MANUFACTURING METHOD FOR EMBOSSING ROLL AND EMBOSSING ROLL

Abstract

Provided are a manufacturing method for an embossing roll which is capable of being manufactured in a wide variety in small quantities and has uneven patterns formed uniformly and precisely without irregularities, and the embossing roll. The manufacturing method for the embossing roll comprises: a step of preparing a cylindrical base material; and a modeling step of modeling embossing onto a surface of the cylindrical base material with a three-dimensional printer based on three-dimensional processing data. It is preferred that the three-dimensional processing data is created by subjecting an embossing roll model to three-dimensional scanning.

Claims

1. A manufacturing method for an embossing roll, the manufacturing method comprising: preparing a cylindrical base material; and modeling embossing onto a surface of the cylindrical base material with a three-dimensional printer based on three-dimensional processing data.

2. A manufacturing method for an embossing roll according to claim 1, wherein the three-dimensional processing data is created by subjecting an embossing roll model to three-dimensional scanning

3. A manufacturing method for an embossing roll according to claim 1, wherein the modeling embossing comprises sintering powder to be sintered laid on the surface of the cylindrical base material.

4. A manufacturing method for an embossing roll according to claim 3, wherein the sintering powder to be sintered is sintered with a laser.

5. A manufacturing method for an embossing roll according to claim 1, wherein the cylindrical base material and the modeling embossing onto the surface of the cylindrical base material are performed with a fully automatic laser plate-making system.

6. An embossing roll, which is manufactured by preparing a cylindrical base material and modeling embossing onto a surface of the cylindrical base material with a three-dimensional printer based on three-dimensional processing data.

7. A manufacturing method for an embossing roll according to claim 2, wherein the modeling embossing comprises sintering powder to be sintered laid on the surface of the cylindrical base material.

8. A manufacturing method for an embossing roll according to claim 7, wherein the sintering powder to be sintered is sintered with a laser.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0024] FIG. 1 is each an explanatory view for schematically illustrating one embodiment of a manufacturing method for an embossing roll according to the present invention. FIG. 1(a) is a schematic relevant part sectional view for illustrating a state in which a cylindrical base material is prepared. FIG. 1(b) is a schematic relevant part sectional view for illustrating a state in which a first layer of uneven patterns is formed on a surface of the cylindrical base material. FIG. 1(c) is a schematic relevant part sectional view for illustrating a state in which a plurality of layers of the uneven patterns are laminated.

[0025] FIG. 2 is an explanatory view for schematically illustrating a modeling step of the manufacturing method for an embossing roll of the present invention.

[0026] FIG. 3 is a schematic view for illustrating an embossing roll manufactured by the manufacturing method for an embossing roll of the present invention.

MODES FOR CARRYING OUT THE INVENTION

[0027] Embodiments of the present invention are described below, but those embodiments are described as examples, and hence it is understood that various modifications may be made thereto without departing from the technical spirit of the present invention. The same members are represented by the same reference symbols.

[0028] As illustrated in FIG. 1(a), first, a cylindrical base material 12 made of a metal or a synthetic resin is prepared. Then, embossing is modeled onto a surface of the cylindrical base material with a three-dimensional printer based on three-dimensional processing data (modeling step).

[0029] The three-dimensional processing data is created by subjecting an embossing roll model to three-dimensional scanning. Further, three-dimensional processing data obtained in advance may also be used.

[0030] Then, as illustrated in FIG. 1(b), a first layer 14a of uneven patterns is formed. In the case of a metal cylindrical base material, the first layer 14a is formed by sintering powder to be sintered laid on the surface of the cylindrical base material. Further, in the case of a synthetic resin cylindrical base material, the first layer 14a is formed by a fused deposition modeling system, a stereo lithography system, an ink-jet system, or the like.

[0031] Then, the formation of the layer illustrated in FIG. 1(b) is repeated to provide a state in which a plurality of layers 14a to 14e are laminated as illustrated in FIG. 1(c). Thus, an embossing roll 18 having fine uneven patterns 16 formed on a surface thereof is manufactured.

[0032] The modeling step may be performed as follows. As illustrated in FIG. 2, a chuck cone (not shown) is inserted into an opening 20 of the cylindrical base material 12, and the modeling step is performed while the cylindrical base material 12 is rotated. Reference symbol 22 denotes a known three-dimensional printer. With this, the modeling step can be performed through use of the known three-dimensional printer 22. Further, it is also possible to obtain a processing unit having a configuration in which the modeling step is performed through use of the known three-dimensional printer 22 while the cylindrical base material 12 is rotated as described above.

[0033] A three-dimensional printer processing unit can be used by being incorporated into a fully automatic laser plate-making system.

[0034] The embossing roll 18 manufactured as described above is illustrated in FIG. 3. In the manufacturing method for the embossing roll 18 of the present invention, it is possible to form the uneven patterns 16 having a size up to about 10 m on one side.

Examples

[0035] The present invention is hereinafter described in more detail with Examples, but it is needless to say that Examples are only illustrative and not intended to be interpreted in a limited way.

Example 1

[0036] A hollow roll made of iron having a circumference of 600 mm, a surface length of 1,100 mm, and a thickness of 10 mm was prepared as a cylindrical base material, and an embossing roll was manufactured through use of NewFX (fully automatic laser plate-making system manufactured by Think Laboratory Co., Ltd.). A three-dimensional printer processing unit of a type of sintering powder to be sintered was incorporated as a processing unit into the fully automatic laser plate-making system. As three-dimensional processing data, data obtained by subjecting an embossing roll model to three-dimensional scanning in advance was used.

[0037] Powder to be sintered (metal powder that corresponds to die steel SKD11 when sintered) laid on a surface of the hollow roll was sintered with a fiber laser to form a layer. Then, the formation of the layer was repeated to laminate a plurality of layers. Thus, an embossing roll having fine uneven patterns formed on a surface thereof was obtained.

Example 2

[0038] A hollow roll made of CFRP having a circumference of 600 mm, a surface length of 1,100 mm, and a thickness of 10 mm was prepared as a cylindrical base material, and an embossing roll was manufactured through use of NewFX (fully automatic laser plate-making system manufactured by Think Laboratory Co., Ltd.). A three-dimensional printer processing unit of a fused deposition modeling system type was incorporated as a processing unit into the fully automatic laser plate-making system. As three-dimensional processing data, data obtained by subjecting an embossing roll model to three-dimensional scanning in advance was used.

[0039] A thermoplastic synthetic resin (ABS resin) was discharged onto a surface of the hollow roll with a printer head to form a layer. Then, the formation of the layer was repeated to laminate a plurality of layers. Thus, an embossing roll having fine uneven patterns formed on a surface thereof was obtained.

REFERENCE SIGNS LIST

[0040] 12: cylindrical base material, 14a to 14e: layer, 16: uneven pattern, 18: embossing roll, 20: opening, 22: three-dimensional printer.