MULTI-STATION FLEXOGRAPHIC PRINTING PROCESS AND SYSTEM
A multi-station flexographic printing method includes transferring an ink from a first flexo master to a substrate. The first flexo master includes an embossing pattern. The embossing pattern includes lines of a first width or orientation. Ink is transferred from a second flexo master to the substrate. The second flexo master includes an embossing pattern. The embossing pattern includes lines of a second width or orientation. Ink is transferred from a third flexo master to the substrate. The third flexo master includes an embossing pattern. The embossing pattern includes lines of a third width or orientation. Ink is transferred from a fourth flexo master to the substrate. The fourth flexo master includes an embossing pattern. The embossing pattern includes lines of a fourth width or orientation.
1 . A multi-station flexographic printing method comprising:
transferring an ink from a first flexo master to a substrate, wherein the first flexo master comprises an embossing pattern comprising lines of a first width or orientation;
transferring an ink from a second flexo master to the substrate, wherein the second flexo master comprises an embossing pattern comprising lines of a second width or orientation;
transferring an ink from a third flexo master to the substrate, wherein the third flexo master comprises an embossing pattern comprising lines of a third width or orientation; and
transferring an ink from a fourth flexo master to the substrate, wherein the fourth flexo master comprises an embossing pattern comprising lines of a fourth width or orientation.
2 . The method of claim 1 , wherein the embossing pattern of the first flexo master comprises one or more x-axis printing lines.
3 . The method of claim 2 , wherein the one or more x-axis printing lines have a width of less than 10 microns.
4 . The method of claim 2 , wherein the one or more x-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
5 . The method of claim 1 , wherein the embossing pattern of the second flexo master comprises one or more y-axis printing lines.
6 . The method of claim 5 , wherein the one or more y-axis printing lines have a width of less than 10 microns.
7 . The method of claim 5 , wherein the one or more y-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
8 . The method of claim 1 , wherein the embossing pattern of the third flexo master comprises one or more interconnect patterns.
9 . The method of claim 8 , wherein the one or more interconnect patterns have a width in a range between approximately 50 microns and approximately 100 microns.
10 . The method of claim 1 , wherein the embossing pattern of the fourth flexo master comprises one or more connector patterns.
11 . The method of claim 10 , wherein the one or more connector patterns have a width greater than 100 microns.
12 . The method of claim 1 , wherein the transfers of ink from each flexo master to the substrate are sequenced in an order of increasing embossing pattern width.
13 . The method of claim 1 , wherein a different ink composition may be used for each flexo master transfer.
14 . A multi-station flexographic printing method comprising:
transferring an ink from a plurality of flexo masters to a substrate in sequence,
wherein each flexo master comprises an embossing pattern having a different width or orientation.
15 . The method of claim 14 , wherein at least one of the embossing patterns comprises one or more x-axis printing lines.
16 . The method of claim 15 , wherein the one or more x-axis printing lines have a width of less than 10 microns.
17 . The method of claim 15 , wherein the one or more x-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
18 . The method of claim 14 , wherein at least one of the embossing patterns comprises one or more y-axis printing lines.
19 . The method of claim 18 , wherein the one or more y-axis printing lines have a width of less than 10 microns.
20 . The method of claim 18 , wherein the one or more y-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
21 . The method of claim 14 , wherein at least one of the embossing patterns comprises one or more interconnect patterns.
22 . The method of claim 21 , wherein the one or more interconnect patterns have a width in a range between approximately 50 microns and approximately 100 microns.
23 . The method of claim 14 , wherein at least one of the embossing patterns comprises one or more connector patterns.
24 . The method of claim 23 , wherein the one or more connector patterns have a width greater than 100 microns.
25 . The method of claim 14 , wherein the transfers of ink from each flexo master to the substrate are sequenced in an order of increasing embossing pattern width.
26 . The method of claim 14 , wherein a different ink composition may be used for each flexo master transfer.
27 . A multi-station flexographic printing system comprising:
a plurality of flexographic printing stations, wherein each flexographic printing station comprises:
an ink roll;
an anilox roll;
a plate cylinder;
a flexo master disposed on the plate cylinder; and
an impression cylinder,
wherein each flexo master comprises an embossing pattern having a different line width or orientation.
28 . The system of claim 27 , wherein an embossing pattern of a first flexo master of a first flexographic printing station comprises one or more x-axis printing lines.
29 . The system of claim 28 , wherein the one or more x-axis printing lines have a width of less than 10 microns.
30 . The system of claim 28 , wherein the one or more x-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
31 . The system of claim 27 , wherein an embossing pattern of a second flexo master of a second flexographic printing station comprises one or more y-axis printing lines.
32 . The system of claim 31 , wherein the one or more y-axis printing lines have a width of less than 10 microns.
33 . The system of claim 31 , wherein the one or more y-axis printing lines have a width in a range between approximately 10 microns and approximately 50 microns.
34 . The system of claim 27 , wherein an embossing pattern of a third flexo master of a third flexographic printing station comprises one or more interconnect patterns.
35 . The system of claim 34 , wherein the one or more interconnect patterns have a width in a range between approximately 50 microns and approximately 100 microns.
36 . The system of claim 27 , wherein an embossing pattern of a fourth flexo master of a fourth flexographic printing station comprises one or more connector patterns.
37 . The system of claim 36 , wherein the one or more connector patterns have a width greater than 100 microns.
38 . The system of claim 27 , wherein the plurality of flexographic printing stations are sequenced in an order of increasing embossing pattern width.
39 . The method of claim 27 , wherein a different ink composition may be used for each flexo master.