EP3760334A1

EP3760334A1 - Engraved and embossed embossing mold roller having interlocking structure used for manufacturing embossed metal pipe

Info

Publication number: EP3760334A1
Application number: EP18908016.1A
Authority: EP
Inventors: Bohyun Lee; Changyub LEE
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-02-28
Filing date: 2018-12-24
Publication date: 2021-01-06
Anticipated expiration: 2038-12-24
Also published as: CN111432953B; WO2019168260A1; JP7036326B2; EP3760334A4; CN111432953A; KR101884364B1; EP3760334B1; JP2021509361A

Abstract

Disclosed is a mutual engagement type intaglio-relief embossing press roller configured such that, in order to solve a problem in that, at the time of manufacture of an embossed pipe using a pipe mill configured to manufacture a metal pipe, a concave-convex embossed pattern formed on an embossed metal sheet is deformed while the embossed metal sheet passes through male-female engagement type horizontal curving rollers and engagement type horizontal and vertical rounding rollers of the pipe mill, whereby welding is impossible due to mismatch of the concave-convex embossed pattern, the mutual engagement type intaglio-relief embossing press roller forms small-width planes at opposite side edges of the embossed metal sheet in the longitudinal direction so as to be lower than an embossed pattern layer, whereby it is possible to weld a seam portion formed at an embossed metal pipe in the longitudinal direction, and forms a groove in a weld seam portion, whereby it is possible to prevent a weld scar from being exposed outside.

Description

[Technical Field]

The present invention relates to a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe, and more particularly to a mutual engagement type intaglio-relief embossing press roller configured such that, in order to solve a problem in that, at the time of manufacture of an embossed pipe using a pipe mill configured to manufacture a metal pipe, a concave-convex embossed pattern formed on an embossed metal sheet is deformed while the embossed metal sheet passes through male-female engagement type horizontal curving rollers and engagement type horizontal and vertical rounding rollers of the pipe mill, whereby welding is impossible due to mismatch of the concave-convex embossed pattern, the mutual engagement type intaglio-relief embossing press roller forms small-width planes at opposite side edges of the embossed metal sheet in the longitudinal direction so as to be lower than an embossed pattern layer, whereby it is possible to weld a seam portion formed at an embossed metal pipe in the longitudinal direction, and forms a groove in a weld seam portion, whereby it is possible to prevent a weld scar from being exposed outside.

[Background Art]

A pipe mill is an apparatus that rounds a metal sheet that is successively supplied, such as a stainless steel sheet, an iron sheet, a copper sheet, or a brass sheet, through a process of gradually increasing the curvature of the metal sheet and performs welding in the state in which opposite side ends of the rounded metal sheet are matched with each other to manufacture a circular metal pipe.
However, technology for manufacturing an embossed pipe from an embossed metal sheet manufactured using the intaglio-relief embossing press roller using the pipe mill as in the present invention has not yet been disclosed.
Conventionally, in embossed pipe manufacturing, technology for increasing the curvature of a smooth metal sheet while the metal sheet passes between horizontally installed male and female engagement type curving rollers using a metal pipe obtained by melting and extruding metal or a pipe mill, shaping the metal sheet in the form of a pipe while the curved metal sheet passes between a plurality of rounding rollers installed horizontally and vertically so as to be engaged with each other in symmetry, and welding opposite side ends of the shaped pipe in the state of being matched with each other to manufacture an embossed pipe having a seam portion formed in the longitudinal direction is used.
As an example of the conventional art, Korean Registered Patent No. 10-1611572 (registered on April 5, 2016 ) discloses an embossing technology entitled PATTERN FORMING MACHINE FOR METAL PIPES, wherein, when a plunger is moved rearwards, an inner die installed in a housing is pushed by the plunger and thus is moved toward the inner circumferential surface of a metal pipe, and a relief pattern formed on the outer circumferential surface of the inner die is engaged with an intaglio pattern formed on the inner circumferential surface of an outer die, whereby patterns are formed on the surfaces of the metal pipe located between the inner die and the outer die.
Korean Registered Patent No. 10-404895 (registered on October 28, 2003 ) discloses a method of forming embossed protrusions on a metal pipe entitled EMBOSSED PROTRUSION FORMING APPARATUS FOR METAL PIPES, wherein a movable fixing stand fixedly installed at the middle of a frame, left and right movable fixing stands fixedly installed at the frame, and first moving force generation members connected to the rear sides thereof are moved inside a plurality of circular casings so as to be matched therewith in order to form a cylindrical casing having a plurality of circular casing through-holes, a metal pipe is inserted into the cylindrical casing and is fixed therein so as to be in tight contact therewith, a pipe-shaped core having punches mounted in a plurality of through-holes formed in the pipe-shaped circumferential surface thereof is inserted into the metal pipe and is fixed therein so as to be in tight contact therewith such that the casing through-holes formed in the inner surface of the cylindrical casing are matched with large-diameter core through-holes formed in the outer surface of the core, a plunger, which has a size equal to the inner diameter of the core, has a conical front end, and has a bar-shaped body, is inserted using strong pressure of a cylinder of a second moving force generation member such that lower-end bent portions of the punch large-diameter portions protruding inwards inside small-diameter through-holes pushed vertically upwards by the conical inclined surface of the front end of the plunger and thus punches of the dome-shaped large-diameter portions integrally formed with the small-diameter portions are also pushed upwards toward the casing through-holes formed in the inner surface of the casing, whereby the surface of the pipe are bent and protruded and thus a plurality of protrusions is formed on the pipe.
The above disclosed examples of the conventional art are similar to each other in that a pipe is embossed between an outer female die and an inner male die of a metal pipe manufactured by extrusion. However, such embossing is neither accurate nor sophisticated. In addition, embossing is not performed through a continuous process, whereby productivity and competitiveness are deteriorated.
As another example of the conventional art, Korean Registered Patent No. 10-1399231 (registered on May 19, 2014 ) discloses an apparatus for forming circular recesses in a metal pipe entitled PIPE EMBOSSING APPARATUS HAVING IMPROVED STRUCTURE, wherein the apparatus includes a cylinder unit including cylinders configured to be operated by pneumatic pressure and pistons configured to be operated by the cylinders and embossing protrusions formed on the tips of the pistons, and the cylinders of the apparatus strike the embossing protrusions by pneumatic pressure at predetermined intervals based on the center line of the metal pipe in the vertical direction to form circular recesses on the metal pipe.
However, there is a shortcoming in that the above apparatus performs very simple intaglio embossing, whereby it is not possible to obtain a delicate and sophisticated embossed pattern.
Besides, Korean Registered Patent No. 10-1017890 (registered on February 21, 2011 ) entitled DIAMOND-SHAPED DIE ON OUTER CIRCUMFERENCE OF PIPE AND FORMING METHOD USING THE SAME and Korean Registered Patent No. 10-1604011 (registered on March 10, 2016 ) entitled PIPE BELLOWS FORMING APPARATUS are disclosed as technologies related to an apparatus for embossing the outer circumferential surface of a pipe as described above.
For pipes obtained by embossing outer circumferential surfaces of metal pipes having smooth surfaces as described above, however, the embossed pattern is simple and thus it is not possible to obtain a delicate and sophisticated embossed pattern, and metal pipes cut to a predetermined length are mounted in the apparatus one by one such that the outer circumferential surface of each of the metal pipes is embossed, which is very inefficient.
The present invention solves the above problems of the embossed metal pipe manufacturing apparatus and thus is capable of efficiently manufacturing an embossed pipe having a sophisticated and fine embossed pattern using the pipe mill.
A long time was required to successfully manufacture an embossed pipe from an embossed metal sheet using the pipe mill in connection with the present invention, and unexpected problems have occurred. The problems were solved one by one, and therefore a final embossed metal pipe was completed.
One of the problems is that, in the case in which a flat metal sheet passes through the pipe mill, high pressure from male-female engagement type curving rollers, which are installed horizontally and vertically, is applied to the metal sheet while the metal sheet passes between the male-female engagement type curving rollers, whereby the metal sheet is curved while being plastically deformed.
In contrast, an embossed metal sheet has an apparent volume equivalent to twice the thickness of a metal sheet before embossing due to formation of a concave-convex embossed pattern thereon.
As a concrete example, in the case in which metal sheets having thicknesses of 0.5 mm and 1 mm before embossing are used, the heights from the protruding portions of the embossed patterns to the bottom surfaces of the metal sheets after embossing become 1 mm and 2 mm, respectively, while defining a space therein. In the case in which an embossed metal pipe is manufactured using the embossed metal sheet, the embossed pattern has difficulty maintaining the original shape thereof and thus is distorted while the embossed metal sheet passes through the male-female engagement type curving rollers of the pipe mill. In order to solve this, it is necessary to accurately adjust the distance between the male-female engagement type curving rollers depending on the embossed degree.
Also, in the case in which the distance between the male-female engagement type curving rollers is small and thus pressure increases, the embossed pattern is excessively deformed, and at the same time the width of the embossed metal pipe is increased, whereby the sides of the embossed metal pipe may overlap each other in the symmetrical engagement type rounding rollers. In the case in which the distance between the male-female engagement type curving rollers is large, it is not possible to sufficiently curve the metal sheet.
Another problem is related to the seam portion formed at the embossed metal pipe in the longitudinal direction. That is, in the case in which the embossed pipe is manufactured from the embossed metal sheet using the pipe mill, it is substantially impossible to weld the seam portion formed at the embossed pipe in the longitudinal direction.
The present invention relates to a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe as a means for solving the above problems.
The above description may be summarized as follows.
When manufacturing the embossed pipe using the pipe mill, in the case in which the embossed metal sheet or the embossed metal band, embossed by the intaglio-relief engagement embossing roller having high dimensional stability, passes through the pipe mill, the embossed pattern of the embossed metal sheet, which is further thinned by embossing, is deformed and thus the height of the embossed pattern is changed while passing between the horizontal male-female engagement type curving rollers, each of which is made of a high-strength metal material, and between the horizontal and vertical symmetrical engagement type rounding rollers. In addition, there is a difference in length of the embossed pattern in the longitudinal direction due to the difference in pressing force and rotational shear force caused by engagement between the rollers in the longitudinal direction, whereby corresponding portions of the embossed pattern at the weld portion deviate from each other in the height direction and the longitudinal direction, and therefore welding is not possible.
Even in the case in which welding is performed, large numbers of gaps and micro-scale holes are formed in the weld seam portion, whereby it is not possible to secure watertightness and airtightness. In the case in which welding time is increased in order to remove the gaps and the holes, the weld material contaminates the surface of the embossed pattern, whereby the product value of the embossed pipe is lost.
The above problems are solved by a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe presented by the present invention.

[Disclosure]

[Technical Problem]

The present invention relates to a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe configured such that, in manufacturing an embossed metal pipe using a conventional pipe mill configured to manufacture a circular smooth metal pipe, the mutual engagement type intaglio-relief embossing press roller embosses a flat metal sheet in a process before the metal pipe is introduced into the pipe mill so as to be used to manufacture an embossed metal pipe through the pipe mill, and it is an object of the present invention to provide a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe that is capable of providing a more sophisticated and delicate embossed pattern than an embossed pipe manufactured by a conventional embossed pipe manufacturing apparatus, welding a seam portion formed at an embossed pipe in the longitudinal direction at the time of manufacture of the embossed pipe using a pipe mill, preventing a scar of the seam portion from being exposed to the outside, and maximizing production capability together with the properties of the pipe mill capable of performing a continuous process.

[Technical Solution]

In accordance with an aspect of the present invention, the above object can be accomplished by the provision of a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe, the mutual engagement type intaglio-relief embossing press roller including an upper roller having a relief embossing pattern formed thereon and a lower roller having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller includes a roller body, shafts formed at opposite ends of the roller body, a relief embossing pattern unit formed on the surface of the roller body, and first left and right ends formed at opposite side ends of the roller body so as to be lower than the relief embossing pattern unit, and wherein the lower roller includes a roller body, shafts formed at opposite ends of the roller body, an intaglio embossing pattern unit formed on the surface of the roller body, and second left and right ends formed at opposite side ends of the roller body so as to be higher than the intaglio embossing pattern unit.
In accordance with another aspect of the present invention, there is provided a mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe, the mutual engagement type intaglio-relief embossing press roller including an upper roller having a relief embossing pattern formed thereon and a lower roller having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in a state of being engaged with each other, wherein the upper roller includes a roller body, shafts formed at opposite ends of the roller body, a relief embossing pattern unit formed on the surface of the roller body, a band-shaped groove formed on the surface of the roller body in the rotational direction of the roller so as to be lower than the relief embossing pattern unit in order to partition the relief embossing pattern unit at predetermined intervals, first left and right ends formed at opposite side ends of the roller body so as to be lower than the relief embossing pattern unit, and left and right inclined surface formation portions extending from the first left and right ends in the lateral direction so as to be integrally formed therewith, the left and right inclined surface formation portions protruding outwards from points extending from the first left and right ends in the oblique direction, the left and right inclined surface formation portions being rotated in the state of being engaged with second left and right ends of the lower roller to shape opposite ends of a metal sheet so as to have inclined surfaces, and wherein the lower roller includes a roller body, shafts formed at opposite ends of the roller body, an intaglio embossing pattern unit formed on the surface of the roller body, and second left and right ends formed at opposite side ends of the roller body so as to be higher than the intaglio embossing pattern unit.

[Advantageous Effects]

A mutual engagement type intaglio-relief embossing press roller used in manufacture of an embossed metal pipe according to the present invention has the following effects.
First, it is possible to provide a more sophisticated and delicate embossed pattern than an embossed pattern formed on a smooth pipe by a conventional embossing apparatus.
Second, at the time of manufacture of an embossed pipe using a pipe mill, welding is possible and a small-width seam groove is formed in a weld seam portion in the case in which an embossed metal pipe formed by the engagement type intaglio-relief embossing press roller is used, whereby a weld portion is not exposed to the outside, and at least one circumferential groove identical to the small-width seam groove is formed together with the small-width seam groove, whereby a decorative effect is improved together with the sophisticated embossed pattern.

[Description of Drawings]

FIG. 1 is an overall perspective view of an embossed metal pipe manufacturing apparatus including an intaglio-relief embossing press roller according to the present invention.
FIG. 2 is a perspective view of an intaglio-relief embossing press roller according to a first embodiment of the present invention.
FIG. 3 is a front view of the intaglio-relief embossing press roller according to the first embodiment of the present invention.
FIG. 4 is a front view of an intaglio-relief embossing press roller according to a second embodiment of the present invention.
FIG. 5 is a front view of an intaglio-relief embossing press roller according to a third embodiment of the present invention.
FIG. 6 is a front view of an intaglio-relief embossing press roller according to a fourth embodiment of the present invention.
FIG. 7 is a front view of an intaglio-relief embossing press roller according to a fifth embodiment of the present invention.
FIG. 8 is a front view of an intaglio-relief embossing press roller according to a sixth embodiment of the present invention.
FIG. 9 is a front view showing the state in which an embossed metal sheet is manufactured using the intaglio-relief embossing press roller according to the first embodiment of the present invention.
FIG. 10 is a front view showing the state in which an embossed metal sheet is manufactured using the intaglio-relief embossing press roller according to the third embodiment of the present invention.
FIG. 11 is a side sectional view of the embossed metal sheet manufactured using the intaglio-relief embossing press roller according to each of the first and third embodiments of the present invention.
FIG. 12 is a front view showing the state in which an embossed metal sheet is manufactured using the intaglio-relief embossing press roller according to the fifth embodiment of the present invention.
FIG. 13 is a front view showing the state in which an embossed metal sheet is manufactured using the intaglio-relief embossing press roller according to the sixth embodiment of the present invention.
FIG. 14 is a side sectional view of the embossed metal sheet manufactured using the intaglio-relief embossing press roller according to each of the fifth and sixth embodiments of the present invention.
FIG. 15 is a side sectional view schematically showing an embodiment of an embossed metal pipe manufactured using the embossed metal sheet manufactured through the intaglio-relief embossing press roller according to the present invention before welding.
FIG. 16 is a side sectional view schematically showing the embodiment of the embossed metal pipe manufactured using the embossed metal sheet manufactured through the intaglio-relief embossing press roller according to the present invention after welding.
FIG. 17 is a side sectional view showing various forms of a weld seam portion formed in the embossed metal pipe of FIG. 15.

[Best Mode]

A mutual engagement type intaglio-relief embossing press roller (1) used in manufacture of an embossed metal pipe, the mutual engagement type intaglio-relief embossing press roller including an upper roller (10) having a relief embossing pattern formed thereon and a lower roller (20) having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller (10) includes a roller body (101), shafts (102) formed at opposite ends of the roller body, a relief embossing pattern unit (103) formed on the surface of the roller body (101), and first left and right ends (105, 106) formed at opposite side ends of the roller body (101) so as to be lower than the relief embossing pattern unit (103), and wherein the lower roller (20) includes a roller body (201), shafts (202) formed at opposite ends of the roller body, an intaglio embossing pattern unit (203) formed on the surface of the roller body (201), and second left and right ends (205, 206) formed at opposite side ends of the roller body (201) so as to be higher than the intaglio embossing pattern unit (203) .

[Mode for Invention]

FIG. 1 is an overall perspective view of an embossed metal pipe manufacturing apparatus including an intaglio-relief embossing press roller according to the present invention.
In briefly describing a process of manufacturing an embossed metal pipe using the embossed metal pipe manufacturing apparatus shown in FIG. 1, a metal sheet from an uncoiler is first supplied to an intaglio-relief embossing press roller 1 via a guide roller. At this time, various kinds of metal sheets may be used as the metal sheet. As an example, a stainless metal plate is used.
The metal sheet supplied to the intaglio-relief embossing press roller 1 passes between an upper roller 10 having a relief embossing pattern formed thereon and a lower roller 20 having an intaglio embossing pattern formed thereon while the upper roller and the lower roller are rotated in the state of being engaged with each other, whereby the surfaces of the metal sheet are embossed.
The embossed metal sheet discharged through the intaglio-relief embossing press roller 1 is subjected to several steps (STEP 1 to STEP 7) of a pipe mill configured to manufacture a metal pipe, whereby an embossed metal pipe having a seam portion formed in the longitudinal direction is manufactured. Finally, the seam portion is welded, and therefore an entirely unified embossed metal pipe is completed.
The present invention relates to the intaglio-relief embossing press roller 1 shown in FIG. 1.
More specifically, the present invention relates to a mutual engagement type intaglio-relief embossing press roller 1 used in manufacture of an embossed pipe using a conventional pipe mill configured to manufacture a metal pipe having a smooth surface, wherein the mutual engagement type intaglio-relief embossing press roller is capable of providing a sophisticated and delicate embossed pattern, welding a seam portion formed at the embossed pipe in the longitudinal direction at the time of manufacture of the embossed pipe using the pipe mill, forming a small-width groove in a weld seam portion in order to prevent a scar of the seam portion from being exposed to the outside, forming at least one small-width groove identical to the small-width seam groove along the circumferential surface of the roller at predetermined intervals in order to partition the embossed pattern and thus to provide a decorative effect together with the sophisticated and delicate embossed pattern, and maximizing production capability together with the properties of the pipe mill capable of performing a continuous process.
The concrete technical construction of the mutual engagement type intaglio-relief embossing press roller 1 according to the present invention described above will be described in detail with reference to the drawings.
The mutual engagement type intaglio-relief embossing press roller 1 according to the present invention may be realized in various embodiments.
Hereinafter, the mutual engagement type intaglio-relief embossing press roller 1 will be described based on four embodiments of a mutual engagement type intaglio-relief embossing press roller 1 having the same embossing pattern and two embodiments of a mutual engagement type intaglio-relief embossing press roller 1 having an embossing pattern different from the embossing pattern of the four embodiments.

[First embodiment]

As shown in FIGS. 2 and 3, a mutual engagement type intaglio-relief embossing press roller 1 according to a first embodiment of the present invention includes an upper roller 10 having a relief embossing pattern formed thereon and a lower roller 20 having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller 10 includes a roller body 101, shafts 102 formed at opposite ends of the roller body, a relief embossing pattern unit 103 formed on the surface of the roller body 101, and first left and right ends 105 and 106 formed at opposite side ends of the roller body 101 so as to be lower than the relief embossing pattern unit 103, and wherein the lower roller 20 includes a roller body 201, shafts 202 formed at opposite ends of the roller body, an intaglio embossing pattern unit 203 formed on the surface of the roller body 201, and second left and right ends 205 and 206 formed at opposite side ends of the roller body 201 so as to be higher than the intaglio embossing pattern unit 203.
In the first embodiment, a band-shaped groove 104 configured to partition the relief embossing pattern unit 103 and a band-shaped protrusion 204 configured to partition the intaglio embossing pattern unit 203 are not formed.
A mutual engagement type intaglio-relief embossing press roller 1 according to a second embodiment includes a band-shaped groove 104 and a band-shaped protrusion 204.

[Second embodiment]

As shown in FIG. 4, a mutual engagement type intaglio-relief embossing press roller 1 according to a second embodiment of the present invention includes an upper roller 10 having a relief embossing pattern formed thereon and a lower roller 20 having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller 10 includes a roller body 101, shafts 102 formed at opposite ends of the roller body, a relief embossing pattern unit 103 formed on the surface of the roller body 101, a band-shaped groove 104 formed on the surface of the roller body 101 in the rotational direction of the roller so as to be lower than the relief embossing pattern unit 103 in order to partition the relief embossing pattern unit 103 at predetermined intervals, and first left and right ends 105 and 106 formed at opposite side ends of the roller body 101 so as to be lower than the relief embossing pattern unit 103, and wherein the lower roller 20 includes a roller body 201, shafts 202 formed at opposite ends of the roller body, an intaglio embossing pattern unit 203 formed on the surface of the roller body 201, a band-shaped protrusion 204 formed on the surface of the roller body 201 in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit 203 in order to partition the intaglio embossing pattern unit 203 at predetermined intervals, and second left and right ends 205 and 206 formed at opposite side ends of the roller body 201 so as to be higher than the intaglio embossing pattern unit 203.
The protrusion 204 of the lower roller 20 is configured to be inserted into the groove 104 of the upper roller 10.
A mutual engagement type intaglio-relief embossing press roller 1 according to a third embodiment is different from the mutual engagement type intaglio-relief embossing press roller 1 according to each of the first and second embodiments in terms of the structure of opposite side ends of the roller body 101 of the upper roller 10.
Left and right inclined surface formation portions 107 and 108 are formed at opposite side ends of the roller body 101 of the upper roller 10 constituting the mutual engagement type intaglio-relief embossing press roller 1 according to the third embodiment.

[Third embodiment]

As shown in FIG. 5, the mutual engagement type intaglio-relief embossing press roller 1 according to the third embodiment of the present invention includes an upper roller 10 having a relief embossing pattern formed thereon and a lower roller 20 having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller 10 includes a roller body 101, shafts 102 formed at opposite ends of the roller body, a relief embossing pattern unit 103 formed on the surface of the roller body 101, first left and right ends 105 and 106 formed at opposite side ends of the roller body 101 so as to be lower than the relief embossing pattern unit 103, and left and right inclined surface formation portions 107 and 108 extending from the first left and right ends 105 and 106 in the lateral direction so as to be integrally formed therewith, the left and right inclined surface formation portions protruding outwards from points extending from the first left and right ends 105 and 106 in the oblique direction, the left and right inclined surface formation portions being rotated in the state of being engaged with second left and right ends 205 and 206 of the lower roller 20 to shape opposite ends of a metal sheet so as to have inclined surfaces, and wherein the lower roller 20 includes a roller body 201, shafts 202 formed at opposite ends of the roller body, an intaglio embossing pattern unit 203 formed on the surface of the roller body 201, and second left and right ends 205 and 206 formed at opposite side ends of the roller body 201 so as to be higher than the intaglio embossing pattern unit 203.
In the third embodiment, a band-shaped groove 104 configured to partition the relief embossing pattern unit 103 and a band-shaped protrusion 204 configured to partition the intaglio embossing pattern unit 203 are not formed.
A mutual engagement type intaglio-relief embossing press roller 1 according to a fourth embodiment includes a band-shaped groove 104 and a band-shaped protrusion 204.

[Fourth embodiment]

As shown in FIG. 6, the mutual engagement type intaglio-relief embossing press roller 1 according to the fourth embodiment of the present invention includes an upper roller 10 having a relief embossing pattern formed thereon and a lower roller 20 having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in the state of being engaged with each other, wherein the upper roller 10 includes a roller body 101, shafts 102 formed at opposite ends of the roller body, a relief embossing pattern unit 103 formed on the surface of the roller body 101, a band-shaped groove 104 formed on the surface of the roller body 101 in the rotational direction of the roller so as to be lower than the relief embossing pattern unit 103 in order to partition the relief embossing pattern unit 103 at predetermined intervals, first left and right ends 105 and 106 formed at opposite side ends of the roller body 101 so as to be lower than the relief embossing pattern unit 103, and left and right inclined surface formation portions 107 and 108 extending from the first left and right ends 105 and 106 in the lateral direction so as to be integrally formed therewith, the left and right inclined surface formation portions protruding outwards from points extending from the first left and right ends 105 and 106 in the oblique direction, the left and right inclined surface formation portions being rotated in the state of being engaged with second left and right ends 205 and 206 of the lower roller 20 to shape opposite ends of a metal sheet in the oblique direction, and wherein the lower roller 20 includes a roller body 201, shafts 202 formed at opposite ends of the roller body, an intaglio embossing pattern unit 203 formed on the surface of the roller body 201, a band-shaped protrusion 204 formed on the surface of the roller body 201 in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit 203 in order to partition the intaglio embossing pattern unit 203 at predetermined intervals, and second left and right ends 205 and 206 formed at opposite side ends of the roller body 201 so as to be higher than the intaglio embossing pattern unit 203.
A mutual engagement type intaglio-relief embossing press roller 1 according to each of fifth and sixth embodiments has an embossing pattern different from the embossing pattern of the intaglio-relief embossing press roller 1 according to each of the first to fourth embodiments.
As shown in FIG. 7, the intaglio-relief embossing press roller 1 according to the fifth embodiment has substantially the same structure as the intaglio-relief embossing press roller 1 according to the second embodiment shown in FIG. 4 except for the embossing pattern.
As shown in FIG. 8, the intaglio-relief embossing press roller 1 according to the sixth embodiment has substantially the same structure as the intaglio-relief embossing press roller 1 according to the fourth embodiment shown in FIG. 6 except for the embossing pattern.
Hereinafter, the construction of the respective components of the mutual engagement type intaglio-relief embossing press roller 1 according to each of the first to sixth embodiments will be described in more detail.
The intaglio-relief embossing press roller 1 according to each of the first to sixth embodiments is configured such that the upper roller 10 and the lower roller 20, each of which is made of a high-rigidity metal material, are rotated in the state of being engaged with each other.
A pattern constituting the relief embossing pattern unit 103 and a pattern constituting the intaglio embossing pattern unit 203 are formed on the surface of the upper roller 10 and the surface of the lower roller 20, respectively, and the relief embossing pattern unit 103 and the intaglio embossing pattern unit 203 are formed so as to be engaged with each other.
The pattern harmonizes with relief and intaglio volumes and thus has a direct influence on the aesthetics of the embossed metal sheet. The pattern may be selected depending on taste.
As concrete examples, each of the embossing pattern units 103 and 203 shown in FIGS. 2 to 6 has a long rectangular pattern with round ends, and each of the embossing pattern units 103 and 203 shown in FIGS. 7 and 8 has a pattern with a quadrangular pyramidal protrusion.
The intaglio-relief embossing press roller 1 according to each of the first and third embodiments shown in FIGS. 2, 3, and 5 and the intaglio-relief embossing press roller 1 according to each of the second, fourth, fifth, and sixth embodiments shown in FIGS. 4, 6, 7, and 8 are different from each other in terms of whether the small-width band-shaped groove 104 and the small-width band-shaped protrusion 204 are formed on the upper roller 10 and the lower roller 20, respectively.
The band-shaped groove 104 and the band-shaped protrusion 204 are configured to be rotated in the state of being engaged with each other when the upper roller 10 and the lower roller 20 are rotated in the state in which the metal sheet is interposed therebetween. That the band-shaped groove 104 and the band-shaped protrusion 204 are rotated in the state of being engaged with each other means that the band-shaped protrusion 204 pushes the metal sheet into the groove 104 during rotation thereof.
An embossing pattern is partitioned along the circumferential surface of each of the upper roller and the lower roller at predetermined intervals by a corresponding one of the small-width band-shaped groove 104 and the small-width band-shaped protrusion 204 formed as described above, and a decorative effect may be provided together with the embossing pattern by the small-width groove 104 partitioned as described above.
The mutual engagement type intaglio-relief embossing press roller 1 according to the present invention is characterized by the first left and right ends 105 and 106 and the second left and right ends 205 and 206 formed respectively at the opposite side ends of the upper roller 10 and the lower roller 20, as shown in FIGs. 2 to 10.
The first left and right ends 105 and 106 and the second left and right ends 205 and 206 are important in solving a welding problem that occurs at the time of manufacture of the embossed pipe using the embossed metal sheet.
That is, the first left and right ends 105 and 106 and the second left and right ends 205 and 206 formed at the opposite side ends of the intaglio-relief embossing press roller 1 provide small-width planes to opposite side surfaces of the embossed metal sheet, whereby it is possible to solve a problem in that, at the time of manufacture of the embossed pipe using a conventional pipe mill configured to manufacture a smooth metal pipe, a concave-convex embossed pattern formed on the embossed metal sheet is deformed or welding is impossible due to mismatch of the concave-convex embossed pattern formed at the seam portion in the longitudinal direction.
In addition, the present invention is technically characterized by the inclined surfaces formed at the opposite ends of the metal sheet that is introduced into the intaglio-relief embossing press roller 1.
In the case in which the flat metal sheet is introduced into the intaglio-relief embossing press roller 1, the inclined surfaces are formed at the flat metal sheet simultaneously with embossing of the flat metal sheet.
Even in the case in which no inclined surfaces are formed at opposite side surfaces of the flat metal sheet, small-width planes are formed at opposite side surfaces of the embossed metal sheet by the first left and right ends 105 and 106 and the second left and right ends 205 and 206, as shown in FIGS. 9 and 12. Subsequently, when the embossed metal sheet formed as described above is curved and rounded by the pipe mill, opposite side surfaces of the embossed metal sheet come into contact with each other, whereby a V-shape groove is naturally formed at the point at which opposite side surfaces of the embossed metal sheet are in contact with each other due to the difference between the inner diameter and the outer diameter of the rounded metal sheet. However, the width of the V-shape groove may be very small depending on the thickness of the flat metal sheet. In the case in which the inclined surfaces are formed, therefore, molten fusion is easily performed by welding, whereby it is possible to perform neat and strong welding.
As shown in FIGS. 10 and 13, a metal sheet having no inclined surfaces formed at opposite ends thereof is introduced into the intaglio-relief embossing press roller 1 in order to manufacture an embossed metal sheet having inclined surfaces formed at opposite ends thereof.
The embossed metal sheet having the inclined surfaces formed at the opposite ends thereof manufactured through the above processes is shown in FIGS. 11 and 14.
At this time, the metal sheet is embossed using the intaglio-relief embossing press roller 1, and at the same time the inclined surfaces are formed at the opposite ends of the flat metal sheet by the provision of the left and right inclined surface formation portions 107 and 108 formed at the opposite side surfaces of the upper roller 10, as shown in FIGS. 10 and 13.
The angle θ1 between each of the left and right inclined surface formation portions 107 and 108 and a corresponding one of the first left and right ends 105 and 106 ranges from 110 to 135 degrees. The inclined surfaces formed at the opposite ends of the metal sheet by the left and right inclined surface formation portions 107 and 108 are brought into contact with each other to form a weld seam portion 109 having a V-shaped groove 109a. The interior angle θ2 of the V-shaped groove 109a ranges from 20 to 90 degrees.
After the inclined surfaces are formed at the opposite ends of the embossed metal sheet at the time of manufacture of the embossed metal sheet, as described above, the embossed metal sheet passes through a curving roller and a rounding roller of the pipe mill so as to be formed as a round pipe. At this time, the small-width inclined surfaces of the pipe are brought into contact with each other to form a small-width V-shaped groove 109a. The V-shaped groove 109a is melted and fused by welding using the same material, whereby a weld seam portion 109 identical to the groove 104 is formed. As a result, the weld seam portion 109 and the groove 104 form a kind of pattern, whereby aesthetics are improved in addition to the provision of the pattern.
Each of the groove 104 and the weld seam portion 109 has a small width, more specifically a width of 1.6 mm or less.
In order to maintain the widths of the groove 104 and the weld seam portion 109 equal to each other, the width L1 of each of the first left and right ends 105 and 106 formed at the opposite side ends of the upper roller 10 according to the present invention is set to 1/2 the width L2 of the groove 104.
That is, the sum of the width of the first left end 315 and the width of the first right end 316 is equal to the width of the groove 104.
FIG. 15 is a side sectional view schematically showing an embodiment of an embossed metal pipe manufactured using the embossed metal sheet manufactured through the intaglio-relief embossing press roller according to the present invention, and FIG. 17 is a side sectional view showing various forms of a weld seam portion formed in the embossed metal pipe of FIG. 15.
As shown in FIG. 15, an embossed metal pipe manufactured by introducing the embossed metal sheet manufactured using the intaglio-relief embossing press roller 1 according to the present invention into the pipe mill has a weld seam portion 109 formed in the longitudinal direction, and a small-width V-shaped groove 109a is formed in the weld seam portion 109. The V-shaped groove 109a is melted and fused by welding using the same material, whereby a seam groove identical to at least one partition groove formed in the circumferential surface of the roller at predetermined intervals is formed.
As a result, the weld seam portion 109 formed at the embossed metal pipe in the longitudinal direction is integrally connected to the embossed metal pipe through neat and sophisticated welding, and at the same time forms a seam groove identical to another partition groove configured to partition the embossed pattern, whereby an aesthetically pleasing design is exhibited and thus a decorative effect is provided.
FIG. 16 is a view showing the state in which the V-shaped groove 109a in the embossed metal pipe shown in FIG. 15 is welded.
FIG. 17 shows that the weld seam portion 109 according to the embodiment shown in FIG. 15 may be modified in various forms. It is obvious that the weld seam portion 109 including the V-shaped groove may have various other forms in addition to the forms shown in FIG. 17.
The weld seam portion 109 is characterized in that opposite ends of the metal sheet are shaped so as to have inclined surfaces by the left and right inclined surface formation portions 107 and 108, whereby the central portion of the weld seam portion is formed so as to have a V-shaped structure when viewed in a side sectional view. The V-shaped structure may be identically formed to diversify the shape of the surroundings thereof.

[Industrial Applicability]

An intaglio-relief embossing press roller according to the present invention is capable of providing a more sophisticated and delicate embossed pattern than an embossed pattern formed on a smooth pipe by a conventional embossing apparatus. In addition, at the time of manufacture of an embossed pipe using a pipe mill, welding is possible and a small-width seam groove is formed in a weld seam portion in the case in which an embossed metal pipe formed by the engagement type intaglio-relief embossing press roller is used, whereby a weld portion is not exposed to the outside, and at least one circumferential groove identical to the small-width seam groove is formed together with the small-width seam groove, whereby a decorative effect is improved together with the sophisticated embossed pattern. Consequently, the present invention has high industrial applicability.

Claims

A mutual engagement type intaglio-relief embossing press roller (1) used in manufacture of an embossed metal pipe, the mutual engagement type intaglio-relief embossing press roller comprising: an upper roller (10) having a relief embossing pattern formed thereon; and a lower roller (20) having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in a state of being engaged with each other, the upper roller (10) comprising: a roller body (101); shafts (102) formed at opposite ends of the roller body; a relief embossing pattern unit (103) formed on a surface of the roller body (101); first left and right ends (105, 106) formed at opposite side ends of the roller body (101) so as to be lower than the relief embossing pattern unit (103); and left and right inclined surface formation portions (107, 108) extending from the first left and right ends (105, 106) in a lateral direction so as to be integrally formed therewith, the left and right inclined surface formation portions protruding outwards from points extending from the first left and right ends (105, 106) in an oblique direction, the left and right inclined surface formation portions being rotated in a state of being engaged with second left and right ends (205, 206) of the lower roller (20) to shape opposite ends of a metal sheet in the oblique direction, the lower roller (20) comprising: a roller body (201); shafts (202) formed at opposite ends of the roller body; an intaglio embossing pattern unit (203) formed on a surface of the roller body (201); and the second left and right ends (205, 206) being formed at opposite side ends of the roller body (201) so as to be higher than the intaglio embossing pattern unit (203), wherein
an angle (θ1) between each of the left and right inclined surface formation portions (107, 108) and a corresponding one of the first left and right ends (105, 106) ranges from 110 to 135 degrees, inclined surfaces formed at the opposite ends of the metal sheet by the left and right inclined surface formation portions (107, 108) are brought into contact with each other to form a weld seam portion (109) having a V-shaped groove (109a), and an interior angle (θ2) of the V-shaped groove (109a) ranges from 20 to 90 degrees.
The mutual engagement type intaglio-relief embossing press roller according to claim 1, wherein the opposite ends of the metal sheet are shaped so as to have inclined surfaces by the left and right inclined surface formation portions (107, 108), whereby a central portion of the weld seam portion (109) is formed so as to have a V-shaped structure when viewed in a side sectional view.
A mutual engagement type intaglio-relief embossing press roller (1) used in manufacture of an embossed metal pipe, the mutual engagement type intaglio-relief embossing press roller comprising: an upper roller (10) having a relief embossing pattern formed thereon; and a lower roller (20) having an intaglio embossing pattern formed thereon, the upper roller and the lower roller being configured to be rotated in a state of being engaged with each other, the upper roller (10) comprising: a roller body (101); shafts (102) formed at opposite ends of the roller body; a relief embossing pattern unit (103) formed on a surface of the roller body (101); first left and right ends (105, 106) formed at opposite side ends of the roller body (101) so as to be lower than the relief embossing pattern unit (103); and left and right inclined surface formation portions (107, 108) extending from the first left and right ends (105, 106) in a lateral direction so as to be integrally formed therewith, the left and right inclined surface formation portions protruding outwards from points extending from the first left and right ends (105, 106) in an oblique direction, the left and right inclined surface formation portions being rotated in a state of being engaged with second left and right ends (205, 206) of the lower roller (20) to shape opposite ends of a metal sheet in the oblique direction, the lower roller (20) comprising: a roller body (201); shafts (202) formed at opposite ends of the roller body; an intaglio embossing pattern unit (203) formed on a surface of the roller body (201) ; and the second left and right ends (205, 206) being formed at opposite side ends of the roller body (201) so as to be higher than the intaglio embossing pattern unit (203), wherein
an angle (θ1) between each of the left and right inclined surface formation portions (107, 108) and a corresponding one of the first left and right ends (105, 106) ranges from 110 to 135 degrees, inclined surfaces formed at the opposite ends of the metal sheet by the left and right inclined surface formation portions (107, 108) are brought into contact with each other to form a weld seam portion (109) having a V-shaped groove (109a), and an interior angle (θ2) of the V-shaped groove (109a) ranges from 20 to 90 degrees, and wherein
the opposite ends of the metal sheet are shaped so as to have inclined surfaces by the left and right inclined surface formation portions (107, 108), whereby a central portion of the weld seam portion (109) is formed so as to have a V-shaped structure when viewed in a side sectional view.
The mutual engagement type intaglio-relief embossing press roller according to claim 1, wherein
the upper roller (10) further comprises a band-shaped groove (104) formed on the surface of the roller body (101) in a rotational direction of the roller so as to be lower than the relief embossing pattern unit (103) in order to partition the relief embossing pattern unit (103) at predetermined intervals, and
the lower roller (20) further comprises a band-shaped protrusion (204) formed on the surface of the roller body (201) in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit (203) in order to partition the intaglio embossing pattern unit (203) at predetermined intervals, the protrusion (204) being configured to be inserted into the groove (104).
The mutual engagement type intaglio-relief embossing press roller according to claim 1, wherein
the upper roller (10) further comprises a band-shaped groove (104) formed on the surface of the roller body (101) in a rotational direction of the roller so as to be lower than the relief embossing pattern unit (103) in order to partition the relief embossing pattern unit (103) at predetermined intervals,
the lower roller (20) further comprises a band-shaped protrusion (204) formed on the surface of the roller body (201) in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit (203) in order to partition the intaglio embossing pattern unit (203) at predetermined intervals, and
a width (L1) of each of the first left and right ends (105, 106) is 1/2 a width (L2) of the groove (104).
The mutual engagement type intaglio-relief embossing press roller according to claim 1, wherein the metal sheet introduced into the intaglio-relief embossing press roller (1) is shaped in advance such that inclined surfaces are formed at the opposite ends of the metal sheet.
The mutual engagement type intaglio-relief embossing press roller according to claim 3, wherein
the upper roller (10) further comprises a band-shaped groove (104) formed on the surface of the roller body (101) in a rotational direction of the roller so as to be lower than the relief embossing pattern unit (103) in order to partition the relief embossing pattern unit (103) at predetermined intervals, and
the lower roller (20) further comprises a band-shaped protrusion (204) formed on the surface of the roller body (201) in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit (203) in order to partition the intaglio embossing pattern unit (203) at predetermined intervals, the protrusion (204) being configured to be inserted into the groove (104).
The mutual engagement type intaglio-relief embossing press roller according to claim 3, wherein
the upper roller (10) further comprises a band-shaped groove (104) formed on the surface of the roller body (101) in a rotational direction of the roller so as to be lower than the relief embossing pattern unit (103) in order to partition the relief embossing pattern unit (103) at predetermined intervals,
the lower roller (20) further comprises a band-shaped protrusion (204) formed on the surface of the roller body (201) in the rotational direction of the roller so as to be higher than the intaglio embossing pattern unit (203) in order to partition the intaglio embossing pattern unit (203) at predetermined intervals, and
a width (L1) of each of the first left and right ends (105, 106) is 1/2 a width (L2) of the groove (104).
The mutual engagement type intaglio-relief embossing press roller according to claim 3, wherein the metal sheet introduced into the intaglio-relief embossing press roller (1) is shaped in advance such that inclined surfaces are formed at the opposite ends of the metal sheet.