy per exposure step;
• and
• wherein the plurality of criteria for visually assessing the sample against the reference plate for determining the maximum acceptable exposure energy per exposure step are selected from the group consisting of:
• (i) line broadening of horizontal lines;
• (ii) line broadening of vertical lines;
• (iii) dot cupping in a selected percentage screen;
• (iv) any combination of (vi)-(ix).