JP2004148329A - Processing roll manufacturing method, and processing roll - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a processing roll manufacturing method for rapidly engraving a fine and novel design pattern on a processing roll at low cost. <P>SOLUTION: A processing pattern is created by computer graphics, and electric signals is obtained from the processing pattern. The electric signals can also be obtained by scanning an original pattern and working the obtained signals on a computer graphics screen. The substantially flat outer circumferential surface of the roll at least the outer circumferential surface layer of which is formed of silicone rubber is engraved by irradiating the surface with laser beams on the basis of the electric signals. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
BACKGROUND OF THE INVENTION
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a squeezing roll and a manufacturing method thereof, and more specifically, a squeezing roll for processing for processing a car interior covering material, furniture covering material, synthetic leather, wallpaper, steel plate / plywood film, and the like Regarding the method.
[0002]
[Prior art]
As a squeezing roll that is used most frequently as a squeezing roll that does not show a discontinuous (pattern-to-pattern joint) pattern, an electroforming method can be cited. First, take a reversal mold with silicone rubber from a manuscript such as a genuine leather, and plate copper or iron on the silicone rubber mold. Therefore, although it is said to be an electroforming method, the silicone rubber is peeled off and a metal roll called a small mill roll having a diameter of about 50 mm and a length of about 100 mm is rolled many times on the surface with the drawn pattern to transfer the drawn pattern. Assuming that this mill roll is A, the mill roll A is reversely engraved on another mill roll B so that the same drawn pattern as the original is obtained when the mill roll A is inverted to the final thermoplastic sheet. This mill roll B is called a mother roll. This mother roll is pressed repeatedly and rolled while sprinkling strong acid on the surface of the large size machine. When the mother roll finishes rolling, it rolls again to the adjacent position. In the meantime, it is devised so as not to stand out, but a discontinuity (joint) generally called a mill trace can be confirmed. When the thermoplastic sheet is squeezed and pressed under heat and pressure using the obtained squeezing roll for the large machine, the uneven structure of the document is transferred to the surface of the thermoplastic sheet.
[0003]
However, since this method is reprinted to hard metal many times, even if the document has a fine surface uneven structure, it becomes a relatively simple and regular expression of uneven structure, and it is dense. Is damaged. For example, a metal squeezing roll manufactured by such a method is not suitable for stamping a fine structure copied from the surface of natural leather having fine pores and fine wrinkles. In addition, the mother roll wears with repeated use, and the uneven structure becomes shallow, and the first and second squeeze rolls for the large machine become a shallow pattern in order, which is far from the desired design. .
Although there are other methods for producing a metal squeezing roll, it is generally difficult to express a fine pattern. The only method called carving is a relatively good reproducibility of the uneven structure of the original, but it requires a large skin, and the unnecessary part of the skin is taken into the roll.
[0004]
As described above, it is difficult to reproduce a fine uneven structure on a squeeze roll using a metal roll, so a method of engraving the uneven structure on the metal roll surface with a silicone rubber layer is proposed. Has been. In one method, a two-component curable silicone rubber is first poured onto an uneven surface such as a main skin, and the silicone rubber is peeled off after curing to obtain a silicone rubber mold. The silicone rubber mold is squeezed onto a thermoplastic sheet with a press machine or the like. This squeezed thermoplastic sheet is formed into a cylindrical shape by abutting both edges located opposite to each other. Even in this case, the discontinuity of the butt portion cannot be avoided, but as a known method, the region of the edge portion of the thermoplastic sheet that is abutted with each other is once again drawn by the resin matrix under heating and pressure. As a result, there is a method in which a male mold with inconspicuous discontinuities is formed.
[0005]
Next, a two-component curable silicone rubber is poured into or coated on the cylindrical male mold. This layer is cured to form a female mold. The silicone rubber female mold is released from the thermoplastic sheet male mold and bonded to the outer peripheral surface of the squeezing roll made of metal with the uneven structure surface facing outward. Thus, a squeezing roll having a silicone rubber surface that does not have a butt edge is obtained. A smooth thermoplastic sheet can be drawn and pressed under heat and pressure by a drawing roll manufactured based on this known method. The surface structure of the squeezed thermoplastic sheet is continuous and does not have or become inconspicuous at the butt edge discontinuities. However, this method has a problem that it takes a lot of time because it goes through many steps.
In addition, this method requires two weeks or more to create a single squeezing roll, requires craftsmanship, and requires a large apparatus, which requires a large amount of processing costs including wages. Furthermore, there is a drawback that the connection may be conspicuous. If the surface of the silicone rubber is directly carved, the part to be engraved will be deformed if it is a blade or a drill, and it will escape when pressed, making precise engraving difficult.
[0006]
Therefore, with recent technological advancement, there is a drawing roll manufacturing method using a laser beam. (For example, see Patent Document 1))
This drawing roll manufacturing method is a method for obtaining a drawing roll by processing the surface of the silicone rubber while controlling the laser beam with a control signal obtained by optically or mechanically detecting the pattern original surface. The greatest advantage of this method is that it is produced directly without any intermediate steps.
[0007]
However, since the above-described squeezing roll manufacturing method using a laser beam mainly copies natural leather, fabrics, painted walls, and the like that exist in reality, 1) it is difficult to correct defects. 2 There are problems such as that it is difficult to process the connecting portion, 3) it is impossible to create a novel pattern different from the actual one, and 4) it takes much time to save the design manuscript.
[0008]
[Patent Document 1] JP-A-8-224678
[Problems to be solved by the invention]
The object of the present invention is to squeeze a novel design pattern other than those actually existing such as natural leather, woven fabric, and painted wall, or a pattern obtained by arbitrarily processing an original pattern such as natural leather, woven fabric, painted wall, etc. It is an object of the present invention to provide a squeezing roll manufacturing method capable of quickly and inexpensively engraving a surface and a squeezing roll obtained by this manufacturing method. Specifically, an object of the present invention is to provide a squeezing roll for forming the above-described pattern on a squeezing roll made of silicone rubber with an outer peripheral surface layer for continuously fine squeezing the surface of the thermoplastic sheet. It is in providing the manufacturing method and the squeezing roll obtained by this manufacturing method.
[0010]
[Means for Solving the Problems]
In order to solve the above-described problems, the manufacturing method of the squeezing roll of the present invention is as follows.
(1) A drawing pattern is created by computer graphics. Based on an electrical signal obtained from the drawing pattern, at least the outer peripheral surface layer is made of silicone rubber, and a laser beam is applied to the substantially smooth roll outer peripheral surface. A method for producing a squeezing roll, wherein the surface of the outer periphery of the roll is engraved by irradiation
(2) After scanning from the original pattern and processing the pattern on a computer graphics screen, based on the obtained electrical signal, at least the outer peripheral surface layer is made of silicone rubber, and the roll outer peripheral surface is substantially smooth. A method for producing a squeezing roll, characterized in that a laser beam is irradiated to engrave the outer peripheral surface of the roll.
In order to solve the above problems, the squeezing roll of the present invention is
(3) A squeezing roll produced by the method according to (1) or (2).
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of the present invention will be described in detail.
The first drawing and pressing roll manufacturing method of the present invention is characterized in that a drawing pattern is first created by computer graphics. In this case, the squeezing pattern can create any novel pattern without depending on a pattern that actually exists, for example, natural leather, fabric, painted wall, or the like.
In computer graphics, for example, an object shape and a basic shape model are expressed numerically, and a data structured database is constructed in the computer. Then, the geometrical transformation and the relation between figures are processed by the mutual positional relation of lines, surfaces, solids, etc., and graphic calculation processing such as rotation and movement. Also, processing for object expression that determines an attribute such as a surface pattern that expresses the texture of the object is performed. By these treatments, for example, a novel pattern different from that existing in nature such as natural leather can be created.
[0012]
Next, the obtained pattern is subjected to image processing, and the image can be decomposed into pixels by an image input / output device to obtain pixel data of a digitized bit pattern. Based on the electrical signal obtained from the image data, at least the outer peripheral surface layer is made of silicone rubber, and the roll outer peripheral surface can be engraved by irradiating a substantially smooth roll outer peripheral surface with a laser beam.
[0013]
The second squeezing roll manufacturing method of the present invention scans an original pattern, such as natural leather, and performs image processing for processing the pattern on a computer graphics screen. The pixel data of the pit pattern is obtained by being decomposed into pixels by the apparatus. Based on the electrical signal obtained from the image data, at least the outer peripheral surface layer is made of silicone rubber, and a substantially smooth roll outer peripheral surface is irradiated with a laser beam to engrave the roll outer peripheral surface. In this method, it is possible to perform processing such as removing defects or the like of the original pattern by processing the original pattern while using the original pattern as a base.
[0014]
As a roll irradiated with a laser beam, a roll formed by coating a silicone rubber on the surface of a metal roll is usually used. In this roll, at least the outer peripheral surface layer is made of silicone rubber, and the outer peripheral surface is substantially smooth.
[0015]
In the first squeezing roll manufacturing method and the second squeezing roll manufacturing method, the pixel data of the digitized bit pattern separated into pixels by the image input / output device has a rough surface structure and a fine surface structure. Image data representing a rough surface structure and image data representing a fine surface structure, and are irradiated based on electrical signals obtained from the image data representing the rough surface structure. It is desirable to irradiate the outer peripheral surface of a roll formed by coating silicone rubber with a second laser beam that is irradiated based on an electrical signal obtained from one laser beam and image data representing a fine surface structure.
[0016]
In this case, a long wavelength laser beam is used as the first laser beam applied to the outer peripheral surface of the roll. The long wavelength laser beam here means a laser beam having a longer wavelength than that of the second laser beam, but it is preferable to use a wavelength of 700 to 12000 nm, more preferably 10600 nm. Examples of the first laser beam include a laser beam emitted from a carbon dioxide laser, a CO laser, an iodine laser, a YAG laser, etc., but a laser beam emitted from the carbon dioxide laser can have a high output, This is particularly preferable because it is economically advantageous.
[0017]
The first laser beam preferably has an oscillation output of 0.01 to 5 kW, more preferably 0.02 to 2 kW.
[0018]
The first laser beam is a method in which the surface of the silicone rubber is burned and engraved with a laser beam when a long-wavelength laser beam such as a carbon dioxide laser is irradiated. However, with a long-wavelength laser beam, for example, at a wavelength of 10600 nm, the diameter of the focused light is about 100 μm even if the lens is narrowed down. Therefore, a large rough surface structure can be engraved by the first laser beam.
[0019]
The second laser beam is a laser beam having a shorter wavelength than that of the first laser beam, and preferably 100 to 1200 nm, more preferably 200 to 600 nm. Examples of the laser that irradiates the second laser beam include a wavelength conversion YAG laser, a KrF excimer laser, an ArF excimer laser, and the like, but the laser beam irradiated from the wavelength conversion YAG laser has a balance between the spot diameter and the oscillation output. It is particularly preferable from the viewpoint of good points.
[0020]
Further, the oscillation output of the second laser beam is preferably 0.001 to 20 W, and more preferably 0.5 to 10 W.
[0021]
As the second laser beam, for example, an ultraviolet laser beam having a wavelength of 266 nm obtained by converting the wavelength of a laser beam having a wavelength of 1064 nm output from a YAG laser can be used, and output from a KrF excimer laser. A laser beam with a wavelength of 247 nm can be used. A laser beam with a wavelength of 192 nm oscillated from an ArF excimer laser can also be used.
When these laser beams are used, a spot diameter of about 15 μm can be obtained. Therefore, by irradiating the surface of the squeezing roll on which the rough surface structure is engraved with the first laser beam, the rough surface structure is further reduced in pores. The surface of the roll can be engraved, and the entire surface of the roll can be engraved with a novel pattern that has both a rough surface structure and a fine structure. A squeezing roll engraved with a pattern having a structure pattern can be manufactured.
[0022]
In general, when engraving a squeeze roll based on an electrical signal corresponding to an original pattern such as natural leather, the discontinuous part of the butted part is also a joint where the opposite edges of the original pattern are butted together. It cannot be avoided or it takes a great deal of skill and effort to repair the joints.
In the present invention, since 1) an image in which an aperture pattern is created is created by computer graphics, it is possible to create a design pattern that does not originally have a joint portion, and 2) scanning from the original pattern to obtain computer graphics Since an image of the aperture pattern obtained by processing the pattern on the screen is created, the connecting portion can be processed on computer graphics, so that the processing of the connecting portion is extremely easy.
[0023]
In the present invention, when the laser beam is irradiated on the outer peripheral surface of the roll, the laser beam may be directed toward the outer peripheral surface of the roll, and the laser beam irradiation mechanism and the roll may be moved relative to each other. It is desirable to scan the beam in the axial direction of the roll so that the laser beam can be irradiated to the outer peripheral surface of the roll while controlling the spot diameter, output, irradiation position, processing speed and the like.
[0024]
Further, the present invention can engrave a novel design pattern on the outer circumferential surface of the roll, or can produce a squeezing roll having a pattern arbitrarily processed into natural leather or other design designs. In addition, this squeezing roll can be obtained in a short time without going through complicated intermediate processing steps as in the prior art and without requiring craftsmanship skill.
[0025]
The obtained squeezing roll is used as a processing roll for processing a vehicle interior skin material, furniture skin material, synthetic leather, wallpaper, steel plate / plywood film, and the like. For example, after the thermoplastic sheet is softened by heating, the squeezing roll is pressed against the thermoplastic sheet and squeezed and the pattern formed on the roll surface is continuously transferred to the thermoplastic sheet.
[0026]
Design manuscripts (innovative design patterns, natural leather, and other patterns that are arbitrarily processed into design designs) can be stored on optical and electrical magnetic media such as MO and CD, and computer graphics can be easily used at any time. An image can be reproduced on the surface, and at least the outer peripheral surface layer is made of silicone rubber based on the electrical signal obtained from the image data, and the roll outer peripheral surface is irradiated by irradiating a substantially smooth roll outer peripheral surface with a laser beam. Can be sculpted.
[0027]
【Example】
Examples of the present invention will be described below, but the present invention is not limited to these examples.
Example 1
A silicone rubber roll in which a silicone rubber having a thickness of 5 mm was coated on the surface of a metal roll made of iron having a diameter of 250 mm was manufactured. The shaft core portion of the silicone rubber roll was rotatably supported, and the outer circumferential surface of the roll was sequentially irradiated with a laser beam while scanning in the axial direction of the roll toward the surface of the silicone rubber roll. The laser beam at this time is a wavelength using a carbon dioxide laser based on the electrical signal obtained from the diaphragm pattern created by computer graphics and processed in the vertical and horizontal joints. Using a first laser beam of 10600 nm, the outer peripheral surface of the roll was irradiated with a control signal so as to correspond to the rough surface structure.
Next, the outer peripheral surface of the roll engraved with a rough surface structure was irradiated with a laser beam on the outer peripheral surface of the roll while controlling the spot diameter of the laser beam having a wavelength of 266 nm that was wavelength-converted using a YAG laser.
As a result, a silicone rubber roll having a novel surface structure having a fine structure on a rough surface structure was produced. At this time, the time for engraving the outer peripheral surface of the silicone rubber roll was about 20 hours.
Using this silicone rubber roll, a thermoplastic sheet having a surface structure corresponding to the surface structure of the silicone rubber roll is formed on the thermoplastic sheet as a result of being squeezed onto a thermoplastic sheet made of a heat-softened olefinic thermoplastic resin composition. I was able to get it.
[0028]
Example 2
A silicone rubber roll in which a silicone rubber having a thickness of 5 mm was coated on the surface of a metal roll made of iron having a diameter of 250 mm was manufactured. The shaft core portion of the silicone rubber roll was rotatably supported, and the outer circumferential surface of the roll was sequentially irradiated with a laser beam while scanning in the axial direction of the roll toward the surface of the silicone rubber roll. At this time, the laser beam scans the surface structure of natural leather, processes patterns on the computer graphics screen for scratch correction processing, joint processing, etc., and then produces carbon dioxide gas based on the electrical signals obtained. Using a first laser beam having a wavelength of 10600 nm, the surface of the roll was irradiated by controlling the spot diameter, output, irradiation position, processing speed, etc. with a control signal so as to correspond to the rough surface structure of natural leather.
Next, the outer peripheral surface of the roll engraved with the rough surface structure of natural leather was irradiated with a laser beam on the outer peripheral surface of the roll while controlling the spot diameter of the laser beam having a wavelength of 266 nm that was converted using a YAG laser.
As a result, a silicone rubber roll having a surface structure in which a fine structure was further combined on a rough surface structure and a defect portion of natural leather was removed was produced. At this time, the time for engraving the outer peripheral surface of the silicone rubber roll was about 20 hours.
Using this silicone rubber roll, a thermoplastic sheet having a surface structure corresponding to the surface structure of the silicone rubber roll on the thermoplastic sheet as a result of being squeezed into a thermoplastic sheet composed of a heat-softened vinyl chloride thermoplastic resin composition Could get.
[0029]
Example 3
A silicone rubber roll in which a silicone rubber having a thickness of 6 mm was coated on the surface of a metal roll made of iron having a diameter of 250 mm was manufactured. The shaft core portion of the silicone rubber roll was rotatably supported, and the outer circumferential surface of the roll was sequentially irradiated with a laser beam while scanning in the axial direction of the roll toward the surface of the silicone rubber roll. The electrical signal which controlled the laser beam at this time was created as follows. First, the designer created a texture based on a square symbol pattern. Next, this one repeating pattern was spread over the entire area of 20 cm × 20 cm (breeding plate process). This was enlarged 2.0 times in the vertical direction and 1.2 times in the horizontal direction. Thereafter, the depth of the portion between the yarns of the fabric is set to 1600 μm at the deepest part, the depth of the twist (twist) of the warp is 200 μm at the deepest part, and the depth of the weft of the weft is The depth was 100 μm. The matte-type satin-pattern drawing pattern (drawing depth is 300 μm at the maximum), which is created separately, is overlaid on the entire fabric-patterning pattern obtained in this way, and finally the matte processing is performed by performing the longitudinal and lateral joining processing. A pattern for the type of texture drawing was obtained. This aperture pattern was converted into an electrical signal and sent to the laser beam irradiation apparatus side to control the spot diameter, output, irradiation position, processing speed, and the like.
The laser beam irradiation conditions were a carbon dioxide gas laser with a wavelength of 10600 nm, an output of 1.0 kW, and a processing speed of 1000 mm / second.
As a result, it was possible to produce a silicone rubber roll having a novel surface structure that has not been seen in the past. At this time, the time for engraving the outer peripheral surface of the silicone rubber roll was about 5 hours.
Using this silicone rubber roll, a thermoplastic sheet having a surface structure corresponding to the surface structure of the silicone rubber roll is formed on the thermoplastic sheet as a result of being squeezed onto a thermoplastic sheet made of a heat-softened olefinic thermoplastic resin composition. I was able to get it.
[0030]
【The invention's effect】
As described above, according to the present invention, the outer peripheral surface layer for continuously finely drawing the surface of the thermoplastic sheet can easily and inexpensively produce a silicone rubber drawing roll. In the invention, a novel design pattern can be engraved on the roll surface, and in the second invention, a pattern obtained by arbitrarily processing an original pattern such as natural leather or a pattern from which defects of the original pattern are removed is engraved on the roll surface. Can do.

Claims (4)

A drawing pattern is created by computer graphics. Based on an electrical signal obtained from the drawing pattern, at least the outer peripheral surface layer is made of silicone rubber, and a substantially smooth roll outer peripheral surface is irradiated with a laser beam. A method for producing a squeeze roll, wherein the outer peripheral surface of the roll is engraved. After scanning from the original pattern and processing the pattern on a computer graphics screen, based on the obtained electrical signal, at least the outer peripheral surface layer is made of silicone rubber, and the laser is applied to the substantially smooth outer peripheral surface of the roll. A method for producing a squeezing roll, characterized by engraving the outer peripheral surface of the roll by irradiating a beam. A squeezing roll made by the method of claim 1. A squeeze roll produced by the method of claim 2.