First, what is the laser engraving ceramic net roller? What are the characteristics of this ceramic anilox roller?
As we all know, the spatial coherence of the laser is good, and the divergence angle is small and the directivity is good. Therefore, a very high energy density can be formed on the spot formed by the focusing of the laser lens. This directivity has a good power density of 105-1013 m/cm2. The laser beam can be used as a special processing method has been widely used in the field of material processing. Ceramics is a material with high chemical stability, high hardness, wear resistance and corrosion resistance, but conventional processing methods are difficult to achieve the latest development of ceramics in a variety of applications, limiting its function. The laser-engraved ceramic anilox roller utilizes the characteristics of the laser. Under the control of the computer, a mesh is vaporized on the layer of ceramic sprayed on the outer surface of the metal-based roller. Due to the high stability of the laser power and the high accuracy of the computer control, the formed holes can be made to have the same size and depth, the wall is thick and complete, and the mesh arrangement angle is accurate.
The laser-engraved ceramic anilox roller has the characteristics of high hardness, wear resistance, corrosion resistance and high temperature resistance of the ceramic material, which greatly prolongs the service life of the anilox roller. Laser engraved ceramic anilox roller is usually made of chromium oxide ceramic material, and the hardness of the ceramic coating formed by spraying can reach HRC70-72. The ceramic roller processed with this kind of coating has been used on the production line for many years to show what it has. Excellent wear resistance and long life. The chemical stability of the ceramic material itself is excellent, and it is allowed to work in a corrosive environment. However, the structure of the ceramic anilox roller is through a plasma spraying process on the outside surface of the metal roller, and a layer of thick coating is applied. Ceramics. If the design of the ceramic coating structure is unreasonable or the technical measures are not in place, there may be a phenomenon that the ceramic layer is peeled off due to the corrosion of the base material, and this phenomenon has appeared on some of the imported rollers. It can be said that the corrosion resistance of ceramic anilox roll is to be achieved by strict material selection, reasonable structure design and a series of technological measures, which should be guaranteed by the supplier's good reputation.
Ceramic anilox roller is made by using laser as engraving tool. Different laser output parameters can obtain different performance of ceramic anilox roller. Compared with metal anilox roller processing method, laser parameter adjustment is more convenient. The adjustment range can be very wide, so the coverage of the mesh characteristic parameters of the ceramic anilox roller laser-engraved by the laser and the ink reservoir volume of the net is quite wide, basically realizing the function of adjustable anilox roller parameters in a continuous range. It provides convenience for different users of different application goals.
The laser has a small divergence angle and good directivity, and the focused spot can reach a very small size. The number of screen lines of the engraved anilox roller can be very high, the wall edge of the formed mesh is steeper, and the network wall can be made very thin. The wall thickness is usually about one-third thinner than the thickness of the metal anilox mesh, so the same number of lines and the depth of the two anilox roller, ceramic anilox roller volume per unit area More forests are also more conducive to improving the ink transfer rate.
Second, the number of laser engraving ceramic anilox screen, network cable angle and mesh shape Laser engraved ceramic anilox roller The number of screen lines can be processed depends entirely on the characteristics of the laser used, single-mode high-power CO2 laser output laser beam The maximum number of lines that can be produced reaches 1000-1200 lines/inch, and its mesh profile is close to bowl-shaped. For the ceramic anilox roll produced by high-power YAG lasers in recent years, because of the short wavelength of the YAG laser, the wavelengths of the two are different by an order of magnitude compared with the CO2 laser, so that the focal spot diameter can be smaller and the depth of focus can be achieved in the focal plane. The number of screen lines for the longer anilox roller can be as high as 1500 lines/inch or more, and the cross-sectional shape of the mesh is close to the tube shape. For the same number of anilox rolls, the depth of the mesh depth of the ceramic anilox roll processed with YAG laser is deeper, and the ink storage volume is also larger. In other words, using the CO2 laser to achieve the mesh reservoir volume, using YAG laser can be achieved in a higher number of screen lines, this feature is more conducive to further improve the printing quality. Another feature of the pulsed YAG laser is that its laser pulse shape is better, so when the laser interacts with the ceramic material, most of the ceramic material can be directly vaporized, and a small amount of remelted, remelted deposits can be avoided. An uncertain factor may have an effect on the individual performance of the anilox roll. Is it correct to say that YAG laser-engraved ceramic rolls can replace CO2 laser-engraved ceramic rolls? It is not for this reason. Because of preliminary research and testing, there are also some disadvantages in the YAG laser-engraving ceramics. For example, the mesh is relatively easy to clog, which is a common problem with deep holes. The fluctuation of the YAG laser pump source will cause the output laser to fluctuate, resulting in an inconsistent and uneven distribution of an anilox roller, and an uneven distribution. The poor repeatability of the anilox roller affects the use effect. While the CO2 laser can maintain the predictability of good stability during the engraving process, the roll mesh parameter repeatability is good. So far, CO2 laser-engraved ceramic rolls still account for the majority share of the ceramic anilox roller market below 1000 lines per inch. No matter what kind of laser is used to process the anilox roller, the ability to process the angle of the cable is completely affected by the computer. control.
At present, the most common mesh arrangement angles on the market are 300, 450, and 600. The 300, 600, and 600 holes are hexagonal, and the 450 holes are diamond-shaped. In general, the 300 hexagonal mesh has a better black release characteristic. However, the horizontal wall of the mesh will cause more abrasion to the squeegee and the ink roller. The ink film formed by the 600 hexagonal mesh is more uniform, and its hole depth is wider and wider, which is favorable for the release of the ink and the ceramic roller. Case. Hexagonal geometry has a high area utilization ratio. Compared with the equivalent parameters, the hexagonal mesh per unit area is 15% larger than the diamond mesh, and the 450 diamond mesh is used in the metal anilox roll. More often than not, the thickness of the wall is generally between 15μ and 20μ. Larger inter-hole junctions are not conducive to the uniform ink film. In order to achieve a certain ink storage volume under a certain number of lines, it is often required to deepen the depth, which is to improve transfer. Rate and prevent clogging of the mesh are both unfavorable.
Third, the application of laser-engraved ceramic anilox roller - The quantitative ink supply system in the flexographic printing machine The quantitative ink supply system is one of the important factors of the quality of the flexographic printing. Usually it is mainly composed of ceramic anilox roller and scraper. As people's demands for printing quality continue to increase and printer speeds continue to rise, quantitative ink supply systems and structures in flexo presses continue to evolve. The ink supply system has evolved from a forward two-roll structural system to a subsequent forward squeegee system. The two-roll system and the forward squeegee system are suitable for printing machines whose printing quality requirements are not high and which are slow and slow. When the operating speed of the machine exceeds 100 m/min, the effect of the hydraulic pressure tends to separate the squeegee device from the ink roller, thus affecting the transfer characteristics of the ink quantity and the change of printing quality. The reverse squeegee system can solve the problem. The adverse effects of hydraulic pressure during high-speed operation. However, whether it is a reverse squeegee system or a positive squeegee system or a two-roll system, they all belong to an open ink supply structure. In such a structure, a large area of ​​ink is directly exposed to the atmosphere, and ink characteristics and environmental problems are easily caused. The emergence of. The requirement of fine printing and consideration of environmental protection will inevitably lead to a closed-type ink supply system, so a closed double-squeegee ink fountain system emerged. In addition to ceramic anilox rollers and doctor blades, there are auxiliary parts such as ink fountains, ink pumps, ink reservoirs and inking lines. The tightness of the system not only ensures the consistency of the various printing elements in the operation of the machine, but also the basic requirements of environmental protection; the pressure adjustable of the system ensures that the pressure distribution is uniform and the size of the entire contact surface is appropriate. The system is in an optimal operating state, and the system can be quickly docked with the cleaning system, and the internal () ink-removal elements can be completely cleaned in a short time to ensure the efficient operation of the entire printing production line.
Sealed double-squeegee ink fountain system is now more common in medium-to-high-end narrow-width flexographic printing presses, wide-format flexographic printing presses, plate printing machines, coating machines, and coating machines. It is precisely because this structure has many advantages. Outside the transformation of the old machine and equipment upgrades are more willing to use sealed double blade ink fountain system to replace the original ink supply system or coating coating system.
Fourth, the maintenance of ceramic anilox roller Ceramic anilox roller does have many advantages, but if you use improperly or do not pay attention to daily maintenance and then the superiority of ceramic anilox roller can not be fully played, and even can not be used normally The problem is that the characteristics of long life will not be discussed. Summarized the main problems that affect the long-term normal use of engraved ceramic anilox roller: 1) The improper use of accelerated roller wear speed ultimately affects the quality of the product; 2) The user did not explain to the supplier the special requirements under special conditions of use. Take the necessary anticorrosive measures on the ceramic anilox roller, and then blindly use the roller under severe environmental conditions, causing the ceramic roller to have the problems of substrate corrosion, surface blistering and other problems in advance; 3) In order to prevent the clogging of the mesh, timely and correct Cleaning the roller is extremely important. However, improper cleaning methods or blind operation according to the cleaning instructions often cause significant damage to the ceramic anilox roller; 4) scratches on the surface of the anilox roller due to many reasons, and the particles that may be generated from the blade wear may also be It is hard particles that are mixed in the ink and scratches the scratched surface. Such hard small particles may also come from the metal particles in the poor maintenance or quality of the ink pump; 5) collision damage, mainly occurs in the worker operation or the roller shift process.
The countermeasures we can take to address these five major issues are:
1) The laser-engraved ceramic anilox roller has good wear properties, but it is by no means "never worn". The important point in slowing down the wear rate of the ceramic roller and the doctor blade is to properly adjust the pressure applied on the doctor blade. Excessive pressure will accelerate the wear rate of the doctor blade and the anilox roller. Too little pressure will affect the final printing effect. Proper adjustment allows a very thin layer of ink between the roller and the blade to lubricate and reduce wear. Second, the viscosity of the ink is obviously poor in its lubrication, which is not conducive to reducing wear;
2) Good corrosion resistance is another important feature of the laser-engraved ceramic roller. When the user's ceramic anilox roller is in contact with the ink, paint and cleaning agent PH value is too large or too small (PH <4.5 and PH> 11.8) users must provide suppliers with material and process to take enhanced corrosion resistance measures. At present, suppliers are fully capable of producing ceramic rollers with better corrosion resistance and have been promoted in production practice. The selection of the base roll material is extremely important. The corrosion resistance of stainless steel is better, and the aluminum base material is more likely to corrode than the steel base material. It is recommended to use the aluminum base material as the roll under the water base ink condition.
3) Many articles have already introduced methods for the situation of metal and ceramic anilox rollers. It is important to always remind the operator. These cleaning methods can only achieve good results if they are strictly followed. Improper use can lead to changes in roller characteristics and even serious consequences of not being able to continue using it. For example, when ultrasonic cleaning, powder cleaning, and chemical cleaning are used, some people blindly pursue the cleaning effect, blindly increase the power density, increase the jet pressure, or extend the soaking time of the chemical cleaning solution, resulting in irrecoverable losses. In addition, during the cleaning process, inspections must be strengthened, and cleaning and inspections must be carried out in a coordinated manner. Truly, they are truly aware that blind day cleaning often causes adverse consequences. At present, the industry is forming a consensus that manual brushing is still a safe and effective cleaning process. The method can be used as a routine cleaning method, while others are only supplements to this method. In order to improve the effect of hand brushing on the high number of anilox roller, the diameter of the stainless steel wire of stainless steel brush is sometimes made 0.008mm.
4) The scribe lines on the ceramic anilox roll are circumferentially distributed, and the reasons for their occurrence have been mentioned above. In order to reduce their influence, filtration measures and placement of rare earth magnets are used in the ink pump system to capture various types of hardness. Small particles. In order to reduce the influence of scraper wear caused by metal particles, the installation of scraper must be carefully carried out, carefully check the scraper surface and the knife surface is clean and flat, check the flatness of the knife edge after installation, to avoid improper installation caused by knife blade ups and downs Wear and tear
5) Causes of collision damage Most operators are carelessly caused. In addition to strengthening the education of responsibility, the rollers are wrapped with special protective sleeves during transportation or in the workshop. Collision damage often occurs on the roller surface and at the tip corners.
As we all know, the spatial coherence of the laser is good, and the divergence angle is small and the directivity is good. Therefore, a very high energy density can be formed on the spot formed by the focusing of the laser lens. This directivity has a good power density of 105-1013 m/cm2. The laser beam can be used as a special processing method has been widely used in the field of material processing. Ceramics is a material with high chemical stability, high hardness, wear resistance and corrosion resistance, but conventional processing methods are difficult to achieve the latest development of ceramics in a variety of applications, limiting its function. The laser-engraved ceramic anilox roller utilizes the characteristics of the laser. Under the control of the computer, a mesh is vaporized on the layer of ceramic sprayed on the outer surface of the metal-based roller. Due to the high stability of the laser power and the high accuracy of the computer control, the formed holes can be made to have the same size and depth, the wall is thick and complete, and the mesh arrangement angle is accurate.
The laser-engraved ceramic anilox roller has the characteristics of high hardness, wear resistance, corrosion resistance and high temperature resistance of the ceramic material, which greatly prolongs the service life of the anilox roller. Laser engraved ceramic anilox roller is usually made of chromium oxide ceramic material, and the hardness of the ceramic coating formed by spraying can reach HRC70-72. The ceramic roller processed with this kind of coating has been used on the production line for many years to show what it has. Excellent wear resistance and long life. The chemical stability of the ceramic material itself is excellent, and it is allowed to work in a corrosive environment. However, the structure of the ceramic anilox roller is through a plasma spraying process on the outside surface of the metal roller, and a layer of thick coating is applied. Ceramics. If the design of the ceramic coating structure is unreasonable or the technical measures are not in place, there may be a phenomenon that the ceramic layer is peeled off due to the corrosion of the base material, and this phenomenon has appeared on some of the imported rollers. It can be said that the corrosion resistance of ceramic anilox roll is to be achieved by strict material selection, reasonable structure design and a series of technological measures, which should be guaranteed by the supplier's good reputation.
Ceramic anilox roller is made by using laser as engraving tool. Different laser output parameters can obtain different performance of ceramic anilox roller. Compared with metal anilox roller processing method, laser parameter adjustment is more convenient. The adjustment range can be very wide, so the coverage of the mesh characteristic parameters of the ceramic anilox roller laser-engraved by the laser and the ink reservoir volume of the net is quite wide, basically realizing the function of adjustable anilox roller parameters in a continuous range. It provides convenience for different users of different application goals.
The laser has a small divergence angle and good directivity, and the focused spot can reach a very small size. The number of screen lines of the engraved anilox roller can be very high, the wall edge of the formed mesh is steeper, and the network wall can be made very thin. The wall thickness is usually about one-third thinner than the thickness of the metal anilox mesh, so the same number of lines and the depth of the two anilox roller, ceramic anilox roller volume per unit area More forests are also more conducive to improving the ink transfer rate.
Second, the number of laser engraving ceramic anilox screen, network cable angle and mesh shape Laser engraved ceramic anilox roller The number of screen lines can be processed depends entirely on the characteristics of the laser used, single-mode high-power CO2 laser output laser beam The maximum number of lines that can be produced reaches 1000-1200 lines/inch, and its mesh profile is close to bowl-shaped. For the ceramic anilox roll produced by high-power YAG lasers in recent years, because of the short wavelength of the YAG laser, the wavelengths of the two are different by an order of magnitude compared with the CO2 laser, so that the focal spot diameter can be smaller and the depth of focus can be achieved in the focal plane. The number of screen lines for the longer anilox roller can be as high as 1500 lines/inch or more, and the cross-sectional shape of the mesh is close to the tube shape. For the same number of anilox rolls, the depth of the mesh depth of the ceramic anilox roll processed with YAG laser is deeper, and the ink storage volume is also larger. In other words, using the CO2 laser to achieve the mesh reservoir volume, using YAG laser can be achieved in a higher number of screen lines, this feature is more conducive to further improve the printing quality. Another feature of the pulsed YAG laser is that its laser pulse shape is better, so when the laser interacts with the ceramic material, most of the ceramic material can be directly vaporized, and a small amount of remelted, remelted deposits can be avoided. An uncertain factor may have an effect on the individual performance of the anilox roll. Is it correct to say that YAG laser-engraved ceramic rolls can replace CO2 laser-engraved ceramic rolls? It is not for this reason. Because of preliminary research and testing, there are also some disadvantages in the YAG laser-engraving ceramics. For example, the mesh is relatively easy to clog, which is a common problem with deep holes. The fluctuation of the YAG laser pump source will cause the output laser to fluctuate, resulting in an inconsistent and uneven distribution of an anilox roller, and an uneven distribution. The poor repeatability of the anilox roller affects the use effect. While the CO2 laser can maintain the predictability of good stability during the engraving process, the roll mesh parameter repeatability is good. So far, CO2 laser-engraved ceramic rolls still account for the majority share of the ceramic anilox roller market below 1000 lines per inch. No matter what kind of laser is used to process the anilox roller, the ability to process the angle of the cable is completely affected by the computer. control.
At present, the most common mesh arrangement angles on the market are 300, 450, and 600. The 300, 600, and 600 holes are hexagonal, and the 450 holes are diamond-shaped. In general, the 300 hexagonal mesh has a better black release characteristic. However, the horizontal wall of the mesh will cause more abrasion to the squeegee and the ink roller. The ink film formed by the 600 hexagonal mesh is more uniform, and its hole depth is wider and wider, which is favorable for the release of the ink and the ceramic roller. Case. Hexagonal geometry has a high area utilization ratio. Compared with the equivalent parameters, the hexagonal mesh per unit area is 15% larger than the diamond mesh, and the 450 diamond mesh is used in the metal anilox roll. More often than not, the thickness of the wall is generally between 15μ and 20μ. Larger inter-hole junctions are not conducive to the uniform ink film. In order to achieve a certain ink storage volume under a certain number of lines, it is often required to deepen the depth, which is to improve transfer. Rate and prevent clogging of the mesh are both unfavorable.
Third, the application of laser-engraved ceramic anilox roller - The quantitative ink supply system in the flexographic printing machine The quantitative ink supply system is one of the important factors of the quality of the flexographic printing. Usually it is mainly composed of ceramic anilox roller and scraper. As people's demands for printing quality continue to increase and printer speeds continue to rise, quantitative ink supply systems and structures in flexo presses continue to evolve. The ink supply system has evolved from a forward two-roll structural system to a subsequent forward squeegee system. The two-roll system and the forward squeegee system are suitable for printing machines whose printing quality requirements are not high and which are slow and slow. When the operating speed of the machine exceeds 100 m/min, the effect of the hydraulic pressure tends to separate the squeegee device from the ink roller, thus affecting the transfer characteristics of the ink quantity and the change of printing quality. The reverse squeegee system can solve the problem. The adverse effects of hydraulic pressure during high-speed operation. However, whether it is a reverse squeegee system or a positive squeegee system or a two-roll system, they all belong to an open ink supply structure. In such a structure, a large area of ​​ink is directly exposed to the atmosphere, and ink characteristics and environmental problems are easily caused. The emergence of. The requirement of fine printing and consideration of environmental protection will inevitably lead to a closed-type ink supply system, so a closed double-squeegee ink fountain system emerged. In addition to ceramic anilox rollers and doctor blades, there are auxiliary parts such as ink fountains, ink pumps, ink reservoirs and inking lines. The tightness of the system not only ensures the consistency of the various printing elements in the operation of the machine, but also the basic requirements of environmental protection; the pressure adjustable of the system ensures that the pressure distribution is uniform and the size of the entire contact surface is appropriate. The system is in an optimal operating state, and the system can be quickly docked with the cleaning system, and the internal () ink-removal elements can be completely cleaned in a short time to ensure the efficient operation of the entire printing production line.
Sealed double-squeegee ink fountain system is now more common in medium-to-high-end narrow-width flexographic printing presses, wide-format flexographic printing presses, plate printing machines, coating machines, and coating machines. It is precisely because this structure has many advantages. Outside the transformation of the old machine and equipment upgrades are more willing to use sealed double blade ink fountain system to replace the original ink supply system or coating coating system.
Fourth, the maintenance of ceramic anilox roller Ceramic anilox roller does have many advantages, but if you use improperly or do not pay attention to daily maintenance and then the superiority of ceramic anilox roller can not be fully played, and even can not be used normally The problem is that the characteristics of long life will not be discussed. Summarized the main problems that affect the long-term normal use of engraved ceramic anilox roller: 1) The improper use of accelerated roller wear speed ultimately affects the quality of the product; 2) The user did not explain to the supplier the special requirements under special conditions of use. Take the necessary anticorrosive measures on the ceramic anilox roller, and then blindly use the roller under severe environmental conditions, causing the ceramic roller to have the problems of substrate corrosion, surface blistering and other problems in advance; 3) In order to prevent the clogging of the mesh, timely and correct Cleaning the roller is extremely important. However, improper cleaning methods or blind operation according to the cleaning instructions often cause significant damage to the ceramic anilox roller; 4) scratches on the surface of the anilox roller due to many reasons, and the particles that may be generated from the blade wear may also be It is hard particles that are mixed in the ink and scratches the scratched surface. Such hard small particles may also come from the metal particles in the poor maintenance or quality of the ink pump; 5) collision damage, mainly occurs in the worker operation or the roller shift process.
The countermeasures we can take to address these five major issues are:
1) The laser-engraved ceramic anilox roller has good wear properties, but it is by no means "never worn". The important point in slowing down the wear rate of the ceramic roller and the doctor blade is to properly adjust the pressure applied on the doctor blade. Excessive pressure will accelerate the wear rate of the doctor blade and the anilox roller. Too little pressure will affect the final printing effect. Proper adjustment allows a very thin layer of ink between the roller and the blade to lubricate and reduce wear. Second, the viscosity of the ink is obviously poor in its lubrication, which is not conducive to reducing wear;
2) Good corrosion resistance is another important feature of the laser-engraved ceramic roller. When the user's ceramic anilox roller is in contact with the ink, paint and cleaning agent PH value is too large or too small (PH <4.5 and PH> 11.8) users must provide suppliers with material and process to take enhanced corrosion resistance measures. At present, suppliers are fully capable of producing ceramic rollers with better corrosion resistance and have been promoted in production practice. The selection of the base roll material is extremely important. The corrosion resistance of stainless steel is better, and the aluminum base material is more likely to corrode than the steel base material. It is recommended to use the aluminum base material as the roll under the water base ink condition.
3) Many articles have already introduced methods for the situation of metal and ceramic anilox rollers. It is important to always remind the operator. These cleaning methods can only achieve good results if they are strictly followed. Improper use can lead to changes in roller characteristics and even serious consequences of not being able to continue using it. For example, when ultrasonic cleaning, powder cleaning, and chemical cleaning are used, some people blindly pursue the cleaning effect, blindly increase the power density, increase the jet pressure, or extend the soaking time of the chemical cleaning solution, resulting in irrecoverable losses. In addition, during the cleaning process, inspections must be strengthened, and cleaning and inspections must be carried out in a coordinated manner. Truly, they are truly aware that blind day cleaning often causes adverse consequences. At present, the industry is forming a consensus that manual brushing is still a safe and effective cleaning process. The method can be used as a routine cleaning method, while others are only supplements to this method. In order to improve the effect of hand brushing on the high number of anilox roller, the diameter of the stainless steel wire of stainless steel brush is sometimes made 0.008mm.
4) The scribe lines on the ceramic anilox roll are circumferentially distributed, and the reasons for their occurrence have been mentioned above. In order to reduce their influence, filtration measures and placement of rare earth magnets are used in the ink pump system to capture various types of hardness. Small particles. In order to reduce the influence of scraper wear caused by metal particles, the installation of scraper must be carefully carried out, carefully check the scraper surface and the knife surface is clean and flat, check the flatness of the knife edge after installation, to avoid improper installation caused by knife blade ups and downs Wear and tear
5) Causes of collision damage Most operators are carelessly caused. In addition to strengthening the education of responsibility, the rollers are wrapped with special protective sleeves during transportation or in the workshop. Collision damage often occurs on the roller surface and at the tip corners.
BOPP packing tapes are some of the most commonly used tapes in shipping and inventory management today, and with good reason. The special molecular structure and the resin stabilization of polypropylene offer excellent mechanical and optical properties, which are especially useful in a variety of applications, one of which is packaging. BOPP packing tape is made from biaxial oriented polypropylene (BOPP) film. Polypropylene is a thermoplastic polymer (which means it is pliable above a certain temperature, and returns to the solid state after cooling). Now, biaxial oriented polypropylene is a PP film stretched according to the machine direction and across the machine direction. This increases the strength as well as the clarity of the film. The structure also makes the automated and manual application of the packaging tape easier.
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