Patent Application
20110203468
This invention relates to a printing roll such as gravure engraving roll or the like, which is provided by directly forming laser beam-engraved grooves as a concave portion for printing image area on a surface of a diamond-like carbon membrane as an outermost layer, and a method for producing the same.
Generally, the printing system can be divided into five systems of letterpress, lithography, intaglio, stencil and non-plate. The printing roll aimed at the present invention, for example, gravure engraving roll belongs to the intaglio, and is used in a printing system wherein an ink adhered to concave portions for printing image area are transferred to a paper after the ink is scraped out from non-image area. As a printing surface, those having 175 screening lines (printing elements) per 1 inch and a depth of a concave portion (cell) of about 2.5-30 μm are frequently used.
On the other hand, almost of printing inks are oil-based or water-based ones containing inorganic pigment or organic pigment. A basic composition of the ink is fine particles of a coloring pigment and is added with a polymer adhesive mass for equally transferring these fine particles to an objective to be printed, a solvent for imparting fluidity, transferring property and dryness to the ink, an auxiliary agent for suppressing ink bubbling to prevent generation of static electricity.
As the solvent of the oil-based ink, toluene, xylene, ethyl acetate, propyl acetate, methyl ethyl ketone and so on are used, while water, ethanol, propanol and so on are mainly used in the water-based ink. The solvents for the oil-based ink such as toluene, xylene, methyl ethyl ketone and the like are strong in the irritating odor, low in the flash point and high in the volatility, high in the risk of ignition and explosive and are absorbed by human bodies to induce health damage, so that they have significant problems in both of the safety and health. However, papers printed by the oil-based ink are excellent in the gloss and beauty in the appearance, so that they are widely put into practice and can not be completely removed from the printing field.
The water-based ink basically uses water and alcohol, so that it has an excellent advantage in the safety and hygiene as compared with the oil-based ink, but it is common that the quality of the printed matter is poor as compared with those of the oil-based ink.
In case of most common gravure engraving roll among printing rolls, a copper plated layer for the formation of printing surface is formed on a surface of a hollow roll made from an aluminum alloy or a stainless steel and thereafter a surface thereof is further subjected to a hard chromium plating to thereby improve the printing force of the etched copper plated layer. However, the hard chromium plating typically uses a plating bath containing hexavalent chromium, so that it is unfavorable in the working safety and is represented to be a source of environmental pollutant.
As a conventional countermeasure, JP-A-H04-282296, JPA-2002-172752, JP-A-2000-10300 and JP-A-2002-178653 propose a method wherein the surface of the etched copper plated layer as an image forming surface (printing pattern grooves) is coated with a diamond-like carbon film (hereinafter referred to as “DLC film”) instead of the chromium plating. Also, JP-A-H11-309950, JP-A-H11-327124 and JP-A-2000-15770 propose a technique wherein a layer of rubber or a resin is formed on a surface of the hollow roll and thereafter a surface thereof is engraved as a printing area and the DLC film is formed thereon, and JP-A-2007-130996 proposes a technique wherein a layer of a metal of W, Si, Ti, Cr or the like or a carbide thereof with a thickness of less than 1 μm is formed on the surface of the copper plated layer by sputtering method for improving the adhesion property of the DLC film to the etched copper plated layer and thereafter the DLC film is coated thereon.
The conventional gravure engraving roll having the DLC film as mentioned above is merely adopted for protecting the copper plated layer to be etched or the chromium plating subjected to the surface of the copper plated layer or the sputtered layer of tungsten, titanium, chromium or a carbide thereof though the DLC film is used. In JP-A-H04-282296, JP-A-2002-172752, JP-A-2000-10300 and JP-A-2002-178653, the DLC film is used only for protecting the etched copper plated layer, so that there is a problem that the properties inherent to the DLC film can not be developed.
It is, therefore, an object of the invention to propose a printing roll wherein concave portions for sharp printing elements can be maintained over a long time of period by applying the DLC film, which is not used as a protection membrane but is used as a printing plate itself, to gravure printing but also the concave portions having excellent printing characteristics can be engraved and further are excellent in the working properties, maintenance, printing plate life and so on.
It is another object of the invention to propose a method for producing a printing roll wherein the roll is produced by a dry process instead of a wet process including a copper plating step and a chromium plating step as a source of environmental pollutant and is excellent in not only the environment but also the safety and hygiene of workers.
The inventors have made various studies for solving the above problems of the conventional techniques and found that the above problems can be solved by the following means.
The invention lies in a printing roll comprising a roll substrate, a carbide cermet spray coating formed on the surface of the roll substrate and a DLC film layer formed on the surface of the carbide cermet spray coating and having laser beam-engraved grooves as a concave portion for printing image area.
In the printing roll according to the invention, the followings are preferable means:
(1) The DLC film is provided with hydrophilicity by including 0.1-22 atomic % of fine oxide particles of at least one metal selected from Si, Y, Al and Mg;
(2) The DLC film has a thickness of 3-50 μm, a chemical composition of carbon: 70-88 atomic % and hydrogen: 12-30 atomic % and a hardness Hv of 700-3000;
(3) The DLC film having laser beam-engraved grooves has a residual stress of less than 1.0 GPa;
(4) The DLC film has Ra≦0.013 μm and Rz≦0.16 μm as a roughness of a finish polished surface;
(5) The carbide cermet spray coating contains 95-70 mass % of at least one metal carbide selected from WC, TiC, Cr3C2 and MoC and 5-30 mass % of at least one metal selected from Ni, Cr, Mo, Co and Al.
In the printing roll according to the invention, the followings are more preferable means:
(6) A surface roughness of the roll substrate roughened by blast process is adjusted to Ra: 5-12 μm and thereafter a carbide cermet spray coating containing 95-70 mass % of at least one metal carbide selected from WC, TiC, Cr3C2 and MoC and 5-30 mass % of at least one metal selected from Ni, Cr, Mo, Co and Al is formed on the roughened surface;
(7) The surface of the carbide cermet spray coating is made to Ra: 0.05-8.00 μm and Rz: 0.5-20 μm by grinding or grinding-polishing.
Also, the invention proposes a method for producing a printing roll, which comprises roughening a surface of a roll substrate by blast process; forming a carbide cermet spray coating on the roughened surface by spraying process; grinding or grinding-polishing the surface of the carbide cermet spray coating; forming a DLC film on the ground or ground-polished surface of the carbide cermet spray coating; and engraving the surface of the DLC film through laser beams to form laser beam-engraved grooves as a concave portion for printing image area.
In the production method of the printing roll, the followings are preferable means:
(1) The DLC film is provided with hydrophilicity by including 0.1-22 atomic % of fine oxide particles of at least one metal selected from Si, Y, Al and Mg;
(2) A surface roughness of the roll substrate roughened by blast process is adjusted to Ra: 5-12 μm and thereafter a carbide cermet spray coating containing 95-70 mass % of at least one metal carbide selected from WC, TiC, Cr3C2 and MoC and 5-30 mass % of at least one metal selected from Ni, Cr, Mo, Co and Al is formed on the roughened surface;
(3) The surface of the carbide cermet spray coating is made to Ra: 0.05-8.00 μm and Rz: 0.5-20 μm by grinding or grinding-polishing;
(4) The DLC film has a thickness of 3-50 μm, a chemical composition of carbon: 70-88 atomic % and hydrogen: 12-30 atomic % and a hardness Hv of 700-3000;
(5) The surface of the DLC film is finish polished to approximately a roughness of Ra≦0.013 μm and Rz≦0.16 μm;
(6) The DLC film is engraved as a concave portion for printing image area with a heat source of at least one laser beam selected from CO2 laser, YAG laser, Ar laser and excimer laser;
(7) The DLC film has a residual stress of less than 1.0 GPa.
According to the invention, the aforementioned DLC film is used as an image forming layer of the printing roll or an engraved layer of concave portions for printing image area, so that the following effects can be expected:
(1) Since the DLC film is typically hard and excellent in the abrasion resistance, when it is used as an image forming layer of the printing roll, laser beam-engraved grooves as a concave portion for printing image area (engraving surface) can be used over a long time of period without losing the shape;
(2) The DLC film having laser beam-engraved grooves as the concave portion for printing image area has a smooth surface and is excellent in the abrasion resistance, so that it is small in the contact resistance with a printing paper and can increase the printing rate;
(3) When the surface of the DLC film is engraved by laser beams to form the concave portions for printing image area, portions irradiated with laser beams are emitted into air as a gas such as CO2, H2O or the like, so that accurate and beauty engraved grooves can be formed without generating minute fused agglomerates and the quality of the printed matter is improved.
(4) Since the rate of engraving the surface of the DLC film through laser beams is very fast, the production efficiency is improved but also the removal of the DLC fim after use is easy. Further, the members other than the DLC film can be used repeatedly, so that an economical and environmentally-friendly technique can be provided.
(5) The DLC film is formed on the surface of the roll substrate through the intermediate layer made of the carbide cermet spray coating instead of the direct formation, so that even if a large load is applied to the thin DLC film during the printing, the shape of the laser beam-engraved grooves (concave portions for printing image area) is never deformed or buckled.
(6) Since the carbide cermet spray coating having an excellent adhesion property to the roll substrate and the DLC film consisting essentially of carbon and hydrogen is used as the intermediate layer, even if large load is applied to the DLC film in the printing, the film is never peeled off.
(7) Even if the roll substrate is copper and copper alloy, aluminum and aluminum alloy, or nickel and nickel alloy, which is not suitable for the formation of the DLC film, it is possible to form the good DLC film by interposing the intermediate layer made of the carbide cermet spray coating, so that the degree of freedom in the material selection of the roll substrate becomes large.
(8) Since the DLC film formed by using a hydrocarbon-based gas is lipophilic in nature, it is suitable for the use of oil-based printing inks. In the invention, however, it is possible to impart hydrophilicity to the surface of the DLC film by co-precipitating fine particles of the metal oxide into the film, so that it can be used in both the oil-based and water-based printing inks.
(9) In the method according to the invention, the film is not formed by using the chemicals having a large environmental load such as copper plated layer or chromium plated layer, or the etching engraving method with such a chemical is not used, so that the environmental load can be reduced but also there can be provided a production process being excellent in the safety and hygiene of workers.
a) is a section view of a DLC film when Rz value as a surface roughness of a spray coating is large, and (b) is a section view of a DLC film applied on a surface of a spray coating having small Ra and Rz values;
(a) shows a distribution state of water droplets fallen onto a lipophilic DLC film;
(b) shows a distribution state of colloidal silica powder remaining on a DLC film after evaporation of water droplets of the state (a);
(c) shows a distribution state of water droplets fallen onto a hydrophilic DLC film;
(d) shows a distribution state of colloidal silica powder remaining on a DLC film after evaporation of water droplets of the state (c).
(1) Grinding, Grinding-Polishing Step of Roll Surface;
As a substrate for the gravure engraving roll can be used a pipe wherein an inside of the roll is hollowed for weight saving. In general, this engraving roll is finished to have a surface roughness Ra of about 5-12 μm by grinding or grinding-polishing the surface with a lathe or a polishing machine. As a material of the roll substrate are preferable Al and Al alloy, Ti and Ti alloy, and so on, but cast iron and carbon steel (including alloyed steels such as stainless steel) may be used. Also, composite materials reinforced with plastic or glass fibers or carbon fibers may be used. In case of cast roll, cast cavities may be generated in the roll surface, so that they are repaired by spot welding, a method of embedding metal pins or the like in advance.
(2) Step of Blasting Roll Surface;
The surface of the roll substrate subjected to grinding or grinding-polishing is subjected to blasting with Al2O3 grids to render into a given roughened state. If a high-speed flame spraying method is applied at a subsequent step of forming a spray coating, a flying speed of hard spraying particles becomes large (for example, not less than 300 m/s), so that the roughening treatment with blasting may be omitted. Because, when hard carbide cermet spraying particles come into collision with the roll surface at a large flying speed, they stick on the surface of the substrate to form a coating having a strong adhesion force.
(3) Step of Forming Spray Coating;
In the invention, a spray coating of carbide cermet is formed on the surface of the roll substrate prior to the formation of DLC film as a surface for printing image area. As a carbide used are preferable WC, TiC, Cr3C2, MoC and so on as a single or composite carbide, and hard WC and WC—Cr3C2 are particularly preferable. As a metal component is included 5-30 mass % of at least one metal selected from Ni, Cr, Mo, Co and Al. In case of the single carbide, it is difficult to form a coating having a good adhesion property by the spraying method, and if the coating is formed, it is porous and unsuitable as a ground layer for DLC film. In case of the cermet spraying powder material formed by adding the metal component to the carbide, the metal component is fully fused in a hot spraying source to improve a joining force to the roll substrate and to enhance mutual bonding force among particles constituting the coating, while the generation of pores is suppressed in minimum. Moreover, the size of the carbide cermet spraying particles is preferable to be a range of 5-70 μm as a particle size. When the particle size is less than 5 μm, it is difficult to continuously and equally feed the particles to a spraying gun, while when it exceeds 70 μm, the particles are not completely fused in the hot spraying source and hence the resulting coating is liable to be porous.
In the formation of the carbide cermet spray coating, a plasma spraying method in air, a plasma spraying method under a reduced pressure, a high-speed flame spraying method, an explosive spraying method and the like are preferable, and the high-speed flame spraying method is particularly preferable. In the high-speed flame spraying method, the temperature of the hot spraying source is relatively low (1800-2200° C.), but the speed is not less than 1000/s, so that the change of properties due to thermal decomposition of the carbide can be suppressed but also large kinetic energy is applied to the spraying particles and hence these particles can be adhered and deposited with strong impact force to form a dense coating.
The thickness of the carbide cermet spray coating is preferably a range of 30-200 μm. When the thickness of the coating is less than 30 μm, it is liable to easily form a coating having partially many pores and it is difficult to obtain an equal coating. While, when the thickness exceeds 200 μm, remarkable effects are not obtained as a ground coating for DLC film and the production cost is rather increased.
(4) Step of Finishing Surface of Carbide Cermet Spray Coating;
In this step, the surface of the carbide cermet spray coating is ground with a diamond-based grind stone or a polishing agent or finished into a mirror state by polishing after the grinding. The finishing degree of the surface of the carbide cermet spray coating in this step exerts a large influence on the effect of DLC film at subsequent step. The surface roughness of the spray coating through this step can be made to ranges of Ra: 0.05-8.00 μm and Rz: 0.5-20 μm, but it is particularly important to control Rz. For instance,
In general, when large area, boldfaces, large numerical symbols and so on are printed in the gravure printing, even if the surface roughness of the spray coating has approximately Ra=0.05-8.00 μm and Rz=0.5-20 μm, good laser beam-engraved grooves are obtained as long as the thickness of the DLC film formed on the coating is not less than 40 μm. Conversely, when printing precise small letters, numerical symbol and lines, the surface roughness of the spray coating is finished into ranges of Ra=0.05-0.8 μm and Rz=0.5-1.5 μm and the DLC film is formed on such a surface at a thickness of 3-5 μm.
As mentioned above, it is necessary that the surface of the carbide cermet spray coating for forming the DLC film adopted in the invention is finished so as to render into a thickness corresponding to two times or more Rz value of the surface roughness.
(5) Step of Forming DLC Film;
This step is a treatment that DLC film adapted in the invention is formed on the ground or ground-polished surface of the carbide cermet spray coating. The DLC film formed on the spray coating surface according to the invention can be formed by any method such as an ionization deposition method, an arc ion plating method, a plasma buster method and a high-frequency, high-voltage pulse superimposed type plasma CVD method (referred to as “plasma CVD method” hereinafter). The followings are concretely explained with respect to plasma CVD method suitable for the formation of thick film and an apparatus thereof.
In the plasma CVD apparatus, a gas introduction device for introducing an organic gas for the formation of the film into the reaction vessel 41 (not shown) and a vacuum device for vacuuming the reaction vessel 41 (not shown) are connected to the reaction vessel 41 through valves 47a and 47b, respectively.
In order to form the DLC film on the surface of the body to be treated using the plasma CVD apparatus, the printmaking roll 42 is first placed in a given position inside the reaction vessel 41, and the vacuum device is actuated to discharge air from the inside of the reaction vessel 41, and then an organic gas is introduced into the reaction vessel 41 through the gas introduction device.
Then, a high-frequency voltage is applied from the plasma generating power source 45 to the printmaking roll 42. Since the reaction vessel 41 is electrically a neutral state through a ground wire 48, the printmaking roll 42 becomes relatively negative potential, and hence plus ions in the plasma are generated around the negatively charged printmaking roll 42.
When high-voltage pulses (negative high-voltage pulses) are applied from the high-voltage pulse generating power source 44 to the printmaking roll 42, plus ions in the plasma of the introduced organic gas are attracted and adsorbed onto the surface of the printmaking roll 42. Onto the surface of the printmaking roll 42 is formed a DLC film by such a treatment. Namely, it is considered that a DLC film of amorphous hydrocarbon solid consisting of carbon hydrogen as a finally main component is precipitated in vapor phase around the printmaking roll 42 to form a DLC film coating therearound.
Moreover, the inventors have presumed that the DLC film of amorphous hydrocarbon solid formed by the above plasma CVD apparatus is produced through the following processes (a)-(d):
(a) the ionization of the introduced hydrocarbon gas is caused (neutral particles called as radical are also existent);
(b) the ions and radicals changed from the hydrocarbon gas are impulsively collided to the negatively charged surface of the printmaking roll 42;
(c) C—H bond having a small bonding energy is cut by energy in the collision and thereafter activated C and H repeat polymerization reaction to form a polymer, whereby amorphous hydrocarbon solid consisting essentially of carbon and hydrogen is precipitated in vapor form; and
(d) the DLC film made of a deposited layer of amorphous hydrocarbon solid is formed on the surface of the printmaking roll 42 by the above reaction (c).
Moreover, ion implantation of a metal or the like to the printmaking roll 42 may be conducted by varying an output power of the high-voltage pulse generating power source 44 in the above apparatus to the following (a)-(d):
(a) case of heavily conducting ion implantation: 10-40 kV;
(b) case of conducting both ion implantation and coating formation: 5-20 kV;
(c) case of conducting only coating formation: several hundred V to several kV;
(d) case of heavily conducting sputtering or the like: several hundred V to several kV.
In the high-voltage pulse generating power source 44, it is possible to repeatedly generate pulses having a pulse width of 1 μmsec-10 msec and a pulse number of 1-plural times.
Also, the output frequency of high-frequency voltage from the plasma generation power source 45 may be varied in a range of several ten kHz to several GHz.
As the organic gas for the formation of the film introduced into the reaction vessel 41 in the plasma CVD apparatus are used hydrocarbon-based gases each consisting essentially of carbon and hydrogen as shown in the followings (i)-(iii) and organic metal compounds obtained by adding at least one of Si, Al, Y and Mg thereto:
(i) CH4, CH2CH2, C2H2, CH3CH2CH3, CH3CH2CH2CH3 of vapor phase at room temperature (18° C.);
(ii) C6H5CH3, C6H5CH2CH, C6H4(CH3)2, CH3(CH2)4CH3, C6H12, C6H4Cl of liquid phase at room temperature;
(iii) Organic Si Compounds (Liquid Phase)
(C2HSO2)4Si, (CH3O)4Si, [(CH3)4Si]2O
As the gas introduced into the reaction vessel 41, the gas of vapor phase at room temperature can be introduced into the reaction vessel 41 as it is, whereas the compound of liquid phase is gasified by heating and the resulting gas (steam) is supplied to the reaction vessel 41, whereby the DLC film can be formed.
Moreover, the DLC film formed on the ground or ground-polished surface of the carbide cermet spray coating has the following properties:
(a) Ratio of Carbon and Hydrogen Contents Constituting DLC Film
The DLC film is hard and excellent in the abrasion resistance, but generates a large residual stress in the film formation, so that the flexibility is lacking. Therefore, if local fine defects are caused in the DLC film or slight engraved difference is locally generated during the engraving through laser, the DLC film is apt to be easily peeled off due to the residual stress, so that it is important to mitigate the residual stress.
As a countermeasure, the invention draws attention to the ratio of carbon and hydrogen constituting the DLC film, and particularly the hydrogen content is controlled to 12-30 atomic % as a whole to thereby impart the abrasion resistance and flexibility to the DLC film. Concretely, the hydrogen content included in the DLC film is made to 12-30 atomic %, while the reminder is the carbon content. The formation of the DLC film having such a composition can be attained by mixing a compound having a different hydrogen content occupied in the hydrocarbon gas for the formation of the film.
Moreover, the DLC film having the aforementioned hydrogen content has a micro-Vickers hardness of Hv: 700-3000 as a surface hardness, so that it is far soft and has a flexibility withstanding to a certain deformation as compared with DLC films formed on tool steels and the like.
(b) Residual Stress of DLC Film Suitable for Engraving with Heat Source of Laser Beams
In the DLC film of solid phase state precipitated from the hydrocarbon gas of vapor phase is necessarily caused residual stress. In the DLC film having a large residual stress, the thicker the film thickness, the larger the residual stress, so that the residual stress is finally larger that the adhesion strength of the film, resulting in the peeling of the DLC film. At the present, many kinds of apparatuses are developed as the method of forming the DLC film, but one of the applied conditions is a limit thickness determined by the residual stress of the resulting DLC film.
Even if the DLC film having a relatively thick thickness is formed, the residual stress concentrates into concave portions of the film formed by engraving through laser beams, and hence the DLC film is locally broken or peeled off, so that it is very important to determine an optimal value of the residual stress in the DLC film.
From the reasons as mentioned above, the inventors measured the residual stress of the DLC film by the following method. The evaluation of the residual stress of the DLC film is carried out by forming a DLC film on a reed-shaped thin quartz substrate (size: width 5 mm×length 50 mm×thickness 0.5 mm) fixed to one end of a test specimen and measuring displacement amount (δ) of the quartz substrate before and after the film formation to determine the residual stress of the film, and concretely the residua stress (σ) is calculated according to the following Stoney equation:
E: Young's modulus of substrate=76.2 GPa
v: Poisson's ratio of substrate=0.14
b: thickness of substrate=0.5 mm
l: length of substrate formed with DLC film
δ: displacement amount
d: thickness of DLC film
Table 1 shows a summary of residua stress values of various DLC films determined by the above method. As seen from the results, the residual stress of the DLC film formed by a method such as arc ion plating method, ionization deposition method or the like is 10-18 GPa, while the residual stress of the DLC film formed by plasma CVD method is as very low as 0.30-0.98 GPa.
Moreover, when the maximum forming thickness of the DLC film is attempted in this test, in the plasma CVD method, the film forming time becomes longer, but the film having a thickness of 50 μm was formed. However, in the other film formation, it is difficult to form the film having the thickness of not less than 3 μm.
(c) The DLC film formed by the method of the invention is possible to be immediately subjected to engraving through laser beams. However, in the invention, in order to properly cope therewith in accordance with the nature of the printing ink, it is designed that hydrophilicity is imparted to the surface of the DLC film so as to develop sufficient wettability against water soluble printing inks. That is, metal fine particles are co-precipitated into the DLC film obtained by the above method and further oxidized to form fine particles of metal oxide, whereby the surface is changed into a surface having a hydrophilicity to improve the wettability to the water-soluble printing ink.
In general, when amorphous-like DLC film itself containing no metal oxide is formed by any one of the above plasma CVD method, ionization deposition method, arc ion plating method and plasma buster method, the surface of the DLC film indicates lipophilicity, so that the wettability with the oil-based ink is good, but there is a tendency that the wettability with the water-soluble printing ink adopted as a good printing ink for environment is bad, which is a large possibility of causing the decrease of quality in the printed matters.
According to the invention, therefore, those containing the organic metal compound is used as a starting material for the formation of the DLC film or an organic gas for the film formation. In the DLC film formed by the method using the organic metal compound gas, fine particles of the metal are co-precipitated and changed into fine particles of metal oxide, whereby hydrophobicity can be changed into hydrophilicity.
The method of forming DLC film while co-precipitating metal fine particles will be concretely described below.
The kind of the gas introduced into the reaction vessel 41 shown in
As an example of the organic metal compound gas, for example, if it is intended to precipitate fine particles of Si, (C2HSO)4Si, (CH3O)4Si, [(CH3)3Si] and the like are preferable. On the other hand, in order to precipitate Al, Y, MG or the like, a gas with a composition of Al, Y, Mg added instead of Si in the above-mentioned organic metal compound may be used. Also, even in case of using the organic metal compound formed by adding an element such as Si, Al, Y, Mg or the like to (C11H19O2) group or (C12H21O2) group, amorphous film consisting essentially of carbon and hydrogen and dispersedly containing an element such as Si, Al, Y, Mg or the like can be formed. Moreover, the organic compound gas of vapor phase at room temperature can be introduced into the reaction vessel 41 as it is, but the compound of liquid phase is gasified by heating and the resulting steam supplied to the reaction vessel 41. When amorphous film is formed by using the organic Si compound gas, fine particles of Si are co-precipitated and incorporated into the film and there is particularly a possibility that a part of Si is strongly bonded to carbon to produce SiCx, which does not obstruct the function and effects of the invention.
The particle size of the metal particles in the DLC film co-precipitated by using the above organic metal compound gas is Si≈2.34 Å (2.34×10−10 m), Al≈2.86 Å (2.86×10−10 m), Y≈3.64 Å (3.64×10−10 m), Mg≈3.20 Å (3.20×10−10 m), so that these fine particles are difficult to be determined by not only an optical microscope but also an electron microscope as shown in
As the method of oxidizing the metal fine particles co-precipitated in the DLC film, there may be mentioned the following methods;
(a) the particles are heated in an oxygen gas or in a gas atmosphere containing oxygen gas; and
(b) they are oxidized by an oxygen gas plasma. These methods are described below.
(a) Method of Heating in an Atmosphere Containing Oxygen Gas;
When the DLC film containing predetermined fine particles (at least one metal selected from Si, Al, Y and Mg or an alloy thereof) is heated in air or under an environment of an atmosphere containing oxygen gas, super-fine particles included in the DLC film are oxidized and changed from the surface of the film to form an oxide. Concretely, they are changed into chemically stable oxide of Si→SiO2, Al→Al2O3, Y→Y2O3 or the like to develop the hydrophilicity. In this case, the upper limit of the heating temperature is 500° C. When the heating temperature exceeds 500° C., the DLC film consisting essentially of carbon and hydrogen is deteriorated. The hearting time is determined depending on the changing rate of the fine oxide particles included in the DLC film, but is for example, about 0.1 hr-10 hr. Moreover, when all of super-fine particles included in the DLC film are changed into oxide, if the heating time is elongated thereover, the DLC film may be deteriorated thermally.
(b) Method of Oxidizing by Oxygen Gas Plasma;
For example, when plasma is generated by using a plasma CVD apparatus of
The amorphous DLC film formed by the aforementioned method and containing the metal oxide is confirmed that the film is wettable with water because the contact angle of the surface with droplet fallen thereon as measured for hydrophilicity is smaller by 34-42% that those of DLC film containing no metal oxide as described below.
Contact angle of DLC film containing metal oxide with water droplet: 15-20° (hydrophilicity)
Contact angle of DLC film containinmg no metal oxide with water droplet: 70-72° (lipophilicity)
Moreover, the content of the metal oxide fine particles co-precipitated into the DLC film is preferably 0.1-22 atomic %. When it is less than 0.1 atomic %, the control is difficult and sufficient effect is not obtained even if a slight amount of oxide particles is co-precipitated. When it exceeds 22 atomic %, there is no remarkable effect in the difference on the water wetting effect.
The fine particles of the metal oxide co-precipitated in the DLC film are excellent in the hydrophilicity, and hard and good in the abrasion resistance.
The thickness of the DLC film formed on the roll substrate by any of the above methods is suitably within a range of 3-50 μm irrespectively of the presence or absence of the co-precipitation of the metal oxide fine particles. When the thickness of the DLC film is less than 3 μm, the engraving accuracy through laser beams at subsequent step is slightly lowered to shorten the life of the DLC film. While when it exceeds 50 μm, a long time is taken and the rise of production cost is caused.
(6) Finish Polishing Step;
The DLC film made on the roll substrate through the above steps is subjected to finish polishing by buffing, if necessary, as shown in
(7) Step of Engraving Through Laser Beams;
Laser beam-engraved grooves as a concave portion of printing image area are formed by irradiating laser beams to the surface of DLC film formed on the roll substrate through the above steps.
At this step, CO2 laser, YAG laser or Ar laser is used as a laser source. The surface of the DLC film is subjected to an irradiation treatment with laser beams while rotating the roll or moving the laser heat source. This operation is carried out automatically by a computer in which laser beams are adjusted by lens in accordance with the size of the engraved groove (width, depth). As a result, the DLC film itself is locally heated by the laser beams, while only the overheated DLC film is vaporized and emitted in the form of gas such as CO2, H2O or the like into air, so that fused matter is not retained on the surface of the DLC film at all and the engraved grooves can be formed precisely and accurately.
Laser output: 50 W-1 kW
Pulse frequency: 10000 Mz-50000 Hz
Progression rate: 0.1-300 mm/min
In this example, a coating is formed on an aluminum substrate by various methods, and thereafter a DLC film is formed on the surface of the coating, and then the adhesion strength of the DLC film is measured by a scratch test defined according to an adhesion test method of thin film on glass substrate of JIS R3255.
(1) Substrate
As a test piece substrate is used aluminum of 1050 grade defined in JIS H4000, which is cut into a test specimen of a size having width 50 mm×length 70 mm×thickness 5 mm.
(2) Film Forming Method and Kind of Coating
Onto one-side surface of the above A1 test specimen is formed a coating as a ground layer for DLC film by the following film forming method.
(i) Spraying method: WC-12 mass % Co, WC-20 mass % Ni-7 mass % Cr, TiC-20 mass % Ni, Cr3C2-20 mass % Ni-7 mass % Cr, Cu, Ni, Cr
Only Cr is by atmospheric plasma method, and others are by a high-speed flame spraying method, and the thickness of each film is 50 μm.
(ii) PVD method: Cr, Ar
A coating having a thickness of 3 μm is formed by a physical deposition method using electron beam source.
(iii) Electric plating method: Cu, Ni, Cr
A coating of 5 μm is formed by an electric plating method.
(3) Method of Forming DLC Film
A DLC film having a thickness of 5 μm is formed on each surface of the coatings by a plasma CVD method. In this example, a DLC film is directly formed on A1 test specimen as Comparative Example.
(4) Scratch Test
The scratch test is carried out according to an adhesion test method of a thin film using glass as a substrate defined in JIS R3255, in which a scratched state generated by moving a diamond needle while applying a load of 30 N to the needle is observed and recorded by a magnifying glass.
(5) Scratch Test Results
The results of the scratch test are summarized in Table 2. As seen from these results, the DLC films formed on the surfaces of Cu, Ni and Al are poor in the adhesion property irrespectively of any film forming methods such as spraying method, PVD method, electric plating method and so on and are easily peeled off. However, the DLC film formed on the Cr coating indicates a very good adhesion property even if the coating is formed by any film forming methods. Provided that Cr coating formed by the spraying method is porous, the DLC film formed on the coating is confirmed to be lacking in the smoothness because it exerts on the coating.
Since the Cr coating obtained by the PVD method or electric plating method is smooth, the DLC film formed on the coating is also smooth, which is sufficiently applicable for the object of the invention. However, it is poor in the productivity, and has a difficulty to the application to large members, and further the Cr coating by the electric plating has a problem in the safety and hygiene because Cr6+ is used in the production step.
On the contrary, the DLC films (No. 1-4) formed on the carbide cermet spray coating according to the invention indicate good adhesion property, and hence the phenomenon of peeling the DLC film is not substantially observed, and if the peeling is observed, it is very local and small area.
Moreover,
In this example, water-wetted state of DLC film co-precipitated with various metal oxides is examined, while the soundness of the DLC film is evaluated by subjecting the test specimen formed with the DLC film at a folded state of 90° to a salt spray test.
(1) Spray Coating as a Test Substrate
As a test substrate is used SK steel, from which is cut out a test specimen having a size of width 30 mm×length 70 mm×thickness 3 mm, and only one-side surface thereof is roughened by plasma working and thereafter a coating of WC-20Ni-7Cr (numeral value is mass %) is formed at a thickness of 80 μm by high-speed flame spraying method. Further, the surface is subjected to finish polishing of Ra: 0.5-0.8 μm.
(2) Properties of DLC Film
The following metal is co-precipitated into the DLC film over a full surface of the spray coating in the test specimen and then oxidized by an oxygen plasma treatment to form an oxide film having a thickness of 3 μm.
(a) Kind of co-precipitating oxide and co-precipitated state
Single oxide: SiO2, Y2O3, Al2O3, MgO
Composite oxide: SiO2/Y2O3, SiO2/Al2O3, Al2O3/Y2O3
Moreover, the content of the single oxide or composite oxide in the DLC film is 0.5 atomic %, and the ratio of the two metal oxides in the composite oxide is 1:1.
Also, the hydrogen content in the DLC film is 20 atomic % and the reminder is carbon.
(3) Test Methods
(a) Water-wetting test: The water wetting test is carried out by dropping tap water on the surface of the test specimen and visually observing water wetted state on the surface of the DLC film.
(b) Test for corrosion resistance: The test specimen is folded from its central portion at 90° and then subjected to a salt spray exposure test defined in JIS ZZ2371 for 96 hours to research the presence or absence of red rust.
(4) Test Results
The test results are summarized in Table 3. As seen from the test results, water dropped on the DLC film co-precipitated with fine particles of the metal oxide is wetted over its full surface, whereas the generation of red rust is not observed on the DLC film even when the DLC film not co-precipitated with the oxide is folded at 90° as a contact angle and subjected to the salt spray exposure test as it is. From these results, it has been confirmed that the DLC film formed on surface of the carbide cermet spray coating and co-precipitated with fine particles of the oxide does not cause cracking and peeling phenomenon in the film itself and has a corrosion resistance equal to that of the DLC film containing no oxide film even if being subjected to some deformation.
In this example, lipophilicity (hydrophobicity) and hydrophilicity (lipophobicity) are given to the DLC film according to the invention to research wetting state of water and oil against the film surface.
(1) Test Substrate and Spray Coating
As a test substrate is used SUS 304 steel, from which is cut out a test specimen having a size of width 50 mm×length 100 mm×thickness 3.2 mm, and thereafter only one-side surface thereof is subjected to a plasma roughening treatment and then a WC-12 mass % Co cermet coating of 100 μm in thickness is formed on the roughened surface by a high-speed flame spraying method. Further, the surface of the spray coating is finished to Ra: 1.1-1.4 μM and Rz: 5-9 μm.
(2) Properties of DLC Film
On the surface of the spray coating is formed a DLC film at a thickness of 5 μM, and then the DLC film is changed into hydrophilicity by subjecting to a treatment as mentioned below:
(a) hydrophobic DLC film: film comprising hydrogen content of 18 atomix % and the reminder of carbon;
(b) hydrophilic DLC film: film formed by co-precipitating 1.2 atomic % of SiO2 as an example of metal oxide on the surface of the DLC film.
(3) Test Method
An aqueous slurry polishing agent containing colloidal silica is applied dropwise to the surface of the DLC film of the test specimen, which is placed in a hot air furnace of 90° C. to evaporate only water. Thereafter, the distribution state of colloidal silica particles retaining on the surface of the DLC film is observed by a magnifier with 20 magnification to compare quality of water wetting. The reason why this method is adopted is due to the fact that it has been confirmed by preliminary experiments that the colloidal silica particles are necessarily retained in the existing places of the aqueous slurry polishing agent after the evaporation of water and the water wetting degree can be seen by equalization of the retaining distribution amount or the like.
(4) Test Results
The test results are summarized in Table 4. As seen from the test results, when the aqueous slurry polishing agent is added dropwise over the full surface of the DLC film containing no SiO2 particles, which indicate hydrophobicity, it is dispersed in form of small and large water puddles immediately. Thereafter, solid-like colloidal silica fine particles locally remains in the hydrophobic DLC film after the evaporation of water in the hot air furnace, and it has been confirmed that the water wetting area is small and irregular distribution state is existent. On the contrary, colloidal silica is equally distributed over the full surface of the DLC film with hydrophilicity suitable for the invention.
On the other hand,
Moreover, when the wetting property of the DLC film is researched with an oil (machine oil) instead of water, an oil film is equally existent on the full surface of the hydrophobic DLC film, but the equal wetting property of the oil film can not be observed on the hydrophilic DLC film containing SiO2.
As seen from the above results, the DLC film according to the invention can give good wettability to both of oil-base and water-base printing inks.
The technique of forming engraved grooves on the DLC film through laser beam irradiation according to the invention is sufficiently applicable to letterpress, lithography, stencil and non-plate systems in addition to the gravure engraving. Also, the form of the substrate may be flat plate in addition to the roll. For example, the DLC film may be formed on the surface of glass, plastic or the like, so that after the formation of the DLC film on these surfaces, it is subjected to laser beam work to form a printing plate, or it is possible to fabricate new art products by retaining various coloring inks on the engraved portions. Furthermore, after the DLC film is formed on a sliding part of a bearing, shaft or the like in machineries, a helical groove may be formed on the film through laser beams to use as a pathway of a lubricant.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-288827 | Nov 2008 | JP | national |
| 2009-078054 | Mar 2009 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2009/069234 | 11/5/2009 | WO | 00 | 5/5/2011 |
