EP0623466A2 - Printing roller with a sleeve of hot, wound fibre-reinforced, thermoplastic material and a plasma-sprayed copper, or copper alloy coating - Google Patents
Printing roller with a sleeve of hot, wound fibre-reinforced, thermoplastic material and a plasma-sprayed copper, or copper alloy coating Download PDFInfo
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- EP0623466A2 EP0623466A2 EP19940105693 EP94105693A EP0623466A2 EP 0623466 A2 EP0623466 A2 EP 0623466A2 EP 19940105693 EP19940105693 EP 19940105693 EP 94105693 A EP94105693 A EP 94105693A EP 0623466 A2 EP0623466 A2 EP 0623466A2
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- European Patent Office
- Prior art keywords
- printing roller
- copper
- roller according
- sleeve
- thermoplastic
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Classifications
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- 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
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
- Y10T428/1355—Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
- Y10T428/1359—Three or more layers [continuous layer]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
Definitions
- the invention relates to a pressure roller with a core cylinder and a removable sleeve.
- massive steel rollers are usually electroplated with a copper layer that has a layer thickness in the range from 0.2 to 3.0 mm.
- the engraving required for the gravure printing process can be introduced into this copper layer either chemically, mechanically or with the aid of laser technology.
- the object of the present invention was to provide a printing roller for the intaglio printing process, which allows the functional profile to be changed without great technical effort using the sleeve technology.
- the entire roller should not be replaced, but only a sleeve in order to achieve shorter machine downtimes combined with less effort for the storage and transport of steel rollers and greater flexibility in operation.
- the present invention solves this problem by a pressure roller of the type mentioned in the introduction, in which the sleeve comprises a tubular base body made of a thermoplastic fiber-reinforced plastic material and in which the base body is coated on its outer surface with a layer of copper or a copper alloy produced by plasma spraying.
- the plastic matrix of the thermoplastic fiber-reinforced plastic material is preferably melted by the action of heat, so that the individual layers are welded to one another while maintaining the fiber-matrix distribution of the thermoplastic fiber-reinforced plastic material in the base body while simultaneously forming a homogeneous matrix-rich surface.
- thermoplastic fiber-reinforced material contains carbon, glass, aramid, metal, ceramic, boron or other fibers as continuous or long fibers. Any combination of different fiber materials within the base body is also possible.
- the matrix system consists of thermoplastics, such as, for example, polypropylene (PP), polyamides (PA) such as polyhexamethylene adipamide or poly- ⁇ -caprolactam, high-pressure or low-pressure polyethylene (PE), polyphenylene sulfide (PPS), polycarbonate (PC), polyoxymethylene (POM) , Polyetheretherketonen (PEK) or from thermoplastic polyesters, such as Polyethylene terephthalate (PET) or polybutylene terephthalate (PBT).
- PP polypropylene
- PA polyamides
- PE polyhexamethylene adipamide or poly- ⁇ -caprolactam
- PE polyethylene
- PPS polyphenylene sulfide
- PC polycarbonate
- POM polyoxymethylene
- PEK Polyetheretherketonen
- PET Polyethylene terephthalate
- PBT polybutylene terephthalate
- thermoplastic fiber-reinforced material is in the form of impregnated tapes or fabrics.
- the fiber content is 30 to 80% by weight, preferably 50 to 75% by weight.
- These tapes are produced, for example, by melt, powder or suspension impregnation using the pultrusion process.
- a carrier which is e.g. can consist of metal, several layers of a thermoplastic fiber-reinforced material applied and consolidated online.
- the carrier is set in rotation and wrapped with the thermoplastic fiber-reinforced material, which is in the form of one or more ribbons or fabrics.
- the winding angle can be variably set in a range from 0 ° to ⁇ 90 °.
- the plastic matrix of the fiber composite tape is brought into a molten state by the action of heat, for example with the aid of a gas burner.
- a further likewise fiber-reinforced thermoplastic material with a high matrix content can be applied to the carrier both before and after the application of the fiber-reinforced thermoplastic material described above.
- the fiber content of this second material is significantly lower than that of the first material and is preferably 1 to 30% by weight, particularly preferably 5 to 15% by weight.
- a very homogeneous matrix-rich surface is achieved in this way. Subsequent mechanical processing of the base body is considerably facilitated in this way, since due to the matrix-rich surface during subsequent mechanical processing of the base body, in particular by turning or grinding, there is no risk that near-surface fiber layers will be severed, which leads to weakening and distortion of the main body would lead.
- thermoplastic film strip is used instead of a second low-fiber thermoplastic material applied to the first material, which is also heat-welded to the fiber-rich material.
- a very homogeneous, smooth, matrix-rich surface is achieved.
- the surface is preferably smoothed with a device that has non-stick properties.
- the basic body described above advantageously has a particularly high precision with regard to its geometric dimensions.
- a 1 meter long molded body with a diameter of 100 mm and a wall thickness of ⁇ 3 mm can be manufactured with a wall thickness tolerance of ⁇ 0.3 mm, preferably ⁇ 0.2 mm.
- the plasma-sprayed copper layer is applied directly to the matrix-rich outer surface of the base body.
- the surface is first subjected to a roughening process without the surface geometry being changed significantly.
- the surface is preferably treated with a sandblasting process in preparation for the application of the copper layer.
- the surface can be roughened with sandblasting equipment, preferably mineral blasting material such as fine-grained aluminum oxide, zirconium corundum, etc. being suitable as the abrasive.
- Preferred blasting conditions are a blasting pressure in the range from 1 to 3 bar, a grain size in the range from 20 to 200 ⁇ m, a distance from the nozzle to the surface to be treated in the range from 90 to 120 mm and a movement of the nozzle over the treated surface at a speed in the range of 0.5 to 1 m / sec.
- the micro surface roughness R a of the base body treated in this way is in the range from 6 to 10 ⁇ m, measured in accordance with DIN 4768.
- the macrostructure remains unchanged, there are no fiber breakouts in the surface.
- the roughening process is expediently followed by a cleaning process Compressed air or in an aqueous cleaning bath, if necessary with the help of ultrasound.
- the cleaning process ensures within the scope of the invention that any impurities still present on the surface are effectively removed.
- copper and copper alloys are applied by thermal spraying of powdery material with a particle diameter D50 of ⁇ 20 ⁇ m.
- plasma spraying and high-speed flame spraying are preferably used.
- the nature of the copper powder is matched to the different thermal spray processes.
- the copper powder preferably has a grain size D50 in the range from 8 to 12 ⁇ m, which is determined by the Cilas laser diffraction analysis method.
- the phosphorus content of the copper or copper alloy is in the range from 0.08 to 0.15% and is determined photometrically, while the oxygen content is in the range from 0.2 to 0.3% and is determined by hot extraction in an inert gas stream.
- a phosphorus content of preferably 0.10 to 0.12% as deoxidizing agent has positive effects on the oxidation behavior of the applied copper layer.
- copper alloys can also be used, e.g. Copper-zinc, copper-tin, copper-aluminum, copper-nickel or copper-nickel-zinc, which also contain other alloy components such as May contain iron, manganese, silicon or lead.
- an inert gas or an inert gas mixture is used as the plasma gas, preferably argon in an amount in the range from 30 to 60 l / min.
- the electrical power of the plasma torch is preferably 10 to 15 kW, particularly preferably 12 kW.
- the burner is moved past the rotationally symmetrical base body at a distance in the range from 40 to 100 mm, preferably from 40 to 70 mm, at a speed of 10 to 100 mm / min.
- an application rate in the range of 2 to 8 kg / h is achieved.
- the base body is preferably cooled during the coating process in order to keep the oxide formation low and to prevent internal stresses both in the coating and in the base body.
- CO2 is preferably used in fine crystalline form at a high pressure of approximately 40 to 60 bar.
- the microgranule of the copper powder means that the plasma process can be operated at low energy.
- a carrier made of highly heat-conducting metal, for example aluminum By pulling the base body onto a carrier made of highly heat-conducting metal, for example aluminum, good heat dissipation is achieved during the coating.
- Copper layers which are applied as described above can have a layer thickness in the range from 50 to 500 ⁇ m, preferably from 100 to 300 ⁇ m, the thickness uniformity fluctuating only by 5 to 10%.
- the application in one layer means that the layer has no oxidic intermediate layers.
- the copper layer can be machined particularly well to a dimensionally accurate body by turning. Non-porous, uniform surfaces with roughnesses of R a ⁇ 0.1 ⁇ m are achieved.
- the copper layer is structured mechanically or with the help of laser technology.
- the sleeve can be positively fitted onto a pressure cylinder, for example made of metal.
- the tape laying speed was 0.3 m / s, with a tape tension of 50 N / mm2.
- the plastic matrix of the fiber composite tape was put into a molten state using a gas burner.
- the matrix-rich surface was then roughened by sandblasting to apply the copper layer.
- Electro-corundum an aluminum oxide powder with a proportion of 3% titanium dioxide and a grain size in the range from 63 to 149 ⁇ m, was used as the radiation medium.
- the jet pressure was 2 bar with a jet spacing of 80 mm and with a jet nozzle diameter of 4 mm. After roughening, the surface was cleaned with cleaned compressed air.
- the surface of the base body treated in this way was coated by plasma spraying with a copper powder with a grain size D50 in the range from 8 to 10 ⁇ m. Argon was used as the plasma gas.
- the burner output was 12 kW and the burner was at a distance of 60 mm at a speed of 100 mm / min above that at a speed of 300 rpm rotating base body moved away.
- the surface of the base body was cooled in the area of the plasma flame with CO2 under a pressure of 60 bar and non-stick material was removed by blasting with CO2 snow.
- the copper layer produced in this way had a layer thickness of 300 ⁇ m.
- the copper surface could be machined very well with polycrystalline diamond. After a reduction in diameter of 0.15 mm, a pore-free surface with a roughness Ra of 0.1 microns was reached, measured according to DIN 4768. The mold was deviation of the finished sleeve 0.02 mm, while their positional deviation was 0.03 mm, respectively determined according to DIN ISO 1101.
- the sleeve thus produced was removed pneumatically from the metal carrier with compressed air and stored for a period of 4 weeks. Then the sleeve was pulled back onto the carrier and gave the same shape and position deviation as in the original production.
- FIG. 1 shows a printing roller in an oblique view.
- the pressure roller 1 is highlighted and the core cylinder 2 with a bore 3 for the pneumatic removal of the sleeve made of fiber-reinforced thermoplastic base body 4 with the copper layer 5 can be seen in the enlargement.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Inorganic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Rolls And Other Rotary Bodies (AREA)
- Coating By Spraying Or Casting (AREA)
- Laminated Bodies (AREA)
Abstract
Description
Die Erfindung betrifft eine Druckwalze mit einem Kernzylinder und einer abnehmbaren Hülse.The invention relates to a pressure roller with a core cylinder and a removable sleeve.
Für das Tiefdruckverfahren werden üblicherweise massive Stahlwalzen galvanisch mit einer Kupferschicht, die eine Schichtdicke im Bereich von 0,2 bis 3,0 mm besitzt, überzogen. In diese Kupferschicht läßt sich die für das Tiefdruckverfahren notwendige Gravur entweder chemisch, mechanisch oder mit Hilfe der Lasertechnik einbringen.For the gravure printing process, massive steel rollers are usually electroplated with a copper layer that has a layer thickness in the range from 0.2 to 3.0 mm. The engraving required for the gravure printing process can be introduced into this copper layer either chemically, mechanically or with the aid of laser technology.
Im Bereich des Flexodruckes hat sich die Hülsentechnik bewährt, bei der mit abziehbaren Hülsen aus Nickel oder duroplastischen Faserverbundwerkstoffen, die zusätzlich noch mit Gummi beschichtet werden, gearbeitet wird. Die Hülsen werden auf den Walzenkern aus Metall pneumatisch aufgezogen und können nach Gebrauch leicht wieder entfernt werden. Für das Tiefdruckverfahren ist diese Technik bislang aber noch nicht gangbar, weil geeignete Hülsen mit einer mechanisch bearbeitbaren Kupferschicht bisher noch nicht bereitgestellt werden konnten.In the field of flexographic printing, the sleeve technology has proven itself, in which work is carried out with removable sleeves made of nickel or thermosetting fiber composite materials, which are additionally coated with rubber. The sleeves are pneumatically mounted on the metal roller core and can be easily removed after use. However, this technique has not yet been feasible for gravure printing because suitable sleeves with a mechanically machinable copper layer have not yet been able to be provided.
Aufgabe der vorliegenden Erfindung war es eine Druckwalze für das Tiefdruckverfahren bereitzustellen, welche es erlaubt, ohne großen technischen Aufwand nach der Hülsentechnik einen Wechsel des Funktionsprofils vorzunehmen. Dabei soll nicht die komplette Walze ausgetauscht werden, sondern nur eine Hülse, um damit geringere Maschinenstandzeiten zu erreichen in Kombination mit geringerem Aufwand für die Lagerhaltung und den Transport von Stahlwalzen und einer höheren Flexibilität im Betrieb.The object of the present invention was to provide a printing roller for the intaglio printing process, which allows the functional profile to be changed without great technical effort using the sleeve technology. The entire roller should not be replaced, but only a sleeve in order to achieve shorter machine downtimes combined with less effort for the storage and transport of steel rollers and greater flexibility in operation.
Die vorliegende Erfindung löst diese Aufgabe durch eine Druckwalze der eingangs genannten Gattung, bei der die Hülse einen rohrförmigen Grundkörper aus einem thermoplastischen faserverstärkten Kunststoffmaterial umfasst und bei dem der Grundkörper auf seiner äußeren Oberfläche mit einer durch Plasmaspritzen erzeugten Schicht aus Kupfer oder einer Kupferlegierung überzogen ist.The present invention solves this problem by a pressure roller of the type mentioned in the introduction, in which the sleeve comprises a tubular base body made of a thermoplastic fiber-reinforced plastic material and in which the base body is coated on its outer surface with a layer of copper or a copper alloy produced by plasma spraying.
Vorzugsweise ist die Kunststoffmatrix des thermoplastischen faserverstärkten Kunststoffmaterials durch Hitzeeinwirkung aufgeschmolzen, so daß die einzelnen Lagen unter Erhalt der Faser-Matrixverteilung des thermoplastischen faserverstärkten Kunststoffmaterials im Grundkörper unter gleichzeitiger Bildung einer homogenen matrixreichen Oberfläche miteinander verschweißt sind.The plastic matrix of the thermoplastic fiber-reinforced plastic material is preferably melted by the action of heat, so that the individual layers are welded to one another while maintaining the fiber-matrix distribution of the thermoplastic fiber-reinforced plastic material in the base body while simultaneously forming a homogeneous matrix-rich surface.
Das thermoplastische faserverstärkte Material enthält Kohlenstoff-, Glas-, Aramid-, Metall-, Keramik-, Bor- oder auch andere Fasern als Endlos- oder Langfasern. Eine beliebige Kombination verschiedener Fasermaterialien innerhalb des Grundkörpers ist ebenfalls möglich.The thermoplastic fiber-reinforced material contains carbon, glass, aramid, metal, ceramic, boron or other fibers as continuous or long fibers. Any combination of different fiber materials within the base body is also possible.
Das Matrixsystem besteht erfindungsgemäß aus thermoplastischen Kunststoffen, wie beispielsweise Polypropylen (PP), Polyamiden (PA) wie Polyhexamethylenadipinsäureamid oder Poly-ε-caprolactam, Hochdruck- oder Niederdruckpolyethylen (PE), Polyphenylensulfid (PPS), Polycarbonat (PC), Polyoxymethylen (POM), Polyetheretherketonen (PEK) oder aus thermoplastischen Polyestern, wie z.B. Polyethylenterephthalat (PET) oder Polybutylenterephthalat (PBT).According to the invention, the matrix system consists of thermoplastics, such as, for example, polypropylene (PP), polyamides (PA) such as polyhexamethylene adipamide or poly-ε-caprolactam, high-pressure or low-pressure polyethylene (PE), polyphenylene sulfide (PPS), polycarbonate (PC), polyoxymethylene (POM) , Polyetheretherketonen (PEK) or from thermoplastic polyesters, such as Polyethylene terephthalate (PET) or polybutylene terephthalate (PBT).
Das thermoplastische faserverstärkte Material liegt in Form von imprägnierten Bändern oder Geweben vor. Der Faseranteil beträgt 30 bis 80 Gew.-%, vorzugsweise 50 bis 75 Gew.-%. Die Herstellung dieser Bänder (Tapes) erfolgt z.B. durch Schmelze-, Pulver- oder Suspensionsimprägnierung im Pultrusionsverfahren.The thermoplastic fiber-reinforced material is in the form of impregnated tapes or fabrics. The fiber content is 30 to 80% by weight, preferably 50 to 75% by weight. These tapes are produced, for example, by melt, powder or suspension impregnation using the pultrusion process.
Zur Herstellung von Grundkörpern der erfindungsgemäßen Art, werden auf einen Träger, welcher z.B. aus Metall bestehen kann, mehrere Lagen eines thermoplastischen faserverstärkten Materials aufgebracht und online konsolidiert. Hierzu wird der Träger in Rotation versetzt und mit dem thermoplastischen faserverstärkten Material, welches in Form von einem oder mehreren Bändern oder Geweben vorliegt, umwickelt. Der Wickelwinkel läßt sich variabel in einem Bereich von 0° bis ± 90° einstellen.For the production of base bodies of the type according to the invention, a carrier which is e.g. can consist of metal, several layers of a thermoplastic fiber-reinforced material applied and consolidated online. For this purpose, the carrier is set in rotation and wrapped with the thermoplastic fiber-reinforced material, which is in the form of one or more ribbons or fabrics. The winding angle can be variably set in a range from 0 ° to ± 90 °.
Die Kunststoffmatrix des Faserverbundbandes ist durch Hitzeeinwirkung, beispielsweise mit Hilfe eines Gasbrenners, in einen schmelzflüssigen Zustand versetzt.The plastic matrix of the fiber composite tape is brought into a molten state by the action of heat, for example with the aid of a gas burner.
In einer besonderen Ausführungsvariante der Erfindung kann sowohl vor Aufbringen als auch nach dem Aufbringen des oben beschriebenen faserverstärkten thermoplastischen Materials auf den Träger ein weiteres ebenfalls faserverstärktes thermoplastisches Material mit einem hohen Matrixanteil aufgebracht werden. Der Faseranteil dieses zweiten Materials ist wesentlich geringer als der des ersten Materials und beträgt vorzugsweise 1 bis 30 Gew.-%, besonders bevorzugt 5 bis 15 Gew.-%.In a special embodiment variant of the invention, a further likewise fiber-reinforced thermoplastic material with a high matrix content can be applied to the carrier both before and after the application of the fiber-reinforced thermoplastic material described above. The fiber content of this second material is significantly lower than that of the first material and is preferably 1 to 30% by weight, particularly preferably 5 to 15% by weight.
Erfindungsgemäß wird auf diese Weise eine sehr homogene matrixreiche Oberfläche erzielt. Eine nachträgliche mechanische Bearbeitung des Grundkörpers wird auf diese Weise erheblich erleichtert, da aufgrund der matrixreichen Oberfläche bei einem nachträglichen mechanischen Bearbeiten des Grundkörpers, insbesondere durch Drehen oder Schleifen, nicht die Gefahr besteht, daß oberflächennahe Faserlagen durchtrennt werden, was zu einer Schwächung und einem Verzug des Grundkörpers führen würde.According to the invention, a very homogeneous matrix-rich surface is achieved in this way. Subsequent mechanical processing of the base body is considerably facilitated in this way, since due to the matrix-rich surface during subsequent mechanical processing of the base body, in particular by turning or grinding, there is no risk that near-surface fiber layers will be severed, which leads to weakening and distortion of the main body would lead.
In einer weiteren Ausführungsform der Erfindung ist anstelle eines zweiten faserarmen thermoplastischen Materials ein thermoplastisches Folienband auf das erste Material aufgebracht, das ebenfalls unter Hitzeeinwirkung mit dem faserreichen Material verschweißt ist. Erfindungsgemäß wird so eine sehr homogene, glatte, matrixreiche Oberfläche erzielt. Die Oberfläche wird bevorzugt mit einer Vorrichtung geglättet, die Antihafteigenschaften besitzt.In a further embodiment of the invention, a thermoplastic film strip is used instead of a second low-fiber thermoplastic material applied to the first material, which is also heat-welded to the fiber-rich material. According to the invention, a very homogeneous, smooth, matrix-rich surface is achieved. The surface is preferably smoothed with a device that has non-stick properties.
Der vorstehend beschriebene Grundkörper besitzt vorteilhafterweise eine besonders hohe Präzision in bezug auf seine geometrischen Abmessungen. So kann beispielsweise ein 1 Meter langer Formkörper mit einem Durchmesser von 100 mm und einer Wandstärke von ≦ 3 mm mit einer Wandstärkentoleranz von ± 0,3 mm, vorzugsweise ± 0,2 mm, gefertigt werden.The basic body described above advantageously has a particularly high precision with regard to its geometric dimensions. For example, a 1 meter long molded body with a diameter of 100 mm and a wall thickness of ≦ 3 mm can be manufactured with a wall thickness tolerance of ± 0.3 mm, preferably ± 0.2 mm.
Auf der matrixreichen äußeren Oberfläche des Grundkörpers ist die plasmagespritzte Kupferschicht direkt aufgebracht. Die Oberfläche wird dazu zunächst einem Aufrauhprozeß unterzogen, ohne daß deren Oberflächengeometrie stark verändert wird. Vorzugsweise wird die Oberfläche zur Vorbereitung auf die Auftragung der Kupferschicht mit einem Sandstrahlverfahren behandelt. Hierzu kann eine Aufrauhung der Oberfläche mit Sandstrahlgeräten vorgesehen sein, wobei als Strahlmittel vorzugsweise mineralisches Strahlgut wie feinkörniges Aluminiumoxid, Zirkonkorund u.a. in Frage kommen. Bevorzugte Strahlbedingungen sind dabei ein Strahldruck im Bereich von 1 bis 3 bar, eine Korngröße im Bereich von 20 bis 200 µm, ein Abstand der Düse zu der zu behandelnden Oberfläche im Bereich von 90 bis 120 mm und eine Bewegung der Düse über die behandelte Oberfläche hinweg mit einer Geschwindigkeit im Bereich von 0,5 bis 1 m/sec. Die Mikrooberflächenrauheit Ra des auf diese Weise behandelten Grundkörpers liegt im Bereich von 6 bis 10 µm, gemessen nach DIN 4768. Die Makrostruktur bleibt unverändert, es sind keine Faserausbrüche in die Oberfläche vorhanden.The plasma-sprayed copper layer is applied directly to the matrix-rich outer surface of the base body. For this purpose, the surface is first subjected to a roughening process without the surface geometry being changed significantly. The surface is preferably treated with a sandblasting process in preparation for the application of the copper layer. For this purpose, the surface can be roughened with sandblasting equipment, preferably mineral blasting material such as fine-grained aluminum oxide, zirconium corundum, etc. being suitable as the abrasive. Preferred blasting conditions are a blasting pressure in the range from 1 to 3 bar, a grain size in the range from 20 to 200 μm, a distance from the nozzle to the surface to be treated in the range from 90 to 120 mm and a movement of the nozzle over the treated surface at a speed in the range of 0.5 to 1 m / sec. The micro surface roughness R a of the base body treated in this way is in the range from 6 to 10 μm, measured in accordance with DIN 4768. The macrostructure remains unchanged, there are no fiber breakouts in the surface.
Zweckmäßigerweise folgt dem Aufrauhprozeß ein Reinigungsprozeß durch Druckluft oder in einem wäßrigen Reinigungsbad` gegebenenfalls mit Unterstützung durch Ultraschall. Durch den Reinigungsprozess wird im Rahmen der Erfindung sichergestellt, daß eventuell noch vorhandene Verunreingungen an der Oberfläche wirksam entfernt werden.The roughening process is expediently followed by a cleaning process Compressed air or in an aqueous cleaning bath, if necessary with the help of ultrasound. The cleaning process ensures within the scope of the invention that any impurities still present on the surface are effectively removed.
Das Auftragen von Kupfer und Kupferlegierungen erfolgt erfindungsgemäß durch thermisches Spritzen von pulverförmigem Werkstoff mit einem Teilchendurchmesser D₅₀ von ≦ 20 µm. Erfindungsgemäß kommen vorzugsweise das Plasmaspritzen und das Hochgeschwindigkeitsflammspritzen zum Einsatz. Die Beschaffenheit des Kupferpulvers wird auf die unterschiedlichen thermischen Spritzverfahren abgestimmt. Das Kupferpulver hat vorzugsweise eine Korngröße D₅₀ im Bereich von 8 bis 12 µm, die nach der Analysenmethode Laserbeugung Cilas bestimmt wird. Der Phosphorgehalt des Kupfers oder der Kupferlegierung liegt im Bereich von 0,08 bis 0,15 % und wird fotometrisch bestimmt während der Sauerstoffgehalt im Bereich von 0,2 bis 0,3 % liegt und durch Heißextraktion im Inertgasstrom bestimmt wird. Überraschend zeigte sich, daß ein Phosphorgehalt von vorzugsweise 0,10 bis 0,12 % als Desoxidationsmittel positive Auswirkungen auf das Oxidationsverhalten der aufgetragenen Kupferschicht ausübt. Neben reinem Kupfer können auch Kupferlegierungen verwendet werden, wie z.B. Kupfer-Zink, Kupfer-Zinn, Kupfer-Aluminium, Kupfer-Nickel oder Kupfer-Nickel-Zink, die zusätzlich weitere Legierungsbestandteile wie z.B. Eisen, Mangan, Silizium oder Blei enthalten können.According to the invention, copper and copper alloys are applied by thermal spraying of powdery material with a particle diameter D₅₀ of ≦ 20 μm. According to the invention, plasma spraying and high-speed flame spraying are preferably used. The nature of the copper powder is matched to the different thermal spray processes. The copper powder preferably has a grain size D₅₀ in the range from 8 to 12 μm, which is determined by the Cilas laser diffraction analysis method. The phosphorus content of the copper or copper alloy is in the range from 0.08 to 0.15% and is determined photometrically, while the oxygen content is in the range from 0.2 to 0.3% and is determined by hot extraction in an inert gas stream. Surprisingly, it was found that a phosphorus content of preferably 0.10 to 0.12% as deoxidizing agent has positive effects on the oxidation behavior of the applied copper layer. In addition to pure copper, copper alloys can also be used, e.g. Copper-zinc, copper-tin, copper-aluminum, copper-nickel or copper-nickel-zinc, which also contain other alloy components such as May contain iron, manganese, silicon or lead.
Bei dem Plasmaspritzverfahren wird als Plasmagas ein Inertgas oder eine Inertgasmischung verwendet, vorzugsweise Argon in einer Menge im Bereich von 30 bis 60 l/min. Die elektrische Leistung des Plasmabrenners beträgt bevorzugt 10 bis 15 kW, besonders bevorzugt 12 kW. Der Brenner wird an dem rotationssymmetrischen Grundkörper in einem Abstand im Bereich von 40 bis 100 mm, vorzugsweise von 40 bis 70 mm, mit einer Geschwindigkeit von 10 bis 100 mm/min vorbeibewegt. Unter derartigen Bedingungen wird eine Auftragsrate im Bereich von 2 bis 8 kg/h erreicht.In the plasma spraying process, an inert gas or an inert gas mixture is used as the plasma gas, preferably argon in an amount in the range from 30 to 60 l / min. The electrical power of the plasma torch is preferably 10 to 15 kW, particularly preferably 12 kW. The burner is moved past the rotationally symmetrical base body at a distance in the range from 40 to 100 mm, preferably from 40 to 70 mm, at a speed of 10 to 100 mm / min. Among such Conditions an application rate in the range of 2 to 8 kg / h is achieved.
Der Grundkörper wird während des Beschichtungsvorganges, um die Oxidbildung gering zu halten und um Eigenspannungen sowohl in der Beschichtung, als auch im Grundkörper vorzubeugen, vorzugsweise gekühlt. Zu diesem Zweck wird bevorzugt CO₂ in fein kristalliner Form bei einem hohen Druck von circa 40 bis 60 bar eingesetzt. Es ist zwar bekannt, daß CO₂ zur Kühlung beim thermischen Spritzen Verwendung findet, jedoch ist es für den Fachmann überraschend, daß gleichzeitig ein Strahlen der Oberfläche durch CO₂ stattfindet, wodurch erreicht wird, daß eine Einbettung stark oxidierter, störender Kleinstpartikel in die Beschichtung unterbunden wird.The base body is preferably cooled during the coating process in order to keep the oxide formation low and to prevent internal stresses both in the coating and in the base body. For this purpose, CO₂ is preferably used in fine crystalline form at a high pressure of approximately 40 to 60 bar. Although it is known that CO₂ is used for cooling in thermal spraying, it is surprising for the person skilled in the art that at the same time a radiation of the surface by CO₂ takes place, with the result that embedding of strongly oxidized, disruptive small particles in the coating is prevented .
Die Mikrokörnung des Kupferpulvers bewirkt, daß der Plasmaprozeß bei niederer Energie betrieben werden kann. Durch Aufziehen des Grundkörpers auf einen Träger aus gut wärmeleitendem Metall, beispielsweise Aluminium, wird eine gute Wärmeabfuhr während der Beschichtung erzielt. Kupferschichten, die wie vorstehend beschrieben aufgetragen sind, können in einem Arbeitsgang eine Schichtdicke im Bereich von 50 bis 500 µm aufweisen, vorzugsweise von 100 bis 300 µm, wobei die Dickengleichmäßigkeit nur noch um 5 bis 10 % schwankt. Die Auftragung in einer Lage bewirkt, daß die Schicht keine oxidischen Zwischenlagen aufweist. Die Kupferschicht läßt sich besonders gut zu einem maßgenauen Körper durch Drehen bearbeiten. Es werden porenfreie, gleichmäßige Oberflächen mit Rauheiten von Ra ≦ 0,1 µm erreicht.The microgranule of the copper powder means that the plasma process can be operated at low energy. By pulling the base body onto a carrier made of highly heat-conducting metal, for example aluminum, good heat dissipation is achieved during the coating. Copper layers which are applied as described above can have a layer thickness in the range from 50 to 500 μm, preferably from 100 to 300 μm, the thickness uniformity fluctuating only by 5 to 10%. The application in one layer means that the layer has no oxidic intermediate layers. The copper layer can be machined particularly well to a dimensionally accurate body by turning. Non-porous, uniform surfaces with roughnesses of R a ≦ 0.1 µm are achieved.
Für die fertige Druckwalze wird die Kupferschicht noch mechanisch oder mit Hilfe der Lasertechnologie strukturiert. Die Hülse kann formschlüssig auf einen Druckzylinder, z.B. aus Metall, aufgezogen werden.For the finished printing roller, the copper layer is structured mechanically or with the help of laser technology. The sleeve can be positively fitted onto a pressure cylinder, for example made of metal.
Ein Grundkörper aus Polyamid 6 mit 65 % Glasfaseranteil mit einem Innendurchmesser von 100 mm, einer Länge von 800 mm und einer Wanddicke von 1,8 mm wurde auf einem metallischen Träger aus Aluminium bei gleichmäßiger Rotation in einer Wickelmaschine hergestellt, indem zunächst das glasfaserverstärkte Polyamidmaterial in Umfangsrichtung in einem Winkel von nahezu 90°, bezogen auf die Achse des rotierenden Körpers, gewickelt wurde (= "90°-Lage"). Die Bandablegegeschwindigkeit betrug 0,3 m/s, bei einer Bandspannung von 50 N/mm². Die Kunststoffmatrix des Faserverbundbandes wurde mit Hilfe eines Gasbrenners in einen schmelzflüssigen Zustand versetzt.A base body made of polyamide 6 with 65% glass fiber content with an inner diameter of 100 mm, a length of 800 mm and a wall thickness of 1.8 mm was produced on a metallic carrier made of aluminum with uniform rotation in a winding machine by first the glass fiber reinforced polyamide material in Circumferential direction at an angle of almost 90 °, based on the axis of the rotating body, was wound (= "90 ° position"). The tape laying speed was 0.3 m / s, with a tape tension of 50 N / mm². The plastic matrix of the fiber composite tape was put into a molten state using a gas burner.
Nach den "90°-Lagen" wurden Kreuzwicklungen mit einem variablen Winkel von ± 55° aus einem Faserverbundwerkstoff aus Polyamid 6 mit 65 Gew. % Glasfaser aufgebracht und anschließend wurde die noch schmelzflüssige beziehungsweise plastifizierbare Matrix durch eine zusätzliche Andrück- und Glättungsrolle geglättet.After the "90 ° positions" cross windings with a variable angle of ± 55 ° were applied from a fiber composite material made of polyamide 6 with 65% by weight of glass fiber and then the still molten or plasticizable matrix was smoothed by an additional pressure and smoothing roller.
Die matrixreiche Oberfläche wurde dann zur Auftragung der Kupferschicht durch Sandstrahlen aufgerauht. Als Strahlungsmittel wurde Elektrokorund verwendet, ein Aluminiumoxidpulver mit einem Anteil von 3 % Titandioxid und einer Korngröße im Bereich von 63 bis 149 µm. Der Strahldruck betrug 2 bar bei einem Strahlabstand von 80 mm und bei einem Strahldüsendurchmesser von 4 mm. Nach dem Aufrauhen wurde die Oberfläche mit gereinigter Druckluft gereinigt. Die so behandelte Oberfläche des Grundkörpers wurde durch Plasmaspritzen mit einem Kupferpulver mit einer Korngröße D₅₀ im Bereich von 8 bis 10 µm beschichtet. Als Plasmagas wurde Argon verwendet. Die Brennerleistung betrug 12 kW und der Brenner wurde in einem Abstand von 60 mm mit einer Geschwindigkeit von 100 mm/min über den mit einer Drehzahl von 300 U/min rotierenden Grundkörper hinwegbewegt. Die Oberfläche des Grundkörpers wurde dabei im Bereich der Plasmaflamme mit CO₂ unter einem Druck von 60 bar gekühlt und nicht haftendes Material durch Strahlen mit CO₂-Schnee entfernt.The matrix-rich surface was then roughened by sandblasting to apply the copper layer. Electro-corundum, an aluminum oxide powder with a proportion of 3% titanium dioxide and a grain size in the range from 63 to 149 μm, was used as the radiation medium. The jet pressure was 2 bar with a jet spacing of 80 mm and with a jet nozzle diameter of 4 mm. After roughening, the surface was cleaned with cleaned compressed air. The surface of the base body treated in this way was coated by plasma spraying with a copper powder with a grain size D₅₀ in the range from 8 to 10 μm. Argon was used as the plasma gas. The burner output was 12 kW and the burner was at a distance of 60 mm at a speed of 100 mm / min above that at a speed of 300 rpm rotating base body moved away. The surface of the base body was cooled in the area of the plasma flame with CO₂ under a pressure of 60 bar and non-stick material was removed by blasting with CO₂ snow.
Die so hergestellte Kupferschicht hatte eine Schichtdicke von 300 µm. Die Kupferoberfläche ließ sich sehr gut mit polykristallinem Diamant mechanisch bearbeiten. Nach einer Durchmesserverringerung von 0,15 mm wurde eine porenfreie Oberfläche mit einer Rauheit Ra von 0,1 µm erreicht, gemessen nach DIN 4768. Die Formabweichung der fertigen Hülse betrug 0,02 mm, während ihre Lageabweichung 0,03 mm betrug, jeweils bestimmt nach DIN ISO 1101.The copper layer produced in this way had a layer thickness of 300 μm. The copper surface could be machined very well with polycrystalline diamond. After a reduction in diameter of 0.15 mm, a pore-free surface with a roughness Ra of 0.1 microns was reached, measured according to DIN 4768. The mold was deviation of the finished sleeve 0.02 mm, while their positional deviation was 0.03 mm, respectively determined according to DIN ISO 1101.
Die so hergestellte Hülse wurde pneumatisch mit Druckluft von dem Metallträger entfernt und über einen Zeitraum von 4 Wochen gelagert. Dann wurde die Hülse erneut auf den Träger aufgezogen und ergab die gleiche Form- und Lageabweichung wie bei der urprünglichen Herstellung.The sleeve thus produced was removed pneumatically from the metal carrier with compressed air and stored for a period of 4 weeks. Then the sleeve was pulled back onto the carrier and gave the same shape and position deviation as in the original production.
Zur noch deutlicheren Veranschaulichung der Neuerung ist eine Figur beigefügt, die eine Druckwalze in schräger Ansicht zeigt. Mit Bezugszeichen ist die Druckwalze 1 hervorgehoben und in der Vergrößerung ist der Kernzylinder 2 mit einer Bohrung 3 zur pneumatischen Entfernung der Hülse aus faserverstärktem thermoplastischem Grundkörper 4 mit der Kupferschicht 5 zu erkennen.For an even clearer illustration of the innovation, a figure is attached, which shows a printing roller in an oblique view. The
Claims (9)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE9305806U DE9305806U1 (en) | 1993-04-19 | 1993-04-19 | |
DE9305806U | 1993-04-19 |
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EP0623466A2 true EP0623466A2 (en) | 1994-11-09 |
EP0623466A3 EP0623466A3 (en) | 1994-11-17 |
EP0623466B1 EP0623466B1 (en) | 1998-01-28 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP19940105693 Expired - Lifetime EP0623466B1 (en) | 1993-04-19 | 1994-04-13 | Printing roller with a sleeve of hot, wound fibre-reinforced, thermoplastic material and a plasma-sprayed copper, or copper alloy coating |
Country Status (5)
Country | Link |
---|---|
US (1) | US5468568A (en) |
EP (1) | EP0623466B1 (en) |
JP (1) | JP3434567B2 (en) |
AT (1) | ATE162759T1 (en) |
DE (2) | DE9305806U1 (en) |
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US5735206A (en) * | 1995-03-20 | 1998-04-07 | Erminio Rossini, Spa | Deformable mandrels for rotary printing cylinders |
US5819657A (en) * | 1996-03-11 | 1998-10-13 | Ermino Rossini, Spa | Air carrier spacer sleeve for a printing cylinder |
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EP1985459A3 (en) * | 2007-04-23 | 2009-07-29 | Mdc Max Daetwyler AG | Manufacture of intaglio printing formes |
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- 1994-04-13 DE DE59405143T patent/DE59405143D1/en not_active Expired - Fee Related
- 1994-04-13 AT AT94105693T patent/ATE162759T1/en not_active IP Right Cessation
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Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0732201A1 (en) * | 1995-03-14 | 1996-09-18 | Erminio Rossini S.P.A. | Concentric double sleeve for a rotary printing cylinder |
US5782181A (en) * | 1995-03-14 | 1998-07-21 | Erminio Rossini S.P.A. | Concentric double sleeve for a rotary printing cylinder |
US5735206A (en) * | 1995-03-20 | 1998-04-07 | Erminio Rossini, Spa | Deformable mandrels for rotary printing cylinders |
US5819657A (en) * | 1996-03-11 | 1998-10-13 | Ermino Rossini, Spa | Air carrier spacer sleeve for a printing cylinder |
DE10214989A1 (en) * | 2002-04-04 | 2003-10-30 | Georg Frommeyer | Pressure cylinder used in a printing machine comprises a surface coating made from either a pure nickel layer, a mixed crystal alloy, composite layers or multiple layer systems for engraving a stepped ensemble |
EP1968795A1 (en) * | 2005-12-23 | 2008-09-17 | Commonwealth Scientific and Industrial Research Organisation | Manufacture of printing cylinders |
EP1968795A4 (en) * | 2005-12-23 | 2009-07-22 | Commw Scient Ind Res Org | Manufacture of printing cylinders |
DE102007006207A1 (en) * | 2007-02-08 | 2008-08-14 | Man Roland Druckmaschinen Ag | Printing machine cylinder e.g. impression cylinder, for e.g. web printing machine, has cylinder base body made of fiber-reinforced plastic, and coated with wear-protection layer in area of lateral surface and area of clamping channel |
EP1985459A3 (en) * | 2007-04-23 | 2009-07-29 | Mdc Max Daetwyler AG | Manufacture of intaglio printing formes |
Also Published As
Publication number | Publication date |
---|---|
JPH06320703A (en) | 1994-11-22 |
US5468568A (en) | 1995-11-21 |
JP3434567B2 (en) | 2003-08-11 |
DE59405143D1 (en) | 1998-03-05 |
EP0623466B1 (en) | 1998-01-28 |
ATE162759T1 (en) | 1998-02-15 |
EP0623466A3 (en) | 1994-11-17 |
DE9305806U1 (en) | 1993-06-09 |
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