Method of creating hybrid printing dots in a flexographic printing plate

1. A method of producing a relief image printing element from a photocurable printing blank, the method comprising the steps of:

a) providing a photocurable printing blank, the photocurable printing blank comprising:

i) a backing or support layer; and

ii) one or more photocurable layers disposed on the backing or support layer, wherein the one or more photocurable layers comprise a photocurable composition comprising:

1) a binder;

2) one or more monomers;

3) a photoinitiator; and

4) 0.01 to 2.0 percent by weight of an additive selected from the group consisting of butylated hydroxytoluene; pentaerythritol tetrakis (3-(3,5-di-tert-butyl-4-hydroxy phenyl) propionate); octadecyl 3,5 Di-(tert)-butyl-4-hydroxyhydrocinnamate; pentaerythritol tetrakis (3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate); oxtadecyl-3(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate; ethylene bis(oxyethylene) bis-(3-(5-tert-butyl-4-hydroxy-m-tolyl-propionate; N,N′-hexane-1,6-diylbis(3-(3,5-di-tert-butyl-4-hydroxyphenylpropionamide); benzenepropanoic acid, 3,5-bis (1,1-dimethyl-ethyl)-4-hydroxy-C7-C9 branched alkyl esters; 2-(3-tert-Butyl-2-hydroxy-5-methylphenyl)-5-chloro-2H-benzotriazole; 2-(2-Hydroxy-3,5-diperyl-phenyl) benzotriazole and combinations of the foregoing;

b) selectively imaging the one or more photocurable layers by exposing the one or more photocurable layers to actinic radiation to selectively crosslink and cure portions of the one or more photocurable layers; and

c) developing the one or more photocurable layers to remove uncured portions of the one or more photocurable layers and reveal a relief image therein, said relief image comprising a plurality of relief printing dots;

wherein the presence of the additive at the particular concentration produces relief printing dots having a rounded top below a certain size and relief printing dots having a flat top and a high resolution above the certain size, and

wherein the relief printing dots that have the rounded top are shorter in height that the relief printing dots having the flat top.

2. The method according to claim 1 wherein the additive is present in the one or more photocurable layers at a concentration of between 0.05% and 0.20% by weight, based on the total weight of the composition of the photocurable composition.

3. The method according to claim 1 , wherein the additive is butylated hydroxytoluene.

4. The method according to claim 1 , wherein the printing dots below the certain size are printing dots of size less than 1% .

5. The method according to claim 1 , wherein the round top printing dots have a height that is less than 98% of the height of the flat top dots on the relief image printing element.

6. The method according to claim 1 , wherein the round top printing dots have a height that is less than 95% of the height of the flat top dots on the relief image printing element.

7. The method according to claim 6 , wherein the round top printing dots have a height that is less than 90% of the height of the flat top dots on the relief image printing element.

8. The method according to claim 1 , wherein the developing step comprises solvent development.

9. The method according to claim 1 , wherein the developing step comprises thermal development.

10. The method according to claim 1 , wherein the flat top printing dots have good edge sharpness at a point where a top surface of the printing dot intersects a shoulder of the printing dot.