EP0038385A1 - Metallüberzogene Kunststoff-Intaglio-Druckzylinder und -Druckplatten, Verfahren und Apparat - Google Patents

Metallüberzogene Kunststoff-Intaglio-Druckzylinder und -Druckplatten, Verfahren und Apparat Download PDF

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Publication number
EP0038385A1
EP0038385A1 EP80301218A EP80301218A EP0038385A1 EP 0038385 A1 EP0038385 A1 EP 0038385A1 EP 80301218 A EP80301218 A EP 80301218A EP 80301218 A EP80301218 A EP 80301218A EP 0038385 A1 EP0038385 A1 EP 0038385A1
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EP
European Patent Office
Prior art keywords
cylinder
plastic
base
plastic base
shaft
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP80301218A
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English (en)
French (fr)
Inventor
Karl D. Bardin
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Individual
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Individual
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Publication date
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Priority to EP80301218A priority Critical patent/EP0038385A1/de
Publication of EP0038385A1 publication Critical patent/EP0038385A1/de
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F13/00—Common details of rotary presses or machines
    • B41F13/08—Cylinders
    • B41F13/10—Forme cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41C—PROCESSES FOR THE MANUFACTURE OR REPRODUCTION OF PRINTING SURFACES
    • B41C1/00—Forme preparation
    • B41C1/18—Curved printing formes or printing cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N1/00—Printing plates or foils; Materials therefor
    • B41N1/04—Printing plates or foils; Materials therefor metallic
    • B41N1/06—Printing plates or foils; Materials therefor metallic for relief printing or intaglio printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41N—PRINTING PLATES OR FOILS; MATERIALS FOR SURFACES USED IN PRINTING MACHINES FOR PRINTING, INKING, DAMPING, OR THE LIKE; PREPARING SUCH SURFACES FOR USE AND CONSERVING THEM
    • B41N1/00—Printing plates or foils; Materials therefor
    • B41N1/16—Curved printing plates, especially cylinders
    • B41N1/20—Curved printing plates, especially cylinders made of metal or similar inorganic compounds, e.g. plasma coated ceramics, carbides

Definitions

  • This invention relates to intaglio and gravure printing cylinders and plates, and more particularly to low cost, plastic based, metal surface cylinders and plates and the manufacture thereof.
  • intaglio or rotogravure printing is obtained from cylinders mounted to rotate about their central axis with the outer peripheral surface of the cylinders having been etched with the particular information to be printed.
  • the prior art cylinders generally comprise an outer peripheral layer of copper which when ground and polished to the exact desired diameter is then etched in order to carry the particular information to be printed.
  • the prior art cylinders themselves generally comprise seamless tubing of steel or iron which has been cut to length and counterbored at its ends for the receipt of mounting gudgeons.
  • the gudgeons are secured to the tubing in a variety of methods, such as welding, bolting, etc. with shafts extending from the center of the gudgeons in order to mount the resulting cylindrical drum.
  • the cylinder with the gudgeons and shaft is then mounted in a plating tank so that the entire outer peripheral surface of the cylinder is plated.
  • the copper surface is polished until the exact diameter required in the printing machine is obtained. Then, the image transfer ready cylinder is engraved or etched by one of a variety of well known methods, thereby embedding the desired information into the cylindrical surface. Finally, the cylinder is mounted in the rotogravure printing apparatus and printing is initiated.
  • the rotogravure printing process has long been known as a process having low waste, flexibility and unexcelled quality in the resulting print.
  • this process has only been employed generally for long run production, because of the extremely high cost for the production of cylindrical bases.
  • rotogravure printing process One of the inherent features of the rotogravure printing process is its ability to print a complete 360 degrees while also being able to produce an infinitely variable repeat of information, within the capabilities of the machinery, onto - a roll of paper without any mismatch or registry problem, since the cylinder can be etched about its entire periphery if so required by the design.
  • the rotogravure printing process is presently employed in the production of wallpaper, wrapping paper, printed boxes, package wrappers, as well as catalogues and magazines (as examples of publication and commercial printing applications), and other similar long run continuous patterned printed product lines where .large rolls of paper or substrate can be continuously printed without interruption.
  • Ballard discloses the typical prior art rotogravure cylinders which employ solid metal cylindrical bases, or thick walled metal cylindrical shells, with the etchable metal affixed thereto.
  • Trzyna and Hunn do not disclose an isotonic and isotropic plastic base construction which is capable of meeting the standards and criteria for an operative rotogravure printing cylinder.
  • Trzyna the cylindrical core material was formed in place while Hunn discloses a carveable plastic cylinder for making a relief-type surface.
  • Neither disclosure is capable of teaching a cylindrically-shaped molded plastic supportive base capable of performing as a base of a rotogravure printing cylinder.
  • Barker a flat plastic supporting base is taught which is directly etched in order to provide a printing master. This is completely divergent from the teaching of the present invention wherein plastic is employed as a supporting base only and is not directly etched. Furthermore, the plastic base of the present invention is surrounded with an etchable metal into which the printing information is etched.
  • the first generation or original plate is produced in a solid sheet of pure copper having a thickness ranging generally between 0.020 and 0.125 inches, and consequently, are heavy and expensive. Due to the high cost of investment required for a gravure plate to be etched or engraved, there is a complete lack in the industry of an image ready transfer gravure plate which could be maintained as a stock item ready for direct engraving and immediate use.
  • Another object of this invention is to provide rotogravure or intaglio printing cylinders having the characteristic features defined above which are perfectly balanced and uniformly concentric.
  • Another object of this invention is to provide rotogravure or intaglio printing cylinders having the characteristics defined above, which resist bending during the printing process at every point about the periphery of the cylinders.
  • Another object of the invention is to provide rotogravure or intaglio printing cylinders having the characteristics defined above which are easily handled during assembly in the printing equipment.
  • a further object of the invention is to provide rotogravure or intaglio printing cylinders having the characteristics defined above which can be manufactured in any desired length and can accommodate any diameter rotation-inducing shaft.
  • Another object of this invention is to provide gravure or intaglio printing cylinders having the characteristic. features defined above which accommodate end-mounted driving means which eliminates the use of gudgeons.
  • Another object of this invention is to provide gravure or intaglio printing plates which can be maintained as a stock item ready for direct engraving or etching and immediate use when required.
  • the rotogravure or intaglio printing cylinder of the present invention eliminates all of the prior art difficulties by providing a molded plastic base cylinder of substantially the size and shape of the rotogravure cylinder required, which is plated about its entire peripheral surface with either copper or nickel and then etched.
  • polypropylene is employed as the plastic for the cylinder.
  • the cylinder is provided with a single bore along the central axis of the cylinder to accommodate the rotation-inducing shaft of the printing apparatus.
  • Another embodiment employs axially extending arcuately disposed fingers or lugs which engage the ends of the cylinder and are mounted to a rotationally driven plate.
  • a cylinder is commercially obtainable, having perfect balance and perfect concentricity about its central axis.
  • This heretofore unobtainable result is now realized by providing a molded plastic base which comprises both isotonic and isotropic distribution of the plastic throughout the cylindrical base. Since the isotonic and isotropic bases are stress and void free, every point on the outer peripheral surface of the cylinder exhibits precisely identical compression resistant forces.
  • the cylinder base is plastic
  • the cylinder base of the present invention is easily and economically machined to have an outer peripheral surface which is perfectly concentric with the central axis of the cylinder.
  • a rotogravure or intaglio printing cylinder which is extremely lightweight and easily handled.
  • the molded plastic base cylinder is preferably either driven by a bore through the central axis of the cylinder at a diameter equal to the driving shaft diameter or by end driving plates.
  • the resulting rotogravure or intaglio printing cylinder which is obtained after coating and engraving or etching, incorporates a uniform cross-sectional area throughout its length at right angles to the central axis, and a constant uniform material density throughout-the-entire cylinder, completely stress and void free. Consequently, every point on the outer peripheral surface of the cylinder has exactly the same amount of resistance to buckling or deformation as every other point thereof.
  • Another advantage of the cylinder of the present invention is its ability to easily withstand the high pressures which result during the printing process without any deformation at any point of the cylinder. This same result is also achieved with an even lighter plastic cylinder by carefully engineering the amount and position of the material removed for the weight relief, while still maintaining the structural integrity of the cylinder itself.
  • the rotogravure printing cylinder of the present invention incorporates a base material capable of being manufactured by pouring, casting, or extruding the plastic material in a suitable mold or die, a large variety of different diameters and lengths can be easily obtained. Also, any desired driving shaft size can be accommodated by merely boring the base cylinder to the desired diameter. As a result, all requirements for varying diameters and lengths for any particular printing operation can be achieved quickly and inexpensively.
  • the gravure plate of the present invention overcomes all of the prior art objections by providing an inexpensive, easily handled, plastic base with an etchable metal surface.
  • the plastic base is extruded in a single sheet having the desired thickness, plated with an etchable metal, and then cut to the particular size required.
  • an image ready transfer plate is provided which can be maintained as a stock item, ready for direct engraving or etching of the desired image or information into the etchable metal surface and immediate use of the resulting gravure plate.
  • the gravure process is capable of achieving color variation by altering both the area of the etching and the depth of the etching.
  • This capability in the gravure process provides superior tonal variation control than is obtainable with raised surface printing wherein only the area can be varied to achieve the tonal variations.
  • the gravure process is extremely advantageous but heretofore had only been employable for a specific product line because of the expense and difficulty of obtaining and setting a gravure press.
  • this high-quality printing process can be used in a greater variety of applications wherein the use of the process up till now would not have been feasible.
  • the invention accordingly comprises the several steps and the relation of one or more such steps with respect to each of the others, and the articles possessing the features, properties, and relation of elements, which are exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
  • the rotogravure cylinder 20 of the present invention is shown mounted on a typical rotogravure printing machine 22.
  • Cylinder 20 incorporates an outer peripheral surface 26 in which a design or image 28 has been etched.
  • Design 28 is etched on surface 26 of cylinder 20 throughout the entire outer peripheral surface thereof, or as otherwise required by the art work. For simplicity, only a portion of design 28 is shown.
  • impression roller 24 In juxtaposed spaced relationship to cylinder 20 is impression roller 24 which is in intimate contact with rotogravure cylinder 20 during the printing operation.
  • Cylinder 20 is partially immersed in an ink tray 25 and is in frictionally engagement with a doctor blade 27, which wipes off the excess-ink returning this-excess to ink tray 25.
  • the web of substrate or paper 29 to be printed passes between rotogravure cylinder 20 and impression roller 24 and is maintained in firm intimate contact with cylinder 20 by properly adjusting roller 24.
  • the rotogravure printing process is extremely advantageous since the depth of the etching on the surface is controllably varied as well as the area of the etching, in order to control tonal variations of the printed material.
  • the intimate contact of the substrate or paper 29, upon which the printing is placed, with cylinder 20 is extremely important in order to assure the transfer of all available ink to the printing surface and to achieve the tonal variations obtainable from the cylinder.
  • impression roller 24 must maintain constant force and pressure on the rotogravure cylinder 20 with printing paper 29 moving therebetween, in order to assure the desired printed result.
  • impression roller 24 maintains a constant force of about 150 pounds per linear inch against the printing cylinder 20. This force is dependent upon the material being printed and may range between about 50 and 300 pounds per linear inch.
  • Impression roller 24 generally comprises a metal tube 60, which incorporates bearings for rotation, with a natural or synthetic rubber or other synthetic material covering 61.
  • the radial thickness of covering 61 generally ranges between 1/4 of an inch to 1 inch with 3/8 of an inch being typical.
  • covering 61' has a hardness between 60° and 90°, measured on the Shore A scale, with a Shore hardness of 80° being typical.
  • plastic base 30 of this invention is shown prior to plating, with keyway bore 32 incorporated therein extending along the central axis of cylinder 30.
  • plastic base cylinder 30 is manufactured by casting or pouring polypropylene in a mold of the desired diameter which may incorporate a tapered plug for providing keyway shafting bore 32.
  • the cylinder can be manufactured by extrusion of the plastic through a suitable die.
  • the first method is in situ in which a mold or suitable cavity is filled with dry resin. Then, the mold and resin unit is slowly brought to the melt temperature and then slowly cooled down. If desired, vacuum may be used in order to remove air bubbles.
  • the second preferred method is a casting process in which the resin is first pre-melted and degassed in an extruder.or similar apparatus, and then the plastic resin melt is poured into a suitable mold or cavity which has been preheated. The entire cavity and resin unit must be insulated and allowed to slowly cool down. Again, vacuum may be desirable in order to remove air bubbles.
  • the final process in which a suitable plastic base cylinder can be economically produced is through extrusion.
  • the plastic resin is pre-melted and extruded through a suitable die into an insulated receiver.
  • the extruded product must be annealed after cooling in order to release stresses. If care is not exercised both in the cooling process and in the annealing process, shrink voids may form which, of course, would render the cylinder totally ineffective.
  • cylinder 30 is removed and trimmed to the exact diameter desired for the cylinder prior to plating. Also, as is more fully described below, it is desirable to form rounded corners 34 at both ends of the cylinder during the trimming operation in order to prevent any plating build-up in these areas.
  • a universally applicable base cylinder is formed, without a shaft bore, since the shaft bore if so desired can easily be machined during the trimming operation.
  • This procedure is preferred since (1) shaft diameters vary, (2) a precision sized bore can most economically be achieved by boring the shaft-receiving hole after the molding operation; and (3) alternative driving methods may be desired.
  • the shafting bore is preferable constructed with a concentricity of -0.0005 inches. In this way, the requisite balance is achieved.
  • polypropylene provided the most unique combination of characteristics for use as the cylinder base.
  • polypropylene has a low molecular weight, is solvent resistant, has sufficient hardness, is platable, can be easily molded, can be easily machined, is strong and is of relatively low cost.
  • Another plastic material which has been found to also have sufficient combination of characteristics to be usable as the cylinder is polyphenylene sulfide. Other plastics could be employed but are believed to be less desirable.
  • fillers As is well known in the art, by incorporating fillers into the plastic material during the molding process, additional specific characteristics may be obtained.
  • One of the advantages that can be achieved by employing fillers in the molded plastic material is that the adhesion and platability of the plastic can be enhanced. Also the mechanical properties or physical characteristics of the plastic can also be enhanced. Generally, such fillers as glass, carbon, asbestos, metallic flakes, or silica are employed.
  • fillers is not mandatory for the successful plating of the plastic cylinder of this invention since the entire outer surface of the cylinder is plated. As a result, the use of fillers is not required. In fact, the use of fillers is not suggested for the cylinder of this invention, unless the filler is homogeneously distributed throughout the entire plastic cylinder. This arrangement is preferred, since the plastic cylinder of the present invention can best be utilized by manufacturing a generally required diameter and machining the diameter down to the desired specifications. As a result, if only surface fillers are employed, the effect of the filler will not be obtained if the cylinder diameter is machined below the effective depth of the filler.
  • fillers is more desirable in the construction of the metal-plated, plastic-base-printing plate of this invention.
  • surface fillers which promote the adhesion of an etchable metal to its surface may be very useful since adhesion becomes an important factor when encapsulation of the entire plastic base is not anticipated.
  • the plastic base cylinder of the present invention is preferably manufactured in a single molding operation as an entire homogeneous cylinder which is then machined to the desired outer diameter and also machined to incorporate the desired driving system, which incorporates, in the two preferred embodiments, a cylindrically shaped, elongated shafting bore along the central axis of the cylinder.
  • one embodiment of the driving system for the rotogravure cylinder of the present invention is the use of the keyway bore 32 through which a cooperating shaft is mounted-in order to drive cylinder 20 of the present invention.
  • keyway bore 32 is preferred for its simplicity of manufacture and use, various potential problems may develop during its use.
  • cylinder 20 of the present invention depends upon the successful power transmission from the rotationally inducing drive source to surface 26 of cylinder 20, with sufficient consistency and dependability to overcome the force of the friction drive of impression roller 24 and cause the printing media 29 to be frictionally driven therebetween. Since cylinder 20 is driven along its center line, it is necessary to transmit and distribute the driving forces from the center line of the drive shaft out through base 30 to surface 26 where the rotary shear forces are induced at the interface between cylinder 20 and impression roller 24.
  • base 30 incorporates a plurality of lug-receiving cavities 60' formed in both ends of base 30, along with a plate receiving cavity 63 similarly formed on both ends of base 30 and cooperating with lug-receiving cavities 60.
  • the actual number of lug receiving cavities 60 which are formed in base 30 and their precise position depends upon both the design considerations and force requirements to which the cylinder will be exposed.
  • each lug-receiving cavity is preferably formed in base 30 at the optimum radial distance from the center line of base 30.
  • the optimum radial spacing for the lug-receiving cavities depends.upon many factors such as base material, driving forces required, base diameter, and diameter of alternate bases to be driven by same equipment. With these major factors in mind, the optimum lug cavity position is determined and then formed in the ends of the base with extreme precision.
  • Base 30 also incorporates an elongated shaft receiving bore 64 extending entirely through base 30.
  • shaft receiving bore 64 comprises a concentricity of ⁇ 0.0005 inches.
  • This embodiment of the driving system of the present invention is then completed by providing an elongated shaft 65, a fixed driving flange 61, and an adjustably positionable lockable driving flange 66.
  • Shaft 65 is manufactured with concentricity tolerances identical to shaft receiving bore 64 and a diameter to which shafting receiving bore 64 was made. In this way, a rotationally driven shaft is provided along which cylinder 30 can be mounted in order to achieve an intrinsically balanced cylinder construction.
  • Flange 61 is securely mounted to shaft 65 and incorporates a substantially flat plate member 67 and a plurality of outwardly projecting lugs 62 which are securely journaled in or mounted to plate 67.
  • the actual radial position of lug 62 about plate 67 and the arcuate distances between the lugs is a matter of design choice, as discussed above in reference to lug-receiving cavities 62 of base 30.
  • a typical lug construction and arrangement is shown in Figure 9.
  • lug-receiving cavities 60 and plate receiving cavity 63 are constructed to be identically compatible with lugs 62 and plate 67, base 30 when mounted on shaft 65 is moved axially along shaft 65 until each lug 62 is securely positioned within a lug-receiving cavity 60 and plate 67 is securely contained in plate receiving cavity 63 at the first end of base 30.
  • the driving system is then completed and ready for a successful driving operation by securely positioning adjustably positionable, lockable flange system 66 in position with lugs 62 of plate 68 thereof securely retained in lug-receiving cavities 60 and plate 68 secured in plate receiving cavity 63 at the other end of base 30.
  • driving flanges 61 and 66 are securely positioned in their receiving cavities ready for rotationally driving base 30, flange 66 is locked in position, and the rotogravure cylinder of the present invention is ready for operation.
  • multi-positionable, lockable flange assembly 66 also comprises a locknut 70, a threaded extension member 71, journaled in plate 68 and extending therefrom in a direction opposite from lugs 62, and an adjustable, slidable, collar assembly 72.
  • Collar assembly 72 comprises a split ring, shaft engaging collar - and a screw locking means 73 for securely locking collar 72 in any position along shaft 65.
  • the sliding and locking flange assembly 66 is secured and locked in any desired position by first adjustably sliding flange assembly 66 along shaft 65 until lugs 62 and plate 68 are securely positioned within their respective cavities. Then, screw means 73 is tightened causing the arms of split ring collar 72 to advance towards each other, and securely and lockingly engage shaft 65. The flange locking is then completed by rotating locknut 70 in the direction causing plate 68 to advance axially into base 30 against locked collar assembly 72, thereby assuring secure receiving cavities.
  • plastic base 30 will not in any way affect its performance as an operative rotogravure printing cylinder.
  • the plastic base rotogravure printing cylinder of the present invention provides a variety of important benefits heretofore unattainable with prior art systems.
  • the major benefits obtained with the cylinder of the present invention is the attainment of an intrinsically balanced rotogravure cylinder which is both dynamically and statically balanced.
  • the plastic base possesses an inherent quality of self-lubrication, which allows a closely toleranced shaft bore construction while still providing an easily achievable slide fit of the shaft through the cylinder's shaft bore regardless of the length of the cylinder.
  • the present.invention achieves an image-ready rotogravure cylinder base which can be easily adapted to any printing press journal configuration without any variation in the basic design of the cylinder itself.
  • the plastic base cylinder is ready for plating. It has been found that a variety of metals can be electrodeposited upon the plastic base cylinder, with copper plating preferred for its low cost and ease of workability.
  • the plating process can best be understood by referring to Figures 3 and 6 wherein plastic base cylinder 30 is shown mounted for rotation in electrolyte reservoir 36.
  • Plastic base cylinder 30 is mounted on a titanium shaft 38 which is connected for rotating plastic base cylinder 30 in electrolyte reservoir 36.
  • current-conduction presented no difficulty since the base material was metallic.
  • the use of plastic base cylinder 30 presents additional problems since the plastic is in of itself non-conductive.
  • the preferred anode employed are bar copper anodes 44 which are located parallel to the face of base cylinder 30. It has been found that the best plating is attained by employing anodes parallel and equidistant to-the axis of the cylinder.
  • base cylinder 30 is rotated by means of the titanium shaft 38 which can be controlled by any suitable.variable speed motor drive through drive connection 45.
  • the electrolyte tank in which electrolyte 36 is contained may be independent of base cylinder 30, titanium shaft 38, and the various driving and current conducting equipment. In this way, the tank can be mounted on a lifting device which allows the tank and its contained electrolyte to be raised up to base cylinder 30 in order to permit immersion of base cylinder 30 up to 50% or more of its diameter during the electrodepositing process. Although this arrangement is not required, the flexibility achieved has been found to be advantageous.
  • intaglio printing cylinder 20 comprises a cylinder incorporating a shafting bore 32, a plastic base cylinder 30 and an outer peripheral metal deposited coating 46, which encapsulates the plastic base and is ready for final polishing and etching.
  • metal-plated coating 46 is of a sufficient depth to exceed the exact outer diameter requirement for the rotogravure or intaglio printing cylinder.
  • cylinder 20 is then polished to impart the desired surface characteristics to metal plating 46 while also achieving the precise diameter desired in the particular rotogravure printing system.
  • cylinder 20 which is at this time an image transfer ready cylinder is then sent for etching of the particular information on to metal-plated surface 46 in order to impart the particular printing information to cylinder 20.
  • the etchable metal coating comprises a thickness of at least 0.010 inches and no greater than 0.040 inches. Furthermore, the metal surface should have a hardness of at least 140 Vickers when measured on the Vickers Scale.
  • the plating processes comprise first conditioning the peripheral surface of the plastic cylinder with various conditioning agents in order to establish a surface which is readily receptive of the metal being electrodeposited. Once the surface is properly conditioned, the cylinder is placed in an electrolytic plating bath in order to deposit a thin coating of the etchable metal on the surface of the cylinder. This electrolytic plating, if employed, renders the previously non-conductive surface conductive. Then, the cylinder is mounted as described above in the electrolyte reservoir and rotated while the etchable metal is plated about the entire exposed surface of the plastic base cylinder.
  • the metal plated plastic base cylinder is polished to the exact diameter desired for the particular rotogravure process, and the image transfer ready cylinder is then engraved or etched with the desired image or information, and is then ready for use in the printing equipment.
  • the outer surface of the plastic base is first treated with a conditioning solution which develops sites on the plastic surface where bonds between the-plastic and-the copper deposit may be established.
  • the conditioning agent also renders the plastic surface wettable by the subsequent electrolytic copper solution.
  • the surface is treated with an acid bath and then further treated with additional surface preparation solutions.
  • additional solutions further enhances the plastic surface for the subsequent plating by making the surface more receptable to the formation of an adherent, fine-grain metallic deposit.
  • the surface can be treated with a solution which deposits a thin metallic film on the surface of the plastic in order to further promote the deposition of the desired adherent, fine-grain, metal deposit..
  • the cylinder is placed in an electrolytic copper bath to establish a thin copper coating on the cylinder surface. In this way, the previously non-conductive surface becomes conductive.
  • the cylinder is mounted in a copper electro-plating bath and rotated, as described above, until the desired thickness of copper has been deposited on the entire exposed surface of the plastic base cylinder.
  • the copper surface is then treated in a manner well known in the art in order to provide a clean, bright copper surface ready for polishing and etching.
  • the typical plastic polymer for the cylindrical base of the present invention has a thermal expansion co-efficient of "6" at 25°C-100°C and, according to the Handbook of Chemistry and Physics, copper has a thermal expansion co-efficient of "16.8" at 25°C-100°C.
  • an adhesion of 9.6 pounds per inch has been found to be sufficient to permit normal thermal cycling without any detachment problems.
  • This normal thermal cycling includes temperature changes through all stages of manufacture, elevated warehouse temperatures encountered during storage, and temperature rises encountered in the printing press due to friction or contact with a hot substrate.
  • 9.6 pounds per inch has been found to be preferred, at similar adhesion would be within the scope of this disclosure, as well as vastly different adhesion rates, when alternative materials or conditions are employed.
  • the first step in the process is to treat the surface of the plastic base cylinder of the present invention with Enplate Conditioner 474 at 150°F. for 20 minutes. This is then followed by a water rinse.
  • the second step is to additionally treat the surface of the plastic base cylinder of this invention with 20% hydrochloric acid (by volume) for one minute followed by a water rinse. Then the plastic base cylinder is treated with Enplate Sensitizer 432 for one minute, water rinsed, and then treated with Enplate Activator 440 for one.minute followed by a water rinse.
  • the plastic base cylinder is then placed in the electrolytic plating bath which contains Enplate Electrolytic Copper Cu-404 and maintained in this bath for 15 minutes and then water rinsed. Then the cylinder is placed in sulfuric acid, 5 per cent by volume, for one minute and water rinsed.
  • the fully treated and coated cylinder is then mounted on a titanium shaft and secured on the shaft in position with the various collars and associated conductive material mounted on the shaft on both ends of the cylinder, as fully described above.
  • the entire assembly is then secured for rotation in the electrolyte tank which contains Enthobrite Cu-942.
  • the cylinder is rotated in the copper electrolyte until the desired thickness of copper is built-up on the exposed cylinder surface. Generally, a surface coating of about 0.015 inches is desirable.
  • the resulting copper plated plastic based cylinder is then water rinsed, dried, and treated in the manner well known in the art for providing the copper plate with the desired finished qualities.
  • the image transfer ready cylinder of this invention is completed, ready for etching or engraving in the conventional manner to produce the rotogravure printing cylinder of this invention.
  • the attainment of an operative rotogravure printing cylinder having a gravure metallic surface totally supported by a plastic base possesses numerous advantages over prior art cylinders, many of which have been discussed throughout this Application.
  • the major advantages achieved by the present invention are (1) a substantial reduction in weight, (2) perfect intrinsically obtained balance, both dynamically and statically, (3) repeatable economic manufacturability of support base with isotonic and isotropic qualities, (4) handling ease, (5) maintenance of precision-level tolerances with ease and reproducibility, (6) self-lubricating qualities for slidability of precision-made shaft through shaft bore regardless of length of cylinder, (7) deflection resistance, and (8) adaptability to any printing press configuration without modification of basic cylinder design.
  • the rotogravure printing cylinder of the present invention with a driving system capable of delivering these unique'advantageous qualities to a printing press.
  • the combination of the plastic base cylinder and the proper driving system assures rotational driving of the plastic base rotogravure printing cylinder of this invention, in a rotogravure printing press with all of the pressures, frictional forces, and long running operational requirements being attained and all of the prior art difficulties eliminated.
  • the cylindrical plastic supporting base of this invention Among the most important physical characteristics obtained by the cylindrical plastic supporting base of this invention are its isotonic and isotropic qualities. 'By achieving a supporting base which is reproduceably and economically manufactured with stress and void free characteristics in combination with complete, total homogeneity of the support material throughout the entire cylindrical base, the plastic supporting base of this invention establishes an intrinsically balanced cylinder, which realizes deflection- free operation under the pressure loads encountered in rotogravure printing.
  • both embodiments of the intaglio and rotogravure printing cylinder 20 incorporates a precision made shaft bore, which extends axially along the entire length of printing cylinder 20.
  • a precision made shaft bore which extends axially along the entire length of printing cylinder 20.
  • each and every vertical cross-section of the cylinder 20 which is taken perpendicularly through the shafting bore will result in identical cross-sectional areas, since the entire printing cylinder 20 is isotropic, comprising an identical composition density throughout its entire length.
  • cylinder 20 is isotonic being completely stress and void free. Consequently, the pressure applied to cylinder 20 during the printing operation will have identical resisting-forces-at every point on the outer peripheral surface of cylinder 20. In this way, any areas which may otherwise result in buckling or forced deformation during the printing operation are completely eliminated.
  • cylinder 20 comprises a printing cylinder capable of thoroughly and completely resisting all of the compressive forces placed thereon during the printing operation without any deformation or buckling of the printing surface.
  • This "built-in" force resistance of cylinder 20 is extremely important in assuring that the superior advantages of rotogravure printing such as tonal variation control, high production, long continuous operation, and infinitely variable repeat information, can be achieved with the inexpensive, easily- handled cylinder of this invention..
  • this achievement provides a more desirable print quality, imparts greater confidence in the printing cylinder for constant and consistent printing results throughout the entire length of the run, and allows other heretofore unthought-of printed product lines to employ the rotogravure cylinder of this invention at an economical cost.
  • Rotogravure cylinder bases are generally manufactured to performance specifications based on the classic formula for calculating deflection in a simple beam, uniformly loaded. This formula is as follows:
  • the other important variable in this formula is the modulus of elasticity, since the modulus of elasticity of the plastic base is about 1/10 of the modulus of elasticity of a steel base. It has been found that by providing the isotonically distributed cylindrical plastic base of this invention with its stress and void free characteristics with a modulus of elasticity of at least 250,000 psi, the plastic base rotogravure printing cylinder of this invention will perform as a rotogravure cylinder wherein maximum deflection under dynamic conditions will not result in loss of print quality due to unequal pressures.
  • the achievement of this result is also dependent upon the shaft bore having a concentricity of ⁇ 0.0005 inches to the outer circumference for a slide fit of the steel shaft, which is typically and preferably fabricated from AlS1 C1045 hot rolled carbon steel or grade with similar properties, with the plastic base cylinder having electrodeposited circumferential shell of copper with a thickness of between .010 inches and..040 inches and a hardness of 140 Vickers measured on the Vickers Scale.
  • the plastic based rotogravure cylinder of this invention provides a rotogravure cylinder capable of achieving the operative standards placed upon rotogravure printing systems regardless of the force requirements and pressure demands of the rotogravure printing press.
  • a garvure or intaglio plate image ready transfer 50 of this invention is shown with an etchable metal surface 51 mounted to plastic base 52.
  • plastic base 52 may comprise various plastics, however, polypropylene has been found to be best suited for use as the base plastic.
  • One of the major advantages of polypropylene, which is particularly significant with the use of plate 50, is the resistance polypropylene has to the degrading action of the inks employed in the printing process. Since metal surface 51 is preferably secured to only the top surface of base 52, the ink may well come into contact with plastic base 52 about the edges thereof.
  • the use of a plastic, such as polypropylene which has a physical characteristic extremely resistant to degradation by the ink, is an extremely significant factor which must be considered when selecting the particular plastic base.
  • Plastic base 52 may be formed in a variety of plastic forming processes. However, it has been found that the formation of plastic base.52 by extrusion provides the most economical manufacturing method. Once the extruded elongated piece of plastic has been formed, the plastic base is plated with the etchable metal, cut to the desired size, and surface finished if required.
  • plastic base 52 the etachable metal is then secured to the top surface of plastic base 52.
  • various methods of depositing or securing etchable metal 51 to plastic base 52 are possible. Basically, the various processes can be divided into two most distinct techniques. One technique would be to electrodeposit a film of copper, or other etchable metal, onto the surface of plastic base 52, using a process similar to that detailed above. The other technique would be to employ a pre-formed sheet of copper, or other suitable etchable metal which is cut to a desired size, and intimately bond the copper sheet to plastic base 52.
  • etchable metal- surface 51 has been intimately secured to plastic base 52, the metal surface is then polished in order to provide the surface with the desired surface characteristics. Then, as described above, the particular image or information to be printed is directly engraved or etched into metal plate 51 in order to provide a gravure plate ready for operation.
  • the gravure plate of this invention is covered with photo-resist after the plating and polishing operation.
  • image ready transfer plate 50 will be responsive to ultraviolet light, upon exposure, in order to quickly and easily produce a gravure plate having the desired information or image therein.
  • the - photo-resist can be eliminated in order to provide image ready transfer plate 50 which is ready for direct etching or engraving, by other processes, whenever so required by the user.
  • gravure plates presently employed in the industry do not have the flexibility and inexpensive characteristics which are inherent in the gravure plate of the present invention. Because of the extremely high cost in manufacturing and producing the present day gravure plate, no such plate is capable of being maintained as a stock item and must be specially ordered for specific product lines.
  • an inexpensive, easily handled, readily available gravure plate is achieved which can be maintained as a stock item in a plurality of sizes.
  • an image transfer ready plate can be stocked and directly etched or engraved when its use is required, in order to quickly and efficiently attain the gravure plate needed for immediate production. In this way, greater flexibility and useability of gravure plates can be attained and the quality of work inherent in the gravure process can be expanded into areas where the use of this quality process has never been economically feasible.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Printing Plates And Materials Therefor (AREA)
  • Manufacture Or Reproduction Of Printing Formes (AREA)
EP80301218A 1980-04-14 1980-04-14 Metallüberzogene Kunststoff-Intaglio-Druckzylinder und -Druckplatten, Verfahren und Apparat Withdrawn EP0038385A1 (de)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP80301218A EP0038385A1 (de) 1980-04-14 1980-04-14 Metallüberzogene Kunststoff-Intaglio-Druckzylinder und -Druckplatten, Verfahren und Apparat

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP80301218A EP0038385A1 (de) 1980-04-14 1980-04-14 Metallüberzogene Kunststoff-Intaglio-Druckzylinder und -Druckplatten, Verfahren und Apparat

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EP0038385A1 true EP0038385A1 (de) 1981-10-28

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2198085A (en) * 1986-11-29 1988-06-08 Stc Plc Printing apparatus and process
EP0384104A1 (de) * 1989-02-23 1990-08-29 Erminio Rossini S.P.A. Verfahren zur Herstellung von Kunststoffzylindern zum Drucken, insbesondere zum Rakeltiefdruck und Flexodruck und der so erhaltene Zylinder
FR2654676A1 (fr) * 1989-11-21 1991-05-24 Francille Jean Procede de reconditionnement d'un cylindre d'imprimerie et cylindre ainsi obtenu.
EP0623466A2 (de) * 1993-04-19 1994-11-09 Hoechst Aktiengesellschaft Druckwalze mit einer Hülse aus thermisch gewickelten faserverstärkten Thermoplasten und einer plasmagespritzten Kupfer- oder Kupferlegierungsbeschichtung
WO2000059727A1 (en) * 1999-04-07 2000-10-12 Hyperlast Limited Improved gravure printing rollers
WO2003047873A3 (en) * 2001-11-28 2003-10-30 Starbase Ag Printing cylinder manufacture
WO2015162299A1 (en) 2014-04-25 2015-10-29 Meton Gravure Technologies, Ltd Rotogravure printing system and the preparation and use thereof

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Publication number Priority date Publication date Assignee Title
BE498872A (de) * 1949-11-16
US1906738A (en) * 1931-12-14 1933-05-02 Francis J Carroll Printing roller
FR1495785A (fr) * 1965-10-04 1967-09-22 Groove & Welter Plaque d'impression formée de métal et de matière synthétique assemblés
DE1471701A1 (de) * 1964-03-06 1969-02-20 Basf Ag Verfahren zum Herstellen von Druckformen
DE1917115A1 (de) * 1968-04-02 1969-10-23 Union Carbide Corp Druckplatte
FR1591240A (de) * 1968-11-04 1970-04-27
US3598050A (en) * 1968-07-18 1971-08-10 Int Machine Prod Inc Mounting means for a printing roll and associated driving apparatus
GB1290413A (de) * 1969-09-15 1972-09-27 Stauffer Chemical Co
US3820460A (en) * 1970-12-28 1974-06-28 Elreath C Mc Electrotype magnetic printing plate
DE2433612A1 (de) * 1974-07-12 1976-01-29 John Mark Blundell Druckplattenanordnung
DE2433713A1 (de) * 1974-07-12 1976-01-29 John Mark Blundell Schichtmaterial zur herstellung von druckplatten
FR2338805A1 (fr) * 1976-01-26 1977-08-19 Dow Chemical Co Plaques pour la photogravure et procede pour leur confection

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US1906738A (en) * 1931-12-14 1933-05-02 Francis J Carroll Printing roller
BE498872A (de) * 1949-11-16
US3544319A (en) * 1964-03-06 1970-12-01 Basf Ag Production of printing plates
DE1471701A1 (de) * 1964-03-06 1969-02-20 Basf Ag Verfahren zum Herstellen von Druckformen
FR1495785A (fr) * 1965-10-04 1967-09-22 Groove & Welter Plaque d'impression formée de métal et de matière synthétique assemblés
DE1917115A1 (de) * 1968-04-02 1969-10-23 Union Carbide Corp Druckplatte
US3598050A (en) * 1968-07-18 1971-08-10 Int Machine Prod Inc Mounting means for a printing roll and associated driving apparatus
FR1591240A (de) * 1968-11-04 1970-04-27
GB1290413A (de) * 1969-09-15 1972-09-27 Stauffer Chemical Co
US3820460A (en) * 1970-12-28 1974-06-28 Elreath C Mc Electrotype magnetic printing plate
DE2433612A1 (de) * 1974-07-12 1976-01-29 John Mark Blundell Druckplattenanordnung
DE2433713A1 (de) * 1974-07-12 1976-01-29 John Mark Blundell Schichtmaterial zur herstellung von druckplatten
FR2338805A1 (fr) * 1976-01-26 1977-08-19 Dow Chemical Co Plaques pour la photogravure et procede pour leur confection
US4136615A (en) * 1976-01-26 1979-01-30 The Dow Chemical Company Pattern plate of composite structure

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Title
IBM TECHNICAL DISCLOSURE BULLETIN vol. 12, no. 7, December 1963 New York, US H.K. JOHNSTON et al. "Direct or reverse printing plate and method of making and using the same", page 1022 *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2198085A (en) * 1986-11-29 1988-06-08 Stc Plc Printing apparatus and process
GB2198085B (en) * 1986-11-29 1991-02-13 Stc Plc Printing apparatus and process
EP0384104A1 (de) * 1989-02-23 1990-08-29 Erminio Rossini S.P.A. Verfahren zur Herstellung von Kunststoffzylindern zum Drucken, insbesondere zum Rakeltiefdruck und Flexodruck und der so erhaltene Zylinder
AU622809B2 (en) * 1989-02-23 1992-04-16 Erminio Rossini S.P.A. Method for producing plastics cylinders for printing in general, in particular for rotogravure and flexography, and the cylinder obtained
FR2654676A1 (fr) * 1989-11-21 1991-05-24 Francille Jean Procede de reconditionnement d'un cylindre d'imprimerie et cylindre ainsi obtenu.
EP0623466A2 (de) * 1993-04-19 1994-11-09 Hoechst Aktiengesellschaft Druckwalze mit einer Hülse aus thermisch gewickelten faserverstärkten Thermoplasten und einer plasmagespritzten Kupfer- oder Kupferlegierungsbeschichtung
EP0623466A3 (de) * 1993-04-19 1994-11-17 Hoechst Aktiengesellschaft Druckwalze mit einer Hülse aus thermisch gewickelten faserverstärkten Thermoplasten und einer plasmagespritzten Kupfer- oder Kupferlegierungsbeschichtung
US5468568A (en) * 1993-04-19 1995-11-21 Hoechst Aktiengesellschaft Printing roller with a sleeve of thermally wound fiber-reinforced thermoplastics and a plasma-sprayed coating of copper or copper alloy
WO2000059727A1 (en) * 1999-04-07 2000-10-12 Hyperlast Limited Improved gravure printing rollers
WO2003047873A3 (en) * 2001-11-28 2003-10-30 Starbase Ag Printing cylinder manufacture
WO2015162299A1 (en) 2014-04-25 2015-10-29 Meton Gravure Technologies, Ltd Rotogravure printing system and the preparation and use thereof
US10391759B2 (en) 2014-04-25 2019-08-27 Paramount International Services Ltd. Rotogravure printing system and the preparation and use thereof

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