JPS6363373B2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention is an embossing roll (also called an engraving roll or a wrinkling roll) that applies uneven patterns such as wrinkle patterns to the surface of a resin sheet (including leather etc.). This invention relates to a manufacturing method for

The first one shows an outline of an example of an embosser.
Reference numeral 1 denotes a roll of resin sheet (thermoplastic) to be subjected to embossing treatment, which is set in an unwinding machine and is fed out to a heating drum 2 at a predetermined constant speed. The heating drum 2 is driven to rotate in the direction of the arrow, and is heated to a predetermined temperature by introducing steam into the drum. The sheet 1 is conveyed in close contact with substantially the upper half circumference of the drum, and is heated and softened by the heat of the drum and the heat of the external heater 3 during the conveyance process. Next, by passing between a parallel pair of mold rolls 4 that are rotationally driven in the arrow direction and a pressure roll 5 such as a roll, the uneven pattern on the surface of the mold roll is continuously formed on the sheet surface on the mold roll 4 side by roll pressure. A corresponding uneven pattern is formed by embossing. The sheet that has passed between the pair of rolls 4 and 5 is then successively passed through a plurality of cooling rolls 6 in contact with each other, subjected to cooling and hardening treatment, and then sequentially wound up by a winding machine.

There is also a method in which the sheet, which is still in a high-temperature softened state immediately after being rolled in a calender, is sent between a direct mold roll 4 and a pressure roll 5 to undergo embossing treatment.

By the way, in the above-mentioned embosser that embosses the sheet by the roll pressure of the sheet sandwiched between the mold roll 4 and the pressure roll 5, the roll pressure is not good whether it is small or large. If this is not done and the roll pressure is large, the thickness of the sheet will be compressed, resulting in uneven thickness, or internal stress will occur within the sheet thickness, causing the sheet to deteriorate immediately after it passes the rollers, or after being exposed to a high temperature atmosphere. When softening occurs, the embossed pattern may become distorted or disappear.
In order to obtain a good embossing sheet that is sharp and has virtually no internal stress, the roll should be such that the flesh on the surface of the soft sheet 1 is naturally pushed into the engraved pattern recesses on the surface of the mold roll 4 in just the right amount. It needs to be done with pressure.

However, the adjustment range of the appropriate roll pressure is narrow, requiring skill and delicate operation, and the adjustment roll pressure must be maintained and managed with great care.

The mold roll 4 is generally a durable metal roll, and the mold roll 4 is generally manufactured by manufacturing a mill for engraving the metal roll, and using that mill to re-engrav the metal roll surface. Large-scale metalworking equipment requires long lead times and is expensive, which greatly affects product prices. There are carvings made using the etching method, but there are limits to the depth and pattern of the carving.

The present invention has been proposed in view of the above, and it is possible to stably and easily continuously produce a clear and good embossing sheet with substantially no internal stress by relatively rough roll pressure management. Another object of the present invention is to provide a method for manufacturing an embosser mold roll that can be manufactured easily and inexpensively.

First, the structure of a mold roll according to the method of the present invention and an embosser using the same will be explained. That is, the second
As illustrated in FIG.
A drum-shaped (or cylindrical) rigid base 41 made of metal with openings formed therein; b A desired uneven pattern 4 on the surface, which is joined to the outer peripheral surface of the base 41 and rotates integrally with the base without shifting;
4, a continuous microporous porous metallic fleshy uneven pattern layer 43 having c. An air suction duct 45 is provided to bring the porous texture of the layer into a vacuum suction state through the small holes 42 of the base body 41 for each surface area 1 of the uneven pattern layer 43 of the area.

In the illustrated example, 46 is a drum-shaped base 41
The fixed pipe shafts 47, 47, which are the central axis of rotation of the drum-shaped base 41, are bearings interposed between the center bearing holes of the left and right end plates 41 ₁ , 41 ₁ and the shaft 46,
The base body 41 is rotatably supported on the fixed shaft 46 via bearings 47, 47, and power is transmitted to a boss ₄₁₂ provided at the center of the outer surface of one end plate ₄₁₁ to maintain a predetermined constant speed. Rotationally driven.

The air absorption duct 45 built into the base body 41 has a fan-shaped cross section, and is connected to the left and right end plates 41 ₁ , 4 of the drum-shaped base body 41 .
1 A hollow body with approximately the same length as the inner surface dimension of ₁ ,
The constricted portion 45 ₁ of the hollow body having a fan-shaped cross section is fixed to and supported by the pipe shaft 46 by welding or the like, and the arcuate body surface 45 ₂ on the opposite side to the constricted portion 45 ₁ is the base 41 The inner space of the pipe shaft 46 and the inner space of the duct 45 are communicated through a plurality of small holes ₄₆₁ formed along the length of the pipe shaft wall. A large number of relatively large-diameter holes 45 ₃ are formed in the arcuate body surface 45 ₂ . The embosser roll is assembled by adjusting and fixing the shaft 46 so that the arcuate body surface ₄₅₂ of the duct 45 faces toward the pressure roll 5.

In the above configuration, the pipe shaft 46 is connected to the vacuum pump P.
When the air in the shaft 46 is continuously sucked, the inside of the duct 45 becomes negative pressure, and the outside air in the area 1 of the surface facing the pressure roll 5 of the mold roll 4 is absorbed by the porous flesh of the uneven pattern layer 43 in that area → Small hole 42 in base 1
→A suction state occurs through the hole 45 ₃ of the duct arc body surface 45 ₂ . And the pressure roll 5 of this mold roll 4
The vacuum suction state of the opposing surface area 1 is maintained continuously even when the mold roll 4 is driven to rotate because the arcuate body surface 45 ₂ of the duct 45 always faces toward the pressure roll 5 .

In order to improve the vacuum suction efficiency, the arcuate body surface 45 ₂ of _the duct 45 is designed to be as close to the inner surface of the base 41 as possible, or The base body 41 is rotated by pasting a smooth and slippery rubber plate or the like and bringing the arcuate body surface 45 ₂ into contact with the inner surface of the base body 41, or the arcuate body surface 4
It is possible to take measures such as attaching a rubber packing strip ₄₅₄ that contacts the inner surface of _the base body 41 around the arcuate body surface ₄₅₂ to improve the airtightness of the gap between the arcuate body surface 452 and the inner surface of the base body 41.

During rotation of the base body ₄₁ , the holes ₄₂ on the base body 41 side always pass through the holes ₄₅₃ of the circular arc body surface 452 in an average manner, so that the vacuum suction state of the area 1 surface of the mold roll 4 is uniform in each part. A large number of holes with relatively large diameters are formed so that the material is held in place. The arcuate body surface 45 ₂ may be omitted and the duct may be formed with a large opening in that portion.

48, 48 are base bodies 41 for cooling the mold roll 4;
The cooling air introduction pipe is installed by inserting it into the hole drilled in the left and right end plates 41 ₁ , 41 ₁ , and the cooling air sending source (not shown) is the flexible tube 48 ₁ ,
48 ₁ , rotary joints 48 ₂ , 48 ₂ so that cooling air can be continuously introduced into the interior of the base body 41 without any trouble regardless of whether the base body 41 is rotated. The introduced cooling air flows through the small holes 42 in each part of the base 41 other than the vacuum suction area 1, and the engraved pattern layer 4.
It passes through the porous flesh of No. 4 to the outside of the mold roll and cools the mold roll.

Embossing on the sheet is carried out by driving the mold roll 4 and the pressure roll 5 in a rotating state, putting the vacuum pump P connected to the pipe shaft 46 into operation, and introducing cooling air into the interior of the base 41. In , the sheet 1 which has been softened or the sheet 1 which is in a high temperature softened state immediately after being rolled in a calender
is introduced and passed through the mold roll 4 and the pressure roll 5 while following the vacuum suction area 1 of the mold roll 4, and then transferred to the cooling roll 6 section.

Then, during the conveyance process of the introduced sheet 1 along the vacuum suction area 1 of the mold roll 4, the meat on the surface layer of the sheet 1 is properly absorbed into the concave and convex pattern recesses on the surface of the mold roll by the vacuum suction force of the mold roll 4 side. They naturally enter into a state of close contact. The sheet is subjected to appropriate roll pressure by passing between the rolls 4 and 5, and then passes through the vacuum suction area 1 of the mold roll 4 to separate the sheet 1 from the surface of the mold roll 4, so that the surface of the sheet is embossed. is produced continuously.

In this case, the uneven pattern on one surface of the sheet is mainly created by vacuum forming the surface layer of the sheet using the vacuum function of the mold roll 4, and is secondary to the sheet sandwiching and pressing roll pressure of the rolls 4 and 5, using the conventional roll pressure. Unlike the case of embossing with a single embossing method, the importance of roll pressure is reduced. That is, the roll pressure need only be controlled to an arbitrary, low level pressure that does not crush the sheet 1, and the pressure by the pressure roller 5 may be removed in some cases.

That is, as mentioned above, since embossing on one surface of the sheet is mainly performed by vacuum forming the surface layer of the sheet using the vacuum function of the mold roll 4, it is easy to produce a good embossing sheet that is clear and has virtually no internal stress. Continuous and stable manufacturing is possible with proper process control.

In addition, since the concave-convex pattern layer 43 of the mold roll 4 is made of continuous microporous porous metal, the vacuum suction area 1 surface of the mold roll 4 is uniformly vacuumed in each part, so that the sheet surface is in a good condition in each part of the mold roll area 1 surface. The texture of the surface of the mold roll is porous, but the texture is fine and dense, so there is no porous texture on the sheet surface, and the texture of the embossing sheet is smooth. Therefore, a good embossing sheet with better definition can be obtained than the conventional embossing sheet using only roll pressure.

The uneven pattern layer 43 is made of metal, and the base 41
Since it is made of metal, it is durable and has good cooling efficiency, so it is effective and suitable for use as a mold roll for an embosser.

FIG. 4 shows a modification in which the pressure roll 5 is arranged above the mold roll 4, and the mold roll 4
Air suction duct 4 with pipe shaft 46 inside
A hollow watertight duct 49 having a sector-shaped cross section similar to that of the air suction duct 45 is fixed and held on the pipe shaft 46 on the opposite side from the air suction duct 45, and cooling water is introduced into the duct 49 through the pipe ₄₉₁ and discharged from the pipe ₄₉₂ . By doing so, the mold roll 4 is cooled by water cooling. In this case, the arcuate outer surface 49 facing the inner surface of the base 41 of the cooling water introduction duct 45
_For example, a flexible woven fabric or felt 49 ₄ made of stainless steel or other metal fibers with good thermal conductivity is attached to the inner surface of the rotating base 41 so that it is always kept in contact with the inner surface of the rotating base 41 with little resistance, thereby increasing cooling efficiency. It is allowed to do so.

The present invention provides a mold roll 4 utilized as described above.
The invention relates to a rational manufacturing method, and the embodiment shown in FIGS. 5a to 5c will be described below.

That is, as shown in FIG. 5a, a surface unevenness pattern of leather, leather, cloth, etc. is formed on the inner peripheral surface of a cylindrical model 10 such as a wooden mold having an inner diameter D that is approximately the same as the outer diameter of the mold roll to be manufactured. Flexible sheet material (actual sheet material) 1
1. Or pasting and pasting a template sheet material made of heat-resistant paper or the like with a desired uneven pattern formed by a method such as pressing,
The entire inner circumference of the cylindrical model with the mold sheet material 11 pasted thereon is thermally sprayed with metal such as zinc, aluminum, copper, etc. to a predetermined thickness d. This metal sprayed layer 43 becomes the porous textured uneven pattern layer 43 of the mold roll 4, and the temperature of the sprayed metal, spraying speed, spraying angle, spraying distance, etc. are adjusted so that it becomes a dense porous fleshy layer with continuous microporosity. Adjust it appropriately. The thickness d of the thermally sprayed layer 43 is set to an appropriate thickness such that the uneven pattern of the mold sheet material 11 is covered and the entire thermally sprayed layer 43 sufficiently maintains its shape as a cylindrical body. If necessary, the sprayed layer is formed by embedding reinforcing members such as wire mesh within the thickness of the sprayed layer.

The diameter of the mold roll 4 to be manufactured is relatively small and the length dimension is relatively long, so the cylindrical model 10 such as a wooden mold becomes elongated, making it difficult or difficult to paste the mold sheet 11 and metal spraying on the entire inner surface of the model. It may be impossible.

Figures 5b and 5c show an embodiment of a method for manufacturing such a mold roll. The slender cylindrical model 10 is configured into a plurality of segmented models 10 ₁ to 10 _o cut into short rings.

First, the first divided model 10 ₁ and the second divided model 10 ₂ on the left end or right end side of the divided model group 10 ₁ to 10 _o are connected together (12), and the connected divided models 10 ₁ and 10 ₂ are One end side of a long flexible sheet material 11 in the longitudinal direction of a cylinder having a desired uneven pattern on the inner peripheral surface is pasted (FIG. 5C), and a first divided model of the pasted sheet material is prepared. A metal sprayed layer is formed on a surface corresponding to the inner peripheral portion of ₁₀₁ . Next, the third divided model 10 ₃ is integrally connected to the second divided model 10 ₂ through the mold sheet material 11 in its interior, and the divided model 1
After pasting and processing the mold sheet material 11 on the inner peripheral surface of the second divided model 10 ₂ , the mold sheet material 11 is pasted on the inner peripheral surface of the second divided model 10 ₂ , and metal is applied to the inner peripheral surface of the first divided model 10 ₁ in series with the sprayed layer on the side. By forming a thermal spray layer and repeating the same operation for the remaining divided models, a single cylindrical model is obtained in which the inner circumferential surface of the entire required length is successively treated with metal thermal spraying via the mold sheet material pasting layer 11. Get 10.

Next, a drum (or cylinder) 41 which can be made of metal as a base is inserted into the cylindrical model 10 whose inner peripheral surface has been sprayed with metal 43 as described above, and the metal sprayed layer 4 is inserted.
3 and join together. Before inserting the drum 41, the inner circumferential surface of the metal sprayed layer 43 is mechanically polished or otherwise smoothed, if necessary.

Next, the outer cylindrical model 10 is destroyed and the mold sheet 11 is also removed.

The vacuum suction duct etc. are assembled to the drum 41 using the cylindrical model 10 with metal spraying 43 on the inner peripheral surface.
This can be done before or after insertion.

Through the above process, an elongated mold roll 4 with a small diameter can be easily obtained.

In other words, by using actual materials such as leather or cloth or paper patterns and using metal spraying, even items with complex uneven patterns do not require large-scale metal processing equipment, and the lead time is short, simple, and inexpensive. There are great effects that can be produced.

Incidentally, a large number of continuous microporous porous metal engraved pattern layer cylinders 43 with various uneven patterns that fit into the base drum 41 are manufactured, and these cylinders are used by being inserted into and removed from the drum 41. By doing so, the mold roll cost can be further reduced.

For the mold sheet material to be pasted on the inner surface of the cylindrical model, choose a design with as few indistinct seams as possible in the cross-sectional direction of the cylinder, and paste it so that it forms an endless pattern.

[Brief explanation of drawings]

Figure 1 is a schematic configuration diagram of an example of an embosser;
The figure is a cross-sectional view illustrating the structure of one embodiment of the mold roll according to the manufacturing method of the present invention and an example of its use, FIG. 3 is a longitudinal cross-sectional view of the same, and FIG. 4 is a cross-section of another example of the use of the mold roll 5a is an explanatory diagram of the manufacturing procedure for a mold roll, and FIGS. 5b and 5c are explanatory diagrams of the manufacturing procedure for an elongated mold roll. 1 is a sheet material, 2 is a heating drum, 3 is an external heater, 4 is a mold roll, 5 is a pressure roll, and 6 is a cooling roll.

Claims (1)

[Claims] 1. A flexible sheet material 11 having a desired uneven pattern is attached to the entire inner peripheral surface of a cylindrical model 10 having an inner diameter D that is approximately the same as the outer diameter of the mold roll 4 to be manufactured. A continuous microporous porous metal layer is applied to the inner peripheral surface of the flexible sheet material 11 by metal spraying means, and the outer peripheral surface thereof has an uneven pattern that follows the uneven pattern of the mold sheet material 11. After forming a cylindrical layer 43 and inserting a base drum or cylinder 41 having a large number of ventilation holes 42 through the entire circumference into the cylindrical layer 43 and joining the two 43 and 41 together, the outside A method for manufacturing an embosser mold roll, which comprises removing a cylindrical model 10 and a mold sheet material 11. 2 The cylindrical model 10 having an inner diameter D that is approximately the same as the outer diameter of the mold roll 4 to be manufactured is divided into a plurality of short round-cut models 10 ₁ to 10 _o , and the left end of the segmented model group 10 ₁ to 10 _o Alternatively, the first divided model 10 ₁ and the second divided model 10 ₂ on the right end side are connected together 12, and a long flexible piece with a width equal to the inner circumference length of the connected divided models 10 ₁ and 10 ₂ is formed. Flexible sheet material 1 that is made into a sheet and has a desired uneven pattern on its inner surface
After rolling one end of 1 with its uneven pattern surface inside and inserting and fitting into the above-mentioned divided models 10 ₁ and _{10 2} and pasting, A continuous microporous porous layer is formed on the inner surface of the mold sheet by metal spraying, and then the third divided model 10 ₃ is passed through the inner space by rolling the mold sheet material 11 to form the second divided model 10 ₂ . After connecting them together and pasting the mold sheet 11 on the inner peripheral surface of the divided model 10 ₃ , the inner peripheral surface of the mold sheet material 11 stuck on the inner peripheral surface of the second divided model 10 ₂ is attached. By forming a series of metal sprayed layers with the metal sprayed layer on the first divided model 10 ₁ side, and repeating the same operation for the other divided models 10 ₄ to 10 _o , a series of uneven patterns of the overall required length are formed. A base cylinder 41 formed with a layered cylindrical layer 43 and provided with a large number of small ventilation holes on the entire circumference.
is inserted into the above-mentioned thermal sprayed cylindrical layer 43 to join both 43 and 41 together, and then the outer cylindrical model 10 and the mold sheet material 11 are removed. manufacturing method.