JP5339198B2 - Embossing device, backup roll, method of manufacturing processed product, and method of manufacturing backup roll - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an embossing apparatus forming a concavo-convex pattern on a substrate, specifically forming a concavo-convex pattern on a substrate efficiently with a high rate of operation. <P>SOLUTION: The embossing apparatus 10 includes an emboss roll 20 having an emboss mold surface 25 having a concavo-convex shape corresponding to the concavo-convex pattern 55 to be formed on the substrate 50 and a backup roll 30 arranged so as to face the emboss roll and pressing the substrate between the emboss roll and the backup roll. The backup roll has a core member 32 and a front layer 34 formed on the core member and facing the emboss mold surface of the emboss roll. The front layer has a base layer 34 containing a resin 36 and a plating layer 38 formed on the base layer. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to an embossing device that forms an uneven pattern on an original fabric, and more particularly to an embossing device that can efficiently form an uneven pattern on an original fabric at a high operating rate.

  The present invention also relates to a backup roll used in an embossing device that forms an uneven pattern on an original fabric, and more particularly to a backup roll that enables an uneven pattern to be efficiently formed on an original fabric at a high operating rate.

  Furthermore, the present invention relates to a manufacturing method for manufacturing a processed product by forming a concavo-convex pattern on an original fabric, and more particularly to a manufacturing method for a processed product capable of manufacturing a processed product efficiently at a high operating rate.

  Furthermore, the present invention relates to a method for manufacturing a backup roll used in an embossing apparatus for forming a concavo-convex pattern on a raw fabric, and in particular, a backup that enables a concavo-convex pattern to be efficiently formed on a raw fabric at a high operating rate. The present invention relates to a roll manufacturing method.

  Recently, as shown in Patent Document 1, for example, embossing is a widely used processing method. Patent Document 1 discloses a method for producing a release paper (processed product) by embossing an original fabric. This release paper is used as a paper pattern for producing sheet-like materials such as synthetic leather products, decorative sheets, and interior materials.

  In general, when embossing a relatively thin workpiece such as a raw fabric, an embossing device used for embossing is disposed so as to face an embossing roll having an embossing surface and an embossing roll. Backup rolls.

JP 2002-205311 A

  The surface layer portion of the backup roll that is pressed by the embossing mold surface can be deformed corresponding to the uneven shape formed on the embossing mold surface, and can maintain the deformed state at least temporarily. It is preferable that it is comprised. According to such a backup roll, the embossing roll and the backup roll are idled (i.e., idling) before embossing the original fabric, so that the uneven shape corresponding to the uneven shape of the embossed mold surface is obtained. It can be formed on the surface layer of the backup roll. If a female mold is formed on the backup roll, the concavo-convex shape can be accurately transferred to the original without significantly increasing the processing pressure.

  By the way, when a material that is not easily elastically deformed, for example, a metal, is used as the material of the surface layer portion of the backup roll, a female mold cannot be formed on the backup roll by the idle operation. In order to form a concavo-convex shape on the surface layer portion of a metal backup roll, it is necessary to perform complicated processing such as patterning by etching on the surface layer portion. On the other hand, when a material that is easily elastically deformed, for example, a resin, is used as the material of the surface layer portion of the backup roll, it is impossible to maintain a fine uneven shape on the surface layer portion of the backup roll.

  In consideration of such points, a paper roll having a surface layer portion formed by pressing and compacting fibers such as paper and wool is used as a backup roll. However, even when a paper roll is used, the concavo-convex shape formed in advance on the backup roll is gradually flattened as the processing time elapses. When the uneven shape of the backup roll is flattened, the uneven pattern transferred to the original fabric is also flattened.

  In order to avoid this inconvenience, the embossing must be interrupted, the embossing roll and the backup roll must be idled, and the concavo-convex shape must be re-formed (molded) on the surface layer portion of the backup roll.

  Further, in order to determine the necessity of putting the backup roll into the surface layer portion, it is necessary to check the quality of the processed product that has been embossed each time. However, the inspection of the processed product is extremely complicated if the concavo-convex pattern is complicated, and requires a long time (for example, 1 hour). For this reason, in actual production, without checking the quality of the embossed work product on-site, look at the safety and perform mold insertion work regularly, for example, every 3 to 4 hours. Sometimes it is done.

  In other words, at present, an embossing device having a backup roll that can be formed in an uneven shape corresponding to the embossed mold surface by idle operation is operated at an excellent operating rate, and a sufficient uneven production pattern is formed by forming an uneven pattern on the original fabric. It is not possible to manufacture processed products. The present invention has been made in consideration of the above points, and is an embossing device that forms a concavo-convex pattern on an original fabric, and in particular, efficiently forms an concavo-convex pattern on an original fabric at a high operating rate. It is an object of the present invention to provide an embossing device that can perform such a process. In addition, the present invention is a backup roll used in an embossing device for forming an uneven pattern on an original fabric, and in particular, a backup roll that enables an uneven pattern to be efficiently formed on an original fabric at a high operating rate. The purpose is to provide. Furthermore, the present invention is a manufacturing method for manufacturing a processed product by forming a concavo-convex pattern on an original fabric, and in particular, an object of the present invention is to provide a manufacturing method for a processed product capable of manufacturing a processed product efficiently. And Furthermore, the present invention is a method for manufacturing a backup roll used in an embossing apparatus for forming an uneven pattern on an original fabric, and particularly enables an uneven pattern to be efficiently formed on an original fabric at a high operating rate. It aims at providing the manufacturing method of a backup roll.

  An embossing device according to the present invention is an embossing device for forming a concavo-convex pattern on an original fabric, and an embossing roll having an embossed mold surface having a concavo-convex shape corresponding to the concavo-convex pattern to be formed on the original fabric, and the embossing roll And a backup roll that presses the original fabric with the embossing roll, and the backup roll is provided on the core member and the embossing roll. A surface layer portion facing the embossed mold surface, and the surface layer portion includes a base layer containing a resin and a plating layer formed on the base layer.

  The backup roll according to the present invention is a backup roll disposed opposite to an embossing roll of an embossing device that forms an uneven pattern on the original fabric, and is a core member and a surface layer portion provided on the core member, A surface layer portion facing the embossing mold surface formed on the embossing roll, wherein the surface layer portion includes a base layer containing a resin and a plating layer formed on the base layer. To do.

  In the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the resin of the base layer has conductivity, and the plating layer is formed on the conductive resin of the base layer by electrolytic plating. It may be a layer.

  Further, in the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the resin of the base layer may be a reaction curable resin subjected to a curing treatment.

  Furthermore, in the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the base layer may further include metal particles dispersed in the resin. In the backup roll of the embossing apparatus according to the present invention or the backup roll according to the present invention, the plating layer is a layer formed on the conductive resin of the base layer by electrolytic plating using the metal particles as the core of plating. There may be.

  Furthermore, in the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the metal particles may have an average particle size of 20 μm or more and 400 μm or less. In the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the volume ratio occupied by the metal particles in the surface layer portion may be 60% or more and 90% or less. In the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the metal particles may be aluminum, copper, iron, or an alloy thereof. Furthermore, in the backup roll of the embossing device according to the present invention or the backup roll according to the present invention, the surface layer portion of the backup roll may be formed with an uneven shape corresponding to the uneven shape of the embossed mold surface.

  A method for manufacturing a processed product according to the present invention is a manufacturing method for manufacturing a processed product by forming a concavo-convex pattern on an original fabric using any one of the embossing devices according to the present invention described above, wherein the embossing roll and the base The core member formed with a layer is idled, and a step of forming a concavo-convex shape corresponding to the concavo-convex shape of the embossing mold surface of the embossing roll on the base layer, and the base portion having the concavo-convex shape formed thereon Forming a plating layer on the layer to obtain the backup roll, and rotating the embossing roll and the backup roll in a state where the original fabric is sandwiched therebetween, and forming an uneven pattern on the original fabric; It is characterized by providing.

  A method for manufacturing a backup roll according to the present invention is a manufacturing method for manufacturing any one of the above-described backup rolls according to the present invention, wherein the embossing roll and the core member on which the base layer is formed are idled. A step of forming an uneven shape corresponding to the uneven shape of the embossing mold surface of the embossing roll on the base layer, and a step of forming a plating layer on the base layer on which the uneven shape is formed. Features.

  In the method for producing a processed product according to the present invention or the method for producing a backup roll according to the present invention, the resin of the base layer has conductivity, and in the plating step, the plating layer is formed by electroplating of the base layer. It may be formed on a conductive resin.

  Further, in the method for producing a processed product according to the present invention or the method for producing a backup roll according to the present invention, the resin of the base layer is a reactive curable resin, and the production method is performed after the empty operation step. And a curing step of curing the reactive curable resin of the base layer on which the concavo-convex shape is formed.

  Furthermore, in the method for producing a processed product according to the present invention or the method for producing a backup roll according to the present invention, the base layer may further include metal particles dispersed in the resin.

  A first roll base material according to the present invention is a base material for producing a backup roll disposed to face an embossing roll of an embossing device that forms a concavo-convex pattern on a raw fabric, and includes a core member and a core member A base layer provided on the base layer, wherein the base layer includes a conductive resin.

  A second roll base material according to the present invention is a base material for producing a backup roll disposed to face an embossing roll of an embossing device that forms a concavo-convex pattern on an original fabric, and includes a core member and a core member A base layer provided on the base layer, wherein the base layer further includes metal particles dispersed in the resin.

  According to the present invention, it is possible to emboss an original fabric with excellent efficiency. As a result, the processing cost can be reduced.

FIG. 1 is a diagram for explaining an embodiment of the present invention, and is a perspective view showing an embossing device, a backup roll incorporated in the embossing device, and a method of manufacturing a processed product using the embossing device. FIG. 2 is a cross-sectional view showing the backup roll. FIG. 3 is a diagram for explaining the idling operation process. FIG. 4 is a diagram for explaining the curing process. FIG. 5 is a diagram for explaining the plating process. FIG. 6 is a diagram for explaining the embossing process. FIG. 7 is a cross-sectional view for explaining a deformation process that can be estimated for the base layer of the backup roll in the idling operation process. FIG. 8 is a cross-sectional view for explaining a deformation process that can be estimated for the base layer of the backup roll in the idling operation process. FIG. 9 is a cross-sectional view for explaining a deformation process that can be estimated for the base layer of the backup roll in the idling operation process.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the drawings attached to the present specification, for the sake of illustration and ease of understanding, the scale, the vertical / horizontal dimension ratio, and the like are appropriately changed and exaggerated from those of the actual product.

  1 to 9 are diagrams for explaining an embodiment according to the present invention. First of all, an embossing apparatus for manufacturing a processed product by forming an uneven pattern on an original fabric will be described with reference to FIGS. 1 and 2. Here, FIG. 1 is a perspective view for explaining an embossing device and a method of manufacturing a processed product using the embossing device. Moreover, FIG. 2 is sectional drawing which shows the backup roll of an embossing apparatus.

  As shown in FIG. 1, the embossing device 10 includes an embossing roll 20 and a backup roll 30 that is arranged to face the embossing roll 20 and presses the raw fabric 50 between the embossing roll 20. Yes. The embossing device 10 further includes a raw material supply device (not shown) that supplies the raw material 50 between the embossing roll 20 and the backup roll 30.

  As shown in FIG. 1, the embossing roll 20 and the backup roll 30 are each formed in a columnar shape or a cylindrical shape. The embossing roll 20 and the backup roll 30 are disposed so that their outer peripheral surfaces face each other. Further, the embossing roll 20 and the backup roll 30 are arranged so that the central axes L1 and L2 thereof are parallel to each other. The embossing roll 20 and the backup roll 30 are rotatable around their respective central axes L1 and L2.

  The embossing device 10 further includes a control device (not shown). The control device is connected to the rotation drive mechanism of the embossing roll 20, the rotation drive mechanism of the backup roll 30, and the original fabric supply device. And a control apparatus is comprised so that rotation of the embossing roll 20, rotation of the backup roll 30, supply of the raw fabric 50, etc. may be controlled.

  The embossing roll 20 has the embossing type | mold surface 25 containing the uneven | corrugated shape formed on the outer peripheral surface. As shown in FIG. 1, the embossing mold surface 25 comes into contact with the original fabric 50 supplied from the original fabric supply device. As shown in FIG. 1, the embossed mold surface 25 has an uneven shape corresponding to the uneven pattern 55 to be formed on the original fabric 50. The concavo-convex shape of the embossed mold surface 25 is configured as an concavo-convex shape including various roughnesses and depths depending on the use of the processed product to be manufactured. As an example, when the processed product 60 to be manufactured is a release paper (pattern paper) for synthetic leather, the concavo-convex shape of the embossed mold surface 25 is configured to give a leather pattern to the original fabric 50. . The entire embossing roll 20 including the embossing mold surface 25 can be made of a metal such as copper or iron.

  Next, the backup roll 30 disposed to face the embossing roll 20 will be described. The backup roll 30 has substantially the same outer diameter as the embossing roll 20, for example, an outer diameter of 200 mm to 400 mm. The backup roll 30 is configured to be able to rotate at a circumferential speed substantially the same as the circumferential speed of the embossing roll 20 in synchronization with the embossing roll 20.

  As shown in FIG. 1, the backup roll 30 includes a core member 32 formed in a columnar shape or a cylindrical shape, and a surface layer portion 33 formed on the core member 32. The core member 32 is configured to stably support the surface layer portion 33. Specifically, the core member 32 is formed in a columnar shape or a cylindrical shape from a highly rigid metal such as iron or copper.

  As shown in FIG. 1, the surface layer portion 33 faces the embossing mold surface 25 of the embossing roll 20. The surface layer portion 33 is formed with an uneven shape corresponding to the uneven shape of the embossed mold surface 25. As shown in FIG. 2, the surface layer portion 33 includes a base layer 34 provided on the core member 32 and a plating layer 38 formed on the base layer 34.

  As shown in FIG. 2, the base layer 34 includes a resin 36 and metal particles 35 dispersed in the resin 36. The resin 36 functions as a binder resin that fills the space between the large number of metal particles 35 and holds the large number of metal particles 35. The thickness of the base layer 34 can be set as appropriate. As an example, when a release paper for synthetic leather is produced as the processed product 60, the thickness of the base layer 34 can be 5 mm or more and 10 mm or less.

  In the present embodiment, the resin 36 is made of a conductive resin having conductivity. The resin 36 functions as a plating nucleus when the plating layer 38 is formed by electrolytic plating. Examples of such a resin 36 include a silver paste and a resin containing a conductive filler.

  In the present embodiment, the resin 36 is formed as a reactive curable resin. Here, the reaction curable resin is a resin that cures by reacting, and typical examples include a thermosetting resin that cures in response to heat and a photoreaction that cures in response to light. Resin etc. are mentioned. In addition, as the photoreactive resin, ionization of an electron beam curable resin that starts and cures when irradiated with an electron beam, or an ultraviolet curable resin that initiates and cures when irradiated with ultraviolet light. A radiation curable resin is mentioned. In this modification, the curing form of the reaction curable resin is not particularly limited and may be appropriately selected. As an example, in the following description, an example in which the resin 36 is a thermosetting resin will be described. As will be described later, when the resin 36 is a reactive curable resin, after forming an uneven shape on the surface layer portion 33 (base layer 34), the resin 36 is cured to thereby form the surface layer portion 33 (base layer 34). Flattening can be prevented, and the uneven shape formed in the surface layer portion 33 (base layer 34) can be effectively maintained.

  Various materials can be selected as the material forming the metal particles 35. As an example, aluminum, copper, iron, or an alloy thereof can be used. The strength of the material forming the resin 36 and the strength of the material forming the metal particles 35 are preferably greatly different. In this case, as will be described later, the uneven shape of the surface layer portion 33 (base layer 34) formed by plastic deformation of metal particles can be effectively maintained against the restoring force of the resin 36 and the like. .

  In addition, the average particle diameter of the large number of metal particles 35 can be set to various values, for example, corresponding to the uneven shape of the embossed mold surface 25. As an example, when a release paper for synthetic leather is produced as the processed product 60, the average particle diameter of a large number of metal particles 35 can be 20 μm or more and 400 μm or less. In this case, it can be expected that the effects described in detail later will be exhibited extremely effectively. In addition, the shape of the metal particle 35 does not need to be spherical, and can be set to various shapes such as a linear shape.

  Furthermore, in the base layer 34, the metal particles 35 and the resin 36 can be blended at various blending ratios. For example, a metal particle 35 made of aluminum, copper, iron, or an alloy thereof, and a resin 36 made of PET or a resin having the same degree of strength are used. When the pattern paper is produced as the processed product 60, the metal particles 35 and the resin 36 can be blended at a volume ratio of 6: 4 to 9: 1. In other words, the volume ratio of the metal particles 35 in the base layer 34 can be set to 60% or more and 90% or less, for example. In this case, it can be expected that the effects described in detail later will be exhibited extremely effectively.

  In the present embodiment, the metal particles 35 can also function as a nucleus of electrolytic plating when forming the plating layer 38. From the viewpoint of forming the plating layer 38 having a certain thickness, it is preferable that the average particle diameter of the metal particles 35 is reduced and a large amount of the metal particles 35 are uniformly dispersed in the binder resin 36.

  The plating layer 38 is formed so as to cover the base layer 34. In the present embodiment, the plating layer 38 is formed as a metal layer made of copper, nickel, chromium or the like formed by electrolytic plating. The plating layer 38 is formed with a substantially constant thickness along the uneven shape of the base layer 34 so as not to impair the uneven shape of the base layer 34. The plating layer 38 functions to prevent the surface layer portion 33 (base layer 34) from being flattened and to effectively maintain the uneven shape formed on the surface layer portion 33 (base layer 34). In order to effectively exhibit this function, as an example, when a release paper for synthetic leather is produced as the processed product 60, the thickness of the plating layer 38 can be set to 5 μm or more and 12 μm or less.

  Next, an example of a method for manufacturing the processed product 60 by preparing the embossing device 10 and forming the uneven pattern 55 on the original fabric 50 using the prepared embossing device 10 will be described. The method described below includes a step of preparing a roll base material 49 including a core member 32 and a base layer 34 for forming the backup roll 30, and an empty operation step of causing the roll base material 49 to idle with the embossing roll 20. (See FIG. 3), a step performed after the idling operation step, a curing step (see FIG. 3) for curing the resin 36 of the base layer 34, and a step performed after the curing step, The embossing process (refer FIG. 5) which forms the uneven | corrugated pattern 55 in 50 is included.

  First, the process of preparing the roll base material 49 will be described. A roll base 49 comprising a core member 32 and a base layer 34 provided on the core member 32 is prepared. As one specific example, the roll base 49 can be prepared by forming the base layer 34 on the core member 32 as follows. First, a resin solution containing the resin 36 and the metal particles 35 is coated on the core member 32 using various coating methods. Next, the solvent is removed from the resin solution on the core member 32 by baking.

  Next, in the idling operation step, as shown in FIG. 3, the embossing roll 20 and the roll base material 49 (backup roll 30) are idling. Here, “idle operation (idling)” means that the raw fabric 50 is not supplied between the embossing roll 20 and the roll base 49 (backup roll 30), and the embossing roll 20 and the roll base 49 (backup). The roll 30) is rotated. During this idling operation, the embossing mold surface 25 of the embossing roll 20 comes into contact with the outer peripheral surface of the roll base material 49 (backup roll 30), and the concavo-convex convex portions 25a of the embossing mold surface 25 become the roll base material 49 (backup roll 30). ) Will be pressed. At this time, the positional relationship between the embossing roll 20 and the roll base material 49 (backup roll 30) is substantially the same as the positional relationship between the embossing roll 20 and the backup roll 30 when embossing is actually performed on the original fabric 50. It is preferable that it is set to.

  In this idling process, the uneven shape formed on the embossed mold surface 25 is gradually transferred to the base layer (outer peripheral surface) 34 of the roll base material 49 (backup roll 30). When the inventors conducted experiments, according to the embodiment of the present embodiment in which the base layer 34 having the metal particles 35 and the resin 36 is used, the uneven shape of the embossed mold surface 25 is changed to the base layer 34. It was confirmed that transfer was possible with excellent transfer efficiency. Although the mechanism that makes it possible to accurately transfer the concavo-convex shape to the base layer 34 of the backup roll 30 according to the present embodiment is not clear, it will be considered below with reference mainly to FIGS. A possible transfer mechanism will be described. However, the present invention is not limited to the following mechanism.

  When the embossing roll 20 and the roll base material 49 (backup roll 30) are idled and the embossing roll 20 and the roll base material 49 (backup roll 30) are pressed toward each other, as shown in FIG. The embossed mold surface 25 of the roll 20 comes into contact with and presses the base layer 34 of the roll base material 49 (backup roll 30) at the concave and convex portion 25 a. That is, a large pressure is locally applied to the base layer 34 of the roll base material 49 (backup roll 30). When the base layer 34 is pressed by the convex portion 25a of the embossed mold surface 25, it is expected that the resin 36 that is easily elastically deformed first flows in the vicinity of the convex portion 25a and the base layer 34 is slightly deformed. .

  When the embossing roll 20 and the roll base material 49 (backup roll 30) are further strongly pressed toward each other, the embossing surface is not only deformed finally but also due to a large local pressure. The metal particles 35 are plastically deformed around the 25 convex portions 25a. Here, since the metal particles 35 are configured as fine particles, that is, due to shape factors, the rigidity of the metal particles as a whole can be plastically deformed by local pressure from the embossing mold surface 25. . Therefore, as shown in FIG. 8, the convex portion 25a of the embossing mold surface 25 enters the base layer 34, and the metal particles 35 are accurately deformed following the shape of the convex portion 25a of the embossing mold surface 25. Presumed to be gained.

  Further, when the metal particles 35 are plastically deformed, the resin 36 that is more easily deformed than the metal particles 35 is deformed by the plastically deformed metal particles 35 regardless of whether the deformation of the resin 36 is elastic deformation or plastic deformation. It will be kept in the state. As a result, as shown in FIG. 9, even after the embossing mold surface 25 is separated from the base layer 34 of the roll base material 49 (backup roll 30), the recess corresponding to the concavo-convex projection 25a of the embossing mold surface 25. 34 b remains on the base layer 34 of the backup roll 30.

  In this way, by causing the embossing roll 20 and the roll base material 49 (backup roll 30) to run idle, the uneven shape of the embossing mold surface 25 is accurately transferred to the base layer 34 of the backup roll 30, and the embossing mold surface. It is considered that an uneven shape (female type) corresponding to 25 uneven shapes (male type) is formed on the base layer 34 with high accuracy.

  In the idling process as described above, the deformation of the base layer 34 of the roll base material 49 (backup roll 30) is substantially saturated, and the base layer 34 of the roll base material 49 (backup roll 30) is maintained in a substantially constant shape. It is carried out until.

  Next, the reaction curable resin 36 of the base layer 34 formed with the uneven shape is cured. A specific curing method is appropriately selected according to the curing characteristics of the resin 36. As described above, when the resin 36 is made of a thermosetting resin, the resin 36 can be cured by heating the resin 36 using the heating device 42 as shown in FIG. In this manner, the resin 36 of the base layer 34 is cured in a state in which the uneven shape is formed in the idling process. As a result, even if residual stress is accumulated in the resin 36 of the base layer 34, the uneven shape of the base layer 34 is more stably maintained.

  Thereafter, a plating layer 38 is formed on the base layer 34 on which the uneven shape is formed. As a specific method, various methods for forming the plating layer are appropriately selected. In the present embodiment, as shown in FIG. 5, the base layer 34 is immersed in a plating tank 44, and the plating layer 38 is formed on the base layer 34 by electrolytic plating. At this time, both the conductive resin 36 and the metal particles 35 of the base layer 34 function as the core of electrolytic plating. The plating layer 38 is formed with a substantially constant thickness, whereby the uneven shape formed in the base layer 34 remains as it is on the surface of the surface layer portion 33 composed of the base layer 34 and the plating layer 38. The plated layer 38 made of the metal thus formed generally has higher strength than the resin 36 of the base layer 34 when the uneven shape is formed on the base layer 34. Therefore, according to the plated layer 38, the uneven shape of the surface layer portion 33 can be effectively maintained against the restoring force of the resin 36 and the like. Moreover, since the uneven | corrugated shape formed in the base layer 34 is reinforced by the plating layer 38, when external force is applied to the surface layer part 33 in an embossing process, the uneven | corrugated shape of the surface layer part 33 is maintained effectively. Will be able to.

  As described above, the uneven shape is transferred to the roll base 49 composed of the core member 32 and the base layer 34 and the plating layer 38 is formed, thereby forming the backup composed of the core member 32 and the surface layer portion 33 having the uneven shape. A roll is formed.

  Next, the embossing process will be described. In this step, as shown in FIG. 4, the raw fabric 50 is placed between the embossing roll 20 and the backup roll 30 while the embossing roll 20 and the backup roll 30 are rotated (not shown). )). As a result, a concavo-convex pattern 55 corresponding to the concavo-convex shape formed on the embossing mold surface 25 of the embossing roll 20 and the concavo-convex shape formed on the base layer 34 of the backup roll 30 is formed on the original fabric 50 and is processed into a strip shape. 80 is produced continuously.

Incidentally, raw 50 is, for example, paper, and more specifically, may be composed of kraft paper having a 80g / m ² ~200g / m ² about basis weight. The thickness of the original fabric 50 can be several hundreds of micrometers, more specifically, about 25 to 500 μm.

  By the way, in the embossing process, an original fabric 50 having a certain thickness is located between the embossing roll 20 and the backup roll 30. Therefore, the pressure applied during the embossing process from the embossing mold surface 25 of the embossing roll 20 to the outer peripheral surface (surface layer part 33) of the backup roll 30 is applied to the outer peripheral surface (base layer 34) of the roll base 49 during the idling operation process. It is averaged over the pressure applied. That is, the pressure distribution received by the outer peripheral surface of the backup roll 30 (roll base material) is different between the embossing process and the idling process. For this reason, when using the conventional embossing device, as the embossing process proceeds, the uneven shape formed on the outer peripheral surface of the backup roll corresponding to the uneven shape of the embossing mold surface during the idle operation step is It was gradually flattened and smoothed. Then, along with the flattening of the concave and convex shape on the outer peripheral surface of the backup roll functioning as a female mold, there has been a problem that the concave and convex pattern planned on the original fabric cannot be accurately transferred. In order to avoid this inconvenience, the embossing process must be interrupted frequently, the idle operation process must be frequently performed, and the uneven shape must be re-formed (molded) on the outer peripheral surface of the backup roll.

  On the other hand, in the present embodiment, it is possible to prevent the outer peripheral surface of the backup roll from being flattened during embossing and maintain the uneven shape as follows. As a result, regardless of the elapsed time of the embossing process, it is possible to form the concavo-convex pattern 55 on the original fabric 50 with higher accuracy and continuously manufacture the processed product 60.

  First, in the present embodiment, a plating layer 38 made of metal is formed after the idle operation process. Since it is reinforced by the plating layer 38, the outer peripheral surface of the backup roll 30 receiving external force during the embossing process is substantially the same as the outer peripheral surface of the roll base material 49 receiving external force during the idle operation process. It has an uneven shape and a high hardness (strength). For this reason, according to the high-strength plating layer 38 formed so as to reinforce the uneven shape of the base layer 34, the uneven shape of the surface layer portion 33 is prevented from being flattened during the embossing process, and the surface layer portion 33 is prevented. The uneven shape can be effectively maintained. As a result, during the embossing process, the concavo-convex pattern 55 can be accurately formed on the original fabric 50, and the processed product 60 can be continuously manufactured.

  In addition, the resin 36 of the base layer 34 having the irregular shape formed by the idling operation is reactively cured after the idling operation step. Therefore, the surface layer portion 34 has a low strength when the uneven shape is given, and has a high strength when the embossing is performed. For this reason, the uneven | corrugated shape of the base layer 34 formed accurately in the idling operation can be effectively maintained during the embossing process.

  Further, the base layer 34 includes metal particles 35 and a reaction curable resin 36. And the metal particle 35 located in the recessed part 34b in the base layer 34 receives a big force in an empty driving | running | working process, and can be plastically deformed. On the other hand, in the embossing process, an original fabric 50 is interposed between the embossing roll 20 and the backup roll 30. For this reason, the force that the backup roll 30 receives during the embossing process in the vicinity of the recess 34b is smaller than that during the idle operation process. Therefore, the uneven shape in the vicinity of the concave portion 34b of the surface layer portion 33 can be stably maintained.

  Note that the force that the backup roll 30 receives during the embossing process in the vicinity of the convex portion 34a is larger than that during the idle operation process. However, as described above, due to the formation of the plating layer 38 and the reaction hardening of the resin 36 of the base layer 34, the strength of the surface layer 34 is enhanced during the embossing process than during the idle operation process. Therefore, the uneven shape can be stably maintained even in the vicinity of the concave portion 34 b of the surface layer portion 33.

  According to the present embodiment as described above, the surface layer portion 33 of the backup roll 30 has the metal plating layer 38 made of a material having higher strength than the resin 36 included in the base layer 34. And according to this metal plating layer 38, the uneven | corrugated shape of the surface layer part 33 can be maintained during embossing against the restoring force of the resin 36 of the base layer 34, and the force applied via the raw fabric 50. it can.

  The base layer 34 of the backup roll 30 includes a plurality of metal particles 35 and a resin 36 provided between the metal particles 35. For this reason, by causing the embossing roll 20 and the backup roll 30 to idle, the uneven shape formed on the embossing mold surface 25 of the embossing roll 20 can be accurately transferred to the base layer 34 of the backup roll 30. In addition, by deforming the metal particles plastically during the production of the concavo-convex shape, subsequent deformation of the resin 36 in the base layer 34 is constrained.

  Furthermore, according to the present embodiment, the reaction curable resin 36 is cured in this state. Thereby, it becomes possible to effectively suppress the uneven shape formed in the base layer 34 from being flattened during the embossing process.

  From these things, the uneven | corrugated pattern 55 can be formed in the original fabric 50, without performing mold insertion to the backup roll 30 frequently. That is, unnecessary operation stop of the embossing device 10 due to the insertion of the backup roll 30 is avoided, the embossing device 10 is operated at a high operating rate, and the raw fabric 50 is embossed with excellent processing efficiency. I can go. In addition, it is possible to omit a complicated operation such as detecting a situation in which it is necessary to mold the backup roll 30 by inspecting the uneven pattern 55 to be formed. Further, the manufactured processed product 60 has a certain uneven pattern 55 with high accuracy.

  Various modifications can be made to the above-described embodiment within the scope of the present invention.

  For example, in the above-described embodiment, the example in which the release paper for synthetic leather is manufactured as the processed product 60 has been described. However, the present invention is not limited thereto, and it is naturally possible to manufacture the processed product 60 used for other purposes. It is.

  In the above-described embodiment, the example in which the resin 36 of the base layer 34 is a reactive curable resin has been described, but the present invention is not limited thereto. The resin 36 may be formed from a resin that is not reactively curable. Also in such a modification, it can be expected that the uneven shape of the surface layer portion 38 is maintained during the embossing by the plating layer 38.

  Further, in the above-described embodiment, the example in which the base layer 34 includes the metal particles 35 has been described. However, the present invention is not limited to this, and the base layer 34 does not include the metal particles 35 and is formed only from the resin 36, for example. May be. Also in such a modification, it can be expected that the uneven shape of the surface layer portion 38 is maintained during the embossing by the plating layer 38.

  Further, in the above-described embodiment, the example in which the resin 36 of the base layer 34 is conductive has been described. However, the present invention is not limited thereto, and the resin 36 may be nonconductive. Also in such a modification, the plating layer 38 can be formed by electrolytic plating using the metal particles of the resin 36 as the core of the plating.

  Furthermore, although the example in which the plating layer 38 is formed by electrolytic plating has been described in the above-described embodiment, the present invention is not limited to this, and the plating layer 38 may be formed by electroless plating, for example.

  Furthermore, in the above-described embodiment, an example in which the curing process is performed after the idling operation process and the plating process is performed thereafter is shown, but the present invention is not limited thereto. For example, a curing process may be performed after the plating process.

  The present invention will be described in more detail with reference to examples.

  The backup roll according to the example and the backup roll according to the comparative example were prepared, and these two backup rolls were incorporated into the embossing device. Each embossing device incorporated an embossing roll having the same embossing mold surface. The embossing roll, the backup roll according to the example, and the backup roll according to the comparative example will be described below.

  Using two embossing devices, an uneven pattern was formed on the original fabric to produce a processed product. Comparing the transfer efficiency of the concavo-convex shape from the embossing mold surface of the embossing roll to the surface layer part of the backup roll, and the operation rate of the embossing apparatus when producing a processed product with a length of 30,000 m did.

[Emboss roll]
An embossing roll for producing a release paper for synthetic leather as a processed product was used. When the surface roughness was measured in accordance with JISB0601: 2001 at a plurality of locations on the embossing mold surface of the embossing roll, the results were as follows.

Ra: 10 μm to 20 μm Rz: 20 μm to 100 μm Rmax: 500 μm or less

  The outer diameter of the embossing roll was about 300 mm.

[Backup Roll According to Example]
Similar to the above-described embodiment, a backup roll having a core member and a surface layer portion provided on the core member was used. The production of this backup roll used a roll base material having a base layer composed of aluminum metal particles and a resin for bonding the metal particles. The resin of the base layer was a thermosetting silver paste having conductivity and thermosetting. The backup roll according to the example, similarly to the above-described embodiment, performs a blank operation step described below on the roll base material, and then a step of curing the thermosetting resin, and further electroplating It prepared by giving the process of forming a plating layer by. Therefore, the surface layer portion of the obtained backup roll has a base layer and a plating layer formed on the base layer.

  The average particle size of the metal particles was about 300 μm. The volume ratio between the metal particles and the reaction curable resin was 7: 3. The thickness of the surface layer portion was about 7 mm. The material forming the plating layer was chromium, and the thickness of the plating layer was 10 μm. The outer diameter of the backup roll was about 300 mm.

[Backup roll according to comparative example]
A backup roll having a core member and a surface layer portion provided on the core member was used. However, the surface layer portion was configured by pressing and solidifying fibers such as paper and wool.

  The backup roll according to the comparative example has the same configuration as the backup roll according to the example except for the configuration of the surface layer.

[Comparison of transfer efficiency]
The idling operation step in each embossing device was performed at a linear pressure of about 100 kg / cm while pressing the embossing roll and the backup roll toward each other. Judging by visual observation, the nip width during the idling process was 1 cm to 5 cm. The idling operation was performed until the outer surface of the backup roll (the base layer of the roll base material for the backup roll according to the example and the surface layer part for the backup roll according to the comparative example) has a substantially constant shape. . As a result, an idle operation of about one and a half hours was performed for both the backup roll according to the example and the backup roll according to the comparative example. Then, for the backup roll according to the example, the base layer of the roll base material is heated to cause the thermosetting resin of the base layer to undergo a curing reaction, and further, a plating layer is formed on the base layer of the roll base material by electrolytic plating. did.

  About each backup roll, arithmetic mean roughness Ra of the uneven | corrugated shape formed in the surface layer part was measured based on JISB0601: 2001.

  About the backup roll which concerns on a comparative example, the arithmetic mean roughness measured by the surface layer part fell about 35% from the arithmetic mean roughness measured in the position corresponding to the embossing type | mold surface of an embossing roll.

  On the other hand, for the backup roll according to the example, the arithmetic average roughness measured at the surface layer portion was reduced by about 11% from the arithmetic average roughness measured at the corresponding position of the embossing mold surface of the embossing roll. . In other words, the uneven shape formed on the embossing surface of the embossing roll was transferred to the surface layer portion of the backup roll according to the example with extremely high accuracy. The roughness of the surface layer portion of the backup roll according to the example is measured by heating the surface layer portion after the idling operation to cure the thermosetting resin of the surface layer portion, and further applying a plating layer on the base layer by electrolytic plating. Performed after formation.

[Comparison of operating rates]
By using an embossing apparatus incorporating the backup roll prepared as described above, the concavo-convex pattern was transferred to the original fabric to produce a processed product (release paper for synthetic leather). During the embossing process by the embossing device, the quality of the concavo-convex pattern formed on the original fabric is appropriately inspected, and it is confirmed that the concavo-convex pattern is not flattened until it falls outside the general standard of quality standards. A concavo-convex pattern was formed on the original fabric of a length of 30,000 to produce a processed product for 30,000 m. In addition, when the uneven pattern is confirmed to be flat, the embossing process is stopped and the above-described blanking operation is performed, and the mold is put into the surface layer portion of the backup roll (reforming the uneven shape). did. The rotational speed of the embossing roll and the rotational speed of the backup roll rotating at the same peripheral speed as the embossing roll are the same when using the backup roll according to the example and when using the backup roll according to the comparative example. did.

  When the backup roll according to the comparative example was used, it was necessary to perform an idle operation (molding) that required one and a half hours per time at a rate of once every 3 to 4 hours. On the other hand, when the backup roll according to the example was used, it was not necessary to perform idling (molding) while processing a 30,000 m long original fabric. That is, as a result of checking after processing a 30,000 m length of the original fabric, the uneven shape formed on the surface layer portion of the backup roll was hardly flattened.

  As a result, in the embossing apparatus using the backup roll according to the embodiment, when processing the raw material having a length of 30,000 m after performing the empty operation process, the curing process and the plating layer forming process once, in other words, When manufacturing a processed product of 30,000 m, the operating rate was 100%. On the other hand, in the embossing device using the backup roll according to the comparative example, when the raw material having a length of 30,000 m is processed after the empty operation process is performed once, the operation rate is frequently increased during the empty operation process. Since it was necessary to carry out, it became about 70%.

  Moreover, after processing the raw material of a length of 1,500 m, the surface roughness of the backup roll was measured and compared with the surface roughness measured before embossing. About the backup roll which concerns on an Example, the arithmetic mean roughness of the surface layer part measured after processing the raw material of a length of 1,500 m was the same as the roughness measured before processing. On the other hand, for the backup roll according to the comparative example, the arithmetic average roughness of the surface layer portion measured after processing a 1,500 m long raw fabric is reduced by about 7% from the roughness measured before processing. Was.

DESCRIPTION OF SYMBOLS 10 Embossing device 20 Embossing roll 25 Embossing type | mold surface 30 Backup roll 32 Core member 33 Surface layer part 34 Base part layer 35 Metal particle 36 Resin 38 Plating layer 49 Roll base material 50 Original fabric 55 Uneven pattern 60 Processed goods

Claims (10)

An embossing device for forming an uneven pattern on a raw fabric,
An embossing roll having an embossed mold surface having an uneven shape corresponding to the uneven pattern to be formed on the original fabric;
A backup roll that is disposed opposite the embossing roll and that presses the original fabric with the embossing roll; and
The backup roll has a core member, and a surface layer portion provided on the core member and facing the embossing mold surface of the emboss roll,
The embossing device, wherein the surface layer portion includes a base layer containing a resin and a plating layer formed on the base layer. The resin of the base layer has electrical conductivity;
The embossing apparatus according to claim 1, wherein the plating layer is a layer formed on the conductive resin of the base layer by electrolytic plating. The embossing apparatus according to claim 1, wherein the resin of the base layer is a reaction curable resin subjected to a curing process. The embossing device according to claim 1, wherein the base layer further includes metal particles dispersed in the resin. A backup roll arranged opposite to an embossing roll of an embossing device that forms an uneven pattern on the original fabric,
A core member;
A surface layer portion provided on the core member, the surface layer portion facing the embossing mold surface formed on the embossing roll, and
The said surface layer part has a base layer containing resin, and the plating layer formed on the said base layer, The backup roll characterized by the above-mentioned. A manufacturing method for manufacturing a processed product by forming an uneven pattern on an original fabric using the embossing device according to claim 1,
A step of idling the embossing roll and the core member on which the base layer is formed, and forming a concavo-convex shape corresponding to the concavo-convex shape of the embossing mold surface of the embossing roll on the base layer;
Forming a plating layer on the base layer formed with an uneven shape to obtain the backup roll; and
And a step of rotating the embossing roll and the backup roll while sandwiching the original fabric to form an uneven pattern on the original fabric. The resin of the base layer has electrical conductivity;
The method according to claim 6, wherein in the plating step, the plating layer is formed on the conductive resin of the base layer by electrolytic plating. The resin of the base layer is a reaction curable resin;
The said manufacturing method is a process implemented after the said empty driving process, Comprising: The hardening process which hardens the said reaction hardening resin of the above-mentioned base layer in which concavo-convex shape was formed is further provided. 8. The production method according to 6 or 7. The manufacturing method according to claim 6, wherein the base layer further includes metal particles dispersed in the resin. A manufacturing method for manufacturing the backup roll according to claim 5,
A step of idling the embossing roll and the core member on which the base layer is formed, and forming a concavo-convex shape corresponding to the concavo-convex shape of the embossing mold surface of the embossing roll on the base layer;
And a step of forming a plating layer on the base layer on which the concavo-convex shape is formed.

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