GRAVURE
`GRAVURE
`
`Process and Technology
`PracedJ and Technology
`
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`GRAVURE ASSOCIATION OF AMERICA
`GRAVURE ASSOCIATION OF AMERICA
`GRAVURE EDUCATION FOUNDATION
`Petitioner - Owens Corning
`Ex. 1011, p. 1 of 8
`
`Petitioner - Owens Corning
`Ex. 1011, p. 1 of 8
`
`(cid:9)
`

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`Copyright © 1991 by Gravure Education Foundation
`Copyright© 1991 by Gravure Education Foundation
`and
`and
`Gravure Association of America
`Gravure Association of America
`
`All Rights Reserved
`All Rights Reserved
`No part of this book may be reproduced in any way
`No part of this book may be reproduced in any way
`without the permission of the publisher.
`without the pennission of the publisher.
`
`ISBN 1-880290-00-6
`ISBN 1-880290-00-6
`
`Printed by Arcata Graphics Company
`Printed by Areata Graphics Company
`on Multiweb Matte paper
`on Mtdthoeb Matte paper
`from Repap Sales Corp.
`from Repap Sales Corp.
`Book design by Brett Rutherford
`Book design by Brett Rutherford
`Line illustrations by Jane Madson
`Line illustrations by fane Madson
`
`Distributed by
`Distributed by
`GRAVURE ASSOCIATION OF AMERICA
`GRAVURE ASSOCIATION OF AMERICA
`1220A Scottsville Road
`1220A Scottsville Road
`Rochester NY 14624
`Rochester NY 14624
`
`2
`
`Petitioner - Owens Corning
`
`Ex. 1011, p. 2 of 8
`
`Petitioner - Owens Corning
`Ex. 1011, p. 2 of 8
`
`

`
`CHAPTER
`CHAPTER
`
`WHAT IS GRAVURE?
`What is Gravure?
`
`Rotogravure printing is recognized as having advantages over
`Rotogravure printing is recognized as having advantages over
`other printing processes in the production of medium to long
`other printing processes in the production of medium to long
`print runs where uniform color is required. Gravure is the pro-
`print runs where uniform color is required. Gravure is the pro
`cess commonly chosen by publishers, advertisers, packaging
`cess commonly chosen by publishers, advertisers, packaging
`buyers and converters, as well as manufacturers of such products
`buyers and converters, as well as manufacturers of such products
`as floor and wall coverings, woodgrain paneling, and a variety of
`as floor and wall coverings, woodgrain paneling, and a variety of
`vinyl products. Gravure can produce high quality multicolor
`vinyl products. Gravure can produce high quality multicolor
`printing on a variety of materials ranging from film and foil to
`printing on a variety of materials ranging from film and foil to
`light weight coated paper to paperboard.
`light weight coated paper to paperboard.
`The growth and success of gravure are attributed to the sim-
`The growth and success of gravure are attributed to the sim
`plicity of the process. It has fewer variables to control than other
`plicity of the process. It has fewer variables to control than other
`printing processes, ensuring more consistent print quality
`printing processes, ensuring more consistent print quality
`throughout a run. A gravure press is mechanically simple com-
`throughout a run. A gravure press is mechanically simple com
`pared to other printing presses. It has four basic components to
`pared to other printing presses. It has four basic components to
`each printing unit: an engraved cylinder, the ink fountain, the
`each printing unit: an engraved cylinder, the ink fountain, the
`doctor blade, and the impression roller. It is the simplest printing
`doctor blade, and the impression roller. It is the simplest printing
`process to automate and to combine with other converting proc-
`process to automate and to combine with other converting proc
`esses such as laminating, sheeting, folding, creasing, die cutting,
`esses such as laminating, sheeting, folding, creasing, die cutting,
`and slitting. Press speeds of 3,000 feet per minute are now a real-
`and slitting. Press speeds of 3,000 feet per minute are now a real
`ity. Available in widths from under 12 inches to as wide as 6.7
`ity. Available in widths from under 12 inches to as wide as 6.7
`meters, gravure presses are economical to operate and usually re-
`meters, gravure presses are economical to operate and usually re
`quire fewer operators than other competitive processes.
`quire fewer operators than other competitive processes.
`Gravure can print on a broad range of substrates. The widest
`Gravure can print on a broad range of substrates. The widest
`range of ink and coating formulations can be printed by gravure.
`range of ink and coating formulations can be printed by gravure.
`Solvent and water based ink and coatings can be formulated to
`Solvent and water based ink and coatings can be formulated to
`meet specific requirements without concern for compatibility
`meet specific requirements without concern for compatibility
`with the image carrier. The repeat length is infinitely variable,
`with the image carrier. The repeat length is infinitely variable,
`minimizing waste and producing continuous, random, and
`random, and
`minimizing waste and producing continuous,
`nested images from a gapless image carrier.
`nested images from a gapless image carrier.
`
`Facing page: Detail of
`Facing page: Detail of
`electronically engraved
`electronically engraved
`gravure cylinder.
`gravure cylinder.
`
`GRAVURE: PROCESS AND TECHNOLOGY (cid:9)
`GRAVURE; PROCESS AND TECHNOLOGY
`
`Petitioner - Owens Corning
`
`Ex. 1011, p. 3 of 8
`
`3
`
`Petitioner - Owens Corning
`Ex. 1011, p. 3 of 8
`
`

`
`Gravure Cylinders for Textiles
`Gravure Cylinders for Textiles
`While traditional intaglio engravers continued their work
`While traditional
`intaglio engravers continued their work
`with flat plate engravings, the textile industry pioneered the use
`with flat plate engravings, the textile industry pioneered the use
`of intaglio engraved cylinders to print continuous patterns. The
`of intaglio engraved cylinders to print continuous patterns. The
`oldest description of rotary intaglio printing was published in
`oldest description of rotary intaglio printing was published in
`1847 in the French Dictionnaire des Arts et Manufactures. The Dic-
`1847 in the French Diclionmire des Arts et Manufactures. The D/c-
`tionnaire reports some use of engraved rollers for decorating tex-
`tionnaire reports some use of engraved rollers for decorating tex
`tiles as early as 1680. These early cylinders probably employed
`tiles as early as 1680. These early cylinders probably employed
`patterns made of hand-engraved dots or simple line patterns. It is
`patterns made of hand-engraved dots or simple line patterns. It is
`probably safe to say that print variations and imperfections that
`probably safe to say that print variations and imperfections that
`would have been ruinous on paper were tolerated in the produc-
`would have been ruinous on paper were tolerated in the produc
`tion of simple, cheap textiles.
`tion of simple, cheap textiles.
`Textile production was a cottage industry until 1750 when it
`Textile production was a cottage industry until 1750 when it
`was organized into a factory operation. Along with the develop-
`was organized into a factory operation. Along with the develop
`ment of machinery for the mass production of textiles came the
`ment of machinery for the mass production of textiles came the
`first documented commercial intaglio printing press in 1783 and
`first documented commercial intaglio printing press in 1783 and
`the first rotary machine in 1784. Thomas Bell received British Pat-
`the first rotary machine in 1784. Thomas Bell received British Pat
`ent No. 1443 for a rotary intaglio printing machine. The machine
`ent No. 1443 for a rotary intaglio printing machine. The machine
`was designed to print on calico cloth. Drawings from the patent
`was designed to print on calico cloth. Drawings from the patent
`detail the inking unit, printing cylinder, doctor blade, and im-
`detail the inking unit, printing cylinder, doctor blade, and im
`pression cylinder.
`pression cylinder.
`
`Figure 2-6.
`Figure 2-6.
`Calico fabrics brightened
`Calico fabrics brightened
`the otherwise drab and
`the othenvise drab and
`colorless life of these
`colorless life of these
`pioneer wives and daughters.
`pioneer wives and daughters.
`
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`C5r""Ir
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`Figure 2-7. From Thomas Bell's patent of 1784.
`Figure 1-7. From Thomas Bell's patent of 1784.
`
`GRAVURE: PROCESS AND TECHNOLOGY
`GRAVURE: PROCESS AND TECHNOLOGY
`
`Petitioner - Owens Corning
`
`Ex. 1011, p. 4 of 8
`
`15
`15
`
`Petitioner - Owens Corning
`Ex. 1011, p. 4 of 8
`
`

`
`CHAPTER
`CHAPTER
`
`6
`
`THE GRAVURE PRESS AND
`The Gravure Press and
`ITS COMPONENTS
`its Components
`
`All web-fed gravure presses start from an unwinder, which
`All web-fed gravure presses start
`from an unwinder, which
`serves the purpose of unwinding a roll of substrate, keeping ade-
`serves the purpose of unwinding a roll of substrate, keeping ade
`quate tension on the web.
`quate tension on the web.
`The printing unit, the heart of the gravure press, consists of
`The printing unit, the heart of the gravure press, consists of
`the following components, regardless of the application:
`the following components, regardless of the application;
`
`A GENERIC
`A Generic
`PRINTING UNIT
`Printing Unit
`
`• The image carrier, a cylinder engraved with the image to
`•
`The image carrier, a cylinder engraved with the image to
`be printed or transferred.
`be printed or transferred.
`• An ink fountain, a large ink well positioned beneath the
`•
`An ink fountain, a large ink well positioned beneath the
`cylinder, extending the width of the press unit.
`cylinder, extending the width of the press unit.
`• A doctor blade assembly containing a blade which wipes
`• A doctor blade assembly containing a blade which wipes
`excess ink from the non-image areas of the image carrier.
`excess ink from the non-image areas of the image carrier.
`• An impression roller, a rubber-covered metal cylinder
`• An impression roller, a rubber-covered metal cylinder
`which holds the substrate against the engraved image car-
`which holds the substrate against the engraved image car
`rier to obtain proper ink transfer.
`rier to obtain proper ink transfer.
`• A dryer, consisting of a controlled source of heated air,
`• A dryer, consisting of a controlled source of heated air,
`regulated to provide optimum drying of inks or coatings
`regulated to provide optimum drying of inks or coatings
`and remove ink carrier vapors.
`and remove ink carrier vapors.
`
`The limited number of major press components and their
`The limited number of major press components and their
`physical simplicity makes gravure easy to automate, simple to
`physical simplicity makes gravure easy to automate, simple to
`operate, and readily adaptable for additional in-line converting
`operate, and readily adaptable for additional in-line converting
`operations.
`operations.
`
`Facing page:
`Facing page:
`Publication web
`Publication zoeb
`proof press.
`proof press.
`
`GRAVURE: PROCESS AND TECHNOLOGY (cid:9)
`GRAVURE: PROCESS AND TECHNOLOGY
`
`Petitioner - Owens Corning
`Ex. 1011, p. 5 of 8
`
`99
`99
`
`Petitioner - Owens Corning
`Ex. 1011, p. 5 of 8
`
`

`
`Figure 6-1.
`Figure 6-1.
`Generic gravure
`Generic grnvure
`printing unit.
`printing unit.
`
`Gravure Printing
`
`IMPRESSION
`IMPnESSIOH
`CYLINDER
`CYLINDER
`
`DOCTOR
`BLADE
`
`C ETCHED P
`_ crumai^-
`
`INK
`INK
`FOUNTAIN
`fountain
`
`Modern gravure presses are equipped with many levels of
`Modem gravure presses are equipped with many levels of
`automation—including programmable control of all press se-
`automation—including programmable control of all press se
`quences—and digital drives.
`quences—and digital drives.
`Integrated press management systems monitor, control and
`Integrated press management systems monitor, control and
`report:
`report:
`
`• Fault detection, including on-line video monitoring.
`•
`Fault detection, including on-line video monitoring.
`• Preset of job variables.
`•
`Preset of job variables .
`• Production statistics.
`•
`Production statistics.
`•
`Ink consumption data analysis.
`•
`Ink consumption data analysis.
`• Paper consumption data analysis.
`•
`Paper consumption data analysis.
`• Waste analysis.
`• Waste analysis.
`
`In many recently delivered presses, the conventional press
`In many recently delivered presses, the conventional press
`main consoles are replaced by computerized controls where
`main consoles are replaced by computerized controls where
`video displays permit control of the press by means of touch
`video displays permit control of the press by means of touch
`screens or keyboard.
`screens or keyboard.
`
`Every gravure press is a custom-built machine, designed and en-
`Every gravure press is a custom-built machine, designed and en
`gineered for a specific range of products. A packaging press pro-
`gineered for a specific range of products. A packaging press pro
`ducing 26-inch-wide labels is identical in principle to a floor
`ducing 26-inch-wide labels is identical
`in principle to a floor
`covering press printing 15-foot-wide vinyl floor coverings. The
`covering press printing 15-foot-wide vinyl floor coverings. The
`wide range of sizes and substrates, as well as the variety of in-
`wide range of sizes and substrates, as well as the variety of in
`line converting make each gravure press a unique machine.
`line converting make each gravure press a unique machine.
`Each gravure press is designed to satisfy the user's specifications,
`Each gravure press is designed to satisfy the user's specifications,
`based on the end product produced. Some of the factors that de-
`based on the end product produced. Some of the factors that de
`termine press characteristics include:
`termine press characteristics include:
`
`• Substrate to be printed, ranging from light weight PVC
`•
`Substrate to be printed, ranging from light weight PVC
`film to heavy vinyl flooring.
`film to heavy vinyl flooring.
`• Web widths, from narrow wood grain trim under 12
`? Web widths,
`from narrow wood grain trim under 12
`inches, to towels and tissues up to 20 feet wide.
`inches, to towels and tissues up to 20 feet wide.
`
`•
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`n
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`•
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`•
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`•
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`TYPICAL PRESS
`Typical Press
`CONFIGURATIONS
`Configurations
`
`100
`)00
`
`THE GRAVURE PRESS AND ITS COMPONENTS
`THE GRAVURE PRESS AND ITS COMPONENTS
`
`Petitioner - Owens Corning
`
`Ex. 1011, p. 6 of 8
`
`Petitioner - Owens Corning
`Ex. 1011, p. 6 of 8
`
`

`
`Publication presses are designed for high speed printing of high
`Publication presses are designed for high speed printing of high
`quality color publications. Typical products include magazines,
`quality color publications. Typical products include magazines,
`Sunday newspaper magazines, catalogs, newspaper inserts, and
`Sunday newspaper magazines, catalogs, newspaper inserts, and
`advertising printing.
`advertising printing.
`The product requirements of publication gravure are:
`The product requirements of publication gravure are:
`
`GRAVURE
`Gravure
`PUBLICATION
`Publication
`PRESSES
`Presses
`
`• Multiple printed sheets must be folded and assembled
`• Multiple printed sheets must be folded and assembled
`into complete publications on the press, or delivered as
`into complete publications on the press, or delivered as
`folded signatures to the bindery.
`folded signatures to the bindery.
`• Variable cutoffs.
`Variable cutoffs.
`•
`• High speed production.
`• High speed production.
`• Versatile in-line finishing.
`•
`Versatile in-line finishing.
`• Color consistency throughout the entire press.
`• Color consistency throughout the entire press.
`• Adaptability to lower cost substrates.
`• Adaptability to lower cost substrates.
`• Lower start-up and running waste.
`•
`Lower start-up and running waste.
`
`The overwhelming majority of U.S. publication gravure
`The overwhelming majority of U.S. publication gravure
`presses have either 8 or 10 print units. New gravure presses tend
`presses have either 8 or 10 print units. New gravure presses tend
`to be in the 96 to 108-inch web width range; most other presses
`to be in the 96 to 108-inch web width range; most other presses
`range in width from 70 to 92 inches. The same press can produce
`range in width from 70 to 92 inches. The same press can produce
`from one to six different products, with pagination of the signa-
`from one to six different products, with pagination of the signa
`ture from 8 to 128 pages.
`ture from 8 to 128 pages.
`Because of the width and speed of these presses, gravure
`Because of the width and speed of these presses, gravure
`publication plants use an enormous amount of paper. This re-
`publication plants use an enormous amount of paper. This re
`quires sophisticated materials handling technology and a high
`quires sophisticated materials handling technology and a high
`degree of automation in loading paper rolls and splicing the new
`degree of automation in loading paper rolls and splicing the new
`paper roll to the expiring roll when printing at high speed.
`paper roll to the expiring roll when printing at high speed.
`
`Characteristics of Publication Presses
`Characteristics of Publication Presses
`Modern gravure publication presses are generally equipped
`Modem gravure publication presses are generally equipped
`with only one unwinder for eight printing units. The use of wide
`with only one unwinder for eight printing units. The use of wide
`webs has led printers to run only one web per press, and larger
`webs has led printers to run only one web per press, and larger
`diameter paper rolls, minimizing roll changeovers and related
`diameter paper rolls, minimizing roll changeovers and related
`waste.
`waste.
`The roll of paper is transported, usually by automatic or mo-
`The roll of paper is transported, usually by automatic or mo
`torized means, to the unwinder.
`torized means, to the unwinder.
`Publication press unwinders have automatic controls for roll
`Publication press unwinders have automatic controls for roll
`changeover. The mechanics of roll splicing are explained in detail
`changeover. The mechanics of roll splicing are explained in detail
`in the chapter on Web Handling.
`in the chapter on Web Handling.
`Web preconditioning units consist either of a hot air chamber
`Web preconditioning units consist either of a hot air chamber
`or of heated drums, used to bring the paper to optimum tem-
`or of heated drums, used to bring the paper to optimum tem
`perature and moisture conditions before printing.
`perature and moisture conditions before printing.
`Reversible printing units are equipped with two doctor blade
`Reversible printing units are equipped with two doctor blade
`groups, to permit printing of a web that travels from left to right
`groups, to permit printing of a web that travels from left to right
`as well as of a web going from right to left. The doctor blade is
`as well as of a web going from right to left. The doctor blade is
`typically locked in a doctor blade holder, which may be integral
`typically locked in a doctor blade holder, which may be integral
`to the press. Details of the operation and setting of doctor blades
`to the press. Details of the operation and setting of doctor blades
`are provided in the chapter on The Gravure Doctor Blade.
`are provided in the chapter on The Gravure Doctor Blade.
`Publication gravure presses often add a cloth-covered pre-
`Publication gravure presses often add a cloth-covered pre-
`wipe roller to the ink fountain to improve ink application to the
`wipe roller to the ink fountain to improve ink application to the
`print cylinder. On presses with variable cylinder sizes, the depth
`print cylinder. On presses with variable cylinder sizes, the depth
`of cylinder immersion in the ink fountain is adjustable.
`of cylinder immersion in the ink fountain is adjustable.
`
`&
`
`Si
`
`PI
`
`•% IH
`
`Facing page:
`Facing page:
`Figure 6-2.
`Figure 6-2.
`Gravure publication press.
`Gravure publication press.
`
`GRAVURE: PROCESS AND TECHNOLOGY (cid:9)
`GRAVURE: PROCESS AND TECHNOLOGY
`
`Petitioner - Owens Corning
`
`103
`
`Ex. 1011, p. 7 of 8
`
`Petitioner - Owens Corning
`Ex. 1011, p. 7 of 8
`
`

`
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`The sheet fed gravure press can work with either a gravure
`The sheet fed gravure press can work with either a gravure
`printing cylinder or a flat gravure printing plate.
`printing cylinder or a flat gravure printing plate.
`
`Intaglio Plate Printing
`Intaglio Plate Printing
`Intaglio plate printing is used for printing bank notes, cur-
`Intaglio plate printing is used for printing bank notes, cur
`rency, securities, and social printing (traditional "engraving" of
`rency, securities, and social printing (traditional "engraving" of
`business cards and invitations).
`business cards and invitations).
`Intaglio printing presses are generally sheetfed, although
`Intaglio printing presses are generally sheetfed, although
`some intaglio work, such as postage stamps, is done by web.
`some intaglio work, such as postage stamps, is done by web.
`The substrate is printed between an impression roller, and a
`The substrate is printed between an impression roller, and a
`printing cylinder. The ink, a thick paste, is transferred to the print
`printing cylinder. The ink, a thick paste, is transferred to the print
`cylinder by means of separate inking groups (one for each color)
`cylinder by means of separate inking groups (one for each color)
`which consist of ink pan, transfer rollers, milling roller and ink-
`which consist of ink pan, transfer rollers, milling roller and ink
`ing roller.
`ing roller.
`Intaglio printing shares the principle of engraved cylinders
`Intaglio printing shares the principle of engraved cylinders
`with gravure, but the inking system is totally different. The non-
`with gravure, but the inking system is totally different. The non
`printing areas of the printing cylinder are cleaned with cleaning
`printing areas of the printing cylinder are cleaned with cleaning
`paper, supplied from a continuous roll. The image is then trans-
`paper, supplied from a continuous roll. The image is then trans
`ferred from the plate to substrate under extremely high pressure.
`ferred from the plate to substrate under extremely high pressure.
`After printing, the sheets pass into a dryer. Intaglio, the forerun-
`After printing, the sheets pass into a dryer. Intaglio, the forerun
`ner of modern gravure printing, is also still used for fine art
`ner of modem gravure printing, is also still used for fine art
`printing in small presses which consist of simply an engraved
`printing in small presses which consist of simply an engraved
`plate and an impression mechanism which presses the paper
`plate and an impression mechanism which presses the paper
`against the plate. Inking and doctoring are carried out by hand,
`against the plate. Inking and doctoring are carried out by hand,
`and the paper is usually moistened to enhance ink transfer.
`and the paper is usually moistened to enhance ink transfer.
`
`Offset Gravure and Flexo Gravure
`Offset Gravure and Flexo Gravure
`The offset gravure system or "indirect gravure" is used
`The offset gravure system or "indirect gravure" is used
`mainly to print materials with irregular surfaces.
`mainly to print materials with irregular surfaces.
`The unit is a standard gravure print unit, with the addition
`The unit is a standard gravure print unit, with the addition
`of a rubber-covered transfer roller. The substrate is threaded be-
`of a rubber-covered transfer roller. The substrate is threaded be
`tween the standard impression roller and the transfer roller. The
`tween the standard impression roller and the transfer roller. The
`transfer roller is then used to print the image on the product to be
`transfer roller is then used to print the image on the product to be
`decorated. This transfer of image from cylinder to roller to prod-
`decorated. This transfer of image from cylinder to roller to prod
`uct is identical to the image transfer method of offset lithogra-
`uct is identical to the image transfer method of offset lithogra
`phy, hence the name "offset gravure." Typical products are
`phy, hence the name "offset gravure." Typical products are
`wood veneer or decorated metal surfaces. Irregular shapes such
`wood veneer or decorated metal surfaces. Irregular shapes such
`as construction molding and individual parts or products may be
`as construction molding and individual parts or products may be
`carried to the printing nip in a recessed conveyor belt designed to
`carried to the printing nip in a recessed conveyor belt designed to
`hold them.
`hold them.
`A variation of offset gravure is the use of a gravure cylinder
`A variation of offset gravure is the use of a gravure cylinder
`in place of an anilox roll on a flexo press. The flexo plate cylinder
`in place of an anilox roll on a flexo press. The flexo plate cylinder
`is mounted with a smooth rubber blanket and the image from the
`is mounted with a smooth rubber blanket and the image from the
`gravure engraved cylinder is printed onto the rubber blanket and
`gravure engraved cylinder is printed onto the rubber blanket and
`then transferred to the substrate. This application is usually re-
`then transferred to the substrate. This application is usually re
`ferred to as flexo gravure. Examples of this application are clear
`ferred to as flexo gravure. Examples of this application are clear
`film overwraps for towels and tissues and premium plastic han-
`film overwraps for towels and tissues and premium plastic han
`dle bags used for advertising where high quality reproductions
`dle bags used for advertising where high quality reproductions
`are desired.
`are desired.
`
`GRAVURE: PROCESS AND TECHNOLOGY (cid:9)
`GRAVURE: PROCESS AND TECHNOLOGY
`
`Petitioner - Owens Corning
`
`Ex. 1011, p. 8 of 8
`
`117
`117
`
`Petitioner - Owens Corning
`Ex. 1011, p. 8 of 8