Optimization of UV curing
AssigneeUnipixel Displays, Inc.
InventorEd S. Ramakrishnan
Life of this patent
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Abstract
A system and method of preparing a flexoplate so it is suitable for the printing of high resolution patterns. The method includes controlling the curing conditions of the flexoplate, thereby controlling the properties of said flexoplate such as floor thickness, pattern cross-sectional geometry, repeatability of printed features during the printing process, and durability of the flexoplate during the printing process.
Claims23
A method for patterning a flexoblank to form a flexoplate comprising:
- curing a first surface of a flexoblank, wherein the first surface comprises a backing, wherein curing the first surface forms a floor on the first surface, and wherein curing comprises emitting ultraviolet (UV) radiation with a plurality of wavelengths between 250 nm-600 nm and a curing dosage from 0.3 J/cm2 to 1.0 J/cm2;
- disposing a mask on a second surface of a flexoblank, wherein the second surface is opposite the first surface;
- curing the second surface to form a pattern on the second surface, wherein curing the second surface comprise using UV light at a dosage between 5 J/cm2 and 25 J/cm2;
- wherein forming the pattern comprises forming a plurality of lines, wherein the cross-section of each of the plurality of lines is one of a square, a rectangle, a triangle, and a trapezoid, wherein a plurality of valleys are formed in between each set of lines of the plurality of lines, and wherein the valley depth is between 5-20 microns.
A method for patterning a flexoblank to form a flexoplate comprising:
- curing a first surface of a flexoblank, wherein the first surface comprises a backing, wherein curing the first surface forms a floor on the first surface, and wherein curing comprises emitting ultraviolet (UV) radiation with a plurality of wavelengths between 250 nm-600 nm and a curing dosage from 0.3 J/cm2 to 1.0 J/cm2;
- disposing a mask on a second surface of a flexoblank, wherein the second surface is opposite the first surface;
- curing the second surface to form a pattern on the second surface using UV light at a dosage between 5 J/cm2 and 25 J/cm2;
- and
- wherein the pattern comprises a plurality of lines, and wherein a sidewall angle of the plurality of lines is between 20°-70°.
A method of forming a conductive pattern using a flexoplate comprising:
- patterning a flexoblank comprising a first and a second surface, to form a flexoplate wherein patterning comprises:
- disposing a mask on a second surface of the flexoblank;
- curing a first surface using ultraviolet light with a plurality of wavelengths between 250 nm-600 nm and a curing dosage between 0.3 J/cm2 to 1.0 J/cm2, wherein curing the first surface forms a floor on the first surface,
- curing the second surface using UV light at a dosage between 5 J/cm2 and 25 J/cm2;
- forming, subsequent to curing the second surface, a pattern on the second surface, wherein the pattern comprises a plurality of lines with sidewall angles between 20°-70°;
- disposing the patterned flexoblank on a roller;
- printing a first substrate using a first ink and the flexoplate on at least one side of the substrate;
- printing a second substrate on at least one side;
- and
- plating the first and the second substrates, with a conductive material to form the conductive pattern.
Dependencies are inferred from the claim text.