Embossing apparatus and embossing material

Abstract

Compared to conventional technology, the embossed texture is more pronounced, and tearing that occurs during the embossing process is suppressed. [Solution] The first roller and the second roller are intermittently provided with rectangular prism-shaped or truncated square pyramidal protrusions along the circumferential direction of their outer surfaces for embossing. The protrusions of the first roller and the recesses between adjacent protrusions of the second roller are spaced apart with a predetermined gap that, when viewed from the side of the first and second rollers, results in the material to be embossed being trapezoidal. The protrusions of the second roller and the recesses between adjacent protrusions of the first roller are spaced apart with a predetermined gap that, when viewed from the side of the first and second rollers, results in the material to be embossed being trapezoidal.

Description

Technical Field

[0001] The present invention relates to an embossing apparatus and an embossed material. Background Art

[0002] Conventionally, there has been known an embossing apparatus that discharges an embossed material subjected to embossing by inserting an embossed target material such as kraft paper between a first roller and a second roller having protrusions for embossing intermittently projected thereon.

[0003] Patent Document 1 (Utility Model Registration No. 3247328) discloses a first embossing roll having a large number of bubble-shaped protrusions on its circumferential surface for forming a large number of bubble-shaped recesses in web-shaped paper, and a second embossing roll provided opposite to the first embossing roll and having a large number of bubble-shaped protrusions on its circumferential surface for forming a large number of bubble-shaped recesses in the web-shaped paper inserted from an insertion port. The invention describes that the web-shaped paper is pressed by passing between the opposing first embossing roll and second embossing roll, and foamed processed buffer paper having a large number of foamed recesses formed over the entire surface of the web-shaped paper is discharged. Prior Art Literature Patent Literature

[0004] Patent Document 1 Utility Model Registration No. 3247328 Summary of the Invention Problem to be Solved by the Invention

[0005] An object of the present invention is to further enhance the definition of the unevenness of the embossed material and suppress tearing that occurs during embossing, as compared with the prior art. Means for Solving the Problem

[0006] The first embodiment comprises a first roller that is rotationally driven, and a second roller that is positioned opposite the first roller so that the material to be embossed can be inserted between the first roller and the second roller, and is rotationally driven together with the first roller so as to emboss the material to be embossed, wherein the first roller and the second roller have intermittently protruding rectangular prism-shaped or truncated square pyramidal protrusions along the circumferential direction of their outer surfaces for embossing, The embossing apparatus is such that the protrusions of the first roller and the recesses between the two adjacent protrusions of the second roller in the circumferential direction are spaced apart with a predetermined gap that, when viewed from the side of the first and second rollers, results in the material to be embossed being embossed in a trapezoidal shape, and the protrusions of the second roller and the recesses between the two adjacent protrusions of the first roller in the circumferential direction are spaced apart with a predetermined gap that, when viewed from the side of the first and second rollers, results in the material to be embossed being embossed in a trapezoidal shape.

[0007] The second embodiment is an embossing apparatus in which, in the first embodiment, a plurality of first rollers are arranged along the axis of rotation, and a plurality of second rollers are arranged along the axis of rotation, and the convex portion of one first roller and the concave portion of the other first roller adjacent to each other along the axis of rotation are arranged adjacent to each other along the axis of rotation, and the convex portion of one second roller and the concave portion of the other second roller adjacent to each other along the axis of rotation are arranged adjacent to each other along the axis of rotation, and the distance in the axis of rotation between the convex portions of the two first rollers adjacent to each other along the axis of rotation is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape, and the distance in the axis of rotation between the convex portions of the two second rollers adjacent to each other along the axis of rotation is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape.

[0008] The third embodiment is an embossing apparatus in which, in the first or second embodiment, the circumferential surfaces between adjacent protrusions along the circumferential direction of the outer surfaces of the first roller and the second roller are formed to be flat or substantially flat.

[0009] A fourth embodiment is an embossing apparatus in which, in the first or second embodiment, the width of the outer circumferential surface of the first roller and the second roller is formed to be wider than the width of the protrusion.

[0010] The fifth embodiment is an embossing apparatus in which, in the first or second embodiment, four or five of the protrusions are provided at equal intervals along the circumferential direction of the outer surfaces of the first roller and the second roller.

[0011] The sixth embodiment is an embossing apparatus in which, in the first or second embodiment, the corners of the protrusions projecting along the circumferential direction of the outer surfaces of the first roller and the second roller are chamfered with R-chamfers or C-chamfers.

[0012] The seventh embodiment is an embossing apparatus in which, in the first or second embodiment, the edges of the protrusions projecting along the circumferential direction of the outer surfaces of the first roller and the second roller are chamfered with R-chamfers or C-chamfers.

[0013] The eighth aspect is an embossing apparatus in which, in the second aspect, the first roller has a first shaft insertion hole formed therein, and the second roller has a second shaft insertion hole formed therein, and a plurality of first rollers are inserted through the first shaft insertion holes along the axial direction of the first shaft, and a plurality of second rollers are inserted through the second shaft insertion holes along the axial direction of the second shaft, wherein the convex portion of one first roller and the concave portion of the other first roller adjacent to each other along the axial direction of the first shaft are arranged to be adjacent along the axial direction, and the convex portion of one second roller and the concave portion of the other second roller adjacent to each other along the axial direction of the second shaft are arranged to be adjacent along the axial direction.

[0014] The ninth aspect is an embossing apparatus in which, in the eighth aspect, the first shaft has a first key groove formed along the axial direction, a first key protruding from the inner circumferential surface of the first roller that fits into the first key groove, the second shaft has a second key groove formed along the axial direction, a second key protruding from the inner circumferential surface of the second roller that fits into the second key groove, the first keys of one adjacent first roller and the first key of the other first roller protruding from the axial direction of the first shaft are offset along the circumferential direction of the inner circumferential surface, and the second keys of one adjacent second roller and the other second roller protruding from the axial direction of the second shaft are offset along the circumferential direction of the inner circumferential surface.

[0015] The tenth embodiment is an embossing apparatus in which, in the eighth embodiment, a first key is provided projecting from the first shaft along the axial direction, a first key groove is formed on the inner circumferential surface of the first roller into which the first key is fitted, a second key is provided projecting from the second shaft along the axial direction, a second key groove is formed on the inner circumferential surface of the second roller into which the second key is fitted, the first key grooves of one adjacent first roller and the first key groove of the other adjacent first roller along the axial direction of the first shaft are formed at offset positions along the circumferential direction of the inner circumferential surface, and the second key grooves of one adjacent second roller and the second key groove of the other adjacent second roller along the axial direction of the second shaft are formed at offset positions along the circumferential direction of the inner circumferential surface.

[0016] An eleventh embodiment is an embossing apparatus comprising, in the second embodiment, a first support member that rotatably supports the end of the first shaft, a first holding portion that holds the first support member, a second support member that rotatably supports the end of the second shaft, a second holding portion that holds the second support member and is positioned opposite the first holding portion, and a biasing member that biases at least one of the first and second holding portions in a direction that causes one holding portion to come into contact with the other holding portion, and applies a biasing force such that the one holding portion moves in a direction that causes it to separate from the other holding portion as the material to be embossed is inserted.

[0017] The twelfth embodiment is an embossed material manufactured by inserting a material to be embossed between a first roller and a second roller, each roller having intermittently protruding rectangular prism-shaped or truncated square pyramidal protrusions along the circumferential direction of its outer surface, wherein the material has a checkerboard pattern in plan view, with raised embossing on the front surface and raised embossing on the back surface, the raised embossing being formed in a truncated square pyramidal shape, and adjacent raised embossings being connected by wrinkles. [Effects of the Invention]

[0018] According to the first to eleventh embodiments, the contrast of the embossed surface can be enhanced compared to the conventional technology, and tearing that occurs during embossing can be suppressed.

[0019] According to the twelfth embodiment, compared to the prior art, it is possible to provide the market with an embossed material in which the contrast of the embossed surface is more pronounced and no tearing occurs around the embossed area. [Brief explanation of the drawing]

[0020] [Figure 1A] Figure 1A is a top view of the embossing apparatus of the embodiment, as seen from above. [Figure 1B] Figure 1B is a front view of the embossing apparatus according to the embodiment. [Figure 2A] FIG. 2A is a view taken along arrow A in FIG. 1A, and is a perspective view of the embossing device as viewed from the left side. [Figure 2B] FIG. 2B is a view taken along arrow B in FIG. 1A, and is a perspective view of the embossing device as viewed from the right side. [Figure 3A] FIG. 3A is a diagram showing the internal structure of the drive unit in FIG. 2A. [Figure 3B] FIG. 3B is a perspective view of a C-C cross-section of FIG. 1A. [Figure 4A] FIG. 4A (A) and (B) are respectively a front view and a side view of one roller member among a pair of roller members constituting a first roller and a second roller. [Figure 4B] FIG. 4B (A) and (B) are respectively a front view and a side view of the other roller member among a pair of roller members constituting the first roller and the second roller. [Figure 5] FIG. 5 is a perspective view showing a state where a plurality of roller members are inserted along the axial direction of a first shaft. [Figure 6] FIG. 6 is a side view showing a state in which the first roller and the second roller are disposed opposite to each other. [Figure 7] FIG. 7 is a view of the state in which the first roller and the second roller are disposed opposite to each other, as viewed with the outer peripheral surface facing front. [Figure 8] FIG. 8 is a diagram showing an embossed material discharged from between the first roller and the second roller. [Figure 9] FIG. 9 is a plan view showing an embossed material that has been embossed. [Figure 10] FIG. 10 is a diagram corresponding to FIG. 6, and is a diagram explaining the shape of embossments formed by the first roller and the second roller. [Figure 11] FIG. 11 (A) and (B) are diagrams explaining shear stress generated in the embossed material according to the distance between convex portions in the rotation axis direction. MODE FOR CARRYING OUT THE INVENTION

[0021] Hereinafter, embodiments of the embossing apparatus according to the present invention will be described with reference to the drawings.

[0022] (Overall configuration of the embossing machine 200)

[0023] Figure 1A shows a top view of the embossing apparatus 200 of the embodiment, viewed from above. The material to be embossed is supplied from the bottom of Figure 1A, and the embossed material is discharged from the top of Figure 1A. The direction of transport of the material to be embossed is indicated by an arrow. The left side of Figure 1A is defined as the left side of the embossing apparatus 100, and the right side of Figure 1A is defined as the right side of the embossing apparatus 100.

[0024] Figure 1B shows a front view of the embossing apparatus 100 according to the embodiment. The material to be embossed is supplied from the front side in Figure 1B, and the embossed material is discharged from the back side in Figure 1B. The left side in Figure 1B is defined as the left side of the embossing apparatus 100, and the right side in Figure 1B is defined as the right side of the embossing apparatus 100.

[0025] The material to be embossed is, for example, kraft paper. The embossed material is used, for example, as cushioning material.

[0026] The embossing apparatus 100 is broadly composed of a support base 210, a frame section 220, a drive section 230, a driven section 240, a shaft left end support section 250L, a shaft right end support section 250R, a first roller section 100U, and a second roller section 100D. In this embodiment, the first roller section 100U constitutes the driven roller section, and the second roller section 100D constitutes the drive roller section.

[0027] Vibration-damping rubber 211 is attached to the corners of the lower surface of the support base 210, and the support base 210 is placed on the ground via the vibration-damping rubber 211. Vibration-damping rubber 212 is attached to the left and right sides of the upper surface of the support base 210, and the left and right plate members 221L and 221R of the frame section 220 are supported via the vibration-damping rubber 212.

[0028] The frame section 220 is fitted with the drive section 230, the driven section 240, the left end support section 250L of the shaft, and the right end support section 250R of the shaft.

[0029] The first roller section 100U is located on the upper side of the frame section 220 and consists of a first shaft 120U and a plurality of first rollers 110U that are fixed to the first shaft 120U.

[0030] The second roller section 100D is located below the frame section 220 and is positioned opposite the first roller section 100U. It consists of a second shaft 120D and a plurality of second rollers 110D that are fixed to the second shaft 120D.

[0031] The left end support portion 250L and the right end support portion 250R of the shaft support portions 100U and 100D respectively support the left and right ends of the first roller portion 100U and the second roller portion 100D so that they can rotate freely. The drive portion 230 and the driven portion 240 rotate the first roller portion 100U and the second roller portion 100D.

[0032] Figure 2A is a perspective view of the embossing machine 200 from the left side, as seen from arrow A in Figure 1A. Figure 2A is a view of the drive unit 230 from the outside of the frame unit 220.

[0033] Figure 2B is a view B of the arrow in Figure 1A, and is a perspective view of the embossing machine 200 from the right side. Figure 2B is a view of the driven part 240 from the outside of the frame part 220.

[0034] Figure 3A shows the internal structure of the drive unit 230 in Figure 2A.

[0035] Figure 3B shows a perspective view of the CC cross section of Figure 1A. Figure 3B is a view of the driven part 240 from the inside of the frame part 220.

[0036] (Configuration of frame section 220)

[0037] The frame section 220 is composed of a left plate member 221L, a right plate member 221R, discharge-side guide plate members 222 (222U, 222D), supply-side guide plate members 223 (223U, 223D), and connecting members 224 (224UA, 224UB, 224DA, 224DB).

[0038] The left plate member 221L has the drive unit 230 and the left end support unit 250L of the shaft attached to it. The right plate member 221R has the driven unit 240 and the right end support unit 250R of the shaft attached to it.

[0039] The supply-side guide plate members 223 (223U, 223D) are plate-shaped members that are located inside the frame portion 220 and on the supply side, extending in the left-right direction. The supply-side guide plate members 223 (223U, 223D) connect the left plate member 221L and the right plate member 221R. The supply-side guide plate member 223 consists of an upper supply-side guide plate member 223U and a lower supply-side guide plate member 223D. By inserting the material to be embossed between the upper supply-side guide plate member 223U and the lower supply-side guide plate member 223D, the material to be embossed can be guided and moved between the first roller portion 100U and the second roller portion 200D. The material to be embossed is inserted into the embossing device 100 from a tray. Here, a guide that supports and guides the lower surface of the material to be embossed, and a roller member that rolls on the upper surface of the material to be embossed, may be provided between the tray and the supply-side guide plate member 223, so as to smoothly feed the material to be embossed from the tray to the embossing device 100.

[0040] The discharge-side guide plate members 222 (222U, 222D) are plate-shaped members that are located inside the frame portion 220 and on the discharge side, extending in the left-right direction. The discharge-side guide plate members 222 (222U, 222D) connect the left plate member 221L and the right plate member 221R. The discharge-side guide plate member 222 consists of an upper discharge-side guide plate member 222U and a lower discharge-side guide plate member 222D. The embossed material discharged from between the first roller portion 100U and the second roller portion 200D is guided and moved between the upper discharge-side guide plate member 222U and the lower discharge-side guide plate member 222D, allowing the embossed material to be removed.

[0041] The connecting members 224 (224UA, 224UB, 224DA, 224DB) are pipe-shaped members located inside the frame portion 220 and extending in the left-right direction. The connecting members 224UA, 224UB, 224DA, and 224DB connect the left plate member 221L and the right plate member 221R at the discharge side and upper position, the supply side and upper position, the discharge side and lower position, and the supply side and lower position, respectively.

[0042] (Configuration of drive unit 230 and driven unit 240)

[0043] The drive unit 230 consists of a motor 231, a first gear 232, and a second gear 233. The first gear 232 is fixed to the rotating shaft 231A of the motor 231. The first gear 232 meshes with the second gear 233. The second gear 233 is fixed to the left end of the second shaft 120D of the second roller unit 100D. As a result, the rotational driving force of the motor 231 is transmitted to the second shaft 120D of the second roller unit 100D via the rotating shaft 231A, the first gear 232, and the second gear 233, thereby rotating the second roller unit 100D.

[0044] The driven section 240 includes a third gear 241 and a fourth gear 242. The third gear 241 is fixed to the right end of the second shaft 120D of the second roller section 100D. The third gear 241 meshes with the fourth gear 242. The fourth gear 242 is fixed to the right end of the first shaft 120U of the first roller section 100U. As a result, the rotational driving force of the motor 231 is transmitted to the first shaft 120U of the first roller section 100U via the rotating shaft 231A, the first gear 232, the second gear 233, the second shaft 120D of the second roller section 100D, the third gear 241, and the fourth gear 242, thereby rotating the first roller section 100U.

[0045] (Configuration of shaft left end support part 250L and shaft right end support part 250R)

[0046] The left end support portion 250L of the shaft is composed of a first shaft roller bearing 251L, a second shaft roller bearing 252L, a bearing outer ring support portion 253L, a sliding plate 254L, a coil spring 255L, and a coil spring support portion 256L.

[0047] The first shaft roller bearing 251L rotatably supports the left end of the first shaft 120U. The second shaft roller bearing 252L rotatably supports the left end of the second shaft 120D.

[0048] The bearing outer ring support portion 253L is fixed to the left plate member 221L. The bearing outer ring support portion 253L holds the outer circumference of the second shaft roller bearing 252L in a fixed position, and also holds the lower outer circumference of the first shaft roller bearing 251L in a movable position.

[0049] The sliding plate 254L is supported by the left plate member 221L so as to be slidable in the vertical direction. The sliding plate 254L holds the upper outer circumference of the first shaft roller bearing 251L in a fixed position.

[0050] A coil spring fitting portion 254A is provided protruding from the sliding plate 254L. The lower side of the coil spring 255L is fitted into the coil spring fitting portion 254A.

[0051] The coil spring support portion 256L is fixed above the left plate member 221L. The upper end of the coil spring 255L is in contact with the coil spring support portion 256L.

[0052] Similarly, the shaft right end support portion 250R is composed of a first shaft roller bearing 251R, a second shaft roller bearing 252R, a bearing outer ring support portion 253R, a sliding plate 254R, a coil spring 255R, and a coil spring support portion 256R.

[0053] Similarly, the first shaft roller bearing 251R rotatably supports the right end of the first shaft 120U. The second shaft roller bearing 252R rotatably supports the right end of the second shaft 120D.

[0054] The bearing outer ring support portion 253R is fixed to the right plate member 221R. The bearing outer ring support portion 253R holds the outer circumference of the second shaft roller bearing 252R in a fixed position, and also holds the lower outer circumference of the first shaft roller bearing 251R in a movable position.

[0055] The sliding plate 254R is supported by the right plate member 221R so as to be slidable in the vertical direction. The sliding plate 254R fixes and holds the upper outer circumference of the first shaft roller bearing 251R.

[0056] A coil spring fitting portion 254A is provided protruding from the sliding plate 254R. The lower side of the coil spring 255R is fitted into the coil spring fitting portion 254A.

[0057] The coil spring support portion 256R is fixed above the right plate member 221R. The upper end of the coil spring 255R is in contact with the coil spring support portion 256R.

[0058] Here, due to the spring force of the coil spring 255L, when the material to be embossed is not inserted between the first roller portion 100U and the second roller portion 100D, the sliding plate 254L is brought into contact with the bearing outer ring support portion 253L, and the movement of the first roller portion 100U is suppressed. However, when the material to be embossed is inserted between the first roller portion 100U and the second roller portion 100D, the sliding plate 254L moves away from the bearing outer ring support portion 253L in accordance with the thickness of the material to be embossed, against the spring force, causing the first roller portion 100U to move upward. It is desirable to adjust the spring force of the coil spring 255L to such an extent that this effect occurs. The same applies to the spring force of the coil spring 255R.

[0059] Note that coil springs 255L and 255R are just examples, and it is also possible to use any elastic member that provides an elastic force similar to that of a spring, or any biasing member that provides a biasing force similar to that of a spring.

[0060] As described above, in this embodiment, the end of the first shaft 120U is rotatably supported by the first shaft roller bearings 251L and 251R, the first shaft roller bearings 251L and 251R are held by the sliding plates 254L and 254R, the end of the second shaft 120D is rotatably supported by the second shaft roller bearings 252L and 252R, and the bearing outer ring support portion 253L is arranged opposite the sliding plates 254L and 254R. The 253R holds the second shaft roller bearings 252L and 252R, and the coil springs 255L and 255R provided on the sliding plates 254L and 254R bias the sliding plates 254L and 254R in a direction that brings them into contact with the bearing outer ring support portions 253L and 253R, while also applying a biasing force that moves the sliding plates 254L and 254R away from the bearing outer ring support portions 253L and 253R as the embossed material is inserted.

[0061] However, this is just one example, and the bearing outer ring support portions 253L and 253R may be equipped with biasing members similar to coil springs 255L and 255R, thereby making the bearing outer ring support portions 253L and 253R movable.

[0062] In other words, the device comprises a first support member that rotatably supports the end of a first shaft 120U, a first holding portion that holds the first support member, a second support member that rotatably supports the end of a second shaft 120D, and a second holding portion that holds the second support member and is positioned opposite the first holding portion. The device is configured such that at least one of the first and second holding portions is provided with a biasing member, which biases one holding portion to come into contact with the other holding portion and also applies a biasing force such that one holding portion moves away from the other holding portion as the material to be embossed is inserted.

[0063] By adopting this configuration, it is possible to suppress tearing of the material to be embossed during the embossing process.

[0064] (Configuration of the first roller section 100U and the second roller section 100D)

[0065] Figures 4A(A) and (B) are a front view and a side view, respectively, of one of the pair of roller members 111 that make up the first roller 110U and the second roller 110D.

[0066] Figures 4B(A) and (B) are a front view and a side view, respectively, of the other roller member 112 of the pair of roller members that make up the first roller 110U and the second roller 110D.

[0067] In Figures 1A and 1B, one roller member 111 is shown in white and the other roller member 112 is shown in hatched to distinguish them.

[0068] (Shape of the pair of roller members 111 and 112 that constitute the first roller 110U and the second roller 110D)

[0069] As shown in Figures 4A(A), (B) and 4B(A), (B), the outer circumferential surfaces 113 of the roller members 111 and 112 are intermittently provided with rectangular prism-shaped protrusions 114 along the circumferential direction for embossing. In this specification, the rectangular prism-shaped protrusions 114 are not limited to perfectly rectangular prism-shaped protrusions 114, but include substantially rectangular prism-shaped protrusions 114 depending on the draft angle and other factors that are permissible in design and manufacturing. Furthermore, the protrusions 114 may be formed in the shape of a truncated square pyramid, insofar as the effects of the embodiment are achieved.

[0070] Five protrusions 114 are provided at equal intervals along the circumferential direction of the outer surface 113 of the roller members 111 and 112. Alternatively, four protrusions 114 may be provided at equal intervals along the circumferential direction of the outer surface 113 of the roller members 111 and 112.

[0071] A recess 115 is formed between adjacent protrusions 114 along the circumferential direction of the outer peripheral surface 113 of the roller members 111 and 112.

[0072] The circumferential surface 113A between adjacent protrusions 114 along the circumferential direction of the outer circumferential surface 113 of the roller members 111 and 112 is formed flat. In this specification, "flat" of the circumferential surface 113A is not limited to "perfectly flat," but also includes cases where it is substantially flat.

[0073] The width 113W of the outer circumferential surface 113 of the roller members 111 and 112 is wider than the width 114W of the protrusion 114. The width difference d between the width 113W of the outer circumferential surface and the width 114W of the protrusion 114 is adjusted to a value necessary to make the emboss 301 into a desired truncated square pyramidal shape, as will be described later.

[0074] The corners 114N of the protrusions 114 that are provided along the circumferential direction of the outer surface 113 of the roller members 111 and 112 are rounded off.

[0075] The corners 114N of the protrusion 114 are machined into a circular shape with a radius of, for example, 0.5 mm. Alternatively, the corners 114N of the protrusion 114 may be chamfered.

[0076] Furthermore, the edges 114E of the protrusions 114 that protrude along the circumferential direction of the outer circumferential surface 113 of the roller members 111 and 112 are chamfered with a rounded edge (R). Alternatively, the edges 114E of the protrusions 114 may be chamfered with a rounded edge (C).

[0077] The roller members 111 and 112 have shaft insertion holes 118 formed therein. The outer circumference of the shaft insertion hole 118 constitutes the inner circumferential surface 116 of the roller members 111 and 112.

[0078] A key 117 is provided protruding from the inner circumferential surface 116 of one of the roller members 111. The key 117 of the one roller member 111 is positioned so that its central axis coincides with the central axis 114C of the protrusion 114.

[0079] A key 117 is provided protruding from the inner circumferential surface 116 of the other roller member 112. The key 117 of the other roller member 112 is positioned so that its central axis coincides with the central axis 115C of the recess 115.

[0080] Thus, the key 117 of one roller member 111 and the key 117 of the other roller member 112 are each positioned so as to be offset along the circumferential direction of the inner circumferential surface 116 by an angle θ formed by the central axis 114C of the convex portion 114 and the central axis 115C of the concave portion 115.

[0081] In this embodiment, the roller members 111 and 112 are formed by providing a protrusion 114 on the outer circumferential surface 113 of a ring-shaped member. Therefore, when applying a manufacturing method that involves removing the roller members 111 and 112 from a mold, they have a simple shape without undercuts, and can be manufactured at a lower cost compared to roller members with undercuts.

[0082] Furthermore, in this embodiment, the upper end surfaces of the protrusions 114 of the roller members 111 and 112 are parallel to the axis of rotation. However, in order to suppress the embossing material from being conveyed at an angle (skew), the upper end surfaces of the protrusions 114 of the roller members 111 and 112 may be configured to be inclined at a predetermined angle with respect to the axis of rotation. Moreover, it is also possible to implement a design in which the upper end surfaces of the protrusions 114 of the roller members 111 and 112 are not a plane parallel to the axis of rotation, such as by providing grooves or other steps on the upper end surfaces of the protrusions 114, in order to suppress skew.

[0083] Figure 5 is a perspective view showing how multiple roller members 111 and 112 are inserted along the axial direction of the first shaft 120U.

[0084] The arrangement of the multiple roller members 111 and 112 inserted along the axial direction of the second shaft 120D is the same as in Figure 5.

[0085] As shown in Figure 5, a first keyway 121U is formed in the first shaft 120U along the axial direction. The first keyway 121U is shaped to allow the keys 117 of the roller members 111 and 112 to be fitted into it.

[0086] Multiple roller members 111 and 112 are alternately inserted through shaft insertion holes 118 along the axial direction of the first shaft 120U. The multiple roller members 111 and 112 are inserted onto the first shaft 120U such that a key 117 fits into the first keyway 121U.

[0087] For example, 19 roller members 111 and 112 are alternately inserted onto the first shaft 120U.

[0088] The roller members 111 and 112, which are alternately inserted into the first shaft 120U, constitute the first roller 110U. The shaft insertion holes 118 of the roller members 111 and 112, which are alternately inserted into the first shaft 120U, are referred to as the first shaft insertion holes 118U. The key 117 of the roller members 111 and 112, which are fitted into the first keyway 121U of the first shaft 120U, are referred to as the first key 117U.

[0089] Similarly, a second keyway 121D is formed in the second shaft 120D along the axial direction. The second keyway 121D is shaped to allow the key 117 of the roller members 111 and 112 to be fitted into it.

[0090] Multiple roller members 111 and 112 are alternately inserted through shaft insertion holes 118 along the axial direction of the second shaft 120D. The multiple roller members 111 and 112 are inserted onto the second shaft 120D such that a key 117 fits into the second keyway 121D.

[0091] For example, 19 roller members 111 and 112 are alternately inserted onto the second shaft 120D.

[0092] The roller members 111 and 112, which are alternately inserted into the second shaft 120D, constitute the second roller 110D. The shaft insertion holes 118 of the roller members 111 and 112, which are alternately inserted into the second shaft 120D, are referred to as the second shaft insertion holes 118D. The keys 117 of the roller members 111 and 112, which are fitted into the second keyway 121D of the second shaft 120D, are referred to as the second key 117D.

[0093] For example, a total of 38 first rollers 110U, consisting of 19 roller members 111 and 19 roller members 112, are arranged along the rotation axis of the first shaft 120U. Similarly, a total of 38 second rollers 110D, consisting of 19 roller members 111 and 19 roller members 112, are arranged along the rotation axis of the second shaft 120D.

[0094] Figure 7 shows the first roller 110U and the second roller 110D arranged opposite each other, with the outer surface 113 facing forward. For the sake of explanation, Figure 7 shows the first roller 110U and the second roller 110D separately.

[0095] As shown by the dashed line in Figure 7, the protrusion 114 of one first roller 110U and the recess 115 of the other first roller 110U, which are adjacent to each other along the axial direction of the first shaft 120U, are arranged to be adjacent to each other along the axial direction. This corresponds to the fact that the first key 117U of one first roller 110U and the first key 117U of the other first roller 110U, which are adjacent to each other along the axial direction of the first shaft 120U, are projecting at positions offset along the circumferential direction of the inner circumferential surface 116.

[0096] Here, the distance D in the rotational axis direction between the protrusions 114, 114 of the two adjacent first rollers 110U, 110U along the rotational axis direction of the first shaft 120U is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape, as will be described later. The distance D is defined by the width difference d between the width 113W of the outer circumferential surface 113 of the roller members 111, 112 and the width 114W of the protrusion 114.

[0097] Similarly, as shown by the dashed line, the protrusions 114 of one second roller 110D and the recesses 115 of the other second roller 110D, which are adjacent to each other along the axial direction of the second shaft 120D, are arranged to be adjacent to each other along the axial direction. This corresponds to the fact that the second keys 117D of one second roller 110D and the second keys 117D of the other second roller 110D, which are adjacent to each other along the axial direction of the second shaft 120D, are projecting from the inner circumferential surface 116 at offset positions along the circumferential direction.

[0098] Here, the distance D in the rotational axis direction between the protrusions 114, 114 of the two adjacent second rollers 110D, 110D along the rotational axis direction of the second shaft 120D is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape, as will be described later.

[0099] Figure 6 is a side view of the first roller 110U and the second roller 110D in an opposing configuration. Figure 6 shows the insertion position of the material to be embossed 300' before embossing.

[0100] Figure 10 is a diagram corresponding to Figure 6, illustrating the shape of the emboss 301 formed by the first roller 110U and the second roller 110D.

[0101] As shown in Figures 6 and 10, the protrusions 114 of the second roller 110D and the recesses 115 between adjacent protrusions 114, 114 of the first roller 110U are spaced apart by a predetermined gap 114S, such that, in a side view of the second roller 110D and the first roller 110U, the material to be embossed 300' is embossed in a trapezoidal shape. Similarly, due to symmetry, the protrusions 114 of the first roller 110D and the recesses 115 between adjacent protrusions 114, 114 of the second roller 110D are spaced apart by a predetermined gap, such that, in a side view of the first roller 110U and the second roller 110D, the material to be embossed 300' is embossed in a trapezoidal shape.

[0102] In this embodiment, the relationship between the member on which the key is provided and the member on which the keyway is formed may be reversed.

[0103] In other words, a first key may be provided on the first shaft 120U along the axial direction, and a first key groove may be formed on the inner circumferential surface 116 of the first roller 110U into which the first key is fitted. In addition, a second key may be provided on the second shaft 120D along the axial direction, and a second key groove may be formed on the inner circumferential surface 116 of the second roller 110D into which the second key is fitted.

[0104] Furthermore, the first keyway of one first roller 110U and the first keyway of the other first roller 110U, which are adjacent to each other along the axial direction of the first shaft 120U, may be formed at positions offset along the circumferential direction of the inner circumferential surface 116, and the second keyway of one second roller 110D and the second keyway of the other second roller 110D, which are adjacent to each other along the axial direction of the second shaft 120D, may also be formed at positions offset along the circumferential direction of the inner circumferential surface 116.

[0105] (Embossed material 300)

[0106] Figure 8 shows the embossed material 300 being discharged from between the first roller 100U and the second roller 100D.

[0107] Figure 9 is a plan view showing the embossed material 300.

[0108] According to the embossing apparatus 200 of this embodiment, an embossed material 300 can be manufactured by inserting the material to be embossed 300' between a first roller 110U and a second roller 110D, which have intermittently protruding rectangular prism-shaped or truncated square pyramidal protrusions 114 along the circumferential direction of the outer surface 113.

[0109] The embossed material 300 produced by the embossing apparatus 200 of the embodiment has the following characteristics.

[0110] 1) The front surface has raised embossing 301 and the back surface has raised embossing 301, forming a checkerboard pattern when viewed from above.

[0111] 2) The convex embossing 301 is formed in the shape of a truncated square pyramid.

[0112] 3) The two adjacent convex embossed areas 301, 301 are connected by a wrinkled area 302.

[0113] 4) Compared to conventional embossed materials, the embossed surface has a more pronounced contrast, and there is no tearing that occurs during the embossing process.

[0114] Thus, according to the embossing apparatus 200 of this embodiment, the contrast of the embossed surface can be enhanced compared to the conventional technology, and tearing that occurs during embossing can be suppressed.

[0115] Next, the relationship between the configuration of the embossing apparatus 200 of the embodiment and the characteristics of the embossing material 300 will be explained.

[0116] As shown in Figure 8, the rotational direction side surface 301A of the emboss 301 formed on the embossed material 300 is tapered, and the rotational axis direction side surface 301B of the emboss 301 is also tapered, so that the emboss 301 as a whole is formed in a tapered truncated square pyramidal shape. As a result, tearing is less likely to occur around the emboss 301, and the unevenness of the surface is clearly defined.

[0117] (Tapered shape of the side surface 301A in the rotational direction of the embossed 301)

[0118] The formation of the tapered shape on the rotational side surface 301A of the emboss 301 can be explained by Figure 10.

[0119] The gap 114S between the protrusions 114 of the second roller 110D and the recesses 115 between the adjacent protrusions 114, 114 of the first roller 110U is formed in a trapezoidal shape. This trapezoidal gap 114S can be obtained by adjusting the number of protrusions 114 per roller (for example, 5). Because the gap 114S between the protrusions 114 of the second roller 110D and the recesses 115 between the adjacent protrusions 114, 114 of the first roller 110U is formed in a trapezoidal shape, the embossed surface 301 is less prone to tearing and has a distinct uneven surface. Similarly, due to symmetry, the gap 114S between the protrusions 114 of the first roller 110U and the recesses 115 between the adjacent protrusions 114, 114 of the second roller 110D is also formed in a trapezoidal shape.

[0120] (Tapered shape of the side surface 301B in the rotation axis direction of the embossed 301)

[0121] The formation of the tapered shape on the side surface 301B of the emboss 301 in the rotational axis direction can be explained by Figures 8 and 11.

[0122] As shown in Figure 8, the distance D in the rotational axis direction between the protrusions 114, 114 of two adjacent first rollers 110U, 110U along the rotational axis direction of the first roller section 100U is set to a predetermined distance such that the rotational axis direction side surface 301B of the emboss 301 is formed into a tapered shape with pronounced irregularities. However, the distance D is set to a value that is suppressed to the extent that tearing does not occur due to shear stress. The same applies to the distance D in the rotational axis direction between the protrusions 114, 114 of two adjacent second rollers 110D, 110D along the rotational axis direction of the second roller section 100D.

[0123] Figures 11(A) and (B) illustrate the shear stress generated in the embossed material 300 according to the distance D in the rotational axis direction between the protrusions 114, 114.

[0124] As shown in Fig. 11(A), when the distance D in the rotational axis direction between the convex portions 114, 114 is small, the shear stress P1 generated in the embossed material 300 in response to the shear force F applied by the convex portions 114, 114 becomes large. When the distance D is small, the "play" around the emboss 301 is small relative to the large shear stress P1, so tearing is likely to occur in the embossed material 300.

[0125] In contrast, as shown in Fig. 11(B), when the distance D in the rotational axis direction between the convex portions 114, 114 is large, the shear stress P2 (<P1) generated in the embossed material 300 in response to the same shear force F applied by the convex portions 114, 114 becomes small. If the distance D is excessively large, the shear stress P2 decreases, the "play" around the emboss 301 increases, and the unevenness of the emboss becomes indistinct, but tearing is less likely to occur in the embossed material 300.

[0126] Therefore, it is desirable to set the distance D in the rotational axis direction between the convex portions 114, 114 to a value such that embosses 301 with distinct unevenness are formed while being resistant to tearing.

[0127] The distance D in the rotational axis direction between the convex portions 114, 114 is defined by the width difference d between the width 113W of the outer peripheral surface 113 of the first roller 110U and the second roller 110D and the width 114W of the convex portion 114. For example, by setting the width 113W of the outer peripheral surface 113 to 11 mm, setting the width 114W of the convex portion 114 to 7 mm to 9 mm, and setting the width difference d to 2 mm to 4 mm, it was possible to manufacture an embossed material 300 in which embosses 301 with distinct unevenness are formed without any observed tearing.

[0128] Further, the "play" around the embosses 301 caused by the distance D increasing to a certain extent appears as wrinkle portions 302 in the embossed material 300. Since adjacent convex embosses 301, 301 are connected to each other by the wrinkle portions 302, suppression of tear occurrence is ensured.

[0129] Furthermore, the rounded (or chamfered) corners 114N and ridges 114E of the roller protrusions 114 contribute to suppressing tearing of the embossed material 300. If the corners 114N and ridges 114E of the protrusions 114 were not rounded (or chamfered), the shear stress would increase, making the embossed material 300 more prone to tearing.

[0130] The embossing apparatus and embossing material of the embodiment can be modified, such as by omitting, adding, changing, or substituting components, within the scope described in the claims. [Explanation of Symbols]

[0131] 110U First Roller 110D The second Laura 113 Outer surface 114 Convex part 114S Gap 115 recess 200 Embossing machine

Claims

1. A first roller that is driven to rotate, A second roller is positioned opposite the first roller so that the material to be embossed can be inserted between it and the first roller, and is rotationally driven together with the first roller so that the material to be embossed is embossed. Equipped with, The first roller and the second roller are intermittently provided with convex portions in the shape of a rectangular prism or a truncated square pyramid for embossing along the circumferential direction of their outer surfaces. The protrusions of the first roller and the recesses between the two adjacent protrusions of the second roller in the circumferential direction are spaced apart with a predetermined gap that, when viewed from the side, results in the embossed material being embossed in a trapezoidal shape. The protrusions of the second roller and the recesses between the two adjacent protrusions of the first roller in the circumferential direction are spaced apart with a predetermined gap that, when viewed from the side, results in the embossed material being embossed in a trapezoidal shape. Embossing machine.

2. Multiple first rollers are arranged along the axis of rotation, Multiple second rollers are arranged along the axis of rotation, The convex portion of one first roller and the concave portion of the other first roller, which are adjacent to each other along the axis of rotation, are arranged to be adjacent to each other along the axis of rotation, The convex portion of one second roller and the concave portion of the other second roller, which are adjacent to each other along the axis of rotation, are arranged to be adjacent to each other along the axis of rotation. The distance in the rotational axis direction between the convex portions of two adjacent first rollers along the rotational axis direction is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape, The distance in the rotational axis direction between the convex portions of two adjacent second rollers is set to a predetermined distance such that the material to be embossed is embossed into a truncated square pyramidal shape. The embossing apparatus according to claim 1.

3. The circumferential surfaces between adjacent protrusions along the circumferential direction of the outer surfaces of the first roller and the second roller are formed to be flat or substantially flat. The embossing apparatus according to claim 1 or 2.

4. The width of the outer circumferential surface of the first roller and the second roller is formed to be wider than the width of the protrusion. The embossing apparatus according to claim 1 or 2.

5. Four or five of the protrusions are provided at equal intervals along the circumferential direction of the outer surfaces of the first roller and the second roller. The embossing apparatus according to claim 1 or 2.

6. The corners of the protrusions that extend along the circumferential direction of the outer surfaces of the first roller and the second roller are chamfered with R-chamfers or C-chamfers. The embossing apparatus according to claim 1 or 2.

7. The ridges of the protrusions projecting along the circumferential direction of the outer surfaces of the first and second rollers are chamfered with R-chamfers or C-chamfers. The embossing apparatus according to claim 1 or 2.

8. The first roller has a first shaft insertion hole, and the second roller has a second shaft insertion hole. A first shaft through which multiple first rollers are inserted axially via the first shaft insertion hole, A second shaft through which multiple second rollers are inserted axially via the second shaft insertion hole, Equipped with, The convex portion of one first roller and the concave portion of the other first roller, which are adjacent to each other along the axial direction of the first shaft, are arranged to be adjacent to each other along the axial direction, The convex portion of one second roller and the concave portion of the other second roller, which are adjacent to each other along the axial direction of the second shaft, are arranged to be adjacent to each other along the axial direction. The embossing apparatus according to claim 2.

9. The first shaft has a first keyway formed along its axial direction, and the inner circumferential surface of the first roller has a first key protruding from it that fits into the first keyway, The second shaft has a second keyway formed along its axial direction, and the inner circumferential surface of the second roller has a second key protruding from it that fits into the second keyway. The first key of one first roller and the first key of the other first roller, which are adjacent to each other along the axial direction of the first shaft, are projected at positions offset along the circumferential direction of the inner surface, The second key of one second roller and the second key of the other second roller, which are adjacent to each other along the axial direction of the second shaft, are projected at positions offset along the circumferential direction of the inner surface. The embossing apparatus according to claim 8.

10. A first key is provided projecting from the first shaft along the axial direction, and a first key groove is formed on the inner circumferential surface of the first roller into which the first key is fitted, A second key is provided projecting from the second shaft along the axial direction, and a second keyway is formed on the inner circumferential surface of the second roller, which is fitted into the second key. The first keyway of one first roller and the first keyway of the other first roller, which are adjacent to each other along the axial direction of the first shaft, are formed at positions offset along the circumferential direction of the inner surface, The second keyway of one second roller and the second keyway of the other second roller, which are adjacent to each other along the axial direction of the second shaft, are formed at positions offset along the circumferential direction of the inner surface. The embossing apparatus according to claim 8.

11. A first support member that rotatably supports the end of the first shaft, A first holding portion that holds the first support member, A second support member that rotatably supports the end of the second shaft, The second support member is held, and the second holding portion is positioned opposite the first holding portion, A biasing member that biases at least one of the first and second holding portions in a direction that causes one holding portion to come into contact with the other holding portion, and also applies a biasing force to such an extent that the one holding portion moves in a direction that causes it to separate from the other holding portion as the embossed material is inserted. An embossing apparatus according to claim 2, comprising:

12. An embossed material manufactured by inserting a material to be embossed between a first roller and a second roller, each having intermittently protruding rectangular prism-shaped or truncated square pyramidal protrusions along the circumferential direction of its outer surface, The front surface has raised embossing and the back surface has raised embossing, forming a checkerboard pattern when viewed from above. The aforementioned convex emboss is formed in the shape of a truncated square pyramid, The two adjacent raised embossed areas are connected by wrinkles. Embossed material.

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