METHOD OF MANUFACTURING A LOW VOLUME TRANSFER ANILOX ROLL FOR HIGH-RESOLUTION FLEXOGRAPHIC PRINTING
A method of manufacturing a low volume transfer anilox roll includes depositing a first coating material over a contact surface of a cylinder. A plurality of cells are patterned into the contact surface of the cylinder. A second coating material is deposited over the patterned contact surface of the cylinder.
1 . A method of manufacturing a low volume transfer anilox roll comprising:
depositing a first coating material over a contact surface of a cylinder;
patterning a plurality of cells into the contact surface of the cylinder; and
depositing a second coating material over the patterned plurality of cells.
2 . The method of claim 1 , further comprising:
depositing a photoresist material over the deposited first coating material.
3 . The method of claim 1 , further comprising:
removing remaining photoresist material.
4 . The method of claim 1 , wherein one or more cells of the plurality of cells are hexagonal geometry.
5 . The method of claim 1 , wherein one or more cells of the plurality of cells have a width of approximately 5 micrometers or less.
6 . The method of claim 1 , wherein one or more cells of the plurality of cells are configured to hold and transfer a volume of approximately 0.3 BCM or less of ink or other material.
7 . The method of claim 1 , wherein a thickness of the second coating material is increased to reduce a volume of one or more cells of the plurality of cells.
8 . The method of claim 1 , wherein the low volume transfer anilox roll has a density in a range between approximately 2000 LPI and approximately 5000 LPI.
9 . The method of claim 1 , wherein the cylinder comprises a metal or metal alloy.
10 . The method of claim 1 , wherein the first coating material comprises a metal or metal alloy.
11 . The method of claim 1 , wherein the plurality of cells are patterned into the contact surface of the cylinder by a metal master process.
12 . The method of claim 1 , wherein the plurality of cells are patterned into the contact surface of the cylinder by a maskless lithographic process.
13 . The method of claim 1 , wherein the plurality of cells are patterned into the contact surface of the cylinder by an electron beam lithographic process.
14 . The method of claim 1 , wherein the plurality of cells are patterned into the contact surface of the cylinder by a laser ablation process.
15 . The method of claim 1 , wherein the plurality of cells are patterned into the contact surface of the cylinder by an UV lithographic process.
16 . The method of claim 1 , wherein the second coating material comprises a ceramic material.
17 . The method of claim 1 , wherein the second coating material is deposited by a physical vapor deposition process.
18 . The method of claim 1 , wherein the second coating material is deposited by a chemical vapor deposition process.
19 . The method of claim 1 , wherein the second coating material is deposited by an atmospheric plasma enhanced chemical vapor deposition process.
20 . A low volume transfer anilox roll comprising:
a cylinder;
a roller mount disposed on a distal end of the cylinder;
a first coating layer disposed on a longitudinal contact surface around the cylinder;
a plurality of cells patterned into the cylinder; and
a second coating layer disposed over the patterned plurality of cells.