JP2001198977A - Method for manufacturing embossed sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an embossed sheet by which an embossed irregularity pattern can be imparted on the surface of a sheet stock with high precision and reliable reproducibility and an embossed product with outstanding design property can be manufactured at a high speed. SOLUTION: In the method for manufacturing an embossed sheet by which the sheet stock is shaped with an irregularity pattern by inserting the heated sheet stock into a nip between an embossing roll with a specified irregularity pattern for shaping and a pressurizing roll and pressurizing the sheet stock, the lower part of the pressurizing roll is immersed into a water-cooling pan and moisture remaining on the surface of the pressurizing roll is removed by air blowing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing an embossed sheet in which the surface of a sheet-shaped material is embossed.

[0002]

2. Description of the Related Art Heretofore, it has been widely practiced to emboss a surface of a sheet-like raw material to produce an embossed sheet excellent in design. As a method for producing the embossed sheet, generally, a sheet-like raw material such as a synthetic resin sheet is heated, sandwiched between a pressure roll and a mold roll (emboss roll), and continuously pressed. Such is known.

[0003] The embossing roll used in such a method is usually provided on the outer peripheral surface of a cylindrical impression cylinder portion made of a metal such as iron, copper or the like, for example, an embossing roll formed of a number of wood grain conduit grooves to be expressed in an embossed sheet. An embossing pattern having the same shape as that of the embossing pattern and the concavity and convexity thereof being reversed by a known method such as mill engraving, corrosion, electroforming, and the like. In this case, one surface of the sheet material is continuously embossed by a rotary method in which the shaft portion is pivoted to rotate the impression cylinder portion. In addition, the embossing roll is usually hollowed in the inside thereof, cooling water is circulated therein, and simultaneously cools the sheet-shaped raw material conveyed in an appropriately heated and softened state simultaneously with the embossing. Things.

[0004] On the other hand, a pressure roll is generally formed by covering an outer periphery of a cylindrical pressure drum portion made of a metal such as iron with an elastic body such as rubber in a cylindrical shape. Shafts are formed on both end surfaces of the impression cylinder like the embossing roll, and the impression cylinder is driven to rotate around the shaft as a pivot. The inside of the pressure roll is also hollow, and cooling water is allowed to flow through the cavity, so that the raw material is cooled and the rubber on the surface of the pressure roll is not peeled off.

[0005] However, the sheet-like raw material heated as described above is sandwiched between an embossing roll and a pressure roll and is continuously pressed to give an embossed concavo-convex pattern on the sheet-like raw material. Then, it became clear that the following problems would occur. That is, since the surfaces of the embossing roll and the pressure roll are heated by the heated sheet material, the roll surface temperature rises sharply with an increase in the embossing processing speed. However, the embossing roll can suppress and adjust the roll surface temperature even during high-speed operation by cooling from the inside of the roll. Since the coating is formed in a cylindrical shape, the heat conductivity from the inside is poor and the cooling efficiency is poor, so it is difficult to suppress and adjust the surface temperature of the pressure roll, and the surface temperature rises. When the surface temperature difference between the embossing roll and the pressing roll becomes large, the embossed sheet material (embossed sheet) easily winds around the pressing roll having a high surface temperature. What should normally be wound on the embossing roll side,
Once wound around the pressure roll side and separated from the embossing roll, it is again wound around the embossing roll, so that the surface has a defect that gloss unevenness is poor.

Therefore, as a method of cooling the pressure roll, a method of immersing the pressure roll in a water-cooled pan has been used. However, drainage of the pressure roll surface due to unevenness due to surface wear or scratches of the pressure roll has been used. As the water deteriorates, water remains, and the water is pressed around the embossing roll surface in a state of fine irregularities on the surface, uneven gloss is produced on the surface, resulting in a design problem.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide an embossed concave and convex pattern on the surface of a sheet-like raw material with high accuracy and good reproduction. It is an object of the present invention to provide a method for producing an embossed sheet which can be imparted with high quality and can produce an embossed product excellent in design at a high speed.

[0008]

In order to achieve the above object, an embossed sheet manufacturing method according to the present invention is directed to an embossed roll on which a heated sheet-like material is embossed with a predetermined embossing pattern for shaping. In the manufacturing method of shaping a concavo-convex pattern on the sheet-like raw material by inserting and pressing between the pressure rolls, the lower portion of the pressure roll is immersed in a water-cooled pan and then left on the surface of the pressure roll. The method is characterized in that the moisture is removed by blowing air, and by using such a manufacturing method, moisture is removed from the surface by blowing high-speed air onto the surface of the pressure roll. Therefore, regardless of the state of the surface of the pressure roll (deformation due to abrasion, dents, etc.), it is possible to manufacture the sheet with high efficiency, and also to enhance the cooling effect. Les becomes smooth, embossed sheet is to be cooled with wind in the embossing roll, the occurrence of uneven luster of the surface can be prevented. Further, by pressing the draining roll against the surface of the pressure roll before removing the moisture remaining on the surface of the pressure roll by blowing air, the surface temperature of the pressure roll is further easily reduced, and the temperature is stabilized. Enables manufacturing.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic view of a manufacturing apparatus used for manufacturing the embossed sheet of the present invention, and FIG. 2 is a schematic view of a water-cooled pan used for manufacturing the embossed sheet of the present invention. , 3 is a printed web, 4 is a sheet web, 10 is a heating drum, 11,
12 is a preheating roll, 13 is a bonding nip roll, 14 is a backup roll, 15 is a heating roll, 16 is an embossing roll, 17 is a pressure roll, 18 is a water cooling pan, 20 is an air nozzle, 21 is a cooling roll, and 22 is a heater. Respectively.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The production of the embossed sheet 1 of the present invention is shown in FIG.
As shown in the figure, a preheating roll 1 in which the clear raw material 2 is heated
1 and a preheating roll 12 for heating the printed web 3, and a heating drum 10, a bonding nip roll 13, and a backup roll 14 are provided downstream of the preheating rolls 11 and 12. Between the heating drum 10 and the laminating nip roll 13, the clear raw material 2 and the printed raw material 3 that are heated and laminated to each other enter, so that both raw materials are heated and pressed, and the sheet raw material 4 is formed. To form.

The clear raw material 2 and the printed raw material 3 heated by the preheating rolls 11 and 12 are combined with the pressed sheet-like raw material 4.
In order to prevent air from entering into the heating drum 10, each raw material is adjusted and supplied to the heating drum 10 at an angle suitable for the heating and pressing before the heat and pressure bonding.
Further, by providing the backup roll 14 of the laminating nip roll 13 on the side opposite to the heating drum 10, the pressure at the time of laminating the raw material can be made uniform in the width direction of the raw material, and the air prevention effect is increased.

On the downstream side of the heating drum 10, heating rolls 15 for heating the sheet-like raw material 4 are sequentially arranged, and between the heating roll 15 and an embossing roll 16 arranged downstream thereof, a sheet-like shape is provided. A heater 22 for heating the raw material 4 is provided. On the downstream side of the heater 22, an embossing roll 16 for embossing the sheet material 4 is provided.
A pressure roll 17 is disposed in parallel with the embossing roll 16, and the heated sheet-like raw material 4 is inserted and pressed between the pressing rolls 17 to clear the sheet-like raw material 4. An uneven pattern is formed on two surfaces. The lower portion of the pressure roll 17 is immersed in a water-cooled pan 18, and an air nozzle 20 is provided on the upper surface thereof. A space for cooling water is formed inside the embossing roll 16 and the pressure roll 17, and cooling water is injected therein. The embossed sheet 1 having the uneven pattern is peeled off from the embossing roll 16 and guided to the cooling roll 21 on the downstream side to quickly fix the embossing process.

The heating heater 22 is a plurality of infrared heaters arranged in parallel to the width direction of the web, and sufficiently heats the sheet web 4 so that the sheet-shaped web 4 is pressed between the embossing roll 16 and the pressure roll 17. The uneven pattern is surely applied to the raw material 4. The heating roll 15
There is also an effect of heating so that a large temperature drop does not occur due to the influence of the ambient temperature when the sheet-like raw material 4 bonded to the embossing roll 16 moves from above.

The embossing roll 16 itself is well known in the art. The embossing roll 16 is to be applied to the outer peripheral surface of the metal impression cylinder and to the two transparent clear raw sheets 4 of the sheet raw material 4. The concavo-convex pattern is formed by a known method such as mill engraving, corrosion, electroforming, and the like. The cooling water is circulated inside the embossing roll 16 so that the sheet-shaped material conveyed in a heated and softened state is formed. The anti 4 is cooled simultaneously with the embossing.

The pressure roll 17 is formed by covering the outer periphery of an iron core with a rubber-like elastic body such as SBR, NBR, silicon rubber or the like in a cylindrical shape, and the outer peripheral surface of the rubber-like elastic body is formed smoothly. Have been.

The draining roll 19 pressed against the surface of the pressure roll 17 is well known in the art.
Examples of the material include iron, a simple substance of aluminum or one obtained by plating the surface of an iron roll with chromium, and one obtained by coating the outer periphery of an iron core with a rubber-like elastic material similar to that used for the pressure roll 17, The one coated with a rubber-like elastic body having good drainage workability is excellent. Shafts are protruded at both end portions of the impression cylinder portion, and cooling water is circulated inside the drainage roll 19 to pressurize the body. The roller 17 is pressed against the outer peripheral surface of the roll 17 and rotated in the opposite direction to the pressure roll 17, and
7 and the surface of the pressure roll 17 is cooled.

Further, by jetting and blowing air at a high speed from the air nozzle 20 onto the surface of the pressure roll 17, moisture that cannot be removed by the conventional draining roll can be surely and non-contacted. Can be removed. Further, fine adjustment can be easily performed by the injection speed and the spray angle. Further, since it is not affected by the surface smoothness of the pressure roll, it can sufficiently cope with the wear and damage of the pressure roll. The efficiency can be improved, the unevenness of luster that occurs when the water that cannot be removed conventionally remains partially on the surface of the pressure roll does not occur, and the quality stability is also improved.

The sheet material 4 is heated by the heating drum 10 and the heating roll 15,
Heated by The sheet-shaped raw material 4 is inserted between the embossing roll 16 and the pressure roll 17 and pressed between the embossing roll 16 and the pressure roll 17 to apply embossing to the surface of the sheet-shaped raw material 4. Is done. During this time, after the lower part of the pressure roll 17 is immersed in the water-cooled pan 18, water remaining on the surface of the pressure roll 17 is removed by the air nozzle 20, so that the surface of the pressure roll 17 is sufficiently cooled. The embossed sheet material (embossed sheet 1) is thereby peeled off smoothly from the pressure roll 17, wound around the emboss roll 16, cooled by the emboss roll 16, and subsequently cooled by the cooling roll 21 on the downstream side.
The embossing is quickly fixed, and the embossing is completed. Although not described in the present embodiment, when the surface shape of the pressure roll 17, the line speed at the time of embossing, and the increase in the cooling capacity are required, the same draining roll as in the related art is replaced with a cooling pan and an air nozzle. Even if it is arranged to be provided in pressure contact with the surface of the pressure roll 17 during
Of course, it doesn't matter.

Further, the cooling water in the water cooling pan 18 has conventionally been manufactured so that it is injected from one side of the machine, for example, from the man side, and discharged from the gear side. The temperature difference is easily generated in the water, and the unevenness of the cooling of the surface of the pressure roll 17 may cause the gloss unevenness of the sheet when embossed. However, FIGS. 2A to 2C are front views. By injecting cooling water from both ends of the man side and gear side of the machine as shown in the top view and side view and discharging it from the center,
Since the temperature of the cooling water in the water cooling pan 18 is constant, the temperature of the entire surface of the pressure roll 17 is kept constant, and the gloss of the embossed sheet can be easily stabilized.

Colored webs of the clear web 2 and the printed web 3 used for the sheet web 4 of the embossed sheet 1 of the present invention include vinylon, ethylene-vinyl acetate copolymer, nylon and polyethylene. , Polypropylene, AB
S, thermoplastic resin such as acrylic resin, polyethylene,
Polyolefin synthetic paper such as polypropylene or polyester synthetic paper is used. In the case of a doubling specification, the sheet thickness is preferably 50 to 150 μm for both the clear raw material 2 and the printed raw material 3.

[0021]

According to the present invention, the rise in the surface temperature of the outer peripheral surface of the pressure roll is suppressed, so that the embossed sheet is not wound around the pressure roll, and the occurrence of uneven gloss due to the removal of the sheet is eliminated. Was done. Further, since the water remaining on the pressure roll surface is removed by the air nozzle, the water can be removed regardless of the state of the surface of the pressure roll, so that the production can be performed with high efficiency. Since production can be performed without increasing the tension after embossing, sheet elongation can be suppressed, loosening failure due to sheet shrinkage does not occur, and embossed sheets with good shape can be produced at a faster speed than before. Because it can be manufactured, productivity could be improved.

[Brief description of the drawings]

FIG. 1 is a schematic view of an embossed sheet manufacturing apparatus used for manufacturing an embossed sheet of the present invention.

FIG. 2 is a schematic view of a water-cooled pan used for manufacturing the embossed sheet of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Embossed sheet 2 Clear raw material 3 Printed raw material 4 Sheet-shaped raw material 10 Heating drum 11, 12 Preheating roll 13 Lamination nip roll 14 Backup roll 15 Heating roll 16 Embossing roll 17 Pressure roll 18 Water cooling pan 20 Air nozzle 21 Cooling roll 22 Heater

Claims (2)

[Claims] 1. A heated sheet-like material is inserted between an embossing roll provided with a predetermined shaping pattern and a pressure roll, and pressed to form an uneven pattern on the sheet-like material. A method for forming an embossed sheet, comprising: immersing a lower portion of the pressure roll in a water-cooled pan; and removing water remaining on a surface of the pressure roll by blowing air. 2. After the lower part of the pressure roll is immersed in a water-cooled pan, a draining roll is pressed against the surface of the pressure roll, and water remaining on the surface of the pressure roll is removed by blowing air. The method for manufacturing an embossed sheet according to claim 1, wherein: