Application of plastic polymer resin material in rotary embossing process and device

Abstract

The invention discloses application of a plastic polymer resin material in a rotary belling process and device, and belongs to the field of application of plastic materials in packaging and printing. The device comprises a mold assembly, a pressure system and a transmission and positioning system, an upper mold is composed of a roller core and a plastic polymer resin and polymer synthetic fiber tow stacking forming layer, and a molding layer is arranged on the surface of a roller body of a lower mold; the pressure system is divided into two parts, namely dynamic adjustment in a debugging stage and constant maintenance in batch production; the invention further provides a device preparation method which comprises the steps of roller core manufacturing, roller body hardening treatment, forming layer coating and pasting, molding and the like, and the coated paper belling method comprises the steps of pretreatment, mold installation and adjustment, feeding and quality detection. The embossing effect of the medium-gram-weight coated paper can be improved, the cost is reduced, the period is shortened, paper damage is reduced, and stable embossing quality is guaranteed.

Description

Technical Field

[0001] This application pertains to the application of plastic materials in packaging and printing, specifically relating to the application of a plastic polymer resin material in rotary embossing and debossing processes and apparatus. Background Technology

[0002] Embossing is a process that uses tools such as molds or rollers to apply pressure to materials, causing localized plastic deformation and forming raised patterns, text, or three-dimensional shapes. Traditional embossing processes often use flat-to-flat or circular-to-flat structures, which have low registration accuracy and low production efficiency. In particular, the instantaneous pressure of circular-to-circular embossing is high, which can easily cause damage to the bearing material.

[0003] A rotary die for embossing typically consists of a lower die and an upper die. The shapes of the lower and upper dies need to be precisely designed and processed according to the specific embossing pattern or text to ensure that the material can accurately form the expected raised shape during the pressing process. For complex embossing shapes, it may be necessary to use a multi-piece combination die or a die structure capable of three-dimensional forming. The die requires high precision.

[0004] Traditional embossing rollers typically consist of basic components such as a roller body, shaft, bearings, and sealing devices. The roller body is usually made of steel through machining, and the roller surface undergoes surface treatment. The advantage of using metal materials for the roller body is that they have high strength, hardness, and wear resistance. However, the processing difficulty and installation requirements are also high, making it difficult to ensure that the pressure applied to the entire roller surface is completely uniform. This leads to inconsistent pressure on the surface of the material being embossed, resulting in differences in embossing effects and affecting the consistency of product quality. When performing discontinuous graphic embossing, a "guillotine" effect can occur at the junction of the upper and lower dies made of metal materials, easily crushing or breaking the pressure-bearing material at the beginning of the graphic. In addition, existing embossing rollers have significant friction and pressure between the roller surface and the material during operation. After prolonged use, the roller surface is prone to wear. Wear of the embossing roller causes changes in the shape and size of the roller surface, affecting the accuracy and quality of embossing. Regular repair or replacement of the embossing roller is required, which increases production costs and equipment maintenance workload.

[0005] Therefore, the material of the embossing roller is one of the key breakthroughs in embossing technology. Embossing rollers made of excellent materials can better adapt to the characteristics of different papers, improve the embossing effect and the service life of the equipment.

[0006] In the existing technology, some technical solutions for new embossing rollers have emerged, such as: embossing rollers based on ceramic coatings, which have high surface hardness, good wear resistance, and excellent impact resistance, but the manufacturing process is complex and costly; embossing rollers based on composite materials, which combine materials with different properties for embossing rollers, using a metal roller as the base and bonding a layer of polymer material or ceramic material to its surface. This composite material embossing roller can utilize both the high strength and rigidity of the metal base and the special properties of the surface coating material; and there are also technical solutions based on thermoplastic elastomers, which use specific processing techniques to make thermoplastic elastomer materials into embossing rollers or coating layers for embossing rollers. The thermoplastic elastomer particles are first heated to a molten state and then injected into a mold to form a sheet-like coating layer with embossed patterns on the surface. This layer is then coated onto the surface of an ordinary embossing roller by means of bonding or hot pressing, making it more adaptable to materials during the embossing process, able to emboss clear patterns on materials of different shapes and textures, while reducing damage to the materials. Summary of the Invention

[0007] To further improve the embossing effect of cigarette packaging paper, especially medium-grammage coated paper, reduce the manufacturing cost and cycle of embossing rollers, and eliminate the problem of paper damage caused by pressure fluctuations and abrupt changes at the ends of discontinuous embossing patterns, this application provides an embossing roller made of a novel composite material, as well as the application process and steps of this embossing roller in the rotary embossing process of specific cigarette packaging paper. By using an embossing roller made of a plastic material, various complex embossing patterns can be produced according to design requirements, and a novel embossing process is provided.

[0008] One of the objectives of this application is to provide a circular pressing and embossing device for preparing plastic polymer resin materials. This device achieves embossing through the coordinated action of two cylindrical mold rollers and a pressure system. The device is characterized by including a mold assembly, a pressure system, and a transmission and positioning system. The mold assembly includes an upper mold 1 and a lower mold 2. The upper mold 1 includes a roller core and a molding layer formed by stacking plastic polymer resin and polymer synthetic fiber bundles on the surface of the roller core. The thickness of the molding layer is 25-30 mm, and the surface hardness is set to Shore hardness of 80°-85°. The lower mold 2 includes a cylindrical roller body and a molding layer on the surface of the roller body. The molding layer is provided with discontinuous raised patterns at equal intervals. The height of the raised patterns is 0.5 mm, and the roller surface accuracy of the raised patterns is ±0.01 mm. The rotating shafts at both ends of the upper mold 1 and the lower mold 2 adopt a symmetrical installation design. The rotating shafts at both ends are respectively fitted onto the wall plates 3 on both sides. A through groove adapted to the diameter of the rotating shaft is opened in the middle of the wall plate 3.

[0009] The pressure system is divided into two parts: a dynamic pressure adjustment system used during the debugging phase of the mold assembly, and a constant pressure maintenance system used during mass production after debugging. The dynamic pressure regulation system is based on a hydraulic or pneumatic pressure regulation unit, including a pressure sensor, a control system, and a pressure regulation mechanism 4. The pressure sensor is used to accurately measure the real-time pressure value between the upper mold 1 and the lower mold 2 during the embossing and debugging stage, and converts the value into a signal and feeds it back to the control system at a certain frequency. The control system is responsible for processing, analyzing, and calculating the signal from the pressure sensor, and issuing control commands to the pressure regulation mechanism 4. It can set pressure parameters and regulation modes to adapt to production processes and material requirements. The pressure regulation mechanism 4 adopts an elastic bearing seat installed in the through groove of the wall panel 3 and a support device connected to it and providing support force, including a hydraulic cylinder, a pneumatic cylinder, or an electric push rod.

[0010] During the mold assembly debugging stage, in order to prevent uneven force between molds from causing mold damage, elastic bearing seats are used to provide buffer when there are fluctuations in the force between molds, avoiding excessive extrusion of the mold and causing damage. During normal batch production, constant pressure needs to be maintained. Rigid bearing seats are used to accommodate the rotation axis of the mold. The rigid bearing seats are installed on the positioning block 5 in the through groove of the wall plate 3, and pressure-applying equipment, including hydraulic cylinders, air cylinders or electric push rods, are installed on the positioning block 5 to apply constant pressure to the upper mold 1.

[0011] The transmission and positioning system includes positioning blocks 5 that are fitted into the through slots of the two side wall panels 3. The positioning blocks 5 are equipped with bearing mounting seats inside, and the rotating shafts are rotatably connected to the positioning blocks 5 through the bearings. The rotating shafts at both ends of the upper mold 1 and the lower mold 2 are respectively installed in the positioning blocks 5 on both sides. The two rotating shafts on the support side are respectively fitted with bearings at their ends and installed in the corresponding positioning blocks 5 through rigid bearing seats. The two rotating shafts on the transmission side pass through the corresponding positioning blocks 5 and are connected to the transmission box 6. The central axes of the two rotating shafts are in the same vertical mounting plane. A screw lifting device 7 is provided between the positioning blocks 5 corresponding to the two rotating shafts on the support side and the transmission side to adjust the position of the upper mold 1 and realize the adjustment of the distance between the upper mold 1 and the lower mold 2.

[0012] The input end of the transmission box 6 is connected to the output shaft of the drive motor, and the output end is connected to the rotating shafts of the upper mold 1 and the lower mold 2 on the transmission side. All of these connections are made using detachable bushings. The rotating shafts of the upper mold 1 and the lower mold 2 are respectively connected to the upper horizontal bevel gear 6-1 and the lower horizontal bevel gear 6-2, which are horizontally aligned and on the same vertical plane within the transmission box 6. Between these two shafts, two sets of bevel gear transmission rods 6-3 are respectively provided and movably connected to the transmission box 6 via a partition. The outer vertical bevel gears 6-4 on the outer sides of the two bevel gear transmission rods 6-3 mesh with the upper horizontal bevel gears 6-1 and 6-2, which are mounted on the rotating shafts of the upper mold 1 and the lower mold 2, respectively. The inner vertical bevel gears 6-5 on the inner side of the bevel gear transmission rods 6-3 simultaneously mesh with… The drive bevel gear 6-6 at the output shaft end of the drive motor meshes; the bevel gear transmission rod 6-3 near the rotation shaft of the upper mold 1 adopts a structure of solid cylinder and hollow bushing, and the connection part is connected by a cross keyway 6-7 with an extendable length; at the same time, a roller 6-8 is respectively set on the inner end face of the bevel gear at both ends of the bevel gear and fits against it. The other end of the roller 6-8 extends out of the outer wall of the transmission box 6 and is movably connected to two movable and positioning sliders 6-9 respectively. The two sliders 6-9 are installed in the track set on the outer wall of the transmission box 6. A screw lifting device 7 is set between them to adjust the distance between them, so as to match the adjustment of the distance between the upper mold 1 and the lower mold 2, without affecting the transmission state between the upper mold 1 and the lower mold 2.

[0013] The lead screw lifting device 7 includes a housing 7-1, a lifting lead screw 7-2, and an input worm gear 7-3.

[0014] The second objective of this application is to provide a method for preparing a circular pressing / convex device using a plastic polymer resin material, characterized by comprising the following steps: ① Following conventional metal processing techniques, a roller core for the upper mold that meets dimensional requirements is made using high-strength alloy materials; ② The lower die 2 rollers are made of wear-resistant tool steel. The surface of the rollers is covered with a hardened plastic layer, and non-continuous raised patterns are set at equal intervals on the plastic layer. ③ Select a hot-melt polymer resin, heat it to a molten state, and then uniformly coat the molten resin onto the roller core surface of the embossing die 1. Then, uniformly lay the polymer synthetic fiber bundles on the adhesive and use rolling or other methods to make the fiber bundles tightly bond to the roller core surface. Repeat the coating and bonding process until the thickness and hardness of the molding layer reach the predetermined parameter standards, and then perform low-temperature curing and surface smoothing. ④ The molding layer of the upper mold 1 is shaped by pressing the upper mold 1 and the lower mold 2 together. The convex pattern with high hardness on the surface of the lower mold 2 roller is used to continuously apply pressure to the molding layer of the upper mold 1. Under the continuous pressure, the soft material of the molding layer of the upper mold 1 begins to undergo plastic deformation and gradually conforms to the convex contour of the lower mold 2 roller.

[0015] In step ④ of the molding process, the hydraulic system in the dynamic pressure regulation system uses a servo motor to precisely control the pressing force and speed between the upper mold 1 and the lower mold 2, so that the pressure is evenly distributed throughout the contact area and the pressure is gradually increased. At each pressure level, a pressure holding program is initiated to maintain the molding layer under constant pressure for 3-5 minutes, which causes the material molecular structure in the molding layer of the upper mold 1 to rearrange and solidify.

[0016] During the molding process, the circulating water cooling system works simultaneously, quickly removing the heat generated by friction through the spiral cooling pipes inside the mold to prevent the material from overheating locally. After cooling and solidification, the hydraulic device slowly releases the pressure, and the upper mold 1 and lower mold 2 separate. The surface of the molding layer of the upper mold 1 completely replicates the raised pattern of the roller of the lower mold 2.

[0017] The hardening treatment mentioned in step ② refers to spraying a layer of tungsten carbide coating material with high hardness and high wear resistance onto the roller surface through a thermal spraying process, and then performing mechanical processing to process the sprayed roller surface to the design dimensions and surface precision.

[0018] The third objective of this application is to provide a method for embossing discontinuous patterns on coated paper using the aforementioned embossing device, characterized by comprising the following steps: ① Pretreatment of coated paper Real-time monitoring of paper moisture content, using drying or humidification methods, ensures that the moisture content of coated paper (100-150g) to be processed is stable at 5%, improving the paper's plastic deformation ability and reducing the risk of embossing brittleness. ② Installation and adjustment of the embossing die First, install the lower mold 2, then install the upper mold 1. The axes of the upper mold 1 and the lower mold 2 coincide in the vertical direction. The end of the rotating shaft on the support side is fitted with a bearing and installed in the corresponding positioning block 5. The rotating shaft on the transmission side passes through the positioning block 5. A screw lifting device 7 is installed between the positioning blocks 5 on the support side and the transmission side respectively. At the same time, the axial positioning step of the lower mold 2 is tightly fitted with the end face of the positioning block 5 on both side wall plates 3 to fix the mold and perform preliminary coaxiality calibration. The radial runout is required to be ≤0.03mm. The upper mold 1 is fixed by the positioning step, and a test pad is placed between the upper mold 1 and the lower mold 2 to initially adjust the distance between the two rollers. Make initial phase marks at the ends of the upper mold 1 and the lower mold 2, and ensure the pattern alignment by adjusting the gear phase; The center distance between the upper die 1 and the lower die 2 is adjusted by manually adjusting the screw lifting device 7. Each adjustment is ≤0.02mm. A trial pressing is performed to ensure that the embossing depth meets the requirements. The pressure application device is controlled to apply a pressure of 10-15Mpa to the upper die 1. Then, the pressure distribution between the dies is monitored in real time by pressure sensors distributed on the die surface to control the pressure fluctuation of the die for one cycle within ±3% of the applied pressure. Connect the drive-side rotating shafts of the upper mold 1 and lower mold 2 that pass through the positioning block 5 to the transmission box 6, and then adjust the screw lifting device 7 between the outer wall sliders 6-9 of the transmission box 6 in sync with the adjustment of the distance between the upper mold 1 and lower mold 2. ③ The coated paper roll or sheet is fed into the embossing area through an automatic feeding mechanism; with the help of corresponding dynamic correction technology, the deviation of the coated paper feed is controlled within ±0.5mm; ④ Quality Inspection The embossing depth of the embossed coated paper is detected by using existing 3D scanning or other technologies to detect the average depth and roughness of the embossed graphics on the coated paper. The tensile strength and tear resistance of the coated paper after embossing should be monitored online in real time or periodically. The parameters of these two indicators should decrease by less than or equal to 10% after embossing compared to before embossing. If the decrease exceeds this percentage, the pressure applied to the upper die 1 by the pressure-applying equipment should be adjusted. Beneficial effects

[0019] This application uses a molding layer formed by stacking plastic polymer resin and polymer synthetic fiber bundles to make the upper mold, which, together with the non-continuous embossed patterns set at equal intervals on the surface of the lower mold, can achieve clear embossing on medium-weight coated paper, ensuring the accuracy and consistency of embossing; the upper mold molding layer has a certain degree of hardness and plasticity, and the surface of the lower mold roller is hardened and sprayed with tungsten carbide coating to improve wear resistance and precision.

[0020] This application reduces the manufacturing cost and cycle time of the embossing roller, making it more economical compared to traditional metal materials.

[0021] This application eliminates paper damage caused by pressure fluctuations and abrupt changes at the ends of discontinuous embossing patterns. The plasticity of the upper die forming layer allows it to adapt better during pressing, reducing damage.

[0022] The pressure system features dynamic adjustment and constant pressure maintenance. During the commissioning phase, the dynamic pressure adjustment system, based on a hydraulic or pneumatic pressure regulating unit, precisely controls the pressure through pressure sensors, a control system, and a pressure regulating mechanism. During mass production, the constant pressure maintenance system uses rigid bearing seats and pressure application equipment to maintain pressure, minimizing pressure fluctuations during mold rotation and ensuring stable embossing quality. The transmission and positioning system, through a symmetrical installation design and a screw lifting device, achieves precise adjustment of the distance between the upper and lower molds, while the transmission box structure ensures that the transmission state is unaffected during distance adjustment. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the circular pressing and convex pressing device.

[0024] Figure 2 This is a front sectional view of the transmission box.

[0025] Figure 3 This is a diagram of the internal structure of the transmission box.

[0026] Figure 4 This is a schematic diagram of the operation of the bevel gear transmission rod.

[0027] Figure 5 This is a schematic diagram of the bevel gear transmission rod.

[0028] Figure 6 This is a schematic diagram of the structure of the lead screw lifting device.

[0029] In the figure, the components are: upper mold 1, lower mold 2, wall plate 3, pressure adjustment mechanism 4, positioning block 5, transmission box 6, upper horizontal bevel gear 6-1, lower horizontal bevel gear 6-2, bevel gear transmission rod 6-3, outer vertical bevel gear 6-4, inner vertical bevel gear 6-5, driving bevel gear 6-6, cross keyway 6-7, roller 6-8, slider 6-9, and lead screw lifting device 7. Detailed Implementation

[0030] refer to Figure 1-6 This document provides a detailed description of the application of plastic polymer resin materials in the circular die-cutting and embossing process and equipment.

[0031] First, let's look at the structure of the embossing device.

[0032] The circular pressing and embossing device involved in this embodiment mainly consists of a mold assembly, a pressure system, and a transmission and positioning system, with the specific structure as follows: The mold assembly includes an upper mold 1 and a lower mold 2; The upper mold 1 includes a roller core and a molding layer formed by laminating a plastic polymer resin and polymer synthetic fiber bundles on the surface of the roller core. The molding layer has a thickness of 25-30 mm and a surface hardness of 80°-85° on the Shore A scale. The lower mold 2 consists of a cylindrical roller body and a molding layer on the surface of the roller body; the molding layer is provided with discontinuous raised patterns at equal intervals, the height of the raised patterns is 0.5mm, and the roller surface accuracy is ±0.01mm.

[0033] The installation method of the two is as follows: the rotating shafts at both ends of the upper mold 1 and the lower mold 2 adopt a symmetrical installation design. The rotating shafts at both ends are respectively fitted onto the wall panels 3 on both sides. A through groove adapted to the diameter of the rotating shaft is opened in the middle of the wall panel 3.

[0034] Pressure systems include dynamic pressure regulation systems and constant pressure maintenance systems; The dynamic pressure regulation system is used during the mold assembly debugging stage. Based on a hydraulic or pneumatic pressure regulation unit, it includes a pressure sensor, a control system, and a pressure regulation mechanism 4. The pressure sensor measures the real-time pressure value between the upper mold 1 and the lower mold 2 and feeds it back to the control system. After processing the signal, the control system issues a command to the pressure regulation mechanism 4. The pressure regulation mechanism 4 adopts an elastic bearing seat installed in the through groove of the wall plate 3 and a support device, such as a hydraulic cylinder, pneumatic cylinder, or electric push rod.

[0035] The constant pressure maintaining system is used for mass production after debugging. It uses a rigid bearing seat to accommodate the rotating shaft of the mold. The rigid bearing seat is installed on the positioning block 5 in the through groove of the wall plate 3. The positioning block 5 is equipped with a pressure applying device, such as a hydraulic cylinder, air cylinder or electric push rod, to apply constant pressure to the upper mold 1.

[0036] The transmission and positioning system includes positioning blocks 5 that are fitted into the through slots of the two side wall panels 3. The positioning blocks 5 have bearing mounting seats inside, and the rotating shaft is rotatably connected to the positioning blocks 5 through the bearings.

[0037] The rotating shafts at both ends of the upper mold 1 and the lower mold 2 are respectively installed in the positioning blocks 5 on both sides. The two rotating shafts on the support side are respectively fitted with bearings and installed in the corresponding positioning blocks 5 through rigid bearing seats. The two rotating shafts on the transmission side pass through the positioning blocks 5 on the corresponding side and are connected to the transmission box 6. The central axes of the two rotating shafts are in the same vertical mounting plane.

[0038] A screw lifting device 7 is provided between the positioning blocks 5 corresponding to the two rotating shafts on the support side and the transmission side, which is used to adjust the position of the upper mold 1 and realize the adjustment of the distance between the upper mold 1 and the lower mold 2.

[0039] The input end of the transmission box 6 is connected to the output shaft of the drive motor, and the output end is connected to the rotating shafts of the upper mold 1 and lower mold 2 on the transmission side. The connection is made using a separable bushing. The rotating shafts of the upper mold 1 and lower mold 2 are respectively connected to the upper horizontal bevel gear 6-1 and the lower horizontal bevel gear 6-2 inside the transmission box 6. Two sets of bevel gear transmission rods 6-3 are set between them and are movably connected to the transmission box 6 through a partition. The outer vertical bevel gear 6-4 on the outer side of the two bevel gear transmission rods 6-3 meshes with the upper horizontal bevel gear 6-1 and the lower horizontal bevel gear 6-2 respectively, while the inner vertical bevel gear 6-5 on the inner side meshes with the driving bevel gear 6-6 at the end of the output shaft of the drive motor. The bevel gear transmission rod 6-3, located near the rotating shaft of the upper mold 1, employs a structure combining a solid cylinder and a hollow bushing. The connection point uses an extendable cross keyway 6-7. A roller 6-8 is installed on the inner end face of each of the two bevel gears. The other end of the roller 6-8 extends out of the outer wall of the transmission box 6 and is movably connected to two movable and positioning sliders 6-9. The two sliders 6-9 are mounted within a track on the outer wall of the transmission box 6. A screw lifting device 7 is installed between them to adjust the distance, coordinating with the adjustment of the distance between the upper mold 1 and the lower mold 2 without affecting the transmission state. The screw lifting device 7 includes a housing 7-1, a lifting screw 7-2, and an input worm gear 7-3.

[0040] Secondly, the method for preparing the embossing device includes the following steps: ① Making the upper mold roller core: Using high-strength alloy materials, the upper mold roller core that meets the size requirements is made according to conventional metal processing technology.

[0041] ② Fabrication of the lower die 2 rollers: The lower die 2 rollers are made of wear-resistant tool steel. The surface of the rollers is covered with a hardened molding layer, and discontinuous raised patterns are set at equal intervals on the molding layer. The hardening treatment is achieved by spraying a layer of high-hardness, high-wear-resistant tungsten carbide coating material onto the surface of the rollers using a thermal spraying process, followed by machining to achieve the designed dimensions and surface precision of the sprayed rollers.

[0042] ③ Preparation of the upper mold 1 molding layer: Select a hot-melt polymer resin, heat it to a molten state, and uniformly coat the molten resin onto the roller core surface of the upper mold 1. Then, uniformly lay polymer synthetic fiber bundles on the adhesive, and use rolling or other methods to tightly bond the fiber bundles to the roller core surface. Repeat the coating and bonding process until the thickness and hardness of the molding layer reach the predetermined parameter standards, and then perform low-temperature curing and surface smoothing.

[0043] ④ Shaping the upper mold 1 forming layer: The upper mold 1 and the lower mold 2 are pressed together. The convex pattern with higher hardness on the surface of the lower mold 2 roller is used to continuously apply pressure to the upper mold 1 forming layer. Under continuous pressure, the soft material of the upper mold 1 forming layer undergoes plastic deformation and gradually conforms to the convex contour of the lower mold 2 roller.

[0044] During the molding process, the hydraulic system within the dynamic pressure regulation system precisely controls the pressing force and speed between the upper mold 1 and the lower mold 2 via a servo motor, ensuring that the pressure is evenly distributed throughout the contact area and gradually increases. At each pressure level, a pressure-holding program is initiated, maintaining the molded layer under constant pressure for 3-5 minutes, prompting the material molecular structure in the upper mold 1's molded layer to rearrange and solidify. Simultaneously, a circulating water cooling system operates concurrently, rapidly removing heat generated by friction through spiral cooling pipes inside the mold to prevent localized overheating of the material. After cooling and solidification, the hydraulic device slowly releases the pressure, causing the upper mold 1 and lower mold 2 to separate, with the surface of the upper mold 1's molded layer completely replicating the raised pattern of the lower mold 2's rollers. Finally, the method for embossing discontinuous patterns on coated paper using the above-mentioned device includes the following steps: ① Pretreatment of coated paper Real-time monitoring of paper moisture content, using drying or humidification methods, ensures that the moisture content of 100-150g coated paper is stable at 5%, improving the paper's plastic deformation ability and reducing the risk of embossing brittleness.

[0045] ② Installation and adjustment of the embossing die a. First, install the lower mold 2, then install the upper mold 1, ensuring that the axes of the upper mold 1 and the lower mold 2 coincide in the vertical direction. A bearing is fitted onto the end of the rotating shaft on the support side and installed in the corresponding positioning block 5. The rotating shaft on the transmission side passes through the positioning block 5.

[0046] b. A screw lifting device 7 is installed between the positioning blocks 5 on the support side and the transmission side respectively. At the same time, the axial positioning step of the lower mold 2 is tightly fitted with the end face of the positioning block 5 on both side wall plates 3 to fix the mold and perform preliminary coaxiality calibration, requiring radial runout ≤0.03mm. The upper mold 1 is fixed by the positioning step, and a test pad is placed between the upper mold 1 and the lower mold 2 to initially adjust the distance between the two rollers.

[0047] c. Make initial phase marks at the ends of the upper mold 1 and the lower mold 2, and ensure the pattern alignment by adjusting the gear phase.

[0048] d. Adjust the center distance between the upper die 1 and the lower die 2 by manually adjusting the screw lifting device 7. Each adjustment should be ≤0.02mm. Perform a trial pressing to ensure that the embossing depth meets the requirements. Control the pressing equipment to apply a pressure of 10-15Mpa to the upper die 1. Then, monitor the pressure distribution between the dies in real time through pressure sensors distributed on the die surface to control the pressure fluctuation of the die during one rotation cycle within ±3% of the applied pressure.

[0049] e. Connect the drive-side rotating shafts of the upper mold 1 and lower mold 2 that pass through the positioning block 5 to the transmission box 6, and then adjust the screw lifting device 7 between the outer wall sliders 6-9 of the transmission box 6 to synchronize with the adjustment of the distance between the upper mold 1 and lower mold 2.

[0050] ③ Coated paper feeding The coated paper roll or sheet is fed into the embossing area via an automatic feeding mechanism. With the help of corresponding dynamic correction technology, the deviation of the coated paper feed is controlled within ±0.5mm.

[0051] ④ Quality Inspection a. Inspect the embossing depth of the coated paper after embossing. Use 3D scanning or other technologies to detect the average depth and roughness of the embossed graphics on the coated paper.

[0052] b. Detect the tensile strength and tear resistance of the coated paper after embossing in real time or periodically. If these two indicators decrease by more than 10% after embossing compared to before embossing, adjust the pressure applied to the upper die 1 by the pressure applying equipment.

[0053] In this embodiment, the upper mold is made of a molding layer formed by stacking plastic polymer resin and polymer synthetic fiber bundles. Combined with the non-continuous embossed patterns evenly spaced on the surface of the lower mold, clear embossing can be achieved on medium-weight coated paper, ensuring accuracy and consistency. The upper mold molding layer possesses both hardness and plasticity, while the surface of the lower mold roller is hardened and coated with tungsten carbide, improving wear resistance and precision. Simultaneously, this reduces the manufacturing cost and cycle time of the embossing roller, eliminating paper damage caused by pressure fluctuations and abrupt changes at the ends of the non-continuous embossing patterns. The dynamic adjustment and constant holding function of the pressure system minimizes pressure fluctuations during mold rotation, ensuring stable embossing quality. The transmission and positioning system, through a symmetrical installation design and a screw lifting device, achieves precise adjustment of the distance between the upper and lower molds, and the transmission box structure ensures that the transmission state is not affected during distance adjustment.

Claims

1. A round-to-round embossing device for a plastic polymer resin material, which is realized by the cooperation of two cylindrical mold rollers and a pressure system, characterized in that, The mould assembly, the pressure system, the transmission and positioning system; The mould assembly comprises an upper mould (1) and a lower mould (2), wherein the upper mould (1) comprises a roller core, and a plastic high-molecular resin and a high-molecular synthetic fiber tows layer are laminated on the surface of the roller core to form a forming layer with a thickness of 25-30 mm and a surface hardness of 80-85 degrees of Shore; the lower mould (2) comprises a cylindrical roller body, and a plastic layer is arranged on the surface of the roller body, and a non-continuous convex pattern is arranged on the plastic layer at equal intervals, the height of the convex pattern is 0.5 mm, and the roller surface precision of the convex pattern is ±0.01 mm; the rotating shafts at the two ends of the upper mould (1) and the lower mould (2) are symmetrically installed, and the rotating shafts at the two ends are sleeved on the wall plates (3) on the two sides, and a through slot with a diameter matched with the rotating shaft is formed in the middle of the wall plate (3); The pressure system is divided into two parts, namely a dynamic pressure adjusting system used by the mould assembly in the debugging stage and a constant pressure maintaining system used in batch production after debugging; The transmission and positioning system comprises positioning blocks (5) clamped in the through slots of the wall plates (3) on the two sides, the positioning blocks (5) are provided with bearing mounting seats inside, the rotating shafts are rotatably connected with the positioning blocks (5) through bearings, the rotating shafts at the two ends of the upper mould (1) and the lower mould (2) are respectively installed in the positioning blocks (5) on the two sides, wherein the two rotating shafts on the support side are respectively sleeved with bearings and installed in the corresponding positioning blocks (5) through rigid bearing seats, and the two rotating shafts on the transmission side are connected with a transmission box (6) after penetrating through the corresponding positioning blocks (5), and the center axes of the two rotating shafts are in the same vertical installation plane; the corresponding positioning blocks (5) between the rotating shafts on the support side and the rotating shafts on the transmission side are provided with screw rod lifting devices (7) for adjusting the position of the upper mould (1) and realizing the adjustment of the distance between the upper mould (1) and the lower mould (2).

2. A cylinder-on-cylinder male die for the production of a plastic polymer resin material as defined in claim 1, wherein The input end of the transmission box (6) is connected with the output shaft of the driving motor, and the output end is connected with the rotating shaft of the transmission side of the upper die (1) and the lower die (2), and the connecting parts are connected by separable shaft sleeves; wherein the rotating shafts of the upper die (1) and the lower die (2) are connected with the upper horizontal bevel gear (6-1) and the lower horizontal bevel gear (6-2) which are arranged horizontally and in the same vertical plane in the transmission box (6), and two groups of bevel gear transmission rods (6-3) are arranged between the two, and are movably connected with the transmission box (6) through a partition plate; the outer vertical bevel gears (6-4) on the outer sides of the two bevel gear transmission rods (6-3) are engaged with the upper horizontal bevel gear (6-1) and the lower horizontal bevel gear (6-2) installed on the rotating shafts of the upper die (1) and the lower die (2) respectively, and the inner vertical bevel gears (6-5) on the inner sides of the bevel gear transmission rods (6-3) are engaged with the driving bevel gears (6-6) at the end of the output shaft of the driving motor at the same time; the bevel gear transmission rod (6-3) close to the rotating shaft of the upper die (1) is in a structure matched with a solid cylinder and a hollow shaft sleeve, and the connecting part is connected by a cross key groove (6-7) with extendable length; at the same time, a roller (6-8) is arranged on the inner side end face of the bevel gears at both ends of the bevel gear transmission rod (6-3) respectively and is attached thereto, the other end of the roller (6-8) extends out of the outer wall of the transmission box (6) and is movably connected with two movable and positioning sliding blocks (6-9) respectively, the two sliding blocks (6-9) are installed in the tracks arranged on the outer wall of the transmission box (6), a screw rod lifting device (7) is arranged between the two to adjust the distance between them, and the adjustment of the distance between the upper die (1) and the lower die (2) is matched.

3. The cylinder-on-cylinder male die set prepared from a plastic polymer resin material according to claim 1, wherein, The dynamic pressure regulating system is based on a hydraulic or pneumatic pressure regulating unit, which includes a pressure sensor, a control system and a pressure regulating mechanism (4); the pressure sensor is used to accurately measure the real-time pressure value between the upper die (1) and the lower die (2) in the pressure transfer debugging stage, and convert the value into a signal and then feedback to the control system at a certain frequency; the control system is responsible for processing, analyzing and operating the signal of the pressure sensor, and issuing control instructions to the pressure regulating mechanism (4), which can set the pressure parameters and adjustment mode to adapt to the production process and material requirements; the pressure regulating mechanism (4) adopts an elastic bearing seat installed in the through groove of the wall plate (3) and a supporting device connected therewith and providing supporting force, including a hydraulic cylinder, a pneumatic cylinder or an electric push rod.

4. The cylinder-on-cylinder male die set prepared from a plastic polymer resin material according to claim 1, wherein, The constant pressure maintaining system adopts a rigid bearing seat to accommodate the rotating shaft of the mold, the rigid bearing seat is installed on the positioning block (5) in the through groove of the wall plate (3), and a pressure applying device including a hydraulic cylinder, a pneumatic cylinder or an electric push rod is installed on the positioning block (5) to apply a constant pressure to the upper die (1).

5. The cylinder-on-cylinder male die set prepared from a plastic polymer resin material according to any one of claims 1 to 4, characterized in that, The screw rod lifting device (7) includes a shell (7-1), a lifting screw rod (7-2) and an input worm (7-3).

6. A method for manufacturing a round-to-round embossing device using a plastic polymer resin material, characterized by, The method comprises the following steps: ① According to the conventional metal processing technology, the upper die (1) roller core meeting the size requirements is made of high-strength alloy material; ②The lower die (2) roller body is made of wear-resistant tool steel, the roller body surface is provided with a plastic layer subjected to hardening treatment, and a non-continuous convex pattern is arranged on the plastic layer at equal intervals; ③A hot melt polymer resin is selected, heated to a molten state, then uniformly coated on the roller core surface of the embossing upper die (1), then the polymer synthetic fiber tows are uniformly laid on the adhesive, and the fiber tows are tightly bonded with the roller core surface through rolling or other ways; the coating and pasting process is repeated until the thickness and hardness of the forming layer reach the predetermined parameter standard, then low-temperature curing and surface smoothing are performed; ④The forming layer of the upper die (1) is shaped, that is, the upper die (1) and the lower die (2) are pressed together, the convex pattern on the roller body surface of the lower die (2) continuously applies pressure to the forming layer of the upper die (1); under the continuous pressure, the soft material of the forming layer of the upper die (1) begins to plastically deform and gradually fits the convex profile of the roller body of the lower die (2).

7. The method of claim 6, wherein the method is characterized by the steps of: In the shaping process of step ④, the hydraulic system in the dynamic pressure adjusting system precisely controls the pressing force and speed between the upper die (1) and the lower die (2) through a servo motor, so that the pressure is uniformly distributed in the entire contact area and gradually increases; the pressure starts the pressure maintaining program at each level to allow the forming layer to maintain a constant pressure for 3-5 minutes, so as to promote the rearrangement and setting of the material molecular structure in the forming layer of the upper die (1); In addition, during the shaping process, the circulating water cooling system works synchronously, quickly removes the heat generated by friction through the spiral cooling pipeline inside the mold, and prevents the local temperature of the material from being too high; after cooling and setting, the hydraulic device slowly releases the pressure, and the upper die (1) and the lower die (2) are separated, and the surface of the forming layer of the upper die (1) completely reproduces the convex pattern of the roller body of the lower die (2).

8. The method of claim 6, wherein the plastic resin material is a thermoplastic resin material. The hardening treatment in step ② is to spray a layer of tungsten carbide coating material with high hardness and wear resistance on the roller surface by thermal spraying process, and then mechanically process the sprayed roller surface to the designed size and surface precision.

9. A method for embossing a non-continuous pattern on a copper plate paper using a plastic polymer resin material embossing device, characterized in that, The method comprises the following steps: ① Pretreatment of copper plate paper Real-time monitoring of paper moisture content, using drying or humidifying means to ensure that the moisture content of the copper plate paper to be processed is stable at 5%, improving the plastic deformation ability of the paper and reducing the risk of embossing brittle fracture; ② Installation and adjustment of embossing mold First, install the lower die (2), then install the upper die (1), and the axes of the upper die (1) and the lower die (2) are coincident in the vertical direction; the end of the rotating shaft of the support side is sleeved with a bearing and installed in the corresponding positioning block (5), and the rotating shaft of the transmission side penetrates the positioning block (5); A screw lifting device (7) is arranged between the positioning blocks (5) of the support side and the transmission side, and the axial positioning step of the lower die (2) is tightly fitted with the end face of the positioning block (5) on the two side walls (3), so as to fix the mold and preliminarily calibrate the coaxiality, with the requirement that the radial circular runout is ≤0.03mm; the upper die (1) is fixed through the positioning step, and a test pad is placed between the upper die (1) and the lower die (2) to preliminarily adjust the distance between the two rollers; Mark the initial phase on the end of the upper die (1) and the lower die (2), and ensure the alignment of the lines through gear phase adjustment; Adjust the center distance of the upper die (1) and the lower die (2) through manual adjustment of the lead screw lifting device (7), with each adjustment amount ≤0.02mm, and perform trial pressing to ensure that the embossing depth meets the requirements; control the pressing equipment to apply a pressure of 10-15Mpa to the upper die (1), and then monitor the pressure distribution between the dies in real time through the pressure sensors distributed on the surface of the dies, so that the pressure fluctuation of the dies during one cycle of rotation is controlled within ±3% of the applied pressure; Connect the transmission side rotating shafts of the upper die (1) and the lower die (2) passing through the positioning block (5) with the transmission box (6), and then adjust the lead screw lifting device (7) between the outer wall sliding blocks (6-9) of the transmission box (6) to synchronize the distance adjustment between the upper die (1) and the lower die (2); ③Put the copper plate paper roll or sheet into the embossing area through the automatic feeding mechanism; Control the material running deviation of the copper plate paper within ±0.5mm through corresponding dynamic correction technology; ④Quality detection Detect the embossing depth of the copper plate paper after embossing, and detect the average depth and roughness of the embossed text on the copper plate paper through existing 3D scanning or other technologies; Detect the tensile strength and tear resistance of the copper plate paper after embossing in real time or periodically, and the parameters of the two indicators after embossing should be less than or equal to 10% compared with those before embossing.

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