Method for thermal development with supporting surface for a development medium

1. A method for forming a relief pattern from a photosensitive element having an exterior surface and containing a composition layer capable of being partially liquefied comprising:

heating the exterior surface to a temperature sufficient to cause a portion of the layer to partially liquefy;

supporting a development medium for contacting with the exterior surface adjacent the partially liquefied portion; and

pressing the development medium and the exterior surface adjacent the partially liquefied portion into contact at a pressure sufficient for at least a portion of the liquefied material of the composition layer to be absorbed and removed in depth by the development medium, to form the relief pattern on the element;

wherein the supporting step comprises contacting a side of the development medium opposite the partially liquefied portion with a non-rotating surface, and providing relative movement between the development medium and the non-rotating surface to cause the development medium to traverse the non-rotating surface, and

wherein the supporting step is with a non-rotating support member that is resistant to displacement under operating forces encountered in the method.

2. The method of claim 1 wherein the supporting step is with a non-cylindrical support member having the non-rotating surface.

3. The method of claim 1 wherein the supporting step is with a support member having the non-rotating surface and having a cross-sectional shape selected from the group consisting of elliptical, parabolic, arcuate, circular, semi-circular, wedge, triangular, rectangular, and polygonal shapes.

4. The method of claim 1 wherein the non-rotating surface is selected from the group consisting of planar surfaces and arcuate surfaces.

5. The method of claim 4 wherein the non-rotating surface is arcuate, and selected from the group consisting of convex surfaces and concave surfaces, wherein the concave surfaces conform to a portion of the exterior surface.

6. The method of claim 1 wherein the non-rotating surface comprises a radius of curvature less than 40 millimeters.

7. The method of claim 1 wherein the non-rotating surface comprises a radius of curvature between 8 and 15 millimeters.

8. The method of claim 1 further comprising traversing the development medium on a projecting edge of the non-rotating surface, wherein said projecting edge provides contact with the exterior surface adjacent the partially liquefied portion.

9. The method of claim 1 wherein the supporting step comprises supporting the development medium with a support member having more than one non-rotating surface each having a radius of curvature, wherein each radius of curvature can be the same or different.

10. The method of claim 1 wherein the supporting step comprises supporting the development medium with a support member having more than one non-rotating surface, the method further comprising indexing the support member to position each of the more than one non-rotating surface adjacent the exterior surface.

11. The method of claim 1 wherein the supporting step comprises supporting the development medium with a support member that is semi-cylindrical having a cylindrical surface portion coinciding with the non-rotating surface.

12. The method of claim 11 wherein the cylindrical surface portion has a radius of curvature less than 40 millimeters.

13. The method of claim 1 further comprising buttressing the non-rotating surface.

14. The method of claim 1 further comprising

supporting the photosensitive element on a base member; and

delivering the development medium to the exterior surface.

15. The method of claim 1 further comprising moving a support member comprising the non-rotating surface.

16. The method of claim 1 further comprising removing the development medium from the exterior surface.

17. The method of claim 1 further comprising tensioning the development medium.

18. The method of claim 1 wherein the photosensitive element is a photopolymerizable printing element.

19. The method of claim 1 wherein the heating step is selected from the group consisting of

a first heating applying heat to the exterior surface of the composition layer adjacent where the development medium contacts the layer, the first heating adapted to heat the exterior surface of the layer;

a second heating to heat the non-rotating surface to a temperature capable of heating the exterior surface of the composition layer while the development medium is contacting the exterior surface of the layer;

a third heating to heat a base member for the photosensitive element to a temperature capable of heating the exterior surface of the composition layer;

combination of the first heating and the second heating;

combination of the first heating and the third heating;

combination of the second heating and the third heating; and

combination of the first heating, the second heating, and the third heating,

wherein the first heating, the second heating, and the third heating, individually or in the above combinations, is capable of heating the exterior surface of the composition layer sufficiently to cause a portion of the layer to liquefy.

20. The method of claim 1 further comprising exposing the photosensitive element to actinic radiation.

21. The method of claim 20 wherein the exposing step is imagewise through an in-situ mask, through a phototool, or by a laser.

22. A flexographic printing form made according to the method of claim 20 .

23. The method of claim 1 wherein the non-rotating surface is stationary.

24. The method of claim 1 further comprising moving the non-rotating surface less than one revolution about an axis.

25. The method of claim 1 , wherein the non-rotating surface penetrates into the exterior surface of the photosensitive element during the pressing step.

26. The method of claim 25 , further comprising controlling the depth that the non-rotating surface penetrates into the exterior surface of the element.