Carrier sheet and method of using the same
View Patent ↗A carrier sheet for providing support to a photocurable printing blank as the photocurable printing blank is conveyed through a plurality of laminating rollers that laminate an oxygen barrier layer to a top surface of the photocurable printing blank. The carrier sheet includes a heat resistant dimensionally-stable backing layer; and a resilient layer mounted on the heat resistant dimensionally-stable backing layer.
1. A method of laminating an oxygen barrier layer to a surface of a flexographic printing blank prior to exposure of the printing blank to actinic radiation to selectively crosslink and cure the flexographic printing blank and create a relief image therein, wherein the flexographic printing blank comprises an in situ mask, and a photocurable layer disposed on a support sheet, the method comprising the steps of:
a) positioning the flexographic printing blank on a carrier sheet such that the carrier sheet supports the flexographic printing blank, wherein the carrier sheet comprises:
i) a heat resistant dimensionally-stable backing layer; and
ii) a resilient layer mounted on, or adhered to, the heat resistant dimensionally-stable backing layer; and
b) passing the flexographic printing blank and the carrier sheet through at least one laminating roller to laminate an oxygen barrier membrane to a surface of the flexographic printing blank, wherein the oxygen barrier membrane covers the in situ mask and any uncovered portions of the photocurable layer.
2. The method according to claim 1 , wherein the flexographic printing blank has a thickness of greater than about 4 mm.
3. The method according to claim 1 , wherein the flexographic printing blank has a Shore A value of less than about 60.
4. The method according to claim 3 , wherein the flexographic printing blank has a Shore A hardness of less than about 50.
5. The method according to claim 1 , wherein at least one of the laminating rollers is maintained at a temperature of at least about 150° F.
6. The method according to claim 1 , wherein the heat resistant dimensionally-stable backing layer comprises a thermoplastic polymer.
7. The method according to claim 6 , wherein the thermoplastic polymer is a polycarbonate.
8. The method according to claim 1 , wherein the heat resistant dimensionally-stable backing layer has a thickness of between about 0.050 and about 0.225 inches.
9. The method according to claim 1 , wherein the resilient layer comprises a compressible layer.
10. The method according to claim 9 , wherein the compressible layer comprises an open cell structure.
11. The method according to claim 10 , wherein the compressible layer comprises an open cell microcellular urethane foam layer.
12. The method according to claim 1 , wherein the resilient layer has a thickness of between about 0.020 and about 0.20 inches.
13. The method according to claim 12 , wherein the resilient layer has a thickness of between about 0.035 and about 0.10 inches.
14. The method according to claim 1 , wherein the resilient layer is bonded to the heat resistant dimensionally-stable backing layer.