JPH09314661A - Preparation of emboss sheet and pipe cover using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To engrave a clear emboss pattern by using an emboss roll wherein projected parts are formed on the bottom faces of recessed parts in such a way that air storing parts for storing air enclosed in the recessed parts are formed when it is brought into press-contact with a sheet. SOLUTION: Conical projected parts 10 are formed on the bottom faces 8a of recessed parts of an emboss roll 5 in such a way that air storing parts for storing air enclosed therein are formed. At the same time when the surface pattern of the emboss roll 5 is brought into press-contact with the surface of a resin film, air existing in the recessed parts 8 is enclosed therein. However, this sealed air is dispersed into the air storing parts 11 along the projected parts 10. Therefore, there exists no possibility of that the sealed air enclosed in the recessed parts 8 is irregularly sealed and the sealed air is sealed in the air storing parts 11 intentionally formed by the conical projected parts 10 on the bottom faces 8a.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an embossed sheet, and more specifically, even if the type of embossed pattern to be engraved on the sheet changes, the embossed pattern is manufactured each time corresponding to the embossed pattern. The present invention relates to a method for manufacturing an embossed sheet that can easily and clearly engrave a desired embossed pattern without changing the conditions. Further, the present invention relates to a pipe cover using this embossed sheet.

[0002]

2. Description of the Related Art An embossed sheet having an embossed pattern of concavo-convex shape formed on one side or both sides is widely used, for example, as a bathroom mat or a heat insulating cover for piping.

Conventionally, the embossed sheet is generally manufactured as follows. This will be described for the case where an embossed pattern is engraved on one surface of a laminated sheet in which a resin film is attached to a resin foam sheet.

First, as shown in FIG. 14, a resin foam sheet 1 made of, for example, a polyolefin foam is heated to a predetermined temperature by a heating device 2a, and a resin film 3 such as an olefin film is formed. It is heated to a predetermined temperature by another heating device 2b. Then, while superposing this resin film 3 on one surface of the resin foam sheet 1, the rubber roll 4 rotating in the direction of arrow p _{2 in} the figure and the arrow p ₁
It is continuously supplied between the later-described embossing rolls 5 that rotate in the direction.

In the process of passing between the rubber roll 4 and the embossing roll 5, the resin foam sheet 1 and the resin film 3
Are pressed by the rubber roll 4 and the embossing roll 5 and adhered to each other to form a laminated sheet. At the same time, the surface pattern of the embossing roll 5 is embossed on the surface of the laminated sheet on the resin film 3 side to transfer the surface pattern, and the desired embossed pattern 6A is engraved. Here, one example of a conventional embossing roll is shown in FIG. 15 as a perspective view, and FIG. 16 is shown as an enlarged perspective view of a part of the surface (A region in FIG. 15). The embossing roll 5 shown here is for forming an embossing pattern as shown in FIG. 17, that is, an embossing pattern in which projections 6 having a quadrangular shape in plan view are regularly arranged on the surface of the embossing sheet. Is. 15, on the surface of the embossing roll 5, a pattern having a negative-positive relationship with the embossing pattern having the protrusions 6 of FIG. 17 is formed.

Now, when the width direction of the embossing roll 5 is indicated by w and the circumferential direction is indicated by r, the above-mentioned patterns are arranged at a predetermined interval in the r direction as shown in FIG. 16 which is a partially enlarged view. A plurality of partition walls 7a having a predetermined height, a plurality of partition walls 7b having a predetermined height arranged in the w direction at predetermined intervals, and a recess having a predetermined depth surrounded by the partition walls 7a, 7b. 8 and the concave portions 8 are distributed on the surface of the embossing roll 5 so as to be adjacent to each other in the w direction and the r direction via each partition wall portion.

When the embossed sheet is manufactured as shown in FIG. 14, the partition walls 7a and 7b described above bite into the softened surface of the resin film 1 and, as a result, the surface after the treatment. By forming a protrusion corresponding to the concave portion 8 on the sheet, the embossed pattern in which the protrusions 6 shown in FIG. 17 are arranged is engraved on the sheet.

[0008]

However, FIG.
~ When embossing is performed using the embossing roll 5 as shown in Fig. 16, in the engraved embossed pattern, as shown in Fig. 18, the top 6a of the protrusion 6 is recessed, In some cases, the edge 6b of the portion does not have a sharp shape, and the embossed pattern is not engraved as a sharp pattern as designed.
Moreover, since the deformation such as the depression of the top or the shape of the edge portion not having a sharp shape varies depending on the location and degree of the individual protrusions, the surface of the embossed sheet has an uneven appearance as a whole.

The occurrence of such a defective shape is based on the following reasons. First, as shown in FIG. 19, at the point where the resin film 3 overlaps the resin foam sheet 1, at the same time, the surface pattern of the embossing roll 5 rotating in the p ₁ direction is pressed against the surface of the resin film 3. At this time, the partition walls 7a and 7b in the surface pattern of the embossing roll 5 become deeper in the sheet as the embossing roll 5 rotates in the p ₁ direction, and the embossing pattern is engraved on the surface of the sheet. After that, the resin film 3 is separated from the surface. In that case, when the embossing roll 5 is pressed against the surface of the resin film 3, the opening of the recess 8 surrounded by the partition walls 7 a and 7 b starts to close on the surface of the resin film 3. Then, as the rotation of the embossing roll 5 progresses, the air in the concave portion 8 escapes from the gap formed by the partition wall portion 7a and the surface of the resin film 3, but after the gap is completely closed, the air Is partially confined in the recess 8 and this sealing air is
a, that is, accumulated on the roll surface side of the embossing roll,
A space 9 will be formed there. Then, when the embossing roll 5 further rotates and the embossing pattern is engraved, the sealing air forming the space 9 is still in a soft state and is being engraved.
As a result, the engraved protrusion 6 has the non-uniform shape defect as described above.

In order to solve such a problem, the heating temperature of the resin foam sheet 1 and the resin film 3 is appropriately selected to change the degree of softening, the roll interval between the rubber roll 4 and the emboss roll 5 and the rotation speed. Properly selected,
Efforts have been made not to form a sealing air space 9 in the surface recess 8 of the embossing roll 5.

However, the above measures are inconvenient for continuous operation of the production line in that appropriate conditions must be set every time the type of surface pattern of the embossing roll 5 changes. In addition, there is a problem that the selection range of the condition setting is narrow, the adjustment work takes a long time, and even if an appropriate condition is set, the rate of occurrence of defective products is not sufficiently suppressed.

Further, the pipe cover formed by processing such an embossed sheet into a cylindrical shape is inferior in surface appearance, and when the pipe cover is curved because the projections forming the embossed pattern are not uniform in shape. In addition, there is a problem that the curved portion is not evenly loaded and wrinkles are concentrated, and that the wrinkles are easily buckled.

The present invention solves the above-mentioned problems in the production of the conventional embossed sheet, and when engraving the embossed pattern, almost no space for sealing air is formed in the concave portion of the surface pattern of the embossing roll, and therefore, the engraving is performed. An object of the present invention is to provide a method for manufacturing an embossed sheet that can easily cope with a change in the type of the embossed pattern to be engraved and can engrave a clear embossed pattern. Moreover, it aims at provision of the pipe cover using this embossed sheet.

[0014]

In order to achieve the above object, in the first aspect of the present invention, the rubber / plastic sheet is formed with a pattern of recesses adjacent to each other through a partition wall. In a method for manufacturing an embossed sheet in which an embossing roll having an exposed surface is pressed and rotated to continuously engrave an embossed pattern on the rubber / plastic sheet, the embossing roll is confined in the recess when the embossing roll is pressed against the sheet. Provided is a method for manufacturing an embossed sheet, which comprises using an embossing roll having a convex portion formed on a bottom surface of a concave portion so as to form an air reservoir for accumulating the air to be entrapped.

As a second aspect of the present invention, the resin film of the laminated sheet obtained by sticking the resin foam sheet and the resin film is formed with a pattern of recesses adjacent to each other through the partition wall. In a method for producing an embossed sheet in which an embossing roll having a surface that is pressed is rotated to engrave an embossed pattern on the resin film side, the embossing roll is trapped in the recess when the sheet is pressed against the sheet. There is provided an embossed sheet manufacturing method characterized by using an embossing roll having a convex portion formed on a bottom surface of a concave portion so as to form an air reservoir for accumulating air.

Further, as a third invention, there is provided a pipe cover characterized in that the embossed sheet obtained by the manufacturing method of the second invention is formed into a cylindrical shape so that the embossed pattern is located on the outer surface. To be done.

In the method of the present invention, the convex portion formed on the bottom surface of the concave portion forms an air reservoir portion for dispersing and storing the sealing air during engraving of the embossed pattern, and the protruding portion forming the embossed pattern by the sealing air. Functions to control shape change. That is, as shown in FIG. 2, even when the embossing roll 5 is pressed against the surface of the resin film 3 and the opening of the recess 8 in the surface pattern of the embossing roll 5 is closed by the resin film 3, As shown in FIG. 3, which is an enlarged view of the region B, the air trapped is the convex portion 10 formed on the concave bottom surface 8 a of the embossing roll 5.
Are dispersed and accumulated in the air accumulation portion 11 formed by. Since the position where the sealing air, which causes the uneven shape change of the embossed pattern, collects can be controlled by the convex portion formed on the bottom surface of the concave portion, the shape change of the protruding portion due to the sealing air can be controlled. , The non-uniform shape defect of the embossed pattern is suppressed.

[0018]

BEST MODE FOR CARRYING OUT THE INVENTION The surface pattern of a region A in FIG. 15 is shown in FIG.
An embossing roll 5 having a pattern as shown in was prepared. That is, this pattern is such that when the embossing roll 5 is pressed against the sheet, the concavity 8 having a diameter x ₁ and a height x ₂ is formed on the bottom surface 8a of the recess 8 of the embossing roll 5. It seems that an air reservoir is formed to store the sealing air trapped inside. A state in which an embossed sheet is manufactured using the embossing roll 5 having such a surface pattern is shown in FIGS. 2 and 3.

The surface pattern of the embossing roll 5 rotating in the p ₁ direction is pressed against the surface of the resin film 3 overlying the resin foam sheet 1, and the resin foam sheet 1 and the resin film 3 are attached to each other. Wear it to make a laminated sheet. At the same time, as the rotation of the embossing roll 5 progresses, the surface pattern of the embossing roll gradually bites into the sheet, forming a protrusion 6 corresponding to the shape of the concave portion 8 and finally separating from the sheet surface. To go. At the same time that the surface pattern of the embossing roll 5 is pressed against the surface of the resin film 3, the opening of the recess 8 is closed from the surface of the resin film 3 from that time, so that the air existing in the recess 8 is removed. You will be trapped there.

However, in the case of this surface pattern, since the conical convex portion 10 is formed on the concave bottom surface 8a of the embossing roll 5 so as to form the air collecting portion 11 for accumulating the air to be confined, the concave portion is formed. The sealing air 9 trapped inside 8 is dispersed along the convex portion 10 in the air reservoir 11. Therefore, the sealing air 9 confined in the concave portion 8 is not irregularly sealed, and the sealing air 9 is the conical convex portion 1 on the bottom surface 8a of the concave portion.
0 is used to seal the air reservoir 11 that is intentionally formed. That is, it is possible to suppress the non-uniform shape defect of the embossed pattern projections 6 due to the sealing air, which has occurred in the conventional manufacturing method.

In the embossed pattern engraved by using the embossing roll 5 having such a surface pattern, as shown in FIG. 4, the conical convex portion 10 of the concave bottom surface 8a is formed on the top portion 6a of the convex portion. Shape corresponding to, that is, the depth is x
A concave portion having a diameter of x _{1 at 2} is formed as a trace of the convex portion 10 having a conical shape. In the surface pattern of this embossing roll 5,
Since the conical protrusion 10 formed on the bottom surface 8a of the recess has a function of forming the air reservoir 11 for dispersing the sealing air 9 in the recess 8, the higher the height x ₂ of the sealing air is, Irregular retention can be prevented. The height x ₂ may be adjusted as appropriate, but if the height x ₂ is too high, the aesthetic appearance of the embossed pattern will be impaired.
₂ is preferably set to 20% or less of the depth of the recess 8.

In the case of the surface pattern shown in FIG. 1, the convex portion 10 on the bottom surface 8a of the concave portion has a conical shape, but the convex portion 10 may have an arched curved surface as shown in FIG. 6
It may be a part of a spherical surface as shown in Fig. 7, or a pyramid whose bottom surface is the recess bottom surface 8a as shown in Fig. 7, or an intersection of the partition wall portions 7a, 7b and the recess bottom surface 8a as shown in Fig. 8. It may be a pyramid having the apex of the bottom surface of the convex portion on the line.

Further, in the case of the surface pattern shown in FIG. 1, the sectional shape of the partition 7a when viewed in the w direction is rectangular, but the sectional shape of the partition 7a is shown in FIG. 9 (a). The trapezoid 7c may be formed as shown in FIG. 9, the triangle shape may be formed as illustrated in FIG. 9B, or the arch shape may be formed as illustrated in FIG. The surface pattern of the embossed sheet obtained by such a shape is a collection pattern of trapezoidal protrusions, but during engraving of the embossed pattern, from the time when the first partition wall is pressed against the surface of the resin film 3 to the next partition wall. The time interval until the portion starts to be pressed against the surface of the resin film 3 is longer by an amount corresponding to the peripheral ratio of the embossing roll 5 than when the partition wall portion 7a has a rectangular sectional shape, and the wall surface of the recess is Since it has a slope, the space for the sealing air is small, which is preferable.

The shape of the bottom surface 8a of the recess is not limited to the square or the rectangle as shown above. For example, FIG.
In the case of the surface pattern shown by, the concave portion 8 has a triangular shape in plan view, and the convex portion 10 of the concave portion bottom surface 8a is formed in a triangular pyramid shape. When the embossing roll having this surface pattern is rotated, the air in the concave portion 8 is dispersed along the convex triangular pyramid 10, and as a result, as shown in FIG. 11, a clear embossing pattern 6 having a triangular shape in plan view is formed. Carved. Also,
In the case of the surface pattern shown in FIG. 12, the plan view shape of the concave portion 8 is circular, and the convex portion 10 on the bottom surface of the concave portion 8 is formed in a conical shape. When the embossing roll having this surface pattern is rotated, the air in the concave portion 8 is dispersed along the convex spherical surface 10, and as a result, the clear embossing pattern 6 having a circular shape in plan view is engraved as shown in FIG. can do.

In the above embodiment, the case where the resin film is attached to the resin foam sheet and the embossed pattern is engraved is shown. However, the present invention is not limited to this, and a rubber Any plastic sheet can be applied.

The embossed sheet obtained by adhering the resin film to the resin foam sheet obtained in the above-mentioned example is cut in the longitudinal direction of the sheet to obtain a belt-shaped sheet having a predetermined width. This strip-shaped sheet is rolled in the width direction so that the embossed sheet is the outer surface, and the abutted end surfaces are heat-sealed to form a pipe shape to obtain a pipe cover. When a pipe cover is manufactured, the use of an embossed sheet in which a groove having a surface pattern is formed in the longitudinal direction of the pipe cover and in a direction perpendicular to the longitudinal direction suppresses the occurrence of horizontal wrinkles. Further, the effect is greater when the surface-formed grooves formed in the longitudinal direction are shallower than those formed in the direction perpendicular to the longitudinal direction. Further, in the pipe cover of the present invention, a resin film may be laminated on the outer surface of the pipe cover in order to protect the surface or improve the workability of the pipe cover for piping. The embossed sheet constituting the pipe cover of the present invention is clearly marked with the shape of the recess bottom surface 8a which is the adhesive surface between the pipe cover and the resin film. There is an advantage that the property is superior.

[0027]

As is apparent from the above description, according to the method of claims 1 and 2, in the process in which the embossing roll rotates while being pressed against the surface of the sheet, the inside of the concave portion in the surface pattern of the embossing roll is The air is dispersed by the convex portion formed on the bottom surface of the concave portion. Therefore, the sealing air in the recess that is engraving the embossed pattern does not stay irregularly, the defective shape due to the sealing air does not occur, and a clear embossed pattern is engraved. Since this effect is exhibited regardless of the type of the embossed pattern to be engraved, it is not necessary to set complicated conditions according to the type of the embossed pattern to be engraved as in the conventional case. In addition, the pipe cover according to claim 3 which is formed of the embossed sheet according to the method of claims 1 and 2, has a clear embossed pattern engraved on the outer peripheral surface thereof, and has a beautiful appearance. Furthermore, wrinkles that occur when bent are small, and wrinkles are less likely to buckle because wrinkles are not concentrated on a part. Further, it has excellent adhesiveness when a resin film is laminated on the outer peripheral surface of the pipe cover.

[Brief description of drawings]

FIG. 1A is a partial perspective view showing an example of a surface pattern of an embossing roll used in the present invention. (B) It is an AA sectional view of (a). (C) It is the top view seen from B of (a).

FIG. 2 is a cross-sectional view showing a state in which an embossing pattern is engraved with an embossing roll used in the method of the present invention.

FIG. 3 is an enlarged view of a region B in FIG.

FIG. 4 is a cross-sectional view showing an example of the shape of a protrusion having an embossed pattern engraved by the method of the present invention.

FIG. 5 (a) is a partial top view showing an example of the surface pattern of an embossing roll used in the method of the present invention. (B) It is an AA sectional view of (a). (C) It is BB sectional drawing of (a).

FIG. 6 (a) is a partial top view showing an example of the surface pattern of an embossing roll used in the method of the present invention. (B) It is an AA sectional view of (a). (C) It is BB sectional drawing of (a).

FIG. 7 (a) is a partial top view showing an example of the surface pattern of an embossing roll used in the method of the present invention. (B) It is an AA sectional view of (a). (C) It is BB sectional drawing of (a).

FIG. 8 (a) is a partial top view showing an example of the surface pattern of an embossing roll used in the method of the present invention. (B) It is an AA sectional view of (a). (C) It is BB sectional drawing of (a).

FIG. 9A is a partial cross-sectional view showing an example of a cross-sectional shape of partition walls arranged in the rotation direction of the embossing roll. (B) It is a fragmentary sectional view showing another example of sectional shape of a partition. (C) It is a partial sectional view showing another example of sectional shape of a partition.

FIG. 10 (a) is a partial perspective view showing an example of a surface pattern of an embossing roll used in the method of the present invention. (B) It is a top view seen from A of (a).

11 is a partial perspective view showing an embossed pattern engraved with the embossing roll having the surface pattern of FIG.

FIG. 12 (a) is a partial perspective view showing an example of the surface pattern of an embossing roll used in the method of the present invention. (B) It is an AA sectional view of (a).

13 is a partial perspective view showing an embossed pattern engraved with the embossing roll having the surface pattern of FIG.

FIG. 14 is a cross-sectional view showing a state in which an embossed pattern is engraved using a conventional embossing roll.

FIG. 15 is a perspective view showing an example of a conventional embossing roll.

FIG. 16 is a partial perspective view showing a part of the surface pattern of a conventional embossing roll.

FIG. 17 is a partial perspective view showing an embossed pattern engraved with the embossing roll having the surface pattern shown in FIG. 16;

FIG. 18 is a cross-sectional view showing an example of the shape of a protrusion having an embossed pattern engraved by a conventional method.

FIG. 19 is a cross-sectional view showing a state in which an embossing pattern is engraved with a conventional embossing roll.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Resin foam sheet 2a, 2b Heating device 3 Resin film 4 Rubber roll 5 Embossing roll 6 Protrusion 6a in embossed pattern 6a Top of protrusion 6b Edge part of protrusion 6 7 Partition 7a Arranged in the direction of rotation of embossing roll 5 Partition wall 7b Partition walls 7c, 7d, 7e arranged in the width direction of the embossing roll 5 Sectional views showing the sectional shapes of other partition walls 8 Recesses 8a Recess bottom surface 9 Space formed by sealing air 10 Recessed bottom surface Convex part 11 Air retention part

Claims (3)

[Claims] 1. The rubber / plastic sheet is embossed on the rubber / plastic sheet by pressing and rotating an embossing roll having a surface in which concave portions adjacent to each other through a partition wall are formed in a pattern. In a method for manufacturing an embossed sheet for continuously engraving a pattern, a convex portion is formed on the bottom surface of the concave portion so that an air trap portion for accumulating air trapped in the concave portion is formed when the embossing roll is pressed against the sheet. A method for manufacturing an embossed sheet, which comprises using an embossing roll that is formed. 2. An embossing roll having a surface in which concave portions adjacent to each other via a partition wall are formed in a pattern on the resin film of a laminated sheet obtained by adhering a resin foam sheet and a resin film. In the method for producing an embossed sheet in which an embossed pattern is continuously engraved on the resin film side by pressing and rotating, an air pool portion that stores air trapped in the recess when the embossing roll is pressed against the sheet. A method for manufacturing an embossed sheet, which comprises using an embossing roll having a convex portion formed on the bottom surface of the concave portion so that 3. A pipe cover, characterized in that the embossed sheet obtained by the manufacturing method according to claim 2 is formed into a cylindrical shape so that the embossed pattern is located on the outer surface.