JP2008018572A - Surface-processed product and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a surface-processed product and a manufacturing method thereof which make it possible to give an unprecedented complicated design to a sheet material by embossing using a flexible die. <P>SOLUTION: The product S having a pattern formed on the surface by embossing using the flexible die 1 is constituted so that it is divided into a plurality of sections R1, R2, R3 and R4. A plurality of embossed patterns E1, E2, E3 and E4 are added respectively to these sections R1, R2, R3 and R4 and one design is formed by combination of the sections R1, R2, R3 and R4 in a plurality. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a surface processed product and a manufacturing method thereof, and in particular, surface processing capable of imparting a plurality of textures in one design by applying a plurality of embossed patterns to one sheet by one processing. The present invention relates to a product and a manufacturing method thereof.

In order to impart a sense of quality, aesthetics, water absorption, etc. to a material such as a sheet material, it is usually practiced to add an embossed pattern to the surface.
For example, such a technique is used for sanitary paper products such as toilet paper and tissue paper, and water-absorbing products such as kitchen paper.
In this way, various products have been developed that have been embossed to improve the texture and appearance (see, for example, Patent Document 1, Patent Document 2, Patent Document 3, Patent Document 4, and Patent Document 5).

The techniques described in Patent Document 1 and Patent Document 2 disclose sanitary paper that is continuously embossed.
Patent Document 3 discloses a technique for embossing a pattern (second emboss) on a ground pattern (first emboss) by performing embossing in two stages.
Furthermore, Patent Document 4 discloses a technique for adding a colored pattern by revealing the color of a base material by forming a recess by embossing.
Furthermore, Patent Document 5 discloses a technique for performing printing by performing an ink jet process after embossing.

Japanese Patent Laying-Open No. 2005-160654 (pages 5 to 7, FIG. 6) JP 2003-073999 A (page 3 and page 4, FIGS. 1 to 3) Japanese Patent Laying-Open No. 2003-116741 (pages 3 and 4 and FIG. 1) JP 2002-285492 A (pages 2 to 4) JP 2003-041488 (pages 3 and 4)

As described above, the products described in Patent Document 1 and Patent Document 2 merely add a continuous repeating pattern to the sheet material, and do not add a complicated design to the sheet material.
Moreover, in the product described in Patent Document 3, a complex design is configured by adding a second embossed pattern on the first embossed pattern, but an embossing process in two stages is necessary, and the work cost and There was a problem that it took time and effort.
Furthermore, in the technique described in Patent Document 4, embossing is performed to form a concave portion, so that the color of the base material is revealed. Cannot be configured.
Further, the technique described in Patent Document 5 has a problem in that ink jet flows after embossing and ink flows along the unevenness caused by embossing, and bleeding may occur. It was.
As described above, conventionally, it is difficult to form a complex design by embossing a sheet material, and particularly when coloring, problems such as ink bleeding occur, so the sheet material itself It was necessary to perform processing for preventing ink bleeding.

The present invention has been made in view of the above circumstances, and the object thereof is a surface capable of imparting an unprecedented complex design to a sheet material by embossing using a flexible die. It is to provide a processed product and a manufacturing method thereof.
Another object of the present invention is to provide a surface processed product and a method for manufacturing the same, which can give a complicated design to a sheet material by a single processing and can avoid problems such as ink bleeding. .

  According to the surface-finished product of the member according to claim 1, the problem is a product having a surface patterned by embossing using a flexible die, and the product is divided into a plurality of sections. This is solved by adding a plurality of embossed patterns to each of the plurality of sections and forming one design by a combination of the plurality of sections.

  Moreover, according to the manufacturing method of the surface processed product of the member according to claim 4, the problem is a method for forming a pattern on the surface of the workpiece by embossing using a flexible die, This can be solved by performing a first step of forming a plurality of sections on the surface of the workpiece and a second step of adding emboss patterns of a plurality of patterns to the plurality of sections.

Thus, according to the present invention, the workpiece is divided into a plurality of sections, and different embossed patterns are given to the sections.
For this reason, it becomes possible by combining these some divisions to comprise the complicated design which is not in the past.
In particular, in the case of products with complex designs such as photographs and paintings, if these contours are extracted and partitioned, different embossed patterns can be added to these partitions. A feeling can be imparted.

Further, in the invention according to claim 1, the embossed pattern of the plurality of patterns is set as a pattern set according to the section, and is configured to give different textures to the plurality of sections. It is preferable that
When configured in this way, for example, in the case of a product with a complicated pattern such as a photograph or painting, various textures such as water texture, soil texture, cloud texture, etc. can be expressed by embossed patterns. In addition to the design expression by color, the design can be expressed by such a texture.
For this reason, it becomes possible to raise the commercial value of a product.

Furthermore, in the invention according to claim 1 or 2, it is preferable that the embossed pattern of the plurality of patterns is applied to the plurality of sections on which colors are printed.
According to a fourth aspect of the present invention, it is preferable that in the first step, a printing process for applying a color to the plurality of sections is performed.
If comprised in this way, embossing can be performed after printing is complete | finished.
For this reason, the problem that ink flows along the recessed part produced by embossing and ink bleeding occurs can be avoided.

Furthermore, in the invention described in claim 4, it is preferable that the second step is configured to simultaneously provide the embossed patterns of the plurality of patterns in one process.

If comprised in this way, since a surface processed product can be manufactured by one process, without performing embossing in multiple times, while manufacturing time is shortened, manufacturing cost can be reduced.

According to the present invention, since a single design can be configured by combining a plurality of sections each having a different embossed pattern, it is possible to configure a complex design that has not existed before.
In particular, in the case of products with complex designs such as photographs and paintings, if these contours are extracted and partitioned, different embossed patterns can be added to these partitions. A feeling can be imparted.
For example, in the case of products with complex designs such as photographs and paintings, various textures such as water texture, soil texture, cloud texture, etc. can be expressed with embossed patterns, in addition to design expression by color The design can also be expressed by such a texture.
For this reason, it becomes possible to raise the commercial value of a product.

In addition, since an embossed pattern can be provided on a photograph or painting after it has been printed, it is possible to avoid the problem of ink bleeding due to ink flowing along the recesses caused by embossing. it can.
Furthermore, since embossing is performed using a flexible die, a plurality of embossed patterns can be added by a single process, which contributes to shortening of manufacturing time and manufacturing cost.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
It should be noted that members, arrangements, and the like described below do not limit the present invention, and it goes without saying that various modifications can be made in accordance with the spirit of the present invention.
1 to 6 are diagrams showing an embodiment of the present invention, FIG. 1 is an explanatory view showing an embossed product, FIG. 2 is a partial perspective view showing a flexible die, FIG. 3 is a hardware configuration diagram of a computer, FIG. 4 is an explanatory view showing an example of a die roller, FIG. 5 is an explanatory view of a main part showing an example of an embossing apparatus, and FIG. 6 is a process view showing a manufacturing process of a surface processed product.

The surface processed product S according to the present embodiment will be described with reference to FIG.
The surface processed product S according to the present embodiment is provided with a different embossed pattern for each section.
The embossed pattern is a pattern mainly formed by making irregularities on a sheet-like member, and is given by pressing a mold having irregularities on the sheet-like member.
As this method, various methods such as a method of directly impressing a concave / convex mold on a cylinder are used, but in this embodiment, embossing is performed using a flexible die engraved with a concave / convex mold. I do. This method will be described later.
FIG. 1 is an example of a surface processed product S according to the present embodiment. Although a simple pattern is used for explanation, in practice, it can be suitably applied to express a complex design in which complex figures and patterns such as photographs and paintings are combined.

As shown in FIG. 1, the surface processed product S according to the present embodiment includes a first embossed pattern E1 in a star-shaped first contour R1, a second embossed pattern E2 in a circular second contour R2, and a moon-shaped first contour R1. A third embossed pattern E3 is attached to the three contour R3, and a fourth embossed pattern E4 is attached to the outer contour.
In this way, since different embossed patterns are given to the respective sections separated by the respective contours, different textures are given to the respective sections.

For this reason, the design of the surface processed product S is constructed not only with the design expressed by the sections but also with the texture expressed by the embossed pattern.
In the present embodiment, a simple star-shaped mark or the like has been described. However, for example, various patterns such as an embossed pattern expressing water and an embossed pattern expressing blocks are given according to the design expressed by the section. For example, the design expressed by the surface processed product S can be given a sense of quality and texture, and the product value can be increased.

In FIG. 2, the structure of the flexible die 1 for embossing the surface workpiece W to form the surface processed product S will be described. In FIG. 2, the size and the like of the unevenness are slightly emphasized for explanation.
The flexible die 1 according to the present embodiment is a pressing die in which irregularities having a certain pattern are formed on a thin plate-like metal plate. However, the material or the like is not limited to this, and any material can be used as long as it can be unevenly processed on the surface, such as a resin plate or a stainless steel plate, and can be installed on the die roller 40. Such a material may be used.

In the flexible die 1 according to the present embodiment, a plurality of protrusions 11 for forming the first embossed pattern E1, a plurality of protrusions 12 for forming the second embossed pattern E2, and a third embossed pattern E3 are formed. The plurality of protrusions 13 and the plurality of protrusions 14 for forming the fourth embossed pattern E4 are formed (only the protrusion 11 and the protrusion 14 are shown in FIG. 2).
These protrusions 11, 12, 13, and 14 are substantially columnar protrusions having a bottom surface corresponding to the shape of each pattern (for example, the protrusion 14 is a columnar protrusion having a substantially S-shaped bottom surface and approximately S A character-like fourth embossed pattern E4 is applied to the surface processed product S), and stands up substantially perpendicularly from the support surface 10.

By using the flexible die 1 processed in this way, the surface processed material W is processed to form the surface processed product S.
The flexible die 1 according to this embodiment is designed by using a known image processing technique.
For example, the flexible die 1 is formed by taking an image to be surface-treated into a computer using a scanner or a CCD camera.
This computer stores an image processing program.

A hardware configuration example of this computer will be described.
An example of the hardware configuration of the computer according to the present embodiment is shown in FIG.
The computer used in the present embodiment includes a CPU 32 as a central processing unit that performs data calculation and control, a RAM 33 as a storage device, a ROM 34, an HDD 35, a storage medium device 36, and a communication device 37 as main components. Yes.

The CPU 32 executes various processes in accordance with programs stored in the ROM 34 or the HDD 35, and is a central unit for executing predetermined processes such as operation management of each functional configuration group and input / output control of each signal. It plays a role.
The RAM 33 appropriately stores data necessary for the CPU 32 to execute various processes.
The received image data is temporarily stored in the RAM 33. The image data is appropriately read at a predetermined timing, and is subjected to image processing according to an image processing program.

The storage medium device 36 includes an external hard disk, a magneto-optical disk, a CD-R, a DVD, a memory stick, and the like.
The communication device 37 serves as a relay point when data transmission / reception is performed, and when data transmission / reception is performed, these data are temporarily stored as appropriate.

The keyboard 38 and the mouse 39 as input devices are appropriately operated when a predetermined command is input to the CPU 32.
Further, information, images, etc. displayed in a predetermined format are output and displayed on the display device 30 and the printer 31.

As described above, the image processing is performed using the configured computer. For example, the image processing may be performed as follows.
First, the range of the portion where image processing is performed on the captured image is set.
Thereafter, the contour may be extracted by gradient or Laplacian, and the contour may be extracted, or binarization processing may be performed at a specified threshold value to detect a portion equal to or higher than the threshold value as the contour.

For example, an origin is set for the captured image, and a two-dimensional coordinate system is set for each pixel from the origin.
Using this two-dimensional coordinate system, the range of the part for image processing is set. For example, the range is defined as (a1, b1) ≦ (x, y) ≦ (a2, b2), etc. (a1, b1, a2, and b2 are integer values representing two-dimensional coordinates in pixel units, respectively). Thus, if the coordinates are set, the contour of the captured image is detected as a two-dimensional coordinate.

An appropriate emboss pattern is input to the drawing in which the contour is extracted in this way.
For example, the image processing program stores a plurality of embossed pattern examples so that the operator can select each contour by computer operation and input an appropriate embossed pattern in the contour. It is configured.
In order to produce the flexible die 1 for forming the surface processed product S shown in FIG. 1 according to this example, the first contour R1 has a lattice pattern, the second contour R2 has a horizontal line pattern, and the third contour R3 has a It is preferable that a wavy pattern (substantially S-shaped pattern) can be selected and input to the block pattern and the fourth contour R4.
When the emboss pattern is input and the design is completed, the design is engraved on the metal plate that is the material of the flexible die 1.

This marking process may be performed by a known method such as a laser processing method, a machining method, or an etching method.
For example, in the case of a laser processing method, by outputting a design set by a computer to a laser processing apparatus (for example, outputting a two-dimensional coordinate signal of a portion to be engraved), a laser beam is irradiated onto a metal plate. And stamp it.
Similarly, in the case of a machining method, a design set by a computer is output to a processing apparatus (for example, a two-dimensional coordinate signal of a portion to be marked is output), and a metal plate is scraped off by a physical method. .
Further, in the case of the etching method, the design set by the computer is output to the light irradiation device (for example, a two-dimensional coordinate signal of the portion to be marked is output) to corrode the concave portion.

Thus, by performing image processing, the flexible die 1 expressing a complicated design such as a photograph or a painting can be formed.
In addition, since the flexible die 1 can be easily produced, the cost can be reduced and the design can be easily changed as compared with the conventional technique in which an uneven pattern is directly engraved on the roller.

Next, a method for performing a surface treatment on the workpiece W will be described with reference to FIGS.
In the present embodiment, the flexible die 1 is used to perform embossing.
FIG. 4 shows an example of the die roller 40.
The die roller 40 according to the present embodiment is a known die roller, and a plurality of magnets 41 are affixed to the side surface thereof so as to be regularly arranged at predetermined intervals along the circumferential direction and the axial direction.

A belt-like die support plate 42 is wound around the surface of the magnet 41 and the flexible die 1 is magnetically fixed to the surface.
In this figure, an example in which one flexible die 1 is magnetically fixed is shown. However, the present invention is not limited to this, and a plurality of flexible dies 1 are arranged in parallel at predetermined intervals along the circumferential direction and the axial direction. The flexible die 1 may be magnetically fixed.
A spur gear 43 is attached to the bottom surface side of the die roller 40 around the rotation shaft 44. The rotating shaft 44 is fixed so as to pass through the centers of both bottom surfaces of the die roller 40, and is configured so that the die roller 40 can rotate as the spur gear 43 rotates.

Next, an example of the embossing device T is shown in FIG. 5 (main parts are schematically shown), and a usage example of the die roller 40 will be described.
As shown in FIG. 5, a roller 50 is disposed below the die roller 40 with a slight gap enough to sandwich the workpiece W to be surfaced. The roller 50 is configured to be rotatable about a rotation shaft 51.

A driving gear 60 is engaged with the spur gear 43 provided in the die roller 40, and a driving force from a driving source (not shown) is transmitted to the driving gear 60.
As a drive source (not shown), for example, a motor is used. The output from the motor is transmitted to the rotating shaft 61 of the drive gear 60 through a reduction mechanism designed to have an appropriate gear ratio while ensuring the necessary torque.

Since the rotation output from a drive source (not shown) is transmitted to the rotation shaft 61 and the drive gear 60 rotates in the A direction, the spur gear 43 meshed with the rotation rotates in the B direction. .
In response to this rotation, the die roller 40 rotates in the same direction (rotates in the B direction).
The die roller 40 is pressed downward in the drawing by a pressing mechanism (not shown). For this reason, the roller 50 rotates in the C direction with the workpiece W being sandwiched between the die roller 40 and the roller 50. At the same time, the workpiece W is transported in the D direction.
At this time, an embossed pattern designed for the flexible die 1 is added to a portion where the flexible die 1 and the workpiece W to be pressed are in pressure contact (portion pressed in the gap between the die roller 40 and the roller 50).
As described above, the surface processed product S is formed by adding the embossed pattern to the surface workpiece W.

Next, a manufacturing process of the surface processed product S according to the present embodiment will be described with reference to FIG.
First, in the symbol fetching step of step 1, the symbol (design) to be processed is fetched into the computer.
As described above, by using a scanner or a CCD camera, a design such as a picture or a photograph is taken into a computer.
Next, in the contour forming step of step 2, the contour of the captured symbol is extracted. As described above, this is realized by performing contour extraction using an image processing technique.

Next, in the design setting step of step 3, appropriate emboss patterns are set in the extracted contours (in each section).
In this way, after the design setting is completed, the flexible die 1 is formed in the flexible die forming step of step 4.
As described above, this is performed by outputting a pattern as designed on the computer to a laser irradiation apparatus, an etching apparatus, or the like, and processing the metal plate with these apparatuses.

After forming the flexible die 1 in this manner, the embossing step of step 5 is performed.
The formed flexible die 1 is magnetically fixed to the die roller 40.
In this way, after setting the flexible die 1, the driving source is driven, the die roller 40 and the roller 50 are driven, and the surface workpiece W is embossed to form the surface processed product S.

In addition, before sending the workpiece W to the die roller 40, it is preferable to perform printing by passing the workpiece W through a printing machine.
That is, embossing is performed after coloring each designed section by printing.
By comprising in this way, the malfunction that printing ink flows along the recessed part formed of the embossing and a bleeding arises can be prevented.
This printing machine is connected to a computer, and is configured to output the captured symbols. The symbols can be printed by a known printing technique.

It is explanatory drawing which shows the embossed product which concerns on one Embodiment of this invention. It is a fragmentary perspective view showing the flexible die concerning one embodiment of the present invention. It is a hardware block diagram of the computer which concerns on one Embodiment of this invention. It is explanatory drawing which shows an example of the die roller which concerns on one Embodiment of this invention. It is principal part explanatory drawing which shows an example of the embossing apparatus which concerns on one Embodiment of this invention. It is process drawing which shows the manufacturing process of the surface processed product which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Flexible die 10 Support surface 11, 12, 13, 14 Protrusion 30 Display apparatus 31 Printer 32 CPU
33 RAM
34 ROM
35 HDD
36 Storage medium device 37 Communication device 38 Keyboard 39 Mouse 40 Die roller 41 Magnet 42 Die support plate 43 Spur gear 44 Rotating shaft 50 Roller 51 Rotating shaft 60 Driving gear 61 Rotating shaft E1 First embossed pattern E2 Second embossed pattern E3 Third embossed Pattern E4 Fourth embossed pattern R1 First contour R2 Second contour R3 Third contour R4 Fourth contour S Surface processed product T Embossing device W Surface processed material (material to be processed)

Claims (6)

A product with a pattern on the surface by embossing using a flexible die,
The product is divided into a plurality of compartments,
A plurality of embossed patterns are added to the plurality of sections,
A surface processed product in which one design is formed by a combination of the plurality of sections.   The surface processing according to claim 1, wherein the embossed patterns of the plurality of patterns are each set as a pattern set according to the section, and each of the plurality of sections has a different texture. Product.   The surface processed product according to claim 1, wherein the plurality of embossed patterns are attached to the plurality of sections on which colors are printed. A method for forming a pattern on the surface of a workpiece by embossing using a flexible die,
A first step of forming a plurality of sections on the surface of the workpiece;
A second step of adding a plurality of embossed patterns to each of the plurality of sections;
A method for producing a surface processed product, characterized in that:   5. The method of manufacturing a surface processed product according to claim 4, wherein in the first step, a printing process is performed to color the plurality of sections. 5. The method of manufacturing a surface processed product according to claim 4, wherein, in the second step, the embossed patterns of the plurality of patterns are simultaneously applied in a single process.

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