Professional Documents
Culture Documents
7_9544A_T
(19)
(57) The present invention describes a method for hesion of the copper substrate and better dimensional
manufacturing rotogravure cylinders with a cylinder base accuracy.
made of aluminum. The method involves the coating of The advantage of this method is the elimination of
the cylinder surface with high velocity spraying, the cop- the surface roughening process and the elimination of
per plating in an appropriate solution, the engraving of the pre-plating process. In addition, the end plates are
the cylinder, and the hardening of the cylinder by chro- manufactured partly from aluminum and partly from steel
mium plating. which further reduces the total weight of the cylinder. The
The spraying process is accomplished by High-Ve- elimination of these processes reduces the weight of the
locity Air-Fuel or High-Velocity Oxygen-Fuel thermal cylinder and the overall manufacturing time considerably.
spraying which leads to less surface porosity, better ad-
EP 2 719 544 A1
2
3 EP 2 719 544 A1 4
method of manufacturing rotogravure cylinders is provid- spraying process is used. In such a process, the particles
ed, wherein a copper support is provided onto a cylindri- are applied with a high speed such as at least 300 m/s
cal base, and a copper engraving layer is electroplated onto the cylinder. Suitably, the cylinder herein rotates
on the copper support, and wherein the copper engraving during the deposition process. The particles will impact
layer is thereafter engraved according to a desired pat- 5 on the cylindrical base, which results in liberation of a
tern and protected with a protection layer. Herein the pro- significant amount of energy in the form of heat. This heat
vision of the copper support comprises the formation of will warm up the particles so as to melt at least partially.
a copper layer circumferential to the base through at least [0024] It is an advantage of the invention that the cop-
partial melting of deposited copper particles per support layer and the copper engraving layer may be
[0017] According to a second aspect of the invention, 10 thin, preferably less than 100 mm each. This is made
an intermediate product is provided, comprising a cylin- possible in that the formed circumferential copper layer
drical base of aluminium onto which a circumferential has a very low porosity, suitably less than 1.0%, prefer-
copper layer extends, the base and the circumferential ably less than 0.5% or even less than 0.2%. This is in
copper layer having a mutual interface, wherein the cir- contrast to the prior art copper support layer of
cumferential copper layer is obtained with inherent com- 15 W02011/073695A2. Analysis of the rotogravure cylin-
pressive stress onto the underlying base and acts as a ders made in accordance with the prior art demonstrated
support for an electroplated copper engraving layer. a large porosity, with a significant spread between indi-
[0018] According to a third aspect of the invention, a vidual cylinders, which was merely overcome through
method of providing a rotogravure cylinder is provided deposition of a thick preplating layer.
comprising the steps of engraving the engraving layer of 20 [0025] In one embodiment, the circumferential layer
the intermediate product with a predetermined pattern has a thickness of at least 50 mm, more preferably at
and subsequent deposition of a protection layer. least 60 mm. This has the advantage that the circumfer-
[0019] According to further aspects of the invention, ential layer may have a thickness substantially corre-
provided are a rotogravure cylinder therewith obtainable sponding to the thickness of the subsequently deposited
and the use of such rotogravure cylinder for the printing 25 copper engraving layer.
of packaging materials by transfer of ink from the roto- [0026] In an alternative, preferred embodiment, the cir-
gravure cylinder to the packaging material. cumferential layer is provided in a thickness of less than
[0020] It was found in investigations leading to the in- 50 mm, preferably less than 40 mm or even at most 30
ventions that the defects resulted from an insufficient ad- mm. A suitable circumferential layer with such a small
hesion. Surprisingly, this adhesion could be improved 30 thickness is achieved with a high velocity spraying step
strongly with the improved process of the invention, in followed by a grinding step.
which the copper was at least partially melted. It was [0027] Most suitably, the circumferential layer is after
moreover unexpected that the improved process result- formation even thinned back. This thinning is for instance
ed in a continuous circumferential layer, so as to give carried out by sawing. A lubricant solution may be applied
rise to compressive stress. 35 simultaneously with the cooling. This process further-
[0021] It is an advantage of the present invention that more results in a suitable polishing of the surface of the
the manufacturing process of gravure cylinder with alu- circumferential layer. The polished circumferential layer
minum base is simplified. Particularly, the roughening is then suitable for the electroplating of the copper en-
treatment of the cylinder surface could be eliminated in graving layer.
comparison to the soft copper surface plating as de- 40
scribed in the above mentioned prior art method of BRIEF INTRODUCTION OF THE FIGURES
W02011/073695.
[0022] More precisely, the invention allows the crea- [0028] These and other aspects of the invention will be
tion of a copper support that may consist of a single layer, further elucidated with respect to the following figures,
and nevertheless matches the difference in properties 45 wherein:
between the base, which is particularly of aluminium, and
the copper engraving layer with a high hardness. This is Fig. 1 shows a diagrammatical bird’s eye view of a
achieved in that the copper support comprises a copper rotogravure cylinder;
layer that extends circumferentially around the base and Fig. 2 shows a diagrammatical cross-sectional view
includes a compressive stress. This compressive stress 50 of the rotogravure cylinder;
more particularly results from cooling down of the circum- Fig. 3 shows a diagrammatical view of end plates for
ferential layer after at least partial melting. The layer the rotogravure cylinder
therein has a inherent tendency to contract, and more
than the underlying base. This is suitably achieved there- ILLUSTRATED DISCUSSION OF DETAILED EMBOD-
in that the copper particles are heated up more than any 55 IMENTS
the cylindrical base.
[0023] The copper particles are suitably deposited in [0029] The figures 1, 2 and 3 are not drawn to scale
a spraying process. More preferably a high velocity and they are only intended for illustrative purposes. Equal
3
5 EP 2 719 544 A1 6
4
7 EP 2 719 544 A1 8
ness of 60-100 mm, for instance 75 mm. In one embodi- percentage of aluminum used. The idea is to keep the
ment, a layer thickness was chosen that was substan- steel part at minimum weight.
tially corresponding to the layer thickness of the copper [0046] The manufacturing of the end plates are made
support. However, thicker layers are not excluded. The using the following simple steps:
deposition process for such an engraving layer is known 5
per se and involves electroplating. Use was made in one a) The outer diameter of the aluminum end plate part
embodiment of a solution of copper sulfate (200 - 230 gr (4, figure 3) is manufactured to fit the internal diam-
CuSO4 X 5H2O) and sulfuric acid (60 - 65 gr H2SO4 per eter of the cylinder base. The inner diameter of the
liter of solution) and a catalyst for hardness. The catalyst aluminum end plate part is made to fit the outer di-
does not have any particular properties and can be found 10 ameter of the steel end plate part.
easily in the market. During the plating, the cylinder is b) The outer diameter of the steel end plate part (5,
revolved with a speed of about 100 rpm. The current den- figure 3) is manufactured to fit the inner diameter of
sity during electroplating in this phase ranges from 20 to the aluminum end plate part.
25 amps/dm 2 for about 80-100min and with a solution c) The assembly of the aluminum and the steel part
temperature maintained at about 30°C. Further details in 15 of the end plates are is accomplished simply by heat-
relation to this process are known from various patents, ing (normal or induction heating) and press fitting the
such as U.S. Pat. No. 4,334,966, No. 4,781,801, two parts.
5,417,841 and 7,153,408, which are herein included by
reference. [0047] Although the above description is the recom-
[0042] In an alternative embodiment, which was tested 20 mended methodology for the manufacturing of a light
particularly in combination with a ground and thin circum- weight gravure cylinder with a base made of aluminum
ferential layer as discussed above, the copper engraving and end plates made from aluminum and steel, it is ap-
layer was formed by deposition and subsequent thinning parent to the experts of the field that small deviations or
and polishing. Here again, a thinning to approximately alterations or modifications can be implemented without
half of the deposited thickness turned out suitable in prac- 25 significant deviations from the present invention.
tice. However, it is not excluded that the thinning removes
merely 20-40% of the deposited thickness. TEST RESULTS
[0043] Thereafter, the cylinder was polished to achieve
desired surface roughness (usually Rz is between [0048] Semimanufactured cylinders made in accord-
0,03mm and 0,07mm) 30 ing with the prior art of W02011/073695A2 and in accord-
[0044] The intermediate product was therewith ready. ance with the invention were subjected to a bond strength
In a subsequent step, this intermediate product was en- test. The semimanufactured cylinders had an aluminum
graved in accordance with a desired and predefined pat- base, a copper support and a copper engraving layer.
tern. Use could be made of any engraving technique No engraving was applied in the copper engraving layer.
known per se, including so called electronic engraving. 35 A protection layer was not applied. The cylinder base in
Use of a laser appears beneficial. The engraving could both semi-manufactured cylinders was identical; merely
be carried out in a different location if so desired. After the manufacture of the copper support differed.
the engraving, a protection layer was applied. This pro- [0049] Bond strength tests were carried out using a
tection layer is suitably a chromium coating layer of about universal testing machine (as supplied from TLCLO,
6 to 10 mm, and was produced by plating in a chromium 40 Dartec Ltd, Stourbridge, England). Therein, shear force
oxide solution (250 - 280 gm of Cr2O3 per solution liter) was applied as close as possible to the aluminum-copper
and sulfuric acid (2.5 - 2.8 gm of H2SO4 per solution liter) interface at a crosshead speed of 1 mm/min. The ultimate
for about 30 min. load to failure was recorded in Newton (N), and repeated
[0045] In order to further reduce the weight of the gra- several times to ensure sufficient statistics. Table 1 pro-
vure cylinder, the end plates of the gravure cylinders (typ- 45 vides the results. It is clear therefrom that the bond
ical cross sections of an end plate is shown in figure 3) strength has been significantly improved. Whereas the
are made of two materials, one light weight (4, figure 3), prior art cylinders had a bond strength that was close to
e.g. aluminum and steel (5, figure 3). The typical thick- the limit or even below the limit of 15 N, the bond strength
ness of the end plates is 25mm.The steel is used for the in the invention is such that any variation does not matter
part of the end plate which comes into contact with the 50 any longer.
support of the printing machines because steel has better
wear resistance and higher strength compared to alumi- Table 1
num. sample preparation bond strength (N)
The dimensions of the end plate are determined by the
customer specifications. This is why the dimensions (and 55 W02011/073659A2 12 N
the keyway) are not shown in Figure 3. The proportion invention 70 N
of aluminum to steel is determined by the dimensions of
the end plate. The bigger the end plate the higher the
5
9 EP 2 719 544 A1 10
6
EP 2 719 544 A1
7
EP 2 719 544 A1
8
EP 2 719 544 A1
9
EP 2 719 544 A1
10
EP 2 719 544 A1
11
EP 2 719 544 A1
12
EP 2 719 544 A1
13
EP 2 719 544 A1
This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.
14