A ROTOGRAVURE PRINTING MEDIA AND METHODS OF MANUFACTURING A ROTOGRAVURE PRINTING DEVICE EMPLOYING THE MEDIA

Abstract: A printing medium or image carrier for application to a printing apparatus or substrate which comprises a plastic composition which is applied to a printing substrate to form a plastic coating covering the substrate, which plastic coating is engraved to provide a printing medium. Preferred plastic compositions are those including epoxide resins such as cycloaliphatic epoxide resins, reaction products of epichlorohydrin and bisphenol A, bisphenol A epoxy resins modified with cresol novolac(s), epoxy-novolac resins, and epoxy-novolac based vinyl esters. The present invention provides for an effective rotogravure printing medium without the use and/or disposal of hazardous chemicals.

Description: A ROTOGRAVURE PRINTING MEDIA AND METHODS OF MANUFACTURING A ROTOGRAVURE PRINTING DEVICE EMPLOYING THE MEDIA This invention relates to a printing medium upon a substrate such as a printing roll or a cylinder. More particularly, this invention relates to the application of a plastic printing media to printing rolls or cylinders employed in rotogravure printing. Rotogravure printing is one of the conventional methods of printing on a sheet, web, or other substrate. The sheet or substrate may be a coated, uncoated, or metallized paper; glassine; plastic films and sheets made from vinyl, cellulose, acetate, polyester and polyethylene; plastic shrink films; paperboard, ; aluminum foil, and fabrics. Rotogravure printing is capable of reproducing both subtle shades of color and black and white, and is particularly well suited for printing great numbers of copies precisely and rapidly. Typical end uses include labels, cartons, paper and plastic cups, trading stamps, wrapping paper, and sheet vinyl flooring. Rotogravure printing is the only commercial printing process which can control both the ink film thickness and the area of coverage. This is achieved by the engraving of recessed microscopic wells, frequently referred to as "cells" nf varying depth and area in the printing medium or image carrier surface. In controlling the size and depth of the wells, the amount of ink available for placement on the substrate is governed to generate an image composed of an arrangement of large and small dots. In a typical rotogravure apparatus, the printing medium or image carrier is a copper film electro-deposited from a chemical bath on a specially prepared steel cylinder. •Prior to the engraving of the recessed wells, the copper is mechanically ground and polished. After engraving, the cylinder requires the addition of plated, hard chromium for durability and wear resistance. During the printing process the cylinder is rotated in a bath of ink. The excess ink is wiped away by a doctor blade and the ink remaining in the engraved cell is then transferred to a substrate, with the substrate acting somewhat like a blotter to which the ink is transferred as discrete dots as the substrate passes between the engraved cylinder and a soft pressure roller. The recommended modern process to prepare a copper image carrier requires the use of electrolytic deposition from an acid/copper bath. A steel base of the required diameter is partly immersed in a chemical copper solution and rotated at a regulated speed. An electrical current running through the solution gradually deposits a coating of copper on the rotating cylinder until the approximate required thickness is achieved. The copper plated cylinder is washed and then polished to final dimensions with a smooth, mirror like surface finish. The copper coating is then engraved, either chemically or electronically. In the chemical engraving process, wells are formed by acid etching of the copper coating. The wells of the cell are formed by a screen running at right angles which prevents the acid from reaching the copper surface. The resulting acid-etched wells are round in shape and slightly smaller at the bottom than at the top. The process of forming the copper coating for the printing cylinder and of chemically engraving the copper coating may result in the formation of waste products which are environmentally hazardous, requiring costly disposal. In accordance with an aspect of the present invention, there is provided a printing medium for application to a printing apparatus (e.g., a rotogravure printing drum or cylinder). The term "printing apparatus", as used herein, means any apparatus or device which transfers an inked image. The medium comprises a plastic composition which is applied to a substrate to form a plastic coating covering the printing substrate, which plastic coating is engraved to provide a printing surface. The plastic composition may be part of an ultra-violet (UV) cured system, a heat cured system, or a room temperature gelled system. In an ultraviolet cured system, the plastic composition preferably includes at least one epoxide resin selected from the group consisting of cycloaliphatic epoxide resins and amine-based epoxide resins. The plastic composition may further include epoxide resins selected from the group consisting of diglycidyl ether-bisphenol A(DGEBA), a reaction product of epichlorohydrin and bisphenol A, bisphenol A epoxy resins modified with cresol novolac(s), or a polyepoxide obtained by reacting a phenolic novolac with epichlorohydrin. Examples of phenolic novolacs include products of reactions of phenol(s) or cresol(s) with formaldehyde(s) , such as orthocresol formaldehyde(s) . In one alternative, the plastic composition may include a bisphenol A epoxy resin modified with cresol novolac(s) and a photoinitiator component. In another alternative, the plastic composition may comprise vinyl esters derived from epoxy novolac compounds. Such vinyl esters preferably are employed in combination with a styrene monomer. Cycloaliphatic epoxides are preferably of the carboxylate type, and most preferably 3,4-epoxycyclohexylmethyl-3,4-epoxy-cyclohexane, which has the following structural formula. Examples of cycloaliphatic epoxides which may be employed include Cyracure (R * UVR-6100 and UVR-6110, ER -4221, which are products of Union Carbide Corporation, Danbury, Connecticut, and Araldite R ' CY179, a product of Ciba-Geigy. UVR-6100 has a Brookfield viscosity at 25°C of from 85 to 115 cP, a specific gravity at 20°C of 1.1395, and an epoxy equivalent weight (EEW) of from 130 to 140. UVR-6110 and ER -4221 each have a Brookfield viscosity (25°C) of from 350 to 450, a specific gravity of 1.175, and an epoxy equivalent weight of 131 to 143. Bisphenol A-epichlorohydrin reaction products have the following general structural formula: Preferably, n is from 1 to about 100. Examples of amine-based epoxy resins which may be employed include, but are not limited to, Ciba-Geigy Epoxy Resin 0500 and Araldite MY720, both of which are products of Ciba-Geigy Corporation, Plastics Department, Hawthorne, New York. Ciba-Geigy Epoxy Resin 0500 is a high functionality amine-based resin, and has an epoxy equivalent weight of from 105 to 115 g/g-mole, a viscosity at 25°C of from 1,500 to 5,000 cps, and a specific gravity of from 1.215 to 1.225. Araldite MY720 is N, N, N , N -tetraglycidyl-4,4' -methylenebisbenzenamine, and has an epoxy value of from 0.75 to 0.85 eσ/lOOg, a weight per epoxide of fro 117 to 134g/g-mole, and a viscosity at 50°C of from about 8,000 to about 18,000 cP. An example of a reaction product of epichlorohydrin and bisphenol A which may be employed is D.E.R. 330, a product of Dow Chemical Company, Midland, Michigan. D.E.R. 330 has a viscosity at 25°C of from 7,000 to 10,000 and an epoxy equivalent weight of from 176 to 185. Bisphenol A epoxy resins modified with cresol novolac(s) include, but are not limited to, Experimental Resin XU-252, a product of Ciba-Geigy Corporation, Resins Department, Hawthorne, New York. XU-252 is a multifunctional epoxy resin, which is a chemically modified bisphenol A epoxy resin having a cresol novolac component as a minor portion of the epoxy resin. The cresol novolac component does not exceed 20 wt.% of the resin. XU-252 has a viscosity at 52°C of from 1,000 to 1,600 CP, an epoxy value of from 0.51 to 0.54 eq./lOOg, a density of from 9.6 to 9.8 pounds per gallon at 25°C, and a flash point (closed cup) of greater than 200°F. Polyepoxides obtained by reacting a phenolic novolac with epichlorohydrin include those having the following structural Preferably, n is from 1 to about 100. An example of a polyepoxide obtained by reacting a phenolic novolac with epichlorohydrin is EPN 1139, a product of Ciba-Geigy. Vinyl esters derived from epoxy-novolac compounds incorporate an epoxy novolac backbone such as that hereinabove described while providing for an easily accessible terminal unsaturation. An example of a vinyl ester derived from an epoxy novolac compound which may be employed is Derakane 470-36, a product of Dow Chemical Company. This product also includes from 30% to 50% by weight of a styrene monomer. Derakane 470-36 has a Brookfield viscosity at 25°C of from 160 to 250, and a specific gravity of 1.071. It is to be understood that each of the epoxide resins may be employed alone in the UV curable system, or in combination with other epoxide resins. For example, a cycloalphatic epoxide resin may be employed in combination with a reaction product of epichlorohydrin and bisphenol A or a polyepoxide obtained by reacting a phenolic novolac with epichlorohydrin. Epoxide resins which may be employed in accordance with the present invention are also generally described in the Modern Plastics Encyclopedia, 1980-1981, pgs. 28-30. The UV curable system may further include a flexibilizing component, a photoinitiator component, a surfactant or surface modifier, a slip agent, and/or a resin modifier. Flexibilizing components which may be employed include, but are not limited to, cycloaliphatic epoxides or polyols such as caprolactone polyester-or-polyether-based polyols such as diols and triols and polypropylene oxide triols, and activated polyolefins. Examples of cycloaliphatic epoxides which may be employed include Cyracure R UVR-6351 and UVR-6379, which are products of Union Carbide Corporation. UVR-6351 has a Brookfield viscosity at 25°C of 850 cP, a specific gravity at 20°C of 1.1204, and an epoxy equivalent weight of from 455 to 465. UVR-6379 has a viscosity of 225 cP, a specific gravity of 1.0531, and an epoxy equivalent weight of from 455 to 465. Caprolactone polyester and polyether-based diols and triols which may be employed include polycaprolactone polyester-based triols having the structural formula: / -f- c - c " --. o - e) . — il wherein n is an integer of at least 1, and R preferably is trimethylol propane or glycerin. Examples of such triols include Tone R0305 and Tone R0310, which are products of Union Carbide Corporation. Tone 0305 has a melting point of 20°C, a viscosity at 25°C of 516cSt and at 55°C of 200cSt, and an average molecular weight of 540. Tone 0310 has a melting point range of from 27°C to 32°C, is a solid at 25°C, has a viscosity of 270cSt at 55°C, and an average molecular weight of 900. Polypropylene oxide triols which may be employed have the formula Preferably, R is glycerin or trimethylol propane and n is from 10 to about 100. Examples of such polypropylene oxide triols are sold by Union Carbide Corporation as Niax LHT-34 and Niax LHT-240. Niax LHT-34 is a glycerin-started polypropylene oxide triol taken to a hydroxyl number of 34, and has a molecular weight of about 5,000, a viscosity at 25°C of 950cP, and a specific gravity of 1.006. Niax LHT-240 is a glycerin-started polypropylene oxide triol taken to a hydroxyl number of 240, and has a molecular weight of 710, a viscosity at 25°C of 270cP, and a specific gravity of 1.021. Examples of activated polyolefins which may be employed include, but are not limited to, activated polybutenes which include an epoxide functionality. Examples of activated polybutenes include Actipol E6, Actipol E16, and Actipol E23. Such activated polybutenes have an epoxide functionality at one end, which provides a means of chemically incorporating hydrophilic characteristics in polar formulations. Actipol E6 has a viscosity (ASTM D445) at 38°C of 65 cST, an average molecular weight of 365, a flash point (ASTM D92) of 154°C, a specific gravity of 0.877 at 60°F, and a refractive index (ASTM D1218) of 1.464. Actipol E16 has a viscosity (ASTM D445) at 99°C of 287 cST, an average molecular weight of 973, a flash point (ASTM D92) of 218°C, a specific gravity at 60°F of 0.904, and a refractive index (ASTM D1218) of 1.495. Actipol E23 has a viscosity (ASTM D445) of 916 cST, an average molecular weight of 1,433, a flash point (ASTM D92) of 280°C, a specific gravity at 60°F of 0.904, and a refractive index (ASTM D1218) of 1.504. Actipol E6, Actipol E16, and Actipol E23 are products of Amoco Chemical Company, Chicago, Illinois. Examples of photoinitiators which may be employed include, but are not limited to, triaryl or triphenyl-sulfonium containing mixtures such as mixtures of triarylsulfonium hexafluoroantimonate salts or triarylsulfonium hexafluorophosphate salts and propylene carbonate, or mixtures containing triphenyl sulfonium hexafluorophosphate and 2-(3H)-dihydro-furanone. A representative example of a mixture of a triarylsulfonium hexafluoro antimonate salt is Cyracure UVI-6974, sold by Union Carbide Corporation. UVl-6974 is a mixture of 50% triarylsufonium hexafluoro antimonate salts and 50% propylene carbonate, and has a viscosity at 30°C of 75cP, and a specific gravity of 1.39. A representative example of a mixture of a triarylsulfonium hexafluorophosphate salt and propylene carbonate is Cyracure UVI-6990, sold by Union Carbide Corporation. UVI-6990 is a mixture of 50% triarylsulfonium hexafluorophosphite salts and 50% propylene carbonate, and has a viscosity at 25°C of 75cP, and a specific gravity of 1.32. A representative example of a mixture of triphenyl sulfonium hexafluorophosphate and 2-(3H)-dihydro-furanone is sold as FX-512, by the 3M Industrial Chemical Products Division of 3M Corporation of St. Paul, Minnesota.FX-512 is a mixture of from 20% to 45% triphenyl sulfonium hexafluorophosphate, 40% of 2(3H)-dihydrofuranone, and the remainder being aromatic sulfonium coproducts. FX-512 has a specific gravity of 1.300 and a boiling point of 204°C. Although the scope of the present invention is not intended to be limited by any theoretical reasoning, the photoinitiators provide for an ionic, preferably a cationic, curing mechanism for the epoxide compound which is triggered by using ultraviolet light from conventional UV exposure sources to produce a coating on the printing substrate which may function as an effective printing medium. The ultraviolet light curing may take place using ultraviolet light having a wavelength of from about 250 nm to about 750 nm. The ultraviolet curing system composition may be exposed to the light for a period of time of from about 15 seconds to about 45 minutes. The ultraviolet exposure source may have a wattage of from about 15 watts to about 400 watts per inch, and may for example, be a fluorescent lamp, a mercury vapor lamp, a carbon arc lamp, actinic or superactinic fluorescent lamps, xenon lamps, or lasers with ultraviolet components such as argon lasers. It is also to be understood that within the scope of the present invention that the ultraviolet curing system compositions herein described may be applied to any cylindrical surface irrespective of whether the surface is employed as a printing surface, and cured under ultraviolet curing conditions such as those hereinabove described to provide crosslinking of the hereinabove described epoxide resins. Surfactants or surface modifiers which may be employed in the UV curing system include but are not limited to nonionic fluoroaliphatic polymeric ester surfactants and organomodified polymethyl siloxane copolymers. An example of a nonionic fluoroaliphatic polymer surfactant is sold as FC-430 by 3M Industrial Chemical Products Division. FC-430 has a Brookfield viscosity at 25°C of 7,000cF, a specific gravity of about 1.1, and a flash point (Seta Flash Closed Cup) of greater than 200°F. An example of an organomodified polymethylsiloxane copolymer surfactant is sold as Silwet Surfactant -7604, by Union Carbide Corporation. Silwet Surfactant L-7604 contains greater than 99% of an organomodified polymethylsiloxane and less that 0.5% toluene. It has a boiling point of greater than 150°C (at 760 mmHg) and a freezing point of 10°F and a specific gravity of 1.06. Slip agents which may be employed include, but are not limited to, ultramicronized wax powders, preferably having a particle size no greater than 10 microns, such as those containing polyethylene particles or polytetrafluoroethylene particles. Examples of such ultramicronized wax powders include those sold by Durachem as Microfine CP-9A and Peflu 727. Microfine CP-9A is a micronized wax powder of polyethylene particles having a maximum particle size of 10 microns and an average particle size of from 2 to 3 microns. Microfine CP-9A has a melting point of from 111-114°C, and a density of 0.960. Peflu 727 is a micronized wax powder of polytetrafluoroethylene particles having a maximum particle size of 10 microns and an average particle size of 5 microns. Peflu 727 has a melting point of greater than 160°C, and a density of about 2.3. Resin modifiers which may be employed in the ultraviolet cured system include, but are not limited to, acrylates such as methacrylate monomers and oligomers and urethane acrylates. Such resin modifiers can enhance the ultraviolet curing of the epoxide resin. An example of a methacrylate compound which may be employed is tetraethylene glycol dimethacrylate, which has the following structure: *3 c c ** C^- i— — om—ζ- c*, O -c - c '- μ 2 - A commercially available tetraethylene glycol dimethacrylate is sold as Photomer R 2009 by Henkel Corporation, Ambler, Pennsylvania. Tetraethylene glycol dimethacrylate is a low viscosity, long chain cross-linker which also imparts solvent resistance, heat resistance, and increased hardness to the plastic composition which forms the coating for the printing substrate. Urethane acrylates which may be employed may be aliphatic urethane acrylates having the following structure: wherein n is an integer of at least 1. An example of such an aliphatic urethane acrylate is sold as Photomer R 6008, by Henkel Corporation. Aliphatic urethane acrylates may be employed to provide the plastic composition with increased abrasion resistance and high temperature stability. The at least one epoxide resin, may be employed in the ultraviolet during system as the only component; however, such epoxide resin preferably is employed in an amount of from about 65 wt. % to about 97.5 wt. %. As hereinabove stated, there may may be one epoxide resin or a mixture of epoxide resins in the ultraviolet curing system. The flexibilizer component, when employed, may be added to the ultraviolet curing system in an amount of up to about 40 wt.%, preferably from about 10 wt.% to about 30 wt.%. The photoinitiator component may be employed in amounts from about 1.0 wt.% to about 4.0 wt.%, preferably at about 3.0 wt.%. The surfactant may be present in amounts from about 0.5 wt.% to about 1.0 wt.%, preferably at about 0.5 wt. %. The resin modifier component, when employed, may be present in an amount of up to about 40wt.%, and preferably from about 15wt.% to about 30wt.%. Representative ultraviolet curing-system plastic compositions which may be employed in accordance with the present invention include the following Formulae I through XVI listed below: Formula I Cyracure UVR-6100 - 68.0wt.% Cyracure UVR-6351 - 28.5wt.% Cyracure UVI-6S74 - 3.0 t.% Silwet L-7604 - 0.5wt.% Cyracure-UVR-6100 70.0wt.% Photomer- 6008 2β .5wt.% Cyracure UVI-6974 3.0wt.% SUwet L-7604 0.5wt.% Formula IX Cyracure VR-6110 48.3 wt. Resin XU 252 48.2 wt.% Formula XVI Resin XU 252 - 96.5 wt.% SUwet L-7604 - 0.5 wt.% FX-512 - 3.0 wt.% Heat cured plastic copositions may include at least one epoxide resin selected from the group consisting of cycloaliphatic epoxide resins and amine-based epoxide resins such as those hereinabove described for use in the ultraviolet curing system. The heat cured plastic compositions may further include epoxide resins selected from those which may be added to the cycloaliphatic or amine-based epoxides in the ultraviolet cure system. In another embodiment, the heat cured plastic composition may include an epoxy resin which is a reaction product of epichlorohydrin and bisphenol A, and a curing agent selected from the group consisting of fluoroaliphatic salt solutions, imidazoles, and amine curing agents. In yet another embodiment, the heat cured plastic composition may include a bisphenol A epoxy resin modified with cresol novolac(s) , and a curing agent selected from the group consisting of fluoroaliphatic salt solutions, imidazoles, and amine curing agents. Preferably, the curing agent is an amine curing agent. The heat cured plastic compositions may also include at least one phenolic resin. Phenolics are generally products of the chemical reaction of phenol and formaldehyde. Phenolics are further described in the Modern Plastics Encyclopedia, 1980-1981, pgs. 40 and 43. An example of a phenoUc resin which may be employed is Methylon 75108, a product of General Electric. The heat cured compositions may further include flexibilizing components) , curing agent(s) , and/or surfactant(s) . The flexibilizing component may be a polyol such as a caprolactone polyester- or polyether-based diol or triol or a polypropylene oxide triol or an activated polyolefin such as those described hereinabove for use in the ultraviolet curing system. Curing agents which may be employed include, but are not limited to, fluoroaliphatic salt solutions, imidazoles, and amine curing agents. A preferred fluoroaliphatic salt solution which may be employed is a solution of 60% of the diethylammonium salt of trifluoromethane sulfonic acid, 20% water, and 20% 2- (2-ethoyethoxy) ethanol. Such a solution is commerciaUy avaUable as FC-520, a product of 3M Industrial Chemical Products Division, and has a boiling point of 210°F, and a pH of from about 4.5 to about 6.0. Imidazoles which may be employed include ethyl-methyl-imidazoles such as 2 -ethyl- 4 methyl iπtidazole, which has the following structure: ) 2-ethyl-4-methyl imidazole is available commercially as EMI-24 from Pacific Anchor Chemical Company. Surfactants which may be employed in the heat cured plastic compositions include, but are not limited to, nonionic fluoroaliphatic polymeric ester surfactants and organomodified polymethyl sUoxane copolymer surfactants such as those hereinabove described for use in the ultraviolet curing system. Amine curing agents which may be employed include, but are not limited to aliphatic amine curing agents and aromatic amine curing agents. In one embodiment, the amine curing agent is an aliphatic amine curing agent. Aliphatic amine curing agents whi^ may be employed include, but are not limited to, HY943 and HY2964, products of Ciba-Geigy Corporation, Plastics Division, Hawthorne, New York. HY943 has a viscosity at 25°C of 3,300 to 6,000 cP, a specific gravity at 25°C of 1.08, and a flash point of 110°C . HY2964 is a low viscosity liquid modified aliphatic amine having a viscosity at 25° C from 40 to 70 cP, a flash point of less than 200°F, and a density of 8.3 pounds per gallon. The epoxide resin (s) may be present in the heat cured composition as the only component; however, the epoxide resin (s) preferably is/are present in an amount of from about 70wt.% to about 98.5wt.%. The phenolic resin, when employed, may be present in an amount up to about 20wt.%. The flexibilizing component may be present in an amount of up to about 30wt.%, preferably from about 8.0wt.% to about 30wt.%. The curing agent may be present in an amount of up to about 10wt.%, and preferably from about 1.0wt.% to about 8.0wt.%. The surfactant may be present in an amount of up to about 1.0wt.%, and preferably from about 0.5wt.% to about 0.6 wt.%. Representative examples of heat cured plastic compositions include the foUowing Formulae XVII through XXXVI listed below. ERL-4221 - 70.0wt.% D.E.R. 330 - 20.0wt.% Niax LHT-34 - 8.4wt.% Formula XIX D.E. R. -330 81.5wt.% EPN-1139 10.0wt.% EMI-24 8.0wt.% FC-430 0.5wt.% FC-430 The room temperature gelation plastic composition includes at least one resinous component, which may be a vinyl ester derived from epoxy novolac compounds such as those hereinabove described, or alternatively, a polyester resin. Preferably, the polyester resin is a rigid, low viscosity unsaturated polyester resin. Styrene monomer may be included with the epoxide resin or the polyester resin. Examples of low viscosity rigid, unsaturated polyester resin compositions are those sold by Reichhold Chemicals, Inc. , Jacksonville, Florida, as Polylite R 32-138 and Polylite R 32-830. Polylite 32-138 has a flash point (Seta closed cup) of 89°F, a specific gravity of from 1.03 to 1.13, and a Brookfield viscosity of from 100 to 200 cp. Polylite - 138 also includes from 34% to 38% of styrene monomer, and has a gel time (in 1.25% Superox MEK peroxide 46-709) of from 10 to 15 minutes. An example of a vinyl ester derived from an epoxy-novolac compound which may be employed is Derakane 470-36, which, as hereinabove described, also includes from 30% to 50% by weight of a styrene monomer, and has a Brookfield viscosity at 25°C of from 160 to 250, and a specific gravity of 1.071. The room temperature gelation system plastic composition may further include at least one catalyst component, preferably a peroxide catalyst component, at least one promoter component, at least one accelerator component, and at least one surfactant. Catalysts which may be employed, when an epoxy novolac-based vinyl ester is the resinous component, include, but are not limited to, peroxide catalysts such as cumene hydroperoxide catalysts and benzoyl peroxide catalysts. The catalyst may be In the form of a solution or a powder. When a polyester resin is employed, the preferred catalyst is a methyl ethyl ketone (MEK) peroxide catalyst, which may be in the form of a solution or powder. Promoter components which may be employed include, but are not limited to, naphthanates, such as cobalt napthanate. The promoter may be in the form of a solution. Accelerators which may be employed include, but are not limited to, anilines such as dimethylanline . Surfactants which may be employed include, but are not limited to, organomodified polymethylsUoxane copolymer surfactants such as those hereinabove described. The resinous component, whether an epoxide resin or a polyester resin, may be present as the only component in the room temperature gelation system, or is present in the system in an amount of from about 97 wt % to about 98.5 wt %. The catalyst component may be present in an amount from about 1.0 wt % to about 2.0 wt %. The promoter component may be present in an amount up to about 0.2 wt %. The accelerator may be present in an amount from about 0.2 wt % to about 0.5 wt %. The surfactant may be present in an amount of up to about 0.4 wt %. Representative examples of room temperature gelation plastic compositions which may be employed in the present invention are given in Formulae XXVII through XLIII listed below. Formula XXXVII Derakane 470-36 - 97.2wt.% Cumene hydroperoxide (80%) - 2.0wt.% Cobalt naphthanate (6%) - 0.2wt.% Dimethylaniline - 0.2 wt.% SUwet L-7604 - 0.4wt.% Formula XXXVIII Derakane 470-36 - 97.9wt.% Cumene hydroperoxide (80%) - 1.0wt.% Cobalt naphthanate (6.6%) - 0.2wt.% Dimethylaniline - 0.5wt.% SUwet L-7604 - 0.4wt.% Formula XXXIX Derakane 470-36 - 98.4wt.% Cumene hydroperoxide (80%) - 1.0wt.% Cobalt naphthanate (6%) - 0.2wt.% SUwet L-7604 - 0.4wt.% Formula XL Derakane 470-36 - 97.4wt.% Benzoyl peroxide - 2.0 wt.% (80% Powder) Dimethylaniline - 0.2wt.% SUwet L-7604 - 0.4wt.% Formula XLI Derakane 470-36 - 98.1wt.% In accordance with another embodiment of the invention, the plastic composition which is applied to the substrate may be a mixture of an expanding polycyclic monomer such as a spiroorthocarbonate or spiroorthoester, formed with a combination of a diepoxy oUgomer such as a diglycidylether, and a lactone in a concentration of from about 1:2.5 to about 1:4.5 by weight of the oUgomer. To this mixture there may be added a catalytic quantity of a boron trihaUde- amine complex and a catalytic quantity of an aromatic photocatalyst which releases a carbonium ion upon ultraviolet irradiation. After the printing medium is applied to the substrate, the printing medium may be cured by ultraviolet Ught and/or by heating. Alternatively, a di- or tri- functional acrylate may be added to the initial mixture. Preferably, the expanding monomer is a spiroorthoester formed in situ by the reaction of a lactone such as ^T ^butyrolactone or ^ -caprolactone with an epoxide. The expanding monomer may also be a polycycUc ring system, wherein the rings are opened during polymerization. The diepoxy oUgomer may be bisphenol- A diglycidyl ether. The aromatic photocatalyst may be a triphenyl sulfonuim hexafluoro antimonate (eg. , FX-512 as hereinabove described) , or arsenate, or phosphate. The Lewis acid tertiary amine complex catalyst may be selected from boron trichloride N,N' - dimethyl piperazine salt, boron trifluoride monoethylamine salt, orthophenylene diamine-boron trifluoride salt, or a 4, 4' diamine diphenylsulfone- boron trichloride salt. The plastic composition may also include a fluorocarbon sulfonic acid salt, which is employed as a flow aid. Examples of such plastic compositions containing the hereinabove described expanding polycycUc monomers and catalysts are further described in U. S . Patent No. 4, 738, 899. A commercially available example of such a plastic composition is sold as EP222003, by Epolin , Inc . , of Newark, New Jersey. This product has a viscosity at room temperature of from about 2,000 to about 4,000 cP, and a specific gravity of 1.1. The plastic composition may be applied to the printing substrate by various means weU known in the art. The method of the present invention is particularly applicable to the appUcation of the plastic composition as a liquid to a printing roll or cyUnder which is employed in a rotogravure printing process. The printing roll or cylinder may be made of aluminum, steel, or plastic. Prior to the appUcation of the plastic composition to the printing roU or cylinder, the printing roU or cylinder may be pretreated by means of a plasma or corona pretreatment to clean and/or alter the surface (i. e. , lower the surface tension) of the cylinder or roU for improved film or coating wetout and bonding strengths. When a corona pretreatment of the surface of the printing roll or cylinder is employed, the surface of the printing roll or cylinder is treated with an accurately- directed electrical bombardment of the surface of the printing roU or cylinder to clean and/or alter the surface of the printing roU or cylinder. An example of such a corona pretretment is the Tan tec HV05 System, as sold by Tampo Print America Inc. , of Schaumburg, Illinois. When an aluminum printing cyUnder is employed, the surface may be pretreated so as to provide an anodized surface. When a steel cylinder is employed, the cylinder may be treated with an oxide such as black oxide, or may be treated so as to provide an iridited surface . Methods of applying the plastic composition include spraying the composition onto the surface of the printing substrate such as the printing roU or cylinder. Such spraying may be accompUshed through the use of a nozzle through techniques known in the art. Other methods which may be employed include dip coating, spin coating, and ring coating. Upon appUcation of the raw plastic composition to the substrate, it is cured so as to form a plastic coating covering the substrate, said coating now capable of being etched to provide a printing surface. Methods of curing include, but are not limited to, ultraviolet irradiation (which may be foUowed by heating) , heating, and gelation at room temperature. The method employed to cure the composition depends upon the particular plastic composition appUed to the printing substrate. After the plastic coating is applied to the substrate and cured, it is engraved so as to provide a printing medium or image carrier. The engraving may be accompUshed by any of various engraving methods known in the art; however, a preferred method of engraving is electronic engraving. Electronic engraving may, in one embodiment, be carried out using a diamond stylus which has an included angle of from about 110° to about 130° . The narrower the included angle, the deeper the stylus cuts into the plastic coating. As the stylus cuts into the coating, it forms a plurality of wells in the coating. Each well has an angled wall, and is smaUer at the bottom than at the top . In one embodiment, the reliability of electronic engraving can be enhanced by employing an air knife device to aid in the removal of chips away from the support, or foot, of the diamond stylus . The air knife dispenses a precise, focused, and continuous or pulsed air stream. The air stream moves in a direction opposite that of the movement of the cylinder. The air stream directs chips away from the support, or foot, of the diamond stylus, the cutting diamond, and the burr cutter in a direction toward a vacuum device, whereby the chips may be removed from the printing surface by the vacuum device located in the cutting head. In one embodiment, prior to engraving, the plastic coating may be contacted (preferably by spraying) with a finely divided fluropolymer as a dry film lubricant for the plastic coating. The dry fUm lubricant provides for lubrication of the support, or foot, of the diamond stylus as the stylus traverses the plastic coating during the engraving. Such lubrication provides for improved penetration of the surface of the plastic coating by the diamond stylus and provides for increased life of the diamond stylus. A preferred finely divided fluorpolymer powder is a micronized tetrafluoroethylene powder. An example of such a micronized tetrafluoroethylene powder is sold by DuPont, WUmington, Delaware, as Vydax. Once the printing medium or image carrier is formed on the substrate, it is ready for the application of printing ink. Examples of gravure type inks which may be applied to the printing medium include aUphatic hydrocarbon inks such as A- Type inks and B-Type inks; nitroceUouse inks (C-Type) ; polyamide inks (D-Type) ; alcohol-based inks (E-Type) ; polystyrene-based inks (M-Type) ; chlorinated rubber-based inks (T-Type) ; vinyl chloride or vinyl acetate copolymer- based inks (V-Type) ; inks employing water as a solvent base (W-Type) ; X-Type inks including heat transfer and sublimation inks; and foam inks. The type of ink employed depends upon the type of surface that is to be printed. Upon appUcation of the ink, any excess ink is removed by a doctor blade. It has been found that a doctor blade formed from a polymer such as polyester, nylon, polyethylene, polypropylene, or polyacetal, and having a tapered edge which contacts the printing medium, conditions the image-bearing surface without substantial wear and is a great improvement over metal doctor blades employed in the art with copper- etched surfaces. Most preferably, a polyester doctor blade is employed for removing the excess ink. Examples of polyester doctor blades having a tapered edge which may be employed in accordance with the present invention are those of Esterlam's E350/E500 range of laminated polyester doctor blades, sold by Esterlam International Limited, of Devon, England. Thus, in accordance with another aspect of the present invention, there is provided a process for preparing a non-metal printing medium for the transfer of an inked image which comprises applying ink to the printing medium, and removing excess ink from the printing medium by contacting the printing medium with a doctor blade, having a tapered edge, said doctor blade being formed from a polymer selected from the group consisting of polyester, nylon , polyethylene, polypropylene and polyacetal to prepare thereby the printing medium for the transfer of an inked image. Preferably, the doctor blade is formed from a polyester. Upon appUcation of the ink, the printing medium and printing substrate are then ready to print any of a wide variety of materials which may be printed by the rotogravure process. Advantages of the present invention include the ability to provide a printing medium or image carrier upon a printing substrate such as a printing cylinder or printing roll which does not require the use and/or disposal of environmentaUy hazardous chemicals during its preparation. The method of the present invention, whereby a plastic composition, as opposed to a metal, is appUed to a printing substrate, thus provides for a more efficient and environmentally safe process for providing a rotogravure printing medium, which also saves the considerable costs associated with the formation and treatment of copper-etched surfaces. It is to be understood, however, that the scope of the present invention is not to be limited to the specific embodiments described above. The invention may be practiced other than as particularly described and stiU be within the scope of the accompanying claims.

Claims: WHAT IS CLAIMED IS: 1. An ultraviolet Ught- curable plastic composition for appUcation to a printing apparatus, said plastic composition including at least one epoxide resin selected from the group consisting of cycloaUphatic epoxide resins and amine-based epoxide resins . 2. The composition of Claim 1 , and further comprising an epoxy resin selected from the group consisting of diglycidyl ether-bisphenol A, a reaction product of epichlorohydrin and bisphenol A, bisphenol A epoxy resins modified with cresol novolac(s) , and polyepoxides obtained by reacting a phenoUc novolac with epichlorohydrin . 3. The composition of Claim 1, and further comprising a flexibUizing component. 4. The composition of Claim 3 wherein said flexibUizing component is selected from the group consisting of cycloaUphatic epoxides, polyols, and activated polyolefins. 5. The composition of Claim 1, and further comprising a photoinitiator component. 6. The composition of Claim 1, and further comprising a surfactant . 7. The composition of Claim 1, and further comprising a sUp agent. 8. The composition of Claim 1 , and further comprising a resin modifier. 9. An ultraviolet Ught-curable plastic composition for application to a printing apparatus, said plastic composition including a vinyl ester formed from an epoxy-novolac compound. T 10. An ultraviolet light-curable plastic composition for application to a printing apparatus, said plastic compostion including a bisphenol A epoxy resin modified with cresol novolac(s) and a photoinitiator component . 11. A heat curable plastic composition for application to a printing apparatus, said plastic composition including at least one epoxide resin selected from the class consisting of cycloaUphatic epoxide resins and amine-based epoxide resins. 12. The composition of Claim 11, and further comprising an epoxy resin selected from the group consisting of diglycidyl ether- bisphenol A, a reaction product of epichlorohydrin and bisphenol A, bisphenol A epoxy resins modified with cresol novolac(s) , and polyepoxides obtained by reacting a phenoUc novolac with epichlorohydrin. 13. The composition of Claim 11, and further comprising a flexibUizing component. 14. The composition of Claim 13 wherein said flexibUizing component is selected from the group consisting of caprolactone polyester- and polyether-based diols and triols, propylene oxide based triols, and activated polyolefins. 15. The composition of Claim 11 , and further comprising a curing agent. 16. The composition of Claim 15 wherein said curing agent is selected from the group consisting of fluoroaliphatic salt solutions, imidazoles, and amine curing agents . 17. A heat curable plastic composition for application to a printing apparatus, said plastic composition including an epoxy resin which is a reaction product of epichlorohydrin and bisphenol A, and a curing agent selected from the group consisting of fluoroaUphatic salt solutions, imidazoles, and amine curing agents. 18. The composition of Claim 17, and further comprising a flexibUizing component. 19. The composition of Claim 18 wherein said flexibUizing component is selected from the group consisting of caprolactone polyester- and polyether-based diols and triols, propylene oxide based triols, and activated polyolef ins . 20. A heat curable plastic composition for application to a printing apparatus, said plastic composition including a bisphenol A epoxy resin modified with cresol novolac(s) , and a curing agent selected from the group consisting of fluoroaliphatic salt solutions, imidazoles, and amine curing agents. 21. The composition of Claim 20, and further comprising a flexibUizing component. 22. The composition of Claim 21 wherein said flexibUizing component is selected from the group consisting of caprolactone polyester- and polyether-based diols and triols, propylene oxide based triols, and activated polyolef ins. 23. A room temperature gelation plastic composition for application to a printing apparatus, said plastic composition comprising a resinous component selected from the group consisting of vinyl esters derived from epoxy-novolac compounds and polyester resins . 24. The composition of Claim 23 wherein said resinous component further comprises a styrene monomer. 25. The composition of Claim 23 , and further comprising at least one catalyst component. 26. The composition of Claim 23 , and further comprising at least one promoter component. 27. The composition of Claim 23 , and further comprising at least one accelerator component. 28. The composition of Claim 23 , and further comprising at least one surfactant. 29. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 1 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 30. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 9 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 31. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 10 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 32. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 11 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 33. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 17 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 34. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 20 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 35. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 23 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium. 36. A process for preparing a non-metal printing medium for the transfer of an inked image, comprising: applying ink to said printing medium; and removing excess ink from said printing medium with a doctor blade having a tapered edge, said doctor blade being formed from a polymer selected from the group consisting of polyester, nylon, polyethylene, polypropylene, and polyacetal to prepare thereby said printing medium for the transfer of an inked image. 37. A plastic composition for application to a printing apparatus, said plastic composition including a mixture of an expanding polycyclic monomer, said expanding polycyclic monomer being selected from the group consisting of a spiroorthocarbonate and a spiroorthoester, said monomer being formed with a combination of diglycidylether and a lactone in a concentration of from about 1 :2.5 to about 1: 4.5 by weight of the diglycidylether . 38. A method of producing a printing medium for a printing apparatus, comprising: applying the plastic composition of Claim 37 to a printing substrate to form a plastic coating covering said substrate; and engraving said plastic coating to provide a printing medium.

Inventors: BRESSLER DAVID E, CALIGARO DANIEL, CHESTNUT W RICHARD, BRESSLER, DAVID, E., CALIGARO, DANIEL, CHESTNUT, W., RICHARD
Applicants: CHESNUT ENG, W.R. CHESNUT ENGINEERING, INC.
Application year: 1991
Main classification: C08G59
IPC codes: B41C1, B41N1, B41N10, G03F7