JP2006088335A - Emboss-processing apparatus and emboss-processing method using it - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an emboss-processing apparatus constituted so as not to lower a shaping ratio when embossing pressure is low, and an emboss-processing method using it. <P>SOLUTION: The emboss-processing apparatus is equipped with a vibration means for vibrating a plate roller and/or a pressure roller for emboss-processing and constituted so that vibration is allowed to act on the shaft of the roller by the vibration means and the vibration frequency of the vibration means is set to frequency twice or more the value calculated by dividing the traveling speed of an embossing target by nip width. The emboss-processing method adapted to the emboss-processing apparatus is also disclosed. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention belongs to the technical field of embossing. In particular, the present invention relates to an embossing apparatus and method for forming a three-dimensional shape on paper, a decorative sheet, cardboard, a calendar, a plastic film, a plastic card, a plastic material, a metal thin plate, and the like.

  The degree of achievement of processing in embossing can be expressed, for example, as the ratio of the depth from the reference surface of the corresponding part in the embossed product to the depth from the reference surface of the predetermined part in the plate roller for embossing, that is, the molding rate is there. The forming rate varies depending on various conditions in embossing and affects the quality of the object to be embossed. For example, if the embossing pressure in embossing is small, the amount of plastic deformation is reduced, so that the forming rate is lowered, and there is a problem in that the pattern into the embossed object becomes shallow. In order to increase the embossing pressure, there is a problem that it requires a device modification such as increasing the size of the hydraulic cylinder and requires considerable cost.

Therefore, there is a proposal to deepen the pattern in anticipation of a reduction in the forming rate due to the embossing conditions (Patent Document 1). In the proposed embossing apparatus, embossing is performed by niping and pressing an object to be embossed by a rigid plate roller (metal embossing roller) and an elastic pressure roller (elastic roller).
However, since there is no change in the molding rate when the embossing pressure is small, the problem that the pattern entry into the embossed object becomes shallow cannot be fundamentally solved. There wasn't.

  The present invention has been made to solve the above problems. The object is to provide an embossing apparatus and method in which the forming rate does not decrease when the embossing pressure is low.

The embossing apparatus according to claim 1 of the present invention is provided with vibration means for vibrating the plate roller and / or the pressure roller for embossing.
The embossing apparatus according to claim 2 of the present invention is the embossing apparatus according to claim 1, wherein the vibration means is a vibration means for applying vibration to the shaft of the plate roller and / or the pressure roller. Is.
The embossing apparatus according to claim 3 of the present invention is the embossing apparatus according to claim 1 or 2, wherein the vibration frequency of the vibration means is twice the value obtained by dividing the traveling speed of the object to be embossed by the nip width. The above frequency is used.
In the embossing method according to claim 4 of the present invention, the embossing is performed by vibrating the plate roller and / or the pressure roller for embossing.

According to the embossing apparatus of the first aspect of the present invention, the embossing plate roller and / or the pressure roller is vibrated by the vibration means. That is, even if the embossing pressure as the average value is small, the embossing pressure as the maximum value can be increased. Therefore, an embossing apparatus in which the forming rate does not decrease when the embossing pressure is small is provided.
According to the embossing apparatus of the second aspect of the present invention, the vibration by the vibration means acts on the shafts of the plate roller and / or the pressure roller. Therefore, high transmission efficiency of vibration can be obtained with a simple mechanism.
According to the embossing apparatus of the third aspect of the present invention, the vibration frequency in the vibration means is a frequency that is twice or more the value obtained by dividing the travel speed of the object to be embossed by the nip width. That is, there is a maximum value of at least two embossing pressures during nip. Therefore, it is possible to eliminate the occurrence of emboss unevenness in the traveling direction of the emboss target object due to vibration.
According to the embossing method according to claim 4 of the present invention, the embossing is performed by vibrating the plate roller and / or the pressure roller for embossing. That is, even if the embossing pressure as the average value is small, the embossing pressure as the maximum value can be increased. Therefore, an embossing method is provided in which the forming rate does not decrease when the embossing pressure is low.

  Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view showing a pressure state (nip state) between an embossing plate roller and a pressure roller. FIG. 2 is a perspective view showing a state in which embossing is performed. FIG. 3 is a block diagram showing an example of the configuration of the embossing apparatus of the present invention. 1-3, 1 is a plate roller, 2 is a pressure roller, 3 is a displacement detector, 4 is a servo controller, 5 is a hydraulic pressure generator, 6 is a hydraulic cylinder, and 100 is an object to be embossed.

  The plate roller 1 is a plate roller for embossing, that is, an emboss roller in which irregularities are formed on the peripheral surface (plate surface) of the roller. The plate roller 1 is a plate roller made of a metal material (rigid material) such as steel or aluminum, or other material.

  The pressure roller 2 is a pressure roller that is used as a pair with the embossing plate roller 1 and presses the object 100 to be embossed against the plate roller 1. The pressure roller 2 is a pressure roller made of a metal material (rigid material) such as steel or aluminum, or other material.

  The displacement detector 3 detects the displacement (expansion / contraction) of the piston rod, which is the output shaft of the hydraulic cylinder 6, and outputs a displacement signal. The displacement detector 3 includes a sensor and a portion that amplifies the sensor output and calculates an output signal. Since the piston rod repeatedly expands and contracts, that is, vibrates, it is necessary to use a sensor having a required response speed and a small phase delay. As the sensor, a known sensor such as an optical type, an eddy current type, or a capacitive type can be used.

  The servo controller 4 receives the displacement signal output from the displacement detector 3 and the target vibration waveform, and generates and outputs an operation signal for the hydraulic pressure generator 5 so that the deviation becomes zero. That is, the servo controller 4 is a controller that operates the hydraulic pressure generator 5 so that the piston rod performs the same vibration as the target vibration waveform. By inputting the waveform of the displacement operation desired to be performed by the piston rod to the servo controller 4 as a target vibration waveform, it is possible to cause the piston rod to perform the displacement operation as it is.

  When the vibration frequency in the target vibration waveform is lower than the traveling speed of the embossing target article 100, the embossing unevenness caused by the vibration waveform occurs in the traveling direction of the embossing target article 100. Therefore, it is necessary to change the frequency of the vibration in accordance with the traveling speed of the embossing target article 100 or to set a frequency at which the embossing unevenness does not occur even at the maximum traveling speed. Accordingly, it is preferable that the frequency is twice or more the value obtained by dividing the traveling speed of the vibration emboss target object by the nip width between the plate roller 1 and the pressure roller 2. For example, when the nip width (as an effective value) is 2.5 cm at a traveling speed of 30 m / min (= 50 cm / sec) ((50 cm / sec) / (2.5 cm)) × 2 = (400 Hz) or more Preferably, the frequency is

  The hydraulic pressure generator 5 receives the operation signal output from the servo controller 4 and generates and outputs the hydraulic pressure. This hydraulic pressure is for operating the hydraulic cylinder 6. That is, the hydraulic pressure generator 5 generates a hydraulic pressure for displacing (stretching) the piston rod of the hydraulic cylinder 6 in two directions of extending and contracting.

The hydraulic cylinder 6 receives the hydraulic pressure output from the hydraulic pressure generator 5 and displaces the piston rod. The displacement of the piston rod of the hydraulic cylinder 6 acts on the shaft of the pressure roller 2 via a link mechanism (not shown) to displace the pressure roller 2. This displacement of the shaft is similarly performed on both sides of the pressure roller 2. Therefore, the displacement is transmitted to both sides of the pressure roller 2 by a link mechanism or by the pair of hydraulic cylinders 6 and the above-described system pair that operates them. The direction of displacement of the pressure roller 2 is a direction connecting the rotation shaft of the pressure roller 2 and a portion (nip portion) that holds the object to be embossed in a nip state.
In the example shown in FIG. 3, the pressure roller 2 is displaced. However, the plate roller 1 may be displaced or both rollers may be displaced.

The configuration has been described above. Next, the operation in the embossing apparatus of the present invention will be described with reference to FIG. FIG. 4 is a flowchart showing the embossing process.
First, in step S1 (vibration waveform setting) in FIG. 4, the operator sets a vibration waveform to be given to the servo controller 4 on an operation control panel (not shown) of the embossing apparatus. Although the waveform is basically a sinusoidal waveform, the present invention is not limited to this waveform. Items to be set are waveform, amplitude, frequency, and the like. There are many items to be embossed, and the material of the object 100 to be embossed differs depending on the item. Since each material has each material property (for example, viscoelastic property), it is necessary to adapt the embossing conditions. If it is a repeat item, the operator sets a vibration waveform that matches the previous condition. If it is not a repeat item, set an existing vibration waveform that is predicted to be compatible, and manually correct the conditions while operating. The manually corrected data is stored as a vibration waveform (waveform, amplitude, frequency). And when there is a repeat, it is applied.

Next, in step S2 (start of processing), the object 100 to be embossed is passed between the plate roller 1 and the pressure roller 2, and niped between the plate roller 1 and the pressure roller 2 to run while applying pressure and heat. Start embossing.
Next, in step S3 (displacement input), the servo controller 4 inputs the set vibration waveform and the displacement signal output by the displacement detector 3.
Next, in step S4 (operation signal generation), the servo controller 4 derives an operation signal for reducing the deviation between the vibration waveform and the displacement signal and outputs the operation signal to the hydraulic pressure generator 5.

  Next, in step S5 (piston rod expansion / contraction), the hydraulic pressure generator 5 generates hydraulic pressure based on the operation signal and outputs it to the hydraulic cylinder 6. The piston rod of the hydraulic cylinder 6 expands and contracts. The expansion and contraction of the piston rod increases or decreases the nip pressure between the plate roller 1 and the pressure roller 2, that is, the emboss pressure, and increases the substantial emboss pressure. Therefore, the molding rate does not decrease when the embossing pressure is small.

  Next, in step S6 (machining end?), The servo controller 4 determines whether or not the embossing is finished based on a signal from the operation control panel or the like. When it is not finished, the process returns to step S3 to repeat the subsequent steps. When finished, servo control in embossing is finished.

  In the above description, the process of performing automatic control (servo control) without changing the vibration waveform set as the target value has been described. When the vibration waveform is corrected during the embossing in order to adapt the conditions, the operator may reset the vibration waveform (vibration waveform input to the servo controller 4) as the target value in the above. When a suitable vibration waveform is obtained, the vibration waveform is stored so that it can be reset during repeat.

  Further, in the above description, the processing when the traveling speed of the embossing target object 100 changes is not shown. In order not only to prevent the occurrence of the embossing unevenness described above but also not to change the shaping rate, it is preferable to output a vibration waveform corresponding to the traveling speed of the embossed object 100 to the servo controller 4. For this purpose, a target vibration waveform corresponding to the traveling speed is calculated and output to the servo controller 4 in the operation control panel of the embossing apparatus. When the traveling speed of the target vibration waveform is high, calculations such as increasing the vibration frequency and increasing the amplitude are performed. When the running speed is slow, calculations such as lowering the frequency and lowering the amplitude are performed.

It is sectional drawing which shows the pressurization state (nip state) in the plate roller for embossing, and a pressure roller. It is a perspective view which shows the state in which the embossing is performed. It is a block diagram which shows an example of a structure in the embossing apparatus of this invention. It is a flowchart which shows the process of the embossing in the embossing apparatus and embossing method of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Plate roller 2 Pressure roller 3 Displacement detector 4 Servo controller 5 Hydraulic generator 6 Hydraulic cylinder 100 It is an object of embossing.

Claims (4)

An embossing apparatus comprising vibration means for vibrating an embossing plate roller and / or a pressure roller. 2. The embossing apparatus according to claim 1, wherein the vibration means is a vibration means for applying vibration to the shaft of the plate roller and / or the pressure roller. 3. The embossing apparatus according to claim 1, wherein the vibration frequency of the vibration means is a frequency that is at least twice the value obtained by dividing the traveling speed of the object to be embossed by the nip width. An embossing method comprising embossing by vibrating a plate roller and / or a pressure roller for embossing.

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