EP1232861A9 - Gravierte walze und verfahren zu seiner herstellung - Google Patents

Gravierte walze und verfahren zu seiner herstellung Download PDF

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Publication number
EP1232861A9
EP1232861A9 EP99968820A EP99968820A EP1232861A9 EP 1232861 A9 EP1232861 A9 EP 1232861A9 EP 99968820 A EP99968820 A EP 99968820A EP 99968820 A EP99968820 A EP 99968820A EP 1232861 A9 EP1232861 A9 EP 1232861A9
Authority
EP
European Patent Office
Prior art keywords
oxide
roll
screen
ceramic coating
accordance
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Withdrawn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
EP99968820A
Other languages
English (en)
French (fr)
Other versions
EP1232861A1 (de
Inventor
Alexandr Sergeevich Shatrov
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Isle Coat Ltd
Original Assignee
Isle Coat Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Isle Coat Ltd filed Critical Isle Coat Ltd
Publication of EP1232861A1 publication Critical patent/EP1232861A1/de
Publication of EP1232861A9 publication Critical patent/EP1232861A9/de
Withdrawn legal-status Critical Current

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Classifications

    • 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
    • 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
    • B41N3/00—Preparing for use and conserving printing surfaces
    • B41N3/03—Chemical or electrical pretreatment
    • B41N3/034—Chemical or electrical pretreatment characterised by the electrochemical treatment of the aluminum support, e.g. anodisation, electro-graining; Sealing of the anodised layer; Treatment of the anodic layer with inorganic compounds; Colouring of the anodic layer
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/024—Anodisation under pulsed or modulated current or potential
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/026—Anodisation with spark discharge
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02—Anodisation
    • C25D11/04—Anodisation of aluminium or alloys based thereon
    • 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
    • B41N3/00—Preparing for use and conserving printing surfaces
    • B41N3/03—Chemical or electrical pretreatment

Definitions

  • This invention relates to the field of producing high-precision rolls with engraved relief surface, which are used in printing equipment, in the production of textiles, for making wallpaper, and for applying lacquers, glues or suspensions to sheet materials, fabrics etc.
  • the invention relates to screen (anilox) rolls for flexographic and offset lithographic printing, which have the finest engraved relief surface.
  • a layer of ink is applied to the screen surface of the roll, consisting of regularly disposed recess-cells. The excess is removed by a doctor.
  • the cells receive a dosed volume of ink, which is then transferred to the surface of the printing form or inking roller.
  • high precision is required in the positioning of the cells on the cylindrical surface of the screen, and also in the shape and depth of the cells themselves.
  • the depth of the cells is from 10 to 50 ⁇ m. Constant contact with the hardened steel doctor causes wear of the screen surface.
  • the mechanical wear process is augmented by the corrosion effect of the inks, which include solutions of salts, organic solvents etc., reducing the serviceable life of the engraved roll.
  • the most widely used screen rolls are those made of construction steel.
  • the cells are rolled onto the cylindrical surface by a knurling roller made of tool steel.
  • the high cost of the knurling roller (which has to be made to a higher order of precision than the screen roll cells) and its low strength make it necessary to use slow, undemanding rolling regimes, and cause the productivity of the process to be low.
  • the steel rolls are chromium-plated.
  • An example of such a roll may be found in US Patent No. 3,613,578.
  • the thickness of the chrome plating should not be more than a few microns (maximum 15 ⁇ m), since increasing the thickness of the plating alters the geometry and volume of the cells in the screen surface. Power contact with the doctor in the course of operation leads to rapid wear of the thin chromium layer and greatly reduces the serviceable life of the roll.
  • aluminium alloys are easy to machine at high cutting speeds and to high precision. Thanks to its high precision and light weight, an aluminium alloy roll has low dynamic inertia and low dynamic imbalance. This enables the roll to rotate more uniformly in operation, and reduces or eliminates vibration and "judder".
  • the proposals include two types of protective coating.
  • the first type consists of a layer of chromium oxide or aluminium oxide 200-250 ⁇ m thick, applied by plasma spraying.
  • the second type is a layer of aluminium oxide 25-50 ⁇ m thick, formed on the cylindrical surface of the roll by anodising in sulfuric acid electrolyte. In this case, the depth of the screen cells cut by the laser beam should not exceed the thickness of the anode-oxide coating.
  • the main problem with the laser engraving (burning-out) process is that it requires the use of very expensive equipment for the automatic control of the laser. Furthermore, the recesses engraved by the laser beam are not always of the correct shape. Differences in the roughness of the walls and bottom of the cells lead to the retention of a certain volume of ink and its random release, which is detrimental to the quality of the printing.
  • Anode oxide coatings consist mainly of amorphous phases of aluminium oxides, so their strength and microhardness are not great.
  • the coatings are hydrated to a considerable degree (their water content exceeds 10%), and also contain in their composition 10-20% of electrolyte anions forming part of the structure of the coating.
  • electrolyte anions forming part of the structure of the coating.
  • the problem with this process is the low thickness of the copper oxide layer on the screen surface of the roll. This layer cannot withstand the mechanical and chemical stresses occurring in a corrosive medium with the screen in friction contact with a steel doctor. Increasing the thickness of the anode-oxide layer to 15-20 microns leads to unacceptable changes in shape and dimensions of the screen surface cells. This is because in anodising, no less than 50% of the thickness of the oxide layer grows out from the surface being treated. Allowing for the thickness of the copper layer applied on top of the anode-oxide layer, it is virtually impossible to obtain screen cells of an acceptable volume. The considerable problems with the anode-oxide layers themselves have already been described.
  • the main aim of this invention is to create a light and relatively cheap engraving roll with virtually no inertia and a long serviceable life for use in various systems for the dosed transfer of liquids and suspensions.
  • Another aim of this invention is to develop an efficient process for producing an engraved roll, including high-precision and high-productivity processes for applying the screen cells, and up-to-date technologies for hardening the screen surface by forming wear- and corrosion-resistant coatings on them without significantly altering the set volumes and shapes of the screen cells.
  • the engraved roll proposed in this invention is made in the form of a high-precision base cylinder of a deformable aluminium alloy.
  • a screen surface with a set disposition, shape and volume of recess-cells is engraved on the working (external) cylindrical surface.
  • a hard wear-resistant oxide-ceramic coating 15-50 ⁇ m thick with microhardness 700-1500 Hv is formed on the screen surface of the roll by the plasma electrolytic oxidation method. The oxide layer bonds strongly with the aluminium base and is applied uniformly in thickness, adequately repeating the configuration of the screen.
  • a fine (1-5 ⁇ m) layer of metallic or organic materials is applied to the porous oxide-ceramic surface.
  • this surface is subjected to a finishing treatment in the form of fine circular polishing with an allowance of 2-10 ⁇ m per side.
  • PEO plasma electrolytic oxidation
  • the oxidation is carried out in ecologically safe, weakly alkaline aqueous electrolytes at a temperature of 15-55°C.
  • Impulse voltage of 50-1000 V (amplitude values) is supplied to the components.
  • the pulse repetition rate is 50-3000 Hz.
  • the current density is from 2 to 100 A/dm 2 .
  • An intercrystalline oxide layer of 700-1500 Hv microhardness, 15-50 ⁇ m thick, is created on the screen surface of aluminium alloy rolls under the effect of plasmo-chemical reactions.
  • the oxide-ceramic coating formed on the surface of the aluminium components consists mainly of a composition of different crystalline phases of the oxides of aluminium (alpha, beta, gamma etc.). Therefore, in spite of their great hardness, they possess a certain plasticity, and compared with ceramic coatings formed by plasma spraying, they are less liable to micro-chipping and flaking on the surface.
  • the porous structure of oxide coatings forms an ideal matrix for the creation of composition coatings by filling this matrix with compounds possessing specific functional properties.
  • this invention makes use of various metals and organic compounds (depending on the functional properties required).
  • Such materials penetrating into the pores and capillaries and forming a film on top 1-5 ⁇ m thick, protect the oxide coatings, while hardly changing the volume of the screen cells or smoothing out their rough surface at all.
  • Unimpregnated oxide-ceramic coatings absorb ink so intensively that difficulties arise when washing off the rolls for a change of ink in the system.
  • the strongly developed surface of the porous structure of the oxide layer gives excellent adhesion between itself and the impregnating compound, and consequently, excellent cohesion strength for the entire composition.
  • Oxide rolls impregnated with one of the metals of the series Ni, Cr, Mo or a compound of one of these metals with its oxides and carbides can be used successfully in systems for letterpress book printing, photogravure printing and flexography, i.e. in those cases in which liquids on aqueous, oil or synthetic bases are being transferred.
  • thin protective layers of metallic compounds may be done by chemical or electrochemical precipitation from aqueous or organic solutions, by chemical precipitation from the gas phase, or by physical precipitation methods.
  • Organic substances for the impregnation of the microporous structure of an oxide-ceramic coating must have good adhesion to ceramic surfaces, or should at least be gripped by the cavities in the ceramic coating. In the reaction process (heating, ultraviolet irradiation, etc.), they form a hard smooth corrosion-resistant layer.
  • the organic layers may possess special properties (lipophilic, hydrophilic or hydrophobic) and may accordingly be used in different printing systems.
  • the most suitable are the widely known self-vulcanising elastomers: butadiene-styrene, butadiene-nitrile, acryl-nitrile, and also paired regulating epoxy and formaldehyde resins and modified elastomers. Others can also be used: polymethyl methacrylate, chlorosulfonated polyethylene, ethylene-propylene elastomer and the like.
  • the external surface of the screen consisting of the projecting intervals (ribs) between the cells, is subjected to fine circular polishing on a precision circular polishing machine.
  • the polishing depth is 2-10 ⁇ m.
  • the aim of the operation is to ensure the maximum symmetry of the external surface relative to the central axis of the roll and the smooth operation of the printing system. Furthermore, due to the fine polishing, the initial period of working in the oxide-ceramic external surface of the roll with a steel doctor, during which the doctor may vibrate severely and wear intensively, can be eliminated.
  • the rough surface of the oxide-ceramic layer at the boundaries (ribs) of the cells can be seen clearly.
  • Rolls of aluminium alloys are easy to machine. Therefore, using high-precision metal-cutting equipment, it is possible to make high-precision rolls with an external surface close to the cylindrical and co-axial with the central axis of the roll. Such lightweight, low-inertia, dynamically balanced rolls do not require further balancing after they have been made.
  • the rolls must be strong enough and rigid enough to prevent deformations due to the forces arising from hydrodynamic pressure in the ink wedge between the roll and the printing form during operation.
  • Fig. 1 Small rolls of length up to 500 mm (Fig. 1) are machined completely (monolithically) from rolled rods of deformable aluminium alloys of grades of the SAE 5000 series (5082, 5086, 5056, 5356), 6000 series (6061, 6063, 6067, 6082), 2000 series (2021, 2024, 2018, 2618) and 7000 series (7075, 7175, 7475).
  • Rolls of medium length up to 1000 mm (Fig. 2) are made sectionally from an aluminium cylinder with deep apertures (3) machined co-axially into the endfaces, into which journals (shanks) (2) of steel or aluminium alloy are pressed.
  • Large rolls of length more than 1000 mm are also made sectionally (Fig. 3). They consist of a high-precision thick-walled bush (5) of aluminium alloy pressed onto a high-precision roll (core) (4) of hardened steel.
  • a significant advantage of this invention is the fact that the cells of the screen surface can easily be knurled at low specific pressure with high productivity and precision. This ensures the long life of the knurling roller. But the best results for precision of the screen and the productivity of the process are achieved by high-speed electronically-controlled engraving with a diamond needle (at about 3000 cells per minute).
  • Another advantage of this invention is the possibility of a calculated increase in the volume of the cells when they are engraved to 10-25% more than the necessary final volume of the cells in the finished cylinder. This is necessary to compensate for a certain reduction in the volume of the cells in the course of the oxidation, impregnation and finishing treatment of the screen surface.
  • a high-precision roll 165 mm long and 38.6 mm in diameter was made from heat-treated SAE 6082 alloy.
  • a screen surface with cell volume exceeding the required volume by 20% was applied to the cylindrical working surface by the diamond engraving method.
  • the lineature (density) of the screen was 100 lines per centimetre.
  • the roll was then subjected to plasma electrolytic oxidation.
  • the roll was placed in a bath of an aqueous solution of an alkaline electrolyte (pH 11.5) at a temperature of 30°C.
  • Electrolysis regimes pulse repetition rate 1000 Hz, current density 40 A/dm 2 , amplitude value of voltage at the end of the process - anode 900 V, cathode 250 V.
  • the roll was fitted to a flexographic printing press for printing packing materials.
  • the roll demonstrated excellent printing qualities.
  • the prints produced after making 3,000,000 copies and 6,000,000 copies were virtually identical.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Metallurgy (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Printing Plates And Materials Therefor (AREA)
  • Inking, Control Or Cleaning Of Printing Machines (AREA)
  • Rolls And Other Rotary Bodies (AREA)
  • Solid-Phase Diffusion Into Metallic Material Surfaces (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Coating By Spraying Or Casting (AREA)
EP99968820A 1999-10-29 1999-10-29 Gravierte walze und verfahren zu seiner herstellung Withdrawn EP1232861A1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/RU1999/000407 WO2001030572A1 (fr) 1999-10-29 1999-10-29 Arbre grave et procede de fabrication correspondant

Publications (2)

Publication Number Publication Date
EP1232861A1 EP1232861A1 (de) 2002-08-21
EP1232861A9 true EP1232861A9 (de) 2002-12-04

Family

ID=20130409

Family Applications (1)

Application Number Title Priority Date Filing Date
EP99968820A Withdrawn EP1232861A1 (de) 1999-10-29 1999-10-29 Gravierte walze und verfahren zu seiner herstellung

Country Status (11)

Country Link
EP (1) EP1232861A1 (de)
JP (1) JP2003512208A (de)
KR (1) KR20020070975A (de)
CN (1) CN1374905A (de)
AU (1) AU2703100A (de)
BR (1) BR9917546A (de)
CA (1) CA2389097A1 (de)
CZ (1) CZ20021368A3 (de)
MX (1) MXPA02004222A (de)
NO (1) NO20021819L (de)
WO (1) WO2001030572A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK178658B1 (da) * 2015-02-04 2016-10-17 Tresu As Kammerrakel

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN101838832B (zh) * 2010-03-12 2011-07-20 北京工业大学 一种柔印陶瓷网纹辊的制备方法
KR101776303B1 (ko) * 2011-01-27 2017-09-07 엘지이노텍 주식회사 그라비아 롤 및 이의 제조 방법
CN110281651A (zh) * 2019-06-28 2019-09-27 上海运城制版有限公司 一种采用阴网点的陶瓷网纹辊
CN112077401A (zh) * 2020-08-25 2020-12-15 常州市平晖机械制造有限公司 花辊电解刻花方法
CN112658829B (zh) * 2020-12-17 2023-10-20 台州奔田机电制造有限公司 一种铁棒打磨刻纹一体式的设备
CN113459648A (zh) * 2021-07-02 2021-10-01 广东省科学院新材料研究所 一种版辊及其加工方法

Family Cites Families (11)

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Publication number Priority date Publication date Assignee Title
FR1601678A (de) * 1968-03-13 1970-09-07
US3631578A (en) 1969-11-20 1972-01-04 Anthony Shangler Apparatus for erecting shelving
US4009658A (en) 1974-04-26 1977-03-01 Pamarco Incorporated Fluid metering roll and method of making the same
DE3046757C2 (de) * 1980-12-12 1985-09-12 W.C. Heraeus Gmbh, 6450 Hanau Tiefdruckzylinder
US4601242A (en) 1985-02-04 1986-07-22 Rockwell International Corporation Copper and ceramic composite ink metering roller
US5514064A (en) 1987-08-20 1996-05-07 Della Torre; Renato Process and means for making metal inking rolls
US5662573A (en) 1988-08-18 1997-09-02 Torre; Renato Della Metal inking roll for use in flexographic printing
DE3900281A1 (de) * 1989-01-07 1990-07-12 Saueressig & Co Tiefdruckzylinder, insbesondere fuer den illustrationsdruck
US4912824A (en) 1989-03-14 1990-04-03 Inta-Roto Gravure, Inc. Engraved micro-ceramic-coated cylinder and coating process therefor
GB9205704D0 (en) 1992-03-16 1992-04-29 Connaught Lab High molecular weight membrane proteins of non-typeable haemophilus
US5411462A (en) 1993-08-30 1995-05-02 Link; Terry G. Lightweight ink transfer roll

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DK178658B1 (da) * 2015-02-04 2016-10-17 Tresu As Kammerrakel

Also Published As

Publication number Publication date
JP2003512208A (ja) 2003-04-02
AU2703100A (en) 2001-05-08
EP1232861A1 (de) 2002-08-21
NO20021819D0 (no) 2002-04-18
BR9917546A (pt) 2002-10-29
WO2001030572A1 (fr) 2001-05-03
MXPA02004222A (es) 2002-10-17
NO20021819L (no) 2002-06-20
CN1374905A (zh) 2002-10-16
KR20020070975A (ko) 2002-09-11
CZ20021368A3 (cs) 2003-01-15
CA2389097A1 (en) 2001-05-03

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