Gravure Cylinder Reactive Sputtering Coating
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Solution Overview
Problem
Existing gravure cylinder manufacturing processes rely on toxic hexavalent chromium for surface reinforcement, leading to environmental pollution and increased operational costs, and alternative methods like vacuum deposition of chromium nitride or carbide result in elevated temperatures and strain on the plated copper.
Innovation Solution
A gravure cylinder with a surface reinforcing coating layer made of chromium nitride or chromium carbide, formed through reactive sputtering on a copper-plated plate base material, which provides wear resistance comparable to hexavalent chromium without toxicity or pollution concerns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chromium plating is used for surface reinforcement, then wear resistance is improved, but environmental pollution and operational costs increase due to toxic hexavalent chromium
Solution Approach 1:
The invention changes the material composition parameters by replacing chromium-based coatings with carbon-based coatings (carbon, graphite, or carbon composite layers). This substitution maintains the required wear resistance while eliminating the environmental and health hazards associated with hexavalent chromium, thus resolving the contradiction between performance and environmental harm
Solution Approach 2:
The invention employs composite material structures, specifically carbon composite layers formed through chemical vapor deposition (CVD) on the copper-plated gravure cylinder surface. This composite approach achieves superior wear resistance comparable to or exceeding traditional chromium plating without the associated environmental pollution and high operational costs
2Strength
If vacuum deposition or ion plating is used to form chromium nitride or chromium carbide, then wear resistance is improved, but temperature increases to about 400°C causing strain on plated copper
Solution Approach 1:
The invention changes the deposition process parameters by using chemical vapor deposition (CVD) at lower temperatures compared to vacuum deposition or ion plating. The CVD process forms carbon-based coatings at temperatures that do not cause significant thermal strain to the plated copper layer, thereby maintaining both wear resistance and structural integrity
Solution Approach 2:
The invention uses carbon-based materials (carbon, graphite, or carbon composites) as alternative coating materials that can be deposited at lower temperatures. These carbon-based coatings provide the necessary wear resistance without requiring high-temperature processes that would strain the copper plating, thus resolving the temperature-related contradiction
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves satisfactory wear resistance and eliminates environmental hazards, offering a cost-effective and efficient alternative for gravure cylinder manufacturing with improved plate life and reduced operational risks.
Implementation Method 1
formed through reactive sputtering on a copper-plated plate base material
Data Source
Figure 1(a)~1(d)
Figure 2
Figure 3(a)~3(e)
AI summary
Provided are a gravure cylinder, which has satisfactory wear resistance as the gravure cylinder and includes a surface reinforcing coating layer having wear resistance equal to or more than that of chromium plating using hexavalent chromium, a method of manufacturing the gravure cylinder, and a method of manufacturing a printed matter using the gravure cylinder. The gravure cylinder includes: a plate base material; a recess layer, which is formed on a surface of the plate base material and includes a large number of recesses formed on the surface; and a surface reinforcing coating layer configured to cover the recess layer with chromium nitride or carbon nitride, in which the surface reinforcing coating layer is formed by reactive sputtering.