Hard Rubber Coating for Intaglio Printing Template

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Solution Overview

Problem

Conventional intaglio printing template production processes are complex, energy-intensive, and environmentally hazardous due to the need for multiple layers, including a soft copper layer and a hard chromium layer, which requires electroplating and uses toxic chromium(VI) trioxide.

Innovation Solution

A single-layer hard rubber elastomer coating with a hardness above 40 Shore D is used on a base for the printing template, eliminating the need for electroplating and reducing the number of processing steps, while still allowing for engraving and effective ink transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a soft copper layer is used for engraving, then engraving ease is improved, but wear resistance deteriorates

Engineering Contradiction:

Improveengraving easeVSAvoidwear resistance

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent divides the printing template into two functionally independent layers: a soft copper layer dedicated to engraving and a hard chromium layer dedicated to wear resistance. This segmentation allows each layer to optimize its specific function without compromise - the copper layer remains soft for easy engraving while the chromium layer provides the necessary durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs a composite structure combining copper and chromium layers. The copper layer provides excellent engraving properties due to its softness, while the chromium layer contributes superior wear resistance. This composite material approach resolves the contradiction by combining materials with complementary properties rather than relying on a single material to fulfill both requirements.

Inventive Principle:

Principle #40Composite materials

2Strength

If a hard chromium layer is applied via electroplating, then wear resistance is improved, but environmental harm and process complexity increase

Engineering Contradiction:

Improvewear resistanceVSAvoidenvironmental harm

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent extracts and eliminates the harmful electroplating process from the production sequence. Instead of using chromium(VI) trioxide electroplating, the invention applies a hard chromium layer through alternative, environmentally friendly methods such as physical vapor deposition or chemical vapor deposition, thereby removing the toxic chromium compounds from the process while maintaining the wear resistance function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the previously harmful electroplating process into a beneficial or neutral process by replacing it with environmentally safe deposition methods. The chromium layer is still applied to provide wear resistance, but the harmful chromium(VI) trioxide is replaced with safer chromium sources or alternative coating technologies that achieve the same protective function without environmental damage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If multiple layers are applied to the printing template, then functionality is improved, but manufacturing complexity and energy consumption increase

Engineering Contradiction:

ImprovefunctionalityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the engraving function and the wear protection function into a unified two-layer structure where the copper layer and chromium layer are applied in sequence as an integrated manufacturing process. This merging allows both functions to be achieved within a single production workflow rather than requiring separate, complex processes, thereby improving functionality while controlling manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies the copper layer first as a preliminary step before applying the chromium layer. This preliminary action of depositing the soft copper base layer enables subsequent engraving operations, after which the hard chromium layer is applied to protect the engraved features. This sequential preliminary action organizes the manufacturing process into logical stages, improving overall functionality while maintaining manageable complexity.

Inventive Principle:

Principle #10Preliminary action

4Manufacturing precision

If chromium(VI) trioxide is used for electroplating, then hard chromium layer deposition is achieved, but toxicity and disposal costs increase

Engineering Contradiction:

Improvechromium layer depositionVSAvoidtoxicity

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical parameters of the chromium deposition process by replacing chromium(VI) trioxide with alternative chromium compounds or entirely different deposition methods. This parameter change maintains the ability to deposit a hard chromium layer with the required properties while eliminating the use of highly toxic chromium(VI) compounds, thereby reducing toxicity and associated disposal costs.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12202291B2Image-providing printing forme, and method for producing a printing forme

Publication Date: 2025.01.21 CONTITECH DEUTSCHLAND GMBH

AI summary

An imaging printing form having a base body with an elastomeric coating, in which the elastomeric coating carries an engraving pattern. The elastomeric coating has a hard rubber with a hardness of greater than 40 Shore D, and more particularly greater than 70 Shore D. The hard rubber is based on butadiene-acrylonitrile rubber (NBR), carboxyl group-containing nitrile rubber (XNBR), hydrogenated acrylonitrile butadiene Rubber (HNBR) or combinations thereof.