Rotogravure cylinders, intermediates and methods

A method for engraving into an intermediate product that is a cylindrical base of aluminum onto which a circumferential copper layer extends, the base and the circumferential copper layer having a mutual interface, wherein the circumferential copper layer as applied to the base and prior to application of a layer thereover has a plurality of properties including a thickness of at most 100 μm, a surface roughness Rz of less than 0.5 μm and a porosity of less than 1.0%, wherein the circumferential copper layer is formed from melted or partially melted and cooled copper particles, whereby the circumferential copper layer imparts compressive stress onto the underlying base, and wherein the intermediate product further comprises a copper engraving layer that is present on the circumferential copper layer, comprising engraving a predetermined pattern into the copper engraving layer.

A rotogravure cylinder comprising a cylindrical base of aluminum onto which a circumferential copper layer extends, the base and the circumferential copper layer having a mutual interface, wherein the circumferential copper layer as applied to the base and prior to application of a layer thereover has a plurality of properties including a thickness of at most 100 μm, a surface roughness Rz of less than 0.5 μm and a porosity of less than 1.0%, wherein the circumferential copper layer is formed from melted or partially melted and cooled copper particles, whereby the circumferential copper layer imparts compressive stress onto the underlying base, and wherein the cylinder further comprises a copper engraving layer that is present on the circumferential copper layer and that is engraved in accordance with a predefined pattern and protected with a protection layer.

A method of manufacturing rotogravure cylinders, wherein a circumferential copper support layer is provided onto a cylindrical base of aluminum, and a copper engraving layer is engraved according to a desired pattern and protected with a protection layer, wherein the provision of the circumferential copper support layer is arranged to obtain a layer as applied to the base and prior to application of a layer thereover has a plurality of properties including a thickness of at most 100 μm, with a surface roughness Rz of less than 0.5 μm and a porosity of less than 1.0%, wherein the circumferential copper layer is formed from melted or partially melted and cooled copper particles, whereby the circumferential copper layer imparts compressive stress onto the underlying base.

A method of printing packaging material with rotogravure cylinders, wherein a circumferential copper support layer is provided onto a cylindrical base of aluminum, and a copper engraving layer is engraved according to a desired pattern and protected with a protection layer, wherein the provision of the circumferential copper support layer is arranged to obtain a layer as applied to the base and prior to application of a layer thereover to have a plurality of properties including a thickness of at most 100 μm, a with a surface roughness Rz of less than 0.5 μm and a porosity of less than 1.0%, wherein the circumferential copper layer is formed from melted or partially melted and cooled copper particles, whereby the circumferential copper layer imparts compressive stress onto the underlying base, applying ink to the rotogravure cylinder and transferring at least some of the ink from the rotogravure cylinder to the packaging material.