Elastic decorative roller and method for manufacturing the same

Abstract

This invention belongs to the field of decorative roller technology and discloses an elastic decorative roller, comprising a core, an elastic buffer layer and a decorative surface layer sequentially covered on the outside of the core. The core is a rigid structure, and the elastic buffer layer is a composite elastic material layer made of polyurethane elastomer, nitrile rubber and modified calcium carbonate mixed in a certain proportion. The three-layer structure of the core, elastic buffer layer and decorative surface layer, with the elastic buffer layer being a composite of polyurethane elastomer, nitrile rubber and modified calcium carbonate, achieves a precise match between elasticity and hardness, tightly adhering to irregular substrates and preventing roller deformation from affecting imprinting accuracy, while also improving wear resistance and durability. The decorative surface layer uses a composite formula of silicone elastomer and wear-resistant agent to improve surface wear resistance and high-temperature resistance, and color powder enables personalized decoration. The two are integrally molded, the decorative texture requires no post-processing, has strong adhesion, is not easy to fall off, and extends the service life of the roller.

Description

Technical Field

[0001] This invention belongs to the field of decorative roller technology, specifically an elastic decorative roller and its preparation method. Background Technology

[0002] Decorative rollers are core components in surface decoration processing. They imprint desired decorative patterns onto the substrate surface through the patterns and textures on the roller surface, and are widely used in industries such as architectural decoration, furniture manufacturing, and textile printing and dyeing.

[0003] Currently, the elastic layer of existing elastic decorative rollers is mostly made of a single rubber material, which makes it difficult to balance hardness and elasticity. Either the elasticity is too strong, causing excessive roller deformation and affecting the accuracy of the pattern, or the hardness is too high, making it impossible to achieve a good bonding effect. At the same time, decorative textures are mostly set on the surface of the elastic layer through post-carving or pasting, resulting in weak adhesion between the texture and the elastic layer. After long-term use, the texture is prone to wear and peeling, leading to a shortened roller life. In addition, the manufacturing process of existing elastic decorative rollers is complex, mostly using segmented molding and secondary bonding, which is cumbersome and has low production efficiency. Therefore, improvements are needed. Summary of the Invention

[0004] The purpose of this invention is to provide an elastic decorative roller and its preparation method to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an elastic decorative roller, comprising a core, wherein an elastic buffer layer and a decorative surface layer are sequentially covered on the outer side of the core, the core being a rigid structure, the elastic buffer layer being a composite elastic material layer made of polyurethane elastomer, nitrile rubber and modified calcium carbonate mixed in proportion, the decorative surface layer and the elastic buffer layer being integrally formed, the surface of the decorative surface layer being provided with an integrally formed decorative texture, the decorative surface layer being made of silicone elastomer, wear-resistant agent and color powder mixed in proportion, the decorative texture being a raised pattern with a pattern depth of 0.3~0.8mm and a pattern spacing of 0.5~2.0mm.

[0006] Preferably, the core is made of 45 steel or aluminum alloy, and the surface of the core is provided with a sandblasted rough layer with a roughness of Ra1.2~Ra2.0μm.

[0007] Preferably, the two ends of the core are fixedly connected to mounting shafts, which are coaxially arranged with the core, and the coaxiality error does not exceed 0.02mm.

[0008] Preferably, the thickness of the elastic buffer layer is 3~8mm, its Shore hardness is 35~55HA, and the mass ratio of the polyurethane elastomer, nitrile rubber and modified calcium carbonate is 60~70:20~25:5~15.

[0009] Preferably, the thickness of the decorative surface layer is 0.8~2.0mm, its Shore hardness is 50~70HA, the mass ratio of the silicone elastomer, wear-resistant agent and color powder is 85~90:5~8:2~5, and the wear-resistant agent is one of nano alumina or polytetrafluoroethylene micro powder.

[0010] A method for preparing an elastic decorative roller, comprising the following specific steps: Step 1: Core pretreatment: The core blank is machined to the preset size, then sandblasted, cleaned and dried for later use. Step 2: Preparation of elastic buffer layer material: Weigh polyurethane elastomer, nitrile rubber and modified calcium carbonate according to the mass ratio, and put the raw materials into an internal mixer for internal mixing. After internal mixing, a uniform elastic buffer layer mixture is obtained. Step 3: Preparation of decorative surface material: Weigh the silicone elastomer, abrasion resistant agent and color powder according to the mass ratio, put the raw materials into a mixer, and stir to obtain a uniform decorative surface mixture; Step 4, Integrated Molding: The pre-treated core is placed into a custom mold. The inner wall of the mold has a concave-convex structure that matches the decorative texture. Then, the elastic buffer layer mixture and the decorative surface layer mixture are injected in sequence. After pre-pressing and vulcanization molding, the elastic buffer layer and the decorative surface layer are integrally molded, and the decorative surface layer forms the preset decorative texture. Step 5, Post-processing: After vulcanization molding is completed, the mold is cooled to room temperature, the semi-finished roller is demolded and removed, the surface of the semi-finished roller is polished and trimmed to remove burrs and excess material, the mounting shaft of the roller is then precision tested and corrected, and finally the roller surface is cleaned and dried to obtain the finished elastic decorative roller.

[0011] Preferably, the sandblasting treatment in step one uses white corundum sand, the sandblasting pressure is 0.3~0.5MPa, the sandblasting distance is 150~200mm; the cleaning uses anhydrous ethanol, the drying temperature is 80~100℃, and the drying time is 10~15min.

[0012] Preferably, the mixing temperature in step two is 120~140℃, the rotation speed is 30~50r / min, and the mixing time is 15~25min.

[0013] Preferably, the mold in step four is made of high-temperature resistant silicon steel, with a preheating temperature of 80~100℃; a pre-pressing temperature of 150~170℃, a pressure of 5~8MPa, and a time of 10~15min; and a vulcanization molding process using segmented heating, with a temperature of 160~180℃, a pressure of 6~10MPa, and a time of 20~30min.

[0014] Preferably, the grinding speed in step five is 1000~1200 r / min, and the grinding accuracy is controlled within 0.01 mm; the accuracy detection is carried out by using a dial indicator to detect the coaxiality of the installed shaft head, and lathe correction is performed when the deviation exceeds 0.02 mm.

[0015] The beneficial effects of this invention are as follows: 1. This invention adopts a three-layer structure consisting of a core, an elastic buffer layer, and a decorative surface layer. The elastic buffer layer is made of polyurethane elastomer, nitrile rubber, and modified calcium carbonate composite, achieving a precise match between elasticity and hardness. It can tightly adhere to irregular substrates and avoid roller deformation affecting printing accuracy, while also improving wear resistance and durability. The decorative surface layer uses a composite formula of silicone elastomer and wear-resistant agent to improve the surface wear resistance and high-temperature resistance. Color powder can achieve personalized decoration. The two are integrally molded, and the decorative texture does not require post-processing. It has strong adhesion, is not easy to fall off, and extends the service life of the roller.

[0016] 2. By setting a sandblasted roughening layer on the surface of the core, this invention effectively increases the contact area between the core and the elastic buffer layer, significantly enhancing the bonding force between the two. This effectively prevents the elastic buffer layer from peeling and falling off during long-term use. This design further improves the overall structural stability of the roller, reduces the failure rate during use, enhances the corrosion resistance of the core, extends the overall service life of the roller, and ensures that the roller can stably perform its decorative embossing function for a long time.

[0017] 3. The preparation method of the present invention adopts an integrated molding process, which integrates the molding process of the elastic buffer layer and the decorative surface layer, eliminating the cumbersome steps of segmented molding and secondary bonding in the traditional process, greatly simplifying the preparation process, effectively shortening the production cycle, and significantly improving production efficiency. At the same time, by precisely controlling the process parameters of each process, the molding accuracy of the roller and the product qualification rate can be effectively guaranteed, reducing the generation of waste in the production process, reducing raw material and labor costs, and making it more suitable for large-scale mass production. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a cross-sectional view of the core structure of the present invention; Figure 3 This is a schematic diagram of the sandblasted roughening layer structure of the present invention; Figure 4 This is a process flow diagram of the present invention.

[0019] In the diagram: 1. Core; 2. Elastic buffer layer; 3. Decorative surface layer; 4. Sandblasted rough layer; 5. Mounting shaft head; 6. Decorative texture. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] like Figures 1 to 4 As shown, this embodiment of the invention provides an elastic decorative roller, including a core 1, an elastic buffer layer 2 and a decorative surface layer 3 sequentially covering the outer side of the core 1. The core 1 is a rigid structure, the elastic buffer layer 2 is a composite elastic material layer, made of polyurethane elastomer, nitrile rubber and modified calcium carbonate mixed in proportion, the decorative surface layer 3 and the elastic buffer layer 2 are integrally formed, the surface of the decorative surface layer 3 is provided with an integrally formed decorative texture 6, the decorative surface layer 3 is made of silicone elastomer, wear-resistant agent and color powder mixed in proportion, the decorative texture 6 is a raised pattern, the pattern depth is 0.3~0.8mm and the pattern spacing is 0.5~2.0mm.

[0022] The device employs a three-layer structure consisting of a core 1, an elastic buffer layer 2, and a decorative surface layer 3. The elastic buffer layer 2 is made of polyurethane elastomer, nitrile rubber, and modified calcium carbonate, achieving a precise match between elasticity and hardness. It can tightly adhere to irregular substrates and prevent roller deformation from affecting printing accuracy, while also improving wear resistance and durability. The decorative surface layer 3 uses a composite formula of silicone elastomer and wear-resistant agent to improve the surface wear resistance and high-temperature resistance. Color powder can achieve personalized decoration. The two are molded as a single piece, and the decorative texture 6 requires no post-processing. It has strong adhesion, is not easy to fall off, and extends the service life of the roller.

[0023] The core 1 is made of 45 steel or aluminum alloy, and the surface of the core 1 is provided with a sandblasted rough layer 4, the roughness of which is Ra1.2~Ra2.0μm.

[0024] The sandblasted rough layer 4 is designed to enhance the bonding force between the core 1 and the elastic buffer layer 2, prevent the elastic buffer layer 2 from peeling off from the core 1, and at the same time improve the corrosion resistance of the core 1 and extend the overall service life of the roller.

[0025] The core 1 has mounting shafts 5 fixedly connected to both ends. The mounting shafts 5 are coaxially set with the core 1, and the coaxiality error does not exceed 0.02mm.

[0026] This design ensures the stability of the roller rotation and avoids the offset of the embossed pattern due to coaxiality deviation.

[0027] The elastic buffer layer 2 has a thickness of 3~8mm and a Shore hardness of 35~55HA. The mass ratio of polyurethane elastomer, nitrile rubber and modified calcium carbonate is 60~70:20~25:5~15.

[0028] Polyurethane elastomer has excellent elasticity and toughness, nitrile rubber can improve the wear resistance and oil resistance of elastic buffer layer 2, and modified calcium carbonate can reduce production costs and improve the molding performance of elastic buffer layer 2. The three work together to make elastic buffer layer 2 have good elasticity, wear resistance and molding performance, which can achieve tight bonding to irregular substrates and avoid excessive roller deformation affecting the printing accuracy.

[0029] The decorative surface layer 3 has a thickness of 0.8~2.0mm and a Shore hardness of 50~70HA. The mass ratio of silicone elastomer, wear-resistant agent and color powder is 85~90:5~8:2~5. The wear-resistant agent is either nano alumina or polytetrafluoroethylene micro powder.

[0030] The silicone elastomer has good elasticity and high temperature resistance, and it has good bonding with the elastic buffer layer 2. The wear-resistant agent uses nano alumina or polytetrafluoroethylene micro powder, which can significantly improve the wear resistance of the decorative surface layer 3 and extend the service life of the decorative texture. The color powder can be selected in different colors according to the decoration requirements to realize the personalized decoration function of the roller.

[0031] A method for preparing an elastic decorative roller, comprising the following specific steps: Step 1: Core pretreatment: The core blank is machined to the preset size, then sandblasted, cleaned and dried for later use. Step 2: Preparation of elastic buffer layer material: Weigh polyurethane elastomer, nitrile rubber and modified calcium carbonate according to the mass ratio, and put the raw materials into an internal mixer for internal mixing. After internal mixing, a uniform elastic buffer layer mixture is obtained. Step 3: Preparation of decorative surface material: Weigh the silicone elastomer, abrasion resistant agent and color powder according to the mass ratio, put the raw materials into a mixer, and stir to obtain a uniform decorative surface mixture; Step 4, Integrated Molding: The pre-treated core is placed into a custom mold. The inner wall of the mold has a concave-convex structure that matches the decorative texture. Then, the elastic buffer layer mixture and the decorative surface layer mixture are injected in sequence. After pre-pressing and vulcanization molding, the elastic buffer layer and the decorative surface layer are integrally molded, and the decorative surface layer forms the preset decorative texture. Step 5, Post-processing: After vulcanization molding is completed, the mold is cooled to room temperature, the semi-finished roller is demolded and removed, the surface of the semi-finished roller is polished and trimmed to remove burrs and excess material, the mounting shaft of the roller is then precision tested and corrected, and finally the roller surface is cleaned and dried to obtain the finished elastic decorative roller.

[0032] The overall process is logically clear and seamlessly connected, eliminating the cumbersome steps of segmented molding and secondary bonding in traditional processes, greatly simplifying the preparation process, effectively shortening the production cycle, and significantly improving production efficiency. At the same time, by precisely controlling the process parameters of each process, the roller molding accuracy and product qualification rate can be effectively guaranteed, reducing the generation of production waste, lowering raw material and labor costs, adapting to large-scale mass production, and taking into account both practicality and economy.

[0033] In step one, the sandblasting treatment uses white corundum sand, the sandblasting pressure is 0.3~0.5MPa, the sandblasting distance is 150~200mm; the cleaning uses anhydrous ethanol, the drying temperature is 80~100℃, and the drying time is 10~15min.

[0034] White corundum sandblasting, combined with a pressure of 0.3~0.5MPa and a distance of 150~200mm, can form a uniform rough surface on the core, enhancing the bonding force with the elastic buffer layer. Anhydrous ethanol cleaning can thoroughly remove surface impurities and oil stains, and drying at 80~100℃ for 10~15min can eliminate moisture residue, avoiding defects such as bubbles and peeling in subsequent molding, laying a solid foundation for subsequent processes, and improving the overall stability of the roller.

[0035] In step two, the mixing temperature is 120~140℃, the rotation speed is 30~50r / min, and the mixing time is 15~25min.

[0036] A mixing temperature of 120~140℃, a rotation speed of 30~50r / min, and a mixing time of 15~25min ensure that the polyurethane elastomer, nitrile rubber, and modified calcium carbonate are fully integrated, avoiding uneven mixing of raw materials that could lead to an imbalance in the performance of the elastic buffer layer. This combination of parameters ensures that the mixture has a uniform texture and meets the required toughness, guaranteeing that the elastic buffer layer has both good elasticity and wear resistance, which meets the application requirements of roller decoration embossing.

[0037] In step four, the mold is made of high-temperature resistant silicon steel, with a preheating temperature of 80~100℃; the pre-pressing temperature is 150~170℃, the pressure is 5~8MPa, and the time is 10~15min; the vulcanization molding adopts segmented heating, with a temperature of 160~180℃, a pressure of 6~10MPa, and a time of 20~30min.

[0038] High-temperature resistant silicon steel molds are suitable for high-temperature vulcanization environments. Preheating at 80~100℃ avoids defects caused by sudden cooling of the mixture. The temperature, pressure, and time parameters of pre-pressing and vulcanization are scientifically matched. Segmented heating and vulcanization can promote a tight bond between the elastic buffer layer and the decorative surface layer, ensuring an integrated molding effect. At the same time, it accurately replicates the decorative texture, ensuring that the embossed pattern is clear and meets the accuracy standards.

[0039] In step five, the grinding speed is 1000~1200r / min, and the grinding accuracy is controlled within 0.01mm. The accuracy is tested by using a dial indicator to check the coaxiality of the installed shaft head. If the deviation exceeds 0.02mm, lathe correction is performed.

[0040] With a grinding speed of 1000~1200r / min and a precision control within 0.01mm, burrs and excess material can be removed from the roller surface, ensuring a smooth surface. A dial indicator is used to check the coaxiality of the installed shaft head. If the deviation exceeds 0.02mm, lathe correction is required to ensure smooth roller rotation, avoid embossing pattern deviation, further improve product qualification rate and usage stability, and extend roller service life.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A flexible decorative roller, comprising a core (1), characterized in that: The core (1) is covered with an elastic buffer layer (2) and a decorative surface layer (3) in sequence. The core (1) is a rigid structure. The elastic buffer layer (2) is a composite elastic material layer, which is made of polyurethane elastomer, nitrile rubber and modified calcium carbonate mixed in proportion. The decorative surface layer (3) and the elastic buffer layer (2) are integrally formed. The surface of the decorative surface layer (3) is provided with an integrally formed decorative texture (6). The decorative surface layer (3) is made of silicone elastomer, wear-resistant agent and color powder mixed in proportion. The decorative texture (6) is a raised and recessed pattern with a pattern depth of 0.3~0.8mm and a pattern spacing of 0.5~2.0mm.

2. The elastic decorative roller according to claim 1, characterized in that: The core (1) is made of 45 steel or aluminum alloy. The surface of the core (1) is provided with a sandblasted rough layer (4) with a roughness of Ra1.2~Ra2.0μm.

3. The elastic decorative roller according to claim 1, characterized in that: The core (1) is fixedly connected to two ends of a mounting shaft (5), which is coaxial with the core (1) and the coaxiality error does not exceed 0.02mm.

4. The elastic decorative roller according to claim 1, characterized in that: The thickness of the elastic buffer layer (2) is 3~8mm, its Shore hardness is 35~55HA, and the mass ratio of the polyurethane elastomer, nitrile rubber and modified calcium carbonate is 60~70:20~25:5~15.

5. The elastic decorative roller according to claim 1, characterized in that: The thickness of the decorative surface layer (3) is 0.8~2.0mm, and its Shore hardness is 50~70HA. The mass ratio of the silicone elastomer, wear-resistant agent and color powder is 85~90:5~8:2~5. The wear-resistant agent is one of nano alumina or polytetrafluoroethylene micro powder.

6. A method for preparing an elastic decorative roller, characterized in that, The specific steps are as follows: Step 1: Core pretreatment: The core blank is machined to the preset size, then sandblasted, cleaned and dried for later use. Step 2: Preparation of elastic buffer layer material: Weigh polyurethane elastomer, nitrile rubber and modified calcium carbonate according to the mass ratio, and put the raw materials into an internal mixer for internal mixing. After internal mixing, a uniform elastic buffer layer mixture is obtained. Step 3: Preparation of decorative surface material: Weigh the silicone elastomer, abrasion resistant agent and color powder according to the mass ratio, put the raw materials into a mixer, and stir to obtain a uniform decorative surface mixture; Step 4, Integrated Molding: The pre-treated core is placed into a custom mold. The inner wall of the mold has a concave-convex structure that matches the decorative texture. Then, the elastic buffer layer mixture and the decorative surface layer mixture are injected in sequence. After pre-pressing and vulcanization molding, the elastic buffer layer and the decorative surface layer are integrally molded, and the decorative surface layer forms the preset decorative texture. Step 5, Post-processing: After vulcanization molding is completed, the mold is cooled to room temperature, the semi-finished roller is demolded and removed, the surface of the semi-finished roller is polished and trimmed to remove burrs and excess material, the mounting shaft of the roller is then precision tested and corrected, and finally the roller surface is cleaned and dried to obtain the finished elastic decorative roller.

7. The method for preparing an elastic decorative roller according to claim 6, characterized in that: The sandblasting treatment in step one uses white corundum sand, with a sandblasting pressure of 0.3~0.5MPa and a sandblasting distance of 150~200mm; the cleaning uses anhydrous ethanol, the drying temperature is 80~100℃, and the drying time is 10~15min.

8. The method for preparing an elastic decorative roller according to claim 6, characterized in that: The mixing temperature in step two is 120~140℃, the rotation speed is 30~50r / min, and the mixing time is 15~25min.

9. The method for preparing an elastic decorative roller according to claim 6, characterized in that: The mold used in step four is a high-temperature resistant silicon steel mold. The preheating temperature is 80~100℃; the pre-pressing temperature is 150~170℃, the pressure is 5~8MPa, and the time is 10~15min; the vulcanization molding adopts segmented heating, with a temperature of 160~180℃, a pressure of 6~10MPa, and a time of 20~30min.

10. The method for preparing an elastic decorative roller according to claim 6, characterized in that: In step five, the grinding speed is 1000~1200 r / min, and the grinding accuracy is controlled within 0.01 mm. The accuracy is tested by using a dial indicator to check the coaxiality of the installed shaft head. If the deviation exceeds 0.02 mm, lathe correction is performed.

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