CN107405802A - 压花辊的制造方法及压花辊 - Google Patents

压花辊的制造方法及压花辊 Download PDF

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CN107405802A
CN107405802A CN201680011266.3A CN201680011266A CN107405802A CN 107405802 A CN107405802 A CN 107405802A CN 201680011266 A CN201680011266 A CN 201680011266A CN 107405802 A CN107405802 A CN 107405802A
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重田龙男
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Think Laboratory Co Ltd
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    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
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    • B31F2201/00—Mechanical deformation of paper or cardboard without removing material
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Abstract

本发明提供能够进行多品种少量生产、无不均而均匀且精密地形成凹凸图案的压花辊的制造方法及压花辊。压花辊的制造方法包含：准备圆筒状母材的工序；以及造形工序，根据三维加工数据，通过三维打印机对圆筒状母材表面实施压花加工而进行造形。优选所述三维加工数据通过对压花辊模型进行三维扫描而制成。

Description

压花辊的制造方法及压花辊
技术领域
本发明涉及压花辊，更具体而言，涉及在压花辊的表面形成微小的凹凸图案的压花辊的制造方法及通过该制造方法而得到的压花辊。
背景技术
以往，作为在表面形成微小的凹凸图案的辊已知有压花辊。压花辊用于对各种片状的物品实施压花加工，除了建筑材料或日用品以外，还用于电气、电子产品的制造。例如对热塑性树脂膜实施压花加工，制作LCD用背光或后投影屏幕等所使用的棱镜片、双凸透镜片、菲涅耳透镜片、防反射膜等电子部件；对金属板实施压花加工，提高外观设计性或使其具有防滑功能。本案申请人提出一种例如专利文献1所记载的压花辊。
制造压花辊时，为了在圆筒状母材的表面形成微小的凹凸图案，进行雕刻、电铸、喷丸处理、放电加工处理、蚀刻处理等。
对于压花辊而言，有时大量制造相同凹凸图案，另一方面，有时需要制造各种凹凸图案的压花辊、多品种且每种少量的凹凸图案的压花辊。对于上述以往的压花辊的制造方法，虽然适于大量生产，但是不适于品种少量生产。
此外，构成凹凸图案的凹凸形状需要无不均而均匀且精密地形成。在制造电气、电子产品时，尤其要求精密度。
在先技术文献
专利文献
专利文献1：日本特开2009-72828
专利文献2：WO2011/125926
专利文献2：WO2012/043515
发明内容
发明要解决的课题
本发明的目的在提供能够进行多品种少量生产、无不均而均匀且精密地形成凹凸图案的压花辊的制造方法及压花辊。
用于解决课题的手段
为了解决上述课题，本发明的压花辊的制造方法包含：准备圆筒状母材的工序；以及造形工序，根据三维加工数据，通过三维打印机对圆筒状母材表面实施压花加工而进行造形。
优选的是，所述三维加工数据通过对压花辊模型进行三维扫描而制成。压花辊模型是指由合成树脂、金属、木材、石膏等制作的模型，可以使用制作成比所制造的压花辊小的模型。
作为圆筒状母材，可以应用金属制或合成树脂制的圆筒状母材的任一方。
作为金属制圆筒状母材的材质，可以应用公知的金属的任一方，但优选通过从由Ni、不锈钢、黄铜、Fe、Cr、Zn、Sn、Ti、Cu、Al形成的组中选出的至少一种材料构成。需要说明的是，由于为至少一种材料，当然也可以为合金。
在金属制圆筒状母材的情况下，优选在所述造形工序中，对敷设在所述圆筒状母材表面的被烧结粉末进行烧结。作为所述被烧结粉末，只要是能够烧结的材料便能够应用，优选为金属、陶瓷。更具体而言，优选为通过从由例如Ni、不锈钢、黄铜、Fe、Cr、Zn、Sn、Ti、Cu、Al、Pt、In、Mg、W、Co、陶瓷形成的组中选出的至少一种材料构成。需要说明的是，由于为至少一种材料，当然也可以为合金。另外，作为陶瓷，只要是通过烧结而成为烧结体的无机物则可以包含任一者，还包含例如WC(碳化钨)或SiC(碳化硅)这样的碳化物、氮化钨或氮化硅这样的氮化物。
优选的是，通过激光器进行所述被烧结粉末的烧结。作为激光器，可以应用公知的激光器。
作为合成树脂制圆筒状母材的材质，能够应用公知的合成树脂的任一者，优选通过从由例如硬质塑料、工程塑料、ABS树脂、环氧树脂、FRP(纤维强化塑料)、CFRP(碳纤维强化塑料)形成的组中选出的至少一种合成树脂材料构成。
在合成树脂制圆筒状母材的情况下，优选通过热熔融沉积方式、光造形方式、喷墨方式等进行所述造形工序。
所述热熔融沉积方式是通过利用打印头向母材表面喷出ABS树脂、聚乳酸树脂等热塑性合成树脂并且反复层叠而进行造形的方法。
所述光造形方式是通过向紫外线硬化性树脂照射紫外线激光且反复层叠而进行造形的方法。
所述喷墨方式是通过利用喷墨头喷射微小粒子状的紫外线硬化性合成树脂，通过紫外线照射使其固化并且反复层叠而进行造形的方法。
优选的是，通过全自动激光制版系统进行所述准备圆筒状母材的工序以及所述造形工序。作为全自动激光制版系统，可以使用例如在专利文献2或专利文献3所记载的全自动凹版制版用处理系统中装入三维打印机处理单元而成的全自动激光制版系统。另外，优选在该全自动激光制版系统中还装入有能够进行三维扫描的三维扫描仪处理单元。
本发明的压花辊通过所述压花辊的制造方法制造而成。
发明效果
根据本发明，具有能够提供可进行多品种少量生产、无不均而均匀且精密地形成凹凸图案的压花辊的制造方法及压花辊的显著效果。
附图说明
图1是示意性地示出本发明的压花辊的制造方法的一个实施方式的说明图，(a)是准备好圆筒状母材的状态，(b)是在圆筒状母材表面形成凹凸图案的第一层的状态，(c)是示出层叠多层凹凸图案的状态的主要部分剖视示意图。
图2是示意性地示出本发明的压花辊的制造方法的造形工序的说明图。
图3是示出通过本发明的压花辊的制造方法制造出的压花辊的示意图。
具体实施方式
以下对本发明的实施方式进行说明，上述实施方式仅为例示，因此无需言及能够在不脱离本发明的技术思想的范围内进行各种变形。需要说明的是，同一构件用同一附图标记表示。
如图1的(a)所示，首先，准备金属制或合成树脂制的圆筒状母材12。接着，根据三维加工数据，通过三维打印机对圆筒状母材表面实施压花加工而进行造形(造形工序)。
三维加工数据通过对压花辊模型进行三维扫描来制成。另外，也可以使用预先取得的三维加工数据。
接着，如图1的(b)所示，形成凹凸图案的第一层14a。在金属制圆筒状母材的情况下，对敷设于所述圆筒状母材表面的被烧结粉末进行烧结而形成。另外，在合成树脂制圆筒状母材的情况下，通过热熔融沉积方式、光造形方式、喷墨方式等而形成。
接着，反复图1的(b)所示的层的形成，如图1的(c)所示，形成层叠有多层14a～14e的状态。如上所述，制造出在其表面形成有微小的凹凸图案16的压花辊18。
对于所述造形工序而言，如图2所示，将卡锥(省略图示)插入圆筒状母材12的开口部20，一边使圆筒状母材12旋转一边进行造形工序即可。附图标记22表示公知的三维打印机。若采用这种方式，能够使用公知的三维打印机22来进行造形工序。另外，也可以采用如下结构的处理单元，该处理单元一边使圆筒状母材12旋转一边使用公知的三维打印机22来进行造形工序。
若采用三维打印机处理单元，则能够装入在全自动激光制版系统而使用。
在图3中示出如上述那样制造的压花辊18。在本发明的压花辊18的制造方法中，形成一边为10μm左右的尺寸的凹凸图案16。
实施例
以下列举实施例对本发明更加具体地进行说明，但上述实施例仅为例示，而不应当限定性地进行解释，这是不言而喻的。
(实施例1)
作为圆筒状母材，准备圆周600mm、面长1100mm、厚度10mm的铁制的中空辊，使用NewFX(株式会社新克制全自动激光制版系统)进行压花辊的制造。在全自动激光制版系统中预先装入被烧结粉末烧结方式类型的三维打印机处理单元作为处理单元。三维加工数据使用预先对压花辊模型进行三维扫描而得到的数据。
通过光纤激光器对敷设在所述中空辊表面的被烧结粉末(被烧结成为相当于模具钢SKD11的金属粉末)进行烧结而形成层。然后，反复形成层，从而层叠有多层。如上所述，得到在其表面形成有微小的凹凸图案的压花辊。
(实施例2)
作为圆筒状母材，准备圆周600mm、面长1100mm、厚度10mm的CFRP制的中空辊，使用NewFX(株式会社新克制全自动激光制版系统)进行压花辊的制造。在全自动激光制版系统中预先装入热熔融沉积方式类型的三维打印机处理单元作为处理单元。三维加工数据使用预先对压花辊模型进行三维扫描而得到的数据。
通过打印头向所述中空辊表面喷出热塑性合成树脂(ABS树脂)而形成层。然后，反复形成层，从而层叠有多层。如上所述，得到在其表面形成有微小的凹凸图案的压花辊。
附图标记说明：
12：圆筒状母材；
14a～14e：层；
16：凹凸图案；
18：压花辊；
20：开口部；
22：三维打印机。

Claims (6)

1.一种压花辊的制造方法，包含：
准备圆筒状母材的工序；以及
造形工序，根据三维加工数据，通过三维打印机对圆筒状母材表面实施压花加工而进行造形。
2.根据权利要求1所述的压花辊的制造方法，其中，
所述三维加工数据通过对压花辊模型进行三维扫描而制成。
3.根据权利要求1或2所述的压花辊的制造方法，其中，
在所述造形工序中，对敷设在所述圆筒状母材表面的被烧结粉末进行烧结。
4.根据权利要求3所述的压花辊的制造方法，其中，
通过激光器进行所述被烧结粉末的烧结。
5.根据权利要求1至4中任一项所述的压花辊的制造方法，其中，
通过全自动激光制版系统进行所述准备圆筒状母材的工序以及所述造形工序。
6.一种压花辊，其通过权利要求1至5中任一项所述的压花辊的制造方法制造而成。
CN201680011266.3A 2015-05-28 2016-05-10 压花辊的制造方法及压花辊 Pending CN107405802A (zh)

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