BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a surface treatment method and a surface treatment
apparatus of graining an aluminum plate as a base of a lithographic printing plate.
2. Background Arts
[0002] A lithographic printing plate, called pre-sensitized (PS) plate, has been well known
and widely used in the art. The PS plate mostly uses an aluminum plate as the base.
To make the PS plate, a long flat or coiled web of aluminum plate is subjected to
surface treatments, including graining, anodizing and/or chemical treatments, and
then the treated surface is coated with a sensitizing solution. After the sensitizing
solution is dried up, the aluminum plate is cut into appropriate lengths.
[0003] Graining is for providing fine grains of uniform roughness on the surface of the
plate material. Since the superficial area of the plate material increased by graining,
the adhesive power of the sensitizing solution or lacquer is reinforced. Also, water
retention in the non-image area is improved. Since the quality of grains has large
influence on the printing effect and the plate wear, graining process needs strict
control.
[0004] In general, brush-graining is adopted as a graining method on the aluminum plate.
In the brush-graining process, abrasive slurry is sprayed over one surface of the
aluminum plate while being conveyed continuously at a constant speed, and then rubbed
on the plate surface by graining brushes. The graining brush are pressed onto the
aluminum plate with its rotary axis oriented in a crosswise direction of the aluminum
plate, and rotated while the aluminum plate is conveyed. In this way, grains are formed
on the surface.
[0005] The abrasive slurry is made by suspending abrasive particles in a solution so that
the abrasive particles have fluidity. For example, a mixture of pumice or crystalline
aluminum hydroxide and water is used as the abrasive slurry, as disclosed in JPA 8-324143.
The abrasive slurry after used for graining is fed back to a slurry supply tank through
a circulation system, and is reused for graining.
[0006] After working continuously for a long time in the graining process, tips of bristles
of the graining brush are worn off or deformed, so the pressure of the graining brush
onto the aluminum plate changes with time. Also because the abrasive particles in
the abrasive slurry are getting crushed into smaller particles as the slurry is reused
repeatedly, the abrasive power gradually lessens. In results, roughness of the grains
partially varies or gradually changes with time during the graining process.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing, a prime object of the present invention is to provide a
surface treatment method by which grains of uniform roughness are economically and
efficiently formed on an aluminum plate to make a printing plate, and an apparatus
for executing the surface treatment method of the invention.
[0008] To achieve the above object in a surface treatment method for forming grains on a
surface of an aluminum plate as a base of a printing plate, wherein abrasive slurry
composed of abrasive materials mixed with water is rubbed on the aluminum plate surface
with a graining brush that is pressed onto the aluminum plate and is turned to brush
the aluminum plate, according to the present invention, the amount of electric power
required for driving the graining brush to turn at a constant speed to brush the aluminum
plate is monitored and maintained constant by changing pressing amount of the graining
brush onto the aluminum plate.
[0009] According to a preferred embodiment of the invention, where the abrasive slurry after
being used for graining is repeatedly reused, the abrasive particles contained in
the abrasive slurry are classified according to their diameters before the abrasive
slurry is reused for graining, such that those abrasive particles with smaller diameters
than a predetermined value are excluded from the abrasive slurry, and only those abrasive
particles with larger diameters than the predetermined value are included in the abrasive
slurry. As the abrasive materials, silica sand or silica abrasives are preferable.
[0010] According the present invention, a surface treatment apparatus for graining a surface
of an aluminum plate as a base of a printing plate is provided with a graining brush
mounted movable in a vertical direction to the surface of the aluminum plate; an electric
power monitoring device for outputting a signal whose level corresponds to the amount
of electric power required for driving the graining brush to turn at a constant speed
while brushing the aluminum plate; a brush shifting device for shifting the graining
brush in the vertical direction to change the pressing amount of the graining brush
onto the aluminum plate; and a control device for controlling the amount of electric
driving power to be maintained constant by decreasing the pressing amount of the graining
brush onto the aluminum plate through the brush shifting device when the output signal
from the electric power monitoring device is above a predetermined level, or increasing
the pressing amount of the graining brush onto the aluminum plate through the brush
shifting device when the output signal from the electric power monitoring device is
below the predetermined level.
[0011] Where the abrasive slurry is circulated to reuse for graining, it is preferable to
provide a classification device that takes in a part of the abrasive slurry from the
slurry supply tank, classifies the abrasive materials in the abrasive slurry according
to their particle diameters, feeds back those abrasive particles with larger diameters
than a predetermined particle diameter to the slurry supply tank, and excludes those
abrasive particles with smaller diameters than the predetermined particle diameter
from the abrasive slurry. The abrasive slurry is continuously circulated between the
slurry supply tank and the classification device, such that the particle diameters
of the abrasive materials contained in the abrasive slurry are maintained in a predetermined
range, preferably in a range from 5 µm to 60 µm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects and advantages of the present invention will become apparent
from the following detailed description of the preferred embodiments when read in
connection with the accompanying drawings, which are given by way of illustration
only and thus are not limiting the present invention, wherein like reference numerals
designate like or corresponding parts throughout the several views, and wherein:
[0013] Figure 1 is a schematic diagram illustrating a surface treatment apparatus for an
aluminum printing plate according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Fig. 1 shows a surface treatment apparatus for a graining process for graining an
aluminum plate to make a printing plate. The surface treatment apparatus is constituted
of a graining bath 11, a slurry supply tank 12, a particle diameter control section
13, and a pressure control section 14. A web of aluminum plate 15 is conveyed on pass
rollers 16 continuously at a constant speed through the graining bath 11 to the right
in the drawing.
[0015] Three rotary graining brushes 17 are placed in the graining bath 11. The graining
brushes 17 have their rotary axis 17a oriented in a crosswise direction of the aluminum
plate 15. The graining brushes 17 are turned in a counterclockwise direction in the
drawing at a constant speed by individual motors 34 that are driven through a driver
35. The three graining brushes 17 are also movable in a vertical direction to a surface
of the aluminum plate 15, and are positioned to be pressed onto the aluminum plate
15.
[0016] The slurry supply tank 12 contains abrasive slurry 20, a mixture of abrasive particles
and water, and is supplied with the abrasive particles and water respectively from
an abrasive material supplement section 18 and a water supplement section 19. A stirring
mill 12a is provided in the slurry supply tank 12, for stirring the abrasive slurry
20 to equalize specific gravity of the slurry 20 in the tank 12.
[0017] The abrasive slurry 20 is fed out by a supply pump 21 into a spray tube 22, and sprayed
over the aluminum plate 15 in the graining bath 11, and then rubbed on the aluminum
plate 15 by the graining brushes 17. Thereby, grains of predetermined roughness are
formed on the surface of the aluminum plate 15. The abrasive slurry 20 after being
used in the graining bath 11 is fed back to the slurry supply tank 12 through a feed
back tube 23, so as to reuse for graining.
[0018] The particle diameter control section 13, consisting of a classifier 24 and a supplemental
amount regulator 25, controls the diameters of the abrasive particles contained in
the abrasive slurry 20 to be maintained in a predetermined range. The abrasive slurry
20 is fed out from the slurry supply tank 12 into the classifier 24 by driving a circulating
pump 26. The classifier 24 classifies the abrasive particles in the abrasive slurry
20 according to the particle diameter, and feeds back those abrasive particles with
larger diameters than a predetermined classification point to the slurry supply tank
12 through a feed back tube 27. Those abrasive particles with smaller diameters than
the classification point are ejected through an ejection tube 28 out of the circulation
system. The ejected abrasive particles with smaller diameters are separated from the
water through a centrifugal separator 29, and then reused as a by-product.
[0019] The supplemental amount regulator 25 is provided with a hydrometer 30 that measures
specific gravity of the abrasive slurry 20 in the slurry supply tank 12. The supplemental
amount regulator 25 regulates the amount of abrasive particles supplied from the abrasive
material supplement section 18 and the amount of water supplied from the water supply
section 19 so as to maintain specific gravity of the abrasive slurry 20 at a set value.
[0020] Since the abrasive particles with smaller diameters are eliminated through the classifier
24 from the abrasive slurry 20 of the slurry supply tank 12, the particle diameters
of the abrasive particles in the abrasive slurry 20 are maintained within the predetermined
range. It is preferable to control the diameters of the abrasive particles to be included
in a range from 5 µm to 60 µm, and defines the lower limit, i.e. 5 µm in this instance,
as the classification point of the classifier 24.
[0021] The pressure control section 14 consists of a brush shifting mechanism 31, an electric
power monitor 32, and a controller 33, and controls the pressure of the graining brush
17 onto the aluminum plate 15 to be maintained constant. The brush shifting mechanism
31 is for example a cylinder mechanism, shifts the graining brushes 17 in the vertical
direction. The electric power monitor 32 monitors the amount of electric power required
for driving the graining brushes 17 while the graining brushes 17 are brushing the
aluminum plate 15, and outputs a signal to the controller 33. The level of the output
signal of the electric power monitor 32 corresponds to the amount of electric driving
power.
[0022] The electric power for driving the graining brush 17 as being in contact with the
aluminum plate 15 varies depending upon the conveying speed of the aluminum plate
15, the turning speed of the graining brushes 17, and the pressure of the graining
brushes 17 onto the aluminum plate 15. Since the conveying speed of the aluminum plate
15 and the turning speed of the graining brushes 17 are constant, if the electric
power for driving the graining brushes 17 is constant, it means that the pressure
of the graining brushes 17 onto the aluminum plate 15 is constant. By increasing the
pressing amount X of the graining brushes 17 onto the aluminum plate 15, the pressure
of the graining brushes 17 onto the aluminum plate 15 rises, and the amount of electric
driving power increases. On the contrary, by decreasing the pressing amount X, the
pressure of the graining brushes 17 onto the aluminum plate 15 lessens, and the amount
of electric driving power decreases.
[0023] Therefore, based on the signal level of the electric power monitor 32, the controller
33 drives the brush shifting mechanism 31 to move the graining brushes 17 up and down
so as to change the pressing amount X thereof onto the aluminum plate 15, so as to
maintain the pressure of the graining brushes 17 onto the aluminum plate 15 constant.
If the output signal from the electric power monitor 32 goes above a predetermined
level, it means that the electric power for driving the graining brushes 17 goes above
a predetermined normal amount. Then, the controller 33 lifts the graining brushes
17 through the brush shifting mechanism 31 to reduce the pressing amount X onto the
aluminum plate 15. If the output signal from the electric power monitor 32 goes below
the predetermined level and thus the electric driving power goes below the normal
amount, the controller 33 lowers the graining brushes 17 to increase the pressuring
amount X onto the aluminum plate 15.
[0024] In this way, the electric power for driving the graining brushes 17 is controlled
to be the normal amount at appropriate timings, so the pressure of the graining brushes
17 onto the aluminum plate 15 is maintained constant. The normal amount of electric
power is an amount necessary for driving the graining brushes 17 to rotate at the
constant speed while pressing the graining brushes 17 onto the aluminum plate 15 with
a desirable pressure.
[0025] Roughness of grains formed on the aluminum plate 15 is dependent on the particle
diameters of the used abrasive particles, the turning speed of the graining brushes
17, and the pressure of the graining brushes 17 onto the aluminum plate 15. According
to the graining process configured as above, the graining brushes 17 are rotated at
the constant speed, and the pressure onto the aluminum plate 15 is controlled to be
constant, and also the diameters of the abrasive particles in the abrasive slurry
20 are controlled to be maintained within the predetermined diameter range. Thus,
roughness of grains formed on the aluminum plate 15 is maintained constant and uniform.
[0026] Since the pressure of the graining brushes 17 and the diameters of the abrasive particles
are controlled at appropriate timings without interrupting the process, no time is
lost by the control. Because only those abrasive particles whose diameters become
too small for graining are excluded from the abrasive slurry 20, those abrasive particles
which still have sufficiently large diameters for graining are prevented from being
wasted. So the consumption of abrasive materials is reduced. With decreasing waste
of abrasive materials, the cost of waste disposal is remarkably reduced.
[0027] The effects of the present invention have been proved by two example experiments
and two comparative experiments.
EXAMPLE 1:
[0028] The first example experiment was carried out using the above described apparatus.
The aluminum plate 15 was 1000 mm wide, and conveyed continuously at a speed of 50
m/minute. The three graining brushes 17 had bristles of 0.48 mm in diameter, and were
turned at a speed of 250 rpm. The abrasive slurry 20 was produced by mixing pumice
having an average diameter of 30 µm with water at a density of 200 g/
l. The classification point of the classifier 24 was set at 15 µm, so as to control
the diameters of the abrasive particles in the abrasive slurry 20 to be not less than
15 µm. The pressing amount X of the graining brushes 17 onto the aluminum plate 15
was controlled at appropriate timings such that electric power required for driving
the graining brushes 17 to brush the aluminum plate 15 was maintained at 9 kW per
one brush.
[0029] It was confirmed from observation on the aluminum plate surface grained through the
above graining process that roughness of grains formed on the aluminum plate surface
was constant and uniform, and any change in the surface roughness with time was not
observed during the operation of the graining process. Since the pressure of the graining
brushes onto the aluminum plate and the diameters of the abrasive particles were automatically
controlled while keeping on operating the graining process, the time efficiency was
remarkably improved in comparison with the conventional graining process which must
be interrupted when to change the abrasive slurry.
COMPARISON 1:
[0030] As a comparison to the first example experiment, the first comparative experiment
was carried out using the same construction under the same conditions as the first
example except that the pressing amount X of the graining brushes 17 were not controlled
but fixed. The pressing amount X was fixed at 25 mm, so the electric power required
for driving the graining brushes 17 was 9 kW per one brush at the start of graining
operation.
[0031] In the first comparative experiment, the graining brushes 17 were gradually worn
off or deformed with time during the operation, so the pressure of the graining brushes
17 onto the aluminum plate 15 changed with time. With the change in the pressure of
the graining brushes 17, roughness of grains formed on the aluminum plate surface
varied so much that the variations went beyond a tolerable range after an elapse of
approximately one hour. From this result, it was proved that maintaining the pressure
of the graining brushes onto the aluminum plate constant is effective for forming
uniform grains on the aluminum plate.
COMPARISON 2:
[0032] The second comparative experiment was carried out using the same apparatus under
the same conditions as the first example except but the classifier 24 was deactivated.
Change in average diameter of the abrasive particles contained in the abrasive slurry
20 and the change in surface roughness of the grained aluminum plate 15 were observed.
[0033] At the start of graining in the second comparative experiment, average diameter per
unit weight of the abrasive particles was 30 µm, and surface roughness of the aluminum
plate was 0.56 µm. The diameters of the abrasive particles in the abrasive slurry
20 decreased with time during the operation, and the average particle diameter came
down to 20 µm after an elapse of approximately three hours. With the decreasing diameters
of the abrasive particles contained in the abrasive slurry 20, the surface roughness
of the aluminum plate 15 was lowered. After an elapse of approximately three hours,
the surface roughness came down to 0.48 µm that is largely out of the tolerable range.
Thereafter, the whole abrasive slurry 20 in the slurry supply tank 12 was changed
with new one, while interrupting the graining process. Immediately after the graining
process was restarted, surface roughness of the aluminum plate was 0.57 µm. From this
result, it was proved that maintaining the diameters of the abrasive particles within
a predetermined range in the abrasive slurry is effective for maintaining roughness
of grains constant.
[0034] According to the second comparative experiment, since the whole abrasive slurry 20
in the slurry supply tank 12 was changed, even those abrasive particles having sufficient
large diameters for graining went to waste, so a large amount of abrasive materials
were consumed in the second comparative experiment. Moreover, it was time-consuming
to interrupt the graining process in order to change the abrasive slurry in the supplement
tank with new one each time the abrasive power was lowered to an intolerable level.
According to a calculation, the consumption of the abrasive materials per unit area
of the aluminum plate in the first example was reduced 33% to 50% in comparison with
the second comparison where the classifier was deactivated. From this result, it was
proved that the method of continually classifying the abrasive particles in the abrasive
slurry to exclude those abrasive particles having smaller diameters than a predetermined
value is not only time-saving but also effective for reducing consumption of the abrasive
material. Because the waste of abrasive particles is greatly reduced, the method of
the present invention cuts the cost of waste disposal.
EXAMPLE 2:
[0035] The second example experiment was carried out using the above described apparatus
under the following conditions. The aluminum plate 15 was 1000 mm wide, and conveyed
continuously at a speed of 50 m/minute. The three graining brushes 17 had bristles
of 0.48 mm in diameter, and were turned at a speed of 200 rpm. The abrasive slurry
20 was produced by mixing silica sand or silica abrasives (SiO
2 = 97%) having an average diameter of 20 µm with water at a density of 200 g/
l. The classification point of the classifier 24 was set at 8 µm. The pressing amount
X of the graining brushes 17 onto the aluminum plate 15 was controlled at appropriate
timings such that electric power required for driving the graining brushes 17 to brush
the aluminum plate 15 was maintained at 7 kW per one brush.
[0036] It was apparent from observation on the aluminum plate surface grained through the
graining process of the second example that grains of uniform roughness were constantly
formed on the aluminum plate surface, and any change in the surface condition with
time was not observed during the operation of the graining process. Since the silica
sand or silica abrasives have higher abrasive power than the pumice, the pressure
of the graining brushes 17 onto the aluminum plate 15 may be a smaller value as compared
to the first example, so the electric power for driving the graining brush 17 was
controlled to be the smaller value. In the second example, the same grain roughness
as obtained in the first example was obtained by using silica sand or silica abrasives
with smaller diameters than the pumice used in the first example. Accordingly, there
were not any scratches on the surface that may be caused by abrasive particles of
lager diameters. Since the price of silica sand or silica abrasives is 60% to 70%
less than that of pumice, the graining process according to the second example cuts
the purchasing cost of abrasive materials as compared to the first example.
[0037] Morever, because aluminum powders produced by the graining of the aluminum plate
are mixed with the used silica sand or silica abrasives, and the mixture of aluminum
powders and silica sand or silica abrasives is suitable for use as a material of light-weight
cellular concrete, heat insulating medium or cement, it is possible to reuse the silica
sand or silica abrasives for these products after the particle diameters decrease
so much that they do not have sufficient abrasive power. Thereby, the amount of industrial
waste and thus the cost of waste disposal are still more reduced.
[0038] As described so far, according to the surface treatment method of the invention,
the electric power for driving the graining brushes as being in contact with the aluminum
plate is monitored and maintained constant by controlling the pressing amount of the
graining brushes onto the aluminum plate, so that the pressure of the graining brushes
onto the aluminum plate is maintained constant even if the graining brushes are worn
off or deformed. The abrasive particles contained in the abrasive slurry are classified
according to the particle diameter, so that only those abrasive particles with diameters
of a predetermined range are fed back to the abrasive slurry. Thereby, grains of uniform
roughness are constantly formed on the aluminum plate. Because the pressure of the
graining brushes and the particle diameters of the abrasive particles are controlled
without interrupting the graining process, the time efficiency is improved.
[0039] Because only those abrasive particles whose diameters become too small for graining
are excluded from the abrasive slurry, those abrasive particles which still have sufficiently
large diameters for graining are prevented from being wasted, so the consumption of
abrasive materials is reduced. As the waste of abrasive particles is reduced, the
cost of waste disposal is reduced.
[0040] Using silica sand or silica abrasives as the abrasive materials, it is possible to
reuse silica sand or silica abrasives as a material of light-weight cellular concrete,
heat insulating medium or cement, after the particle diameters of the silica sand
or silica abrasives decrease so much that they do not have sufficient abrasive power.
Thereby, the waste abrasive materials and thus the cost of waste disposal are still
more reduced.
[0041] Although the present invention has been described with respect to the preferred embodiment
shown in the drawings, the present invention is not to be limited to the above embodiment
but, on the contrary, various modifications may be possible to those skilled in the
art without departing from the scope of appended claims. For example, it is possible
to connect the feed back tube to a classification device like the classifier 24, and
feed back the used abrasive slurry after having the smaller abrasive particles excluded.
1. A surface treatment method for graining a surface of an aluminum plate (15) as a base
of a printing plate, wherein abrasive slurry (20) composed of abrasive materials mixed
with water is rubbed on the aluminum plate surface with a graining brush (17) that
is pressed onto the aluminum plate and is turned to brush the aluminum plate, characterized
in that the amount of electric power required for driving the graining brush to turn
at a constant speed as being in contact with the aluminum plate is monitored and maintained
constant by changing pressing amount (X) of the graining brush onto the aluminum plate.
2. A surface treatment method as claimed in claim 1, wherein the aluminum plate is conveyed
at a constant speed while being brushed by the graining brush.
3. A surface treatment method as claimed in claim 1, wherein the abrasive slurry after
being used for graining is fed back to a slurry supply tank (12), and the abrasive
materials contained in the abrasive slurry are classified according to their particle
diameter before the abrasive slurry is reused for graining, such that those abrasive
materials with smaller particle diameters than a predetermined value are excluded
from the abrasive slurry, and only those abrasive materials with larger particle diameters
than the predetermined value are included in the abrasive slurry.
4. A surface treatment method as claimed in claim 3, wherein the particle diameters of
the abrasive materials contained in the abrasive slurry in the slurry supply tank
are maintained within a range from 5 µm to 60 µm.
5. A surface treatment method as claimed in claim 3, wherein silica sand or silica abrasives
are used as the abrasive materials.
6. A surface treatment method as claimed in claim 5, wherein those abrasive particles
which are excluded from the abrasive slurry are reused as a by-product.
7. A surface treatment method as claimed in claim 5, wherein the abrasive materials having
an average particle diameter of 20 µm is mixed with water at a density of 200 g/l, and the predetermined value for the classifying the abrasive materials according
to the particle diameter is set to 8 µm.
8. A surface treatment method as claimed in claim 3, wherein a part of the abrasive slurry
in the slurry supply tank is continually circulated for classifying the abrasive materials
according to their particle diameter.
9. A surface treatment method as claimed in claim 1, wherein specific gravity of the
abrasive slurry in the slurry supply tank is measured, and abrasive materials or water
is supplemented to the slurry supply tank to maintain the specific gravity of the
abrasive slurry constant.
10. A surface treatment apparatus for graining a surface of an aluminum plate (15) as
a base of a printing plate, wherein abrasive slurry composed of abrasive materials
mixed with water is rubbed on the aluminum plate surface with a graining brush that
is pressed onto the aluminum plate and is turned to brush the aluminum plate, characterized
by comprising:
a graining brush (17) mounted movable in a vertical direction to the surface of the
aluminum plate;
an electric power monitoring device (32) for outputting a signal whose level corresponds
to the amount of electric power required for driving the graining brush to turn at
a constant speed while the graining brush is in contact with the aluminum plate;
a brush shifting device (31) for shifting the graining brush in the vertical direction
to change the pressing amount of the graining brush onto the aluminum plate; and
a control device (33) for controlling the amount of electric driving power to be maintained
constant by decreasing the pressing amount of the graining brush onto the aluminum
plate through the brush shifting device when the output signal from the electric power
monitoring device is above a predetermined level, or increasing the pressing amount
of the graining brush onto the aluminum plate through the brush shifting device when
the output signal from the electric power monitoring device is below the predetermined
level.
11. A surface treatment apparatus as claimed in claim 10, further comprising a conveying
device (16) for conveying the aluminum plate at a constant speed while the aluminum
plate is brushed by the graining brush.
12. A surface treatment apparatus as claimed in claim 10, further comprising:
a feed back device (23) for feeding the abrasive slurry after being used for graining
back into a slurry supply tank (12) so as to reuse the abrasive slurry for graining;
and
a classification device (24) that classifies the abrasive materials contained in the
abrasive slurry of the slurry supply tank according to their particle diameter, and
excludes those abrasive materials with smaller particle diameters than a predetermined
value from the abrasive slurry before being reused for graining.
13. A surface treatment method as claimed in claim 12, wherein the classification device
continually takes in a part of the abrasive slurry from the slurry supply tank, and
feeds back those abrasive materials with larger particle diameters than the predetermined
value to the slurry supply tank so as to maintain the particle diameters of the abrasive
materials contained in the abrasive slurry within a predetermined range, preferably
from 5 µm to 60 mµ.
14. A surface treatment apparatus as claimed in claim 12, further comprising a hydrometer
(30) for measuring specific gravity of the abrasive slurry of the slurry supply tank,
and a supplemental amount regulating device for determining amount of abrasive materials
or water to be supplemented to the abrasive slurry so as to maintain the specific
gravity of the abrasive slurry constant.