Abstract:
Excellent development of planographic printing plates can be achieved by exposing an imaged, negative working, photopolymerizable coating to a high pressure stream of essentially heated but otherwise untreated tap water, whereby the water completely removes only the less cohesive and adhesive (e.g., partially polymerized) regions to the substrate, thereby directly producing a printing plate having an image pattern of highly cohesive and adhesive, oleophilic regions of the coating and hydrophilic regions of the substrate. The coating removal mechanism appears to be due entirely to ablation. The process variables of spray pressure, spray volumetric flow rate, and water temperature can be traded off to achieve one or more targets for plate quality, energy conservation, production rate, and equipment availability.

Description:
RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. §120 from U.S. application Ser. No. 11/821,721 filed Jun. 25, 2007 for “Water Spray Development of Planographic Plates”, which claims priority from U.S. application Ser. No. 11/493,183 filed Jul. 26, 2006 for “Imageable Printing Plate for On-Press Development”, which claims priority from U.S. Provisional Application No. 60/704,140 filed Jul. 29, 2005, for “Imageable Printing Plate for On-Press Development”. 
     BACKGROUND 
     The present invention relates to the development of imaged lithographic plates, and especially to such plates as used for printing. 
     Plates of this type have a radiation-sensitive, oleophilic polymer resin coating on a hydrophilic substrate. Imaging at ultraviolet, visible, or infrared wavelengths produces regions of differential solubility. The plates are developed to remove the more soluble regions of the coating, thereby producing a substantially planographic pattern of oleophilic and hydrophilic regions. The developed plates are then ready for mounting on a cylinder of a printing press, where the plates are subjected to fountain fluid and ink for transfer of ink to a target surface according to the pattern of oleophilic and hydrophilic regions on the plate. Historically, the processing of plates involves immersion of the plate in a sump of developer as the plate passes through a plate processor. The plate then exits the sump, and is typically subjected to a rotating brush or molleton and a nip roll set prior to being rinsed. This method of development relies entirely on chemical dissolution. In an ideal imaged plate, the relatively insoluble regions experience little dissolution over a wide range of immersion dwell time in the developer solution, whereas over the same wide range of dwell time the relatively soluble regions quickly and completely dissolve. 
     In practice, this ideal is not achievable, because the developer solution chemistry, temperature, and dwell time must be traded off to optimize cleanout of background while retaining the small dots of coating that provide good highlights in the printed product. Such optimization typically requires that the developer solution be strongly reactive and the dwell time be of long enough duration, to dissolve all the background, while conditioning agents in the developer solution, such as surfactants, help protect the relatively insoluble regions of the coating from reacting with the reactive ingredient of the developer solution. 
     Solubility differences associated with developing latitude correlate with differences in cohesion (the degree to which coating material “sticks” to itself) and adhesion (the degree to which coating material “sticks” to the substrate). 
     SUMMARY OF THE INVENTION 
     We have discovered that excellent development can be achieved by exposing the entire imaged coating to a high pressure stream of essentially untreated tap water, whereby the liquid completely removes only the less cohesive and adhesive regions from the substrate, thereby directly producing a printing plate having an image pattern of highly cohesive and adhesive, oleophilic regions of the coating and hydrophilic regions of the substrate. 
     In general, the highly cohesive and adhesive coating regions are highly polymerized and the less cohesive and adhesive coating regions are significantly less (relatively partially) polymerized. The high pressure liquid completely removes only the unimaged, partially polymerized regions from the substrate, directly producing a printing plate having an image pattern of highly polymerized, oleophilic regions of the coating and hydrophilic regions of the substrate. 
     The coating removal mechanism appears to be due entirely to ablation. 
     This ablative removal is rendered even more effective by the use of water at elevated temperature, i.e., above 80 deg. F., preferably above about 90 deg. F. and most preferably in the range of about 90-115 deg. F. It is believed that the temperature increase renders the non-image coating more pliable or mobile relative to the substrate, and thus more susceptible to penetration and undercutting of this coating material by the water spray. Increasing the water temperature can be traded off against decreasing the spray pressure and/or spray exposure period, to maintain satisfactory development while optimizing process variables such as capacity and cost of purchased equipment, energy consumption, throughout, maintenance and repair schedule, etc. For example, similar if not better plate quality as measured by a standard screen test can be obtained by increasing the water temperature from 70 deg. F. to 90 deg. F. while reducing water spray pressure from 1800 psi to 1200 psi. 
     At least one nozzle discharges the developer liquid at a discharge pressure and the discharged liquid impinges the plate at a contact pressure that is commensurate with the discharge pressure. With the nozzle spaced above the plate at a working distance, the plate and/or nozzle translate relative to each other in a process direction at a substantially constant average speed. The discharge pressure, nozzle spacing, and average speed are selected such that the high pressure stream of liquid has impinged and developed the entire plate surface with a throughput speed in the range of 3-6 ft/min. 
     Each nozzle preferably has a spray pattern that impinges the plate over a substantially rectangular area (subarea) of the plate, with relative movement between the nozzle and the plate until the entire area of the plate has been developed. The nozzle can reciprocate across the width of a longitudinally transported plate, thereby contacting successive subareas of the plate in a rastering fashion. 
     The method is especially effective with negative working plates having a solvent soluble, photopolymerizable coating. In these plates, the adhesion and cohesion of the regions exposed to radiation imaging is much stronger that the adhesion and cohesion in the unexposed regions. This difference renders the unexposed regions much more susceptible to essentially pure mechanical removal, i.e., via ablation. Although the unexposed coating could readily be solubilized by a conventional solvent based developer solution, highly pressurized, heated tap water according to the present disclosure provides no solvent, so coating dissolution cannot even be an initiating mechanism for coating removal. 
     We have found that as one optimization, negative working newspaper plates can be developed within a commercially acceptable time interval using tap water heated to a temperature in the range of about 90-115 deg. F., with nozzle discharge pressure in the range of about 1000-1500 psi. 
     Another embodiment is directed to a processor comprising a rigid surface for supporting a plate to be developed, a water heater, a pump having an inlet fluidly connectable to a source of tap water and operable to discharge the heated water through an outlet at a pressure of at least about 800 psi, a delivery line connectable to the outlet, and at least one nozzle fluidly connected to the delivery line. A wand or the like is connected to the nozzle, by which the nozzle can be aimed at a plate when supported by the rigid surface and deliver a high pressure stream of liquid onto the coating of the plate. 
     In one variation, the wand is a rod for manually aiming a single nozzle. Such wand can be a rigid pipe or tube connected between the delivery line and the nozzle, or a solid rod or handle projecting from the nozzle body or a tube upstream of the nozzle body. 
     In another variation, the wand is fixed in a frame located above the rigid support. The wand can include a track or other means for reciprocating the nozzle transversely to a continually (intermittent or continuously) conveyed plate, preferably in a rastering fashion. 
     A significant advantage of the invention is that there is little or no chemical treatment required of the waste stream associated with developing the plate. Another significant advantage is that because dissolution of the polymer resin is not relied upon for processing the plate, higher molecular weight resins can be used in the coating, thereby producing more durable oleophilic regions and longer plate life on press. Yet another advantage is that with the preferred rastering motion of the nozzle, the removed coating is carried away off the sides of the plates, thereby avoiding redeposition on the substrate. 
     Use of water at elevated temperature increases the advantage of avoiding redeposition or other fouling of equipment such as brushes and rollers. The high pressure water breaks up the non-image regions of the coating into small bits of material, and use of water at elevated temperature produces even smaller bits than water at ambient temperature. 
     Another advantage is that excess dwell time (time a given point on the coating is subjected to the development fluid) is of little or no consequence. The regions of low cohesion and adhesion in a given area of the coating clean out completely within a few seconds, whereas the regions of high cohesion and adhesion in that same given area can tolerate the high pressure for much a longer time, e.g., minutes. This difference means that careful determination and control of nozzle flow rate and dwell time windows are not needed. This differs from one of our previous inventions, in which a spray of chemically reactive developer solution is applied as a continual flow of fresh developer solution onto each unit area of the coated plate for a local dwell time of less than about 10 seconds, and then immediately removed to avoid excess developer solution dwell time on the highly polymerized but still slightly soluble image regions. 
     Yet another advantage of the ablative removal is that the edge of each imaged dot remains sharp. In conventional development, the chemical reaction for removing the relatively soluble non-image regions produces a reaction gradient which results in a radiused shoulder at the base of the image dots. The ablative removal, especially with heated water, produces a sharp break off between the highly polymerized, cohesive coating regions, which are highly adhered to the substrate, and the relatively nonpolymerized, only mildly adhesive coating regions, which are removed. This effect facilitates equipment set up that can produce plates exhibiting consistent gradations of shadow screen values in the range of 95 to 99%. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic representation of equipment for implementing a basic embodiment of the invention with a manually directed spray nozzle; 
         FIG. 2  is a schematic top view of a processor according to another embodiment, having an automatic spray nozzle situated above and movable transversely with respect to a conveyed plate; 
         FIG. 3  is a schematic end view of the processor shown in  FIG. 2 ; 
         FIG. 4  is a schematic showing the movement path of a single nozzle perpendicularly to the conveying or process direction of the plate, in an embodiment wherein the plate is conveyed intermittently at intervals corresponding to the time required for the nozzle to make a complete pass across the width of the plate; and 
         FIG. 5  is a schematic representation of another embodiment wherein the nozzle reciprocates continuously across the width of the plate and the plate is continuously conveyed beneath the nozzle, thereby producing an oblique, “zigzag” pattern of spray contact on the plate. 
         FIGS. 6A-F  show test results of measured dot values against standard screen values for various water spray temperatures, at six different spray pressures at the spray nozzle. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  represents the basic elements of the present invention, comprising a workstation  12  and a fluid delivery system  14 . The workstation  12  is shown with a pedestal or legs  16 , which support a basin or tub  18 . A worktable  20  is supported within and rises above the basin such that fluid deposited on and overflowing from worktable is captured by the basin. The table  20  provides a flat, rigid support surface for receiving and supporting an imaged plate  22 . In this embodiment, the operator manually places the plate  22  on the table  20 , develops the plate as will be described below, manually removes the plate, and then wipes or otherwise dries the plate. 
     The fluid delivery system  14  comprises an hydraulic pump  24  having an inlet  24   a  connectable to a source S of heated tap water H, and an outlet  24   b  that discharges pressurized water to delivery line  26 . In this context, “water” means tap water or other water sources that have not been modified with compounds for chemically reacting with the plate coating. Tap water is typically supplied under municipal water pressure of about 15 psi. However, the pump  24  can alternatively draw water at S from a sump of standing or recirculating water. The pump should be capable of increasing the pressure to at least in the range of about 200-1000 psi for a simple, hand-operated system, and preferably to a pressure in the range of about 1000-1800 psi for an automated processor. 
     The delivery line  26  can be a hose or similar flexible line, with a manually maneuverable wand  28 , such as a pipe or the like. The wand  28  terminates in a nozzle  30 , which the operator directs obliquely downwardly at the plate  22 . For convenience in handling the line  26  and wand  28 , the line may be routed over a roller  32  or pivoted support adjacent to and above the table  20 . The high pressure fluid preferably emerges as a dense spray  50 , which at a given moment, impinges on a sub area of the plate smaller than the total area of the plate. While the plate  22  is stationary on table  20 , the operator moves the wand across the plate to remove the regions of low cohesion and adhesion from the substrate, while the regions of high cohesion and adhesion remain intact. 
     Preferably, a pressure gauge  34  is connected to the wand  28 , delivery line  26 , or pump outlet  24   b  (each of which is commensurate with a particular discharge pressure for a given nozzle) whereby the operator can through trial and error, correlate satisfactory development with the variables of discharge pressure, nozzle spray pattern, distance of the nozzle from the plate, and nozzle translation rate. 
     With water as the developing fluid, a suspension of coating particles in water overflows into the basin  18  and is directed to a particle filter  36 . The filtrate contains no solvents or resinous material, so it can be discharged via drainpipe  38  through the floor without treatment, as municipal wastewater. Preferably, the drained, filtered liquid is recycled or recirculated as source fluid S, and indicated by the dashed line  38 ′. 
     A series of tests was performed with equipment substantially as shown in  FIG. 1 . A non-diazo based, photopolymerizable, solvent soluble, negative working, UV and IR sensitive coating was applied in a conventional manner to a grained and anodized aluminum substrate. The plate is available from Anocoil Corporation, Rockville, Conn., as Type N-100. The coating weight was 100 mg/ft 2 , drawn down with a wire wound stainless steel rod, and dried for two minutes at 90° C. All plates had a topcoat of PVOH at 140 mg/ft 2 . A first set of newspaper plates were imaged at 100 mj/cm 2  at IR wavelength and sprayed with tap water. A second set of identical newspaper plates were imaged with UV radiation at each of 200, 100, and 50 mj/cm 2 . Each plate was subjected to a nozzle spray of unheated tap water having a 30-40 deg. fan shape producing a narrow rectangular impact pattern that was about 3 to 4 inches in length and less then about ½ inch wide, at a distance of about 1 to 4 inches from the nozzle discharge orifice. Pressure in the delivery line was varied between about 200 psi up to about 1000 psi. 
     These tests confirmed that, with both IR and UV imaging at 1200 dpi in the commercially typical range of 75 to 150 mj/cm 2 , tap water developer at a pressure in line  26  above 200 psi, and with the nozzle maneuvered at about 1 to 4 inches from the plate for a total development time of under one minute, excellent results were obtained. 
     The following table contains descriptions of representative coating constituents for UV and IR sensitive plates similar to the N-100 plates on which preliminary tests were performed and which are expected to be developed satisfactorily with the present invention. 
     
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 
               
             
             
               
                   
               
               
                 Representative Coating Constituents 
               
             
          
           
               
                   
                 #1 
                 #2 
                 #3 
                 #4 
               
               
                   
                   
               
             
          
           
               
                   
                 Meth. Prop  (a)   
                 92.39% 
                 91.99% 
                 92.27% 
                 92.40% 
               
               
                   
                 Sartomer 399  (b)   
                  2.31% 
                  2.31% 
                  2.31% 
                  1.84% 
               
               
                   
                 Clariant Poly 
                  0.46% 
                  0.46% 
                  0.46% 
                  0.92% 
               
               
                   
                 123  (c)   
               
               
                   
                 Triazine AC  (d)   
                  0.45% 
                  0.45% 
                  0.45% 
                  0.45% 
               
               
                   
                 DTTDA  (e)   
                  0.00% 
                  0.40% 
                  0.00% 
                  0.00% 
               
               
                   
                 4-HBSA  (f)   
                  0.00% 
                  0.00% 
                  0.12% 
                  0.00% 
               
               
                   
                 KF-1151  (g)   
                  0.05% 
                  0.05% 
                  0.05% 
                  0.05% 
               
               
                   
                 Pigment Disp  (h)   
                  4.34% 
                  4.34% 
                  4.34% 
                  4.34% 
               
               
                   
                   
                 100.0% 
                 100.0% 
                 100.0% 
                 100.0% 
               
               
                   
                   
               
               
                   
                   (a)  Solvent (1-Methoxy-2-Propanol, Propylene Glycol Methyl Ether available from Arco Chemical Company) 
               
               
                   
                   (b)  Monomer (Dipentaerythritol Monohydroxypentaacrylate available from Sartomer Company, West Chester, Penn.) 
               
               
                   
                   (c)  Polymer 
               
               
                   
                   (d)  Initiator 
               
               
                   
                   (e)  Solvent soluble, partially water soluble compound 
               
               
                   
                   (f)  Release Agent 
               
               
                   
                   (g)  Dye 
               
               
                   
                   (h)  Pigment 
               
             
          
         
       
     
     In general, the preferred composition comprises a non-aqueous solution of (a) a polymer, and one or both of an oligomer and monomer, capable of radically cross-linking with each other when the coating is exposed to imaging radiation, and (b) a non-polymerizable organic compound, wherein the non-polymerizable organic compound is also partially soluble in water such that after imaging of the dried coating as deposited on a substrate, the non-imaged areas are removable from the substrate surface by penetration of water through the non-imaged coating without dissolution of the cross linked polymer, monomer, and/or oligomer of the coating. Preferably, the polymer is selected from the group consisting of acrylates, siloxanes, and styrene maleic anhydrides; the monomer is selected from the group consisting of multifunctional acrylates; and the non-polymerizable organic compound is a substituted aromatic compound, such as DTTDA (an allyl amide derived from tartaric acid) or tetra methyl tartaramide. The non-polymerizable organic compound should have a measurable solubility in water greater than zero and less than 15%. 
     With reference now to  FIGS. 2-5 , more automated embodiments will be described. In such a system, a frame  40  or the like is situated above the plate  22  to be processed, and a spray nozzle  42  is mounted in a wand  44  that extends transversely to the plate longitudinal dimension. The plate  22  has a width W and a length L, and is continually translated longitudinally in a process direction  46 . The nozzle is reciprocable transversely to the process direction between limit positions  42 A and  42 B, as indicated at  48 , for discharging a moving spray  50 . Pneumatic, hydraulic, or electric actuators or motors can readily be employed for this purpose. The plates are translated either intermittently or continuously, as by nip rolls  52 ,  54 , at a substantially constant average speed. Distance H 1  between the discharge orifice of nozzle  42  and the surface of plate  22  is an important process parameter, and for a known plate thickness can be derived from the height H 2  between the nozzle orifice and the table  20 . 
     In the variation shown in  FIG. 4 , the nozzle deposits a rectangular strip  56  of water across the entire plate width while the plate is momentarily at rest, with the strip dimension  58  in the process direction of preferably 2-6 inches. The plate is then advanced an increment, and the nozzle makes an overlapping return pass, with the sequence continued until the entire plate surface  60  has been impacted by the spray. In essence, a sub area of the entire coated area  60  of the plate is continuously subjected to the instantaneous impact pattern  62  of the spray pattern  50 , with such impacted area  62  appearing to move along the plate surface until the entire plate surface  60  has been developed. The impact pattern  62  would generally be 2-6 inches along the length dimension L of the plate, and less then one inch along the width dimension W of the plate. 
     It can be appreciated that with an alternative embodiment, a plurality of stationary nozzles  42  are arranged side-by-side in the frame  40  along the width dimension W of the plate, such that all of strip  56  is impacted simultaneously, i.e., the high pressure water impact area  62  is over the entire strip  56 , which in  FIG. 4  has an impacted area of length  58  and width W. The plate moves continually, with the full-width strip  56  appearing to move along length direction L. 
     In the variation shown in  FIG. 5 , the plate is conveyed continuously in direction  46 , while the instantaneous spray impact pattern  62  is continuously reciprocated  48  across the width of the plate, thereby producing a zigzag of deposited strips over the plate  64  which successively overlap (as represented at  66 ) and which in the aggregate impact the entire surface  60  of the plate. 
     A test was performed with a prototype automated processor as represented in  FIGS. 2-5 , on 14 inch wide, thermally imaged (IR at about 90-100 mj/cm 2 ) newspaper plates having a coating of a type represented in the foregoing Table. The plates were conveyed at a rate of 4 ft/min. The topcoat was removed by prewashing to minimize the time required for the high pressure water stream to ablate the regions of low adhesion and cohesion. Unheated tap water at a line pressure of 1300 psi from a 5 hp pump was discharged through a nozzle at a distance H 1  of about one inch above the plate, producing an impact zone length of about 2-3 inches along the conveying direction. The nozzle cycled back and forth across the width of the plate every 1.5 seconds, producing overlapping strips of spray that covered the entire plate. Development ranged from excellent in the background and highlights to good in the deepest shadows. Optimization of nozzle distance, line pressure, spray pattern, nozzle raster speed, and plate conveying speed is expected to provide excellent results from background to shadows. 
     Another test was performed to determine image loss as between conventional and the inventive high pressure spray process. The conventional method used a common sump type processor with brushes employing a compounded developer containing an organic solvent and surfactants. 
     Procedure:
         1) Obtain three of the Anocoil N-100 IR and UV sensitive negative plates.   2) Use one of these plates to determine the basecoat weight prior to exposure and development.   3) Using a UV exposure frame, blanket expose (full image) the other two plates to 250 mj/cm 2  of UV energy.   4) After these plates have been exposed, develop one through the sump type processor using Anocoil Type S type developer (benzyl alcohol and surfactants) and the other using a prototype high pressure water spray processor.   5) After these plates have been developed determine what the remaining basecoat weight is using the same test employed in step #2.   6) Subtract the coat weight results from step #5 from the result of step #2 in order to determine the amount of image loss related to each of the development processes.       

     Results:
         a) Basecoat weight of unexposed/undeveloped plate—100 mg/ft 2      b) Image remaining after exposure and development in sump processor—91 mg/ft 2      c) Image remaining after exposure and development in spray processor—99 mg/ft 2      d) Image loss due to sump type development—9%   e) Image loss due to spray type development—1%       

     This test demonstrates that the image regions of a typically imaged coating should experience almost no material loss during high pressure water spray development. In a production environment, this means that the image (oleophilic) regions of the developed plate should retain substantially more of the original coating thickness and thus will achieve a greater useful life on-press relative to conventionally developed plates. 
     Practitioners in the relevant field can readily appreciate that more than one nozzle can be employed to develop a given plate. For example, two nozzles can reciprocate collinearly under a single frame, each covering approximately one half the width W of a plate. Alternatively, two frames spaced apart in the process direction, each with one reciprocating nozzle, can span the width of the plate. 
     Similarly, one or both of the nozzle size and line pressure can be modified according to the type of plates to be processed. In general, the main operative factor is impact force of the water on the imaged coating. At relatively lower nozzle discharge pressures, the conveying speed should be low (e.g., about 3 ft/min) and the nozzle should be relatively close to the plate (e.g., 1 to 2 inches) such that the impact force is high but over a relatively small impact area on the plate. At a relatively higher nozzle discharge pressures, the nozzle can be farther from the plate (e.g., 2 to 4 inches) while maintaining a high impact force over a relatively larger area of the plate. At higher conveying speeds (e.g., 5 or 6 ft/min) the pressure could be up to about 1800 psi or more. As will be described below, a tradeoff can be achieved according to which pressure can be reduced if water temperature is increased. 
     At low pressures, the impingement zone on the plate will generally be within ¼ to 2 in 2 , with the nozzle less than about 4 inches from the plate, and an effective plate conveyance speed of at least 2 ft/min. At intermediate pressures, the impingement zone on the plate would be ½ to 2 in 2 , with the nozzle less then about 3 inches from the plate, and an effective plate conveyance speed of 3-5 ft/min. in a high pressure implementation, the impingement zone on the plate would be up to about one square inch, with the nozzle less then about 2 inches from the plate, and an effective plate conveyance speed up to about 6 ft/min. 
       FIGS. 6A-F  present the results of tests performed with the same equipment as the previously described tests, on similarly coated plates subjected to varying magnitudes of water spray pressure and water temperature, but with a 2 hp pressurizing pump. The standard screen values are shown in the left most columns, and the measured screen values over a representative range of temperatures (70, 90, 115, and 130 deg. F.) at a specified spray pressure are shown in the data columns. Good plate development can match the standard screen within +/−1% over the range from 99% shadow dot down to 2% highlight dot. 
     The two tests (70 deg. F.) near ambient temperature were at pressures of 1600 and 1800 psi. These produced good results over the full screen value range of 2% to 99%. Similar good results were produced at the substantially reduced pressure of 1200 psi, when the water temperature was raised to 90 deg. F. This relationship between pressure and temperature effects provides a technique for optimizing a processor system for particular production requirements. 
     The data table for the seemingly best condition (1200 psi@90 deg. F., holding 2% target highlights at 1.7% and 99% target shadows at 99.4%) shows that as the temperature increases at constant pressure, the measured highlights and shadow dots both generally decrease. The data tables for constant temperature of 115 deg. F. show that as pressure increase from 800 psi to 1800 psi, the measured highlight dots for the 2% target and the 99% shadows both decrease. The tables support a suitable design window defined by water temperature in the range of about 80-115 deg. F. and spray discharge pressure in the range of about 800-1400 psi, with the preferred window defined by a pressure in the range of about 1000-1200 psi and a temperature in the range of about 90-115 deg. F. 
     A comparison of the tests performed with tap water and heated water show that satisfactory results can be obtained with tap water, but using heated water offers tradeoffs that can be advantageous. For example, with almost the same equipment on the same type of plates, satisfactory results can be obtained at 1200 psi with both tap water (about 55-60 deg. F.) and water heated to about 95 deg. F. However, the latter results can be achieved with a 2 hp pump vs. a 5 hp pump, i.e., with less than half the power and a commensurate reduction in the flow rate. 
     It should be appreciated that other hardware and process steps can be employed for generating a high pressure spray pattern of sufficient impact force, aiming the spray onto a plate, and moving one or both of the spray and plate until the entire plate surface has been covered. Not all coatings that can be developed with only high pressure water, have as yet been identified. Accordingly, the accompanying claims should not be limited to the preferred and other representative embodiments described herein.