JP6225594B2 - Height data processing apparatus, height data processing method, program, storage medium, embossed plate manufacturing method, sheet manufacturing method - Google Patents

Description

  The present invention relates to a height data processing method for processing height data used for manufacturing an embossed plate.

  As a design of a sheet such as a wallpaper, there is one having a textured uneven shape on the surface, such as a stone pattern or a fabric pattern. In order to manufacture such a sheet, for example, an embossed plate in which a texture uneven shape is formed on the surface is manufactured, and the uneven shape is transferred to a sheet of resin or the like.

  In order to form a concavo-convex shape on an embossed plate, it is necessary to create concavo-convex shape data for the plate. This data is called height data, and represents the height information of the textured uneven shape of the texture by gradation values.

  Height data can be automatically generated on a computer (see, for example, Patent Document 1), but in general, a document having a texture such as a stone pattern or a woven pattern on the surface is actually created. In many cases, the uneven shape on the surface of the original is read and generated by a three-dimensional scanner or the like (see, for example, Patent Document 2).

JP 2001-58459 A JP 2008-158936 A

  However, due to the deflection of the document during three-dimensional scanning and the thickness of the document itself being non-uniform, there may be changes in the height data that are not textured irregularities. In order to remove such a bending shape from the height data, it is necessary for the user to set various parameters and perform image processing to correct the data. This requires a trial and error to set the parameters, which is a heavy burden. In addition, the deflection shape or the like may not be recognized on the image and may be overlooked.

  The present invention has been made in view of the above-described problems, and an object thereof is to provide a height data processing method and the like that can easily remove a bent shape of a document from height data obtained by reading the document.

  A first invention for achieving the above-described object is a height for manufacturing an embossed plate, which is image data obtained by three-dimensionally scanning a document having a concavo-convex shape on a surface and indicating height information as gradation values. With respect to data, corrected height data is created by subtracting the average gradation value of pixels within a predetermined distance from the pixel from the gradation value of each pixel, and the maximum gradation value of the corrected height data is determined. In a relational expression showing a relationship between the height and the height difference obtained by calculating the height difference for a plurality of the distances, a height difference calculating means for obtaining a height difference that is a difference between a value and a minimum value, An appropriate distance calculating means for obtaining the distance such that the height difference is substantially constant with respect to a change in the distance before and after, and the corrected height data when the predetermined distance is a distance calculated by the appropriate distance calculating means. To create And Todeta correction means, a height data processing apparatus which comprises a.

  The change in height of the height data caused by the deflection of the document has a relatively wide frequency band. Therefore, when the above distance is in a range corresponding to such a frequency band, the height difference is large even if the distance is changed. It does not fluctuate and is substantially constant. Therefore, by adopting a distance in such a range and correcting the height data as described above, the deflection shape of the original in the height data can be automatically removed on the computer, and the burden of trial and error by the user is reduced. This reduces the amount of bending, etc., easily and with high accuracy. Thereby, the height data for manufacturing the embossed plate can be corrected, and the embossed plate can be manufactured based on the height data from which the bent shape or the like is removed. If a sheet is manufactured by embossing the surface of the sheet using this embossed plate, a sheet having excellent design properties can be efficiently manufactured with less influence of the bending shape and the like.

The appropriate distance calculating means preferably calculates the distance such that the second-order differential value of the relational expression is zero .
As a result, it is possible to remove an appropriate roughness change component from the height data and remove a deflection shape or the like. Kill removal deflection shape by using the inflection point of the relationship in the above case.

  According to a second aspect of the present invention, each height data for manufacturing an embossed plate, which is image data obtained by performing a three-dimensional scan of a document having a concavo-convex shape on a surface and indicating height information with gradation values, The correction height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the pixel from the gradation value of the pixel, and the maximum value and the minimum value of the gradation value of the correction height data are created. In the relational expression showing the relationship between the distance obtained by calculating the height difference for a plurality of the distances and the relationship between the height difference and the height difference calculating step for obtaining the height difference which is the difference between An appropriate distance calculation step for obtaining the distance such that the height difference is substantially constant with respect to a change in the height, and the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step. A height data processing method characterized by performing the Itodeta modifying step.

  According to a third aspect of the present invention, each height data for manufacturing an embossed plate, which is image data obtained by three-dimensionally scanning a document having a concavo-convex shape on a surface, and indicating height information with gradation values, The correction height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the pixel from the gradation value of the pixel, and the maximum value and the minimum value of the gradation value of the correction height data are created. In the relational expression showing the relationship between the distance obtained by calculating the height difference for a plurality of the distances and the relationship between the height difference and the height difference calculating step for obtaining the height difference which is the difference between An appropriate distance calculation step for obtaining the distance such that the height difference is substantially constant with respect to a change in the height, and the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step. And Itodeta correction step, a program for execution.

  The fourth invention relates to height data for embossed plate production, which is image data obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, and indicating height information with gradation values. The correction height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the pixel from the gradation value of the pixel, and the maximum value and the minimum value of the gradation value of the correction height data are created. In the relational expression showing the relationship between the distance obtained by calculating the height difference for a plurality of the distances and the relationship between the height difference and the height difference calculating step for obtaining the height difference which is the difference between An appropriate distance calculation step for obtaining the distance such that the height difference is substantially constant with respect to a change in the height, and the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step. And Itodeta correction step, a recording medium recording a program for execution.

  The fifth invention relates to height data for embossed plate production, which is image data obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface and indicating height information as gradation values. The correction height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the pixel from the gradation value of the pixel, and the maximum value and the minimum value of the gradation value of the correction height data are created. In the relational expression showing the relationship between the distance obtained by calculating the height difference for a plurality of the distances and the relationship between the height difference and the height difference calculating step for obtaining the height difference which is the difference between An appropriate distance calculation step for obtaining the distance such that the height difference is substantially constant with respect to a change in the height, and the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step. And the embossed plate manufacturing means forms a concavo-convex shape indicated by the corrected height data on the surface by an engraving or etching method based on the corrected height data calculated by the height data correcting step. An embossed plate manufacturing method characterized by manufacturing an embossed plate.

  6th invention is a sheet manufacturing method characterized by embossing the sheet | seat surface using the embossing plate manufactured by the embossing plate manufacturing method of 5th invention.

  According to the present invention, it is possible to provide a height data processing method and the like that can easily remove a bent shape of a document from height data obtained by reading the document.

The figure which shows the height data processing apparatus 1 Diagram showing reading of document 3 The figure which shows the hardware constitutions of the height data processing apparatus 1 The figure which shows the function structure of the height data processing apparatus 1. Flow chart showing height data processing method The figure explaining the example of a blurring process The figure explaining the example of a blurring process The figure which shows the relationship between the blur radius r and the height difference H The figure which shows the example of the spatial frequency distribution of sheets, such as wallpaper Diagram explaining calculation of appropriate blur radius Diagram showing an example of blur processing The figure which shows 9A of embossing plate manufacturing apparatuses The figure which shows the embossing plate manufacturing apparatus 9B The figure which shows the embossing plate manufacturing apparatus 9C Diagram explaining calculation of appropriate blur radius

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First Embodiment]
(1. Height data processing device)
FIG. 1 is a diagram showing a height data processing apparatus 1 according to an embodiment of the present invention. The height data processing device 1 corrects height data obtained by reading a document 3 having a textured concavo-convex shape manufactured in advance with a three-dimensional scanner 2 and removes a deflection shape and the like of the document 3. As described above, the corrected height data is used as block data when forming the textured uneven shape on the surface of the embossed plate.

  The height data processing device 1 is connected to a three-dimensional scanner 2. The three-dimensional scanner 2 includes a control device 20a and a scanning unit 20b. In the three-dimensional scanner 2, the control unit 20 a controls the scanning unit 20 b, performs laser scanning as shown in FIG. 2A, reads the texture irregularities on the surface of the document 3, and uses height data processing apparatus as height data. 1 to send.

  The texture 3 has an uneven shape on the surface of the document 3. As described above, when the document 3 is bent or the thickness of the document 3 itself is not uniform, a bent shape other than the texture uneven shape is formed. It will be included in the height data.

  FIG. 2B is an example of the height data 24 including the deflection shape and the like. The height data 24 is image data indicating the height information of the texture unevenness shape by gradation values. The height data 24 in FIG. 2 (b) is a representation of the texture irregularity shape in a gray scale of 256 gradations with white at the high part and black at the low part. The upper left part is low due to the deflection, and the lower right part. The part is high.

  FIG. 3 is a diagram illustrating a hardware configuration of the height data processing apparatus 1. The height data processing apparatus 1 includes, for example, a control unit 11, a storage unit 12, a media input / output unit 13, a peripheral device I / F (interface) unit 14, a communication unit 15, an input unit 16, a display unit 17, a printing unit 18, and the like. Can be realized by a general computer configured by being connected via the bus 19.

The control unit 11 includes a CPU, ROM, RAM, and the like.
The CPU calls a program stored in the storage unit 12, ROM, recording medium or the like to a work memory area on the RAM and executes it, and drives and controls each unit connected via the bus 18. The ROM permanently holds a computer boot program, a program such as BIOS, data, and the like. The RAM temporarily stores the loaded program and data, and includes a work area used by the control unit 11 to perform various processes.

  The storage unit 12 is, for example, a hard disk drive, and stores a program executed by the control unit 11 in processing to be described later, data necessary for program execution, an OS, and the like. These program codes are read by the control unit 11 as necessary, transferred to the RAM, and read and executed by the CPU.

The media input / output unit 13 is a media input / output device such as a DVD drive, and performs data input / output.
The peripheral device I / F unit 14 is a port for connecting a peripheral device, and transmits / receives data to / from the peripheral device via the peripheral device I / F unit 14. The connection form with the peripheral device may be wired or wireless.
The communication unit 15 includes a communication control device, a communication port, and the like, and mediates communication with other devices via the network.

The input unit 16 is an input device such as a keyboard, a pointing device such as a mouse, or a numeric keypad, and outputs input data to the control unit 11.
The display unit 17 includes a display device such as a liquid crystal panel or a CRT monitor, and a logic circuit (video adapter or the like) for executing display processing in cooperation with the display device. The display unit 17 is input by the control of the control unit 11. Information is displayed on a display device.
The printing unit 18 is a printer or the like, and prints various image data as necessary.
The bus 19 is a path that mediates transmission / reception of control signals, data signals, and the like between the units.

  Next, the functional configuration of the height data processing apparatus 1 will be described with reference to FIG.

  As shown in FIG. 4, the height data processing apparatus 1 includes a height difference calculating unit 21, an appropriate distance calculating unit 22, a height data correcting unit 23, and the like, and height data 24 is stored in the storage unit 12.

  In the height difference calculating means 21, the control unit 11 of the height data processing device 1 subtracts the average gradation value of pixels within a predetermined distance from each pixel from the gradation value of each pixel of the height data 24. Thus, the corrected height data is created, and the height difference that is the difference between the maximum value and the minimum value of the gradation value of the corrected height data is obtained. In general, the above processing for creating the corrected height data is referred to as “blurring processing”, and the above distance is referred to as “blur radius”, and these terms may be used in the following description.

  The appropriate distance calculation means 22 is a relational expression showing the relationship between the blur radius and the height difference obtained by the control unit 11 of the height data processing device 1 calculating the height difference for a plurality of blur radii. The blur radius is determined so that the height difference is substantially constant with respect to the change in blur radius before and after.

  The height data correction means 23 creates correction height data in the same procedure as described above, using the blur radius calculated by the appropriate distance calculation means 22 by the control unit 11 of the height data processing apparatus 1.

(2. Height data processing method)
Next, a height data processing method by the height data processing apparatus 1 will be described. FIG. 5 is a flowchart showing the height data processing method, and each step in the figure is executed by the control unit 11 of the height data processing apparatus 1.

(S1. Acquisition of height data 24)
In the present embodiment, first, the height data processing device 1 acquires the height data 24 stored in the storage unit 12 (S1).

(S2: Calculation of height difference of corrected height data)
The height data processing device 1 performs a blurring process on the height data 24 at each of a plurality of blurring radii, and calculates a height difference H for the height data 24 (corrected height data) after each blurring process (S2).

  Although the blurring process is known, it will be briefly described with reference to FIGS. 6 and 7 show the pixels of the height data 24 by squares. In FIGS. 6A, 7A and 7B, the distance from the center pixel of interest 241a is displayed in the squares. FIG. 6B and FIG. 7C show weighting coefficients at the time of average value calculation in squares. FIG. 6C shows gradation values in the square.

  In the blurring process, for example, as shown in FIG. 6A, the gradation values are equally weighted as shown in FIG. 6B for each pixel within the square attention range centered on the target pixel 241a. The average value is calculated as the average gradation value. Then, the average gradation value is subtracted from the gradation value of the target pixel 241a. The blurring process is performed by performing the above process with each pixel of the height data 24 as the target pixel 241a.

  Here, the distance from the target pixel 241a to the outermost pixel in the target range is the blur radius r. In the example shown in the figure, the distance between the pixel and the surrounding eight pixels is 1, and r = 2.

  As shown in the left diagram of FIG. 6C, when the pixel of interest at the outer edge of the height data 24 is the pixel of interest 241a and the region of interest protrudes from the range of the height data 24, an appropriate boundary condition is set. It is preferable to calculate the average gradation value by setting. For example, when the attention range protrudes from the side of the height data 24 as shown in the left diagram of FIG. 6C, the gradation values of the pixels in the protruding range are changed as shown in the right diagram of FIG. The gradation process can be performed on the assumption that the gradation value of the pixel of the height data 24 is in a line-symmetrical position with respect to the pixel column on the side.

  Further, the attention range is not limited to a square. For example, it may be a rhombus range as shown in FIG. 7 (a) or a range close to a circle as shown in FIG. 7 (b). In addition, regarding the average value, instead of weighting each pixel equally, the average value may be calculated by changing the weight according to the pixel position as shown in FIG. In the example shown in the figure, the closer the pixel is to the center pixel of interest 241a, the greater the weighting, and this is generally called Gaussian blurring.

  In S2, the above-described blurring process is performed for each of a plurality of blurring radii r set in advance, and the difference between the maximum value and the minimum value of the gradation value is calculated as the height difference H for each of the height data 24 after the blurring process. . The setting of the range that can be taken by the blur radius r is arbitrary. For example, when the same pattern is repeated in a woven pattern or the like, a plurality of blur radii r can be defined within the range of the width of the pattern.

(S3: Calculation of appropriate distance)
Next, the height data processing apparatus 1 creates a relational expression between the height difference H and the blur radius r, and sets the blur radius r such that the height difference is substantially constant with respect to the change in the blur radius r before and after the appropriate distance. (S3).

  Here, as shown in FIG. 8A, the relationship between the blur radius r and the height difference H is approximated from the data 40 obtained by calculating the height difference H for a plurality of blur radii r in S2. A relational expression H = f (r) such as a cubic curve is created. 41 in the figure is an approximate line showing the relational expression H = f (r).

  In the case of a sheet such as wallpaper, in the relational expression H = f (r), the height difference H generally increases as the blur radius r increases. This is because when the value of the blur radius r is small, the high-frequency component of the height data 24 is removed, and fine texture irregularities are reduced by the blur processing as shown in FIG. 8B. On the other hand, the value of the blur radius r is increased, and if it is within an appropriate range, the low to medium frequency components representing the deflection of the document 3 in the height data 24 and the uneven thickness of the document 3 are removed. As shown in FIG. 8C, a fine uneven shape remains. However, if the value of the blur radius r is further increased and exceeds an appropriate range, the low to medium frequency components cannot be removed, and the height difference H increases due to the components.

  In the range A where the value of the blur radius r is small and the range C where the value is large, the slope of the approximate line 41 indicating the relational expression H = f (r) is large. On the other hand, in the intermediate range B, the inclination is small and the height difference H is substantially constant. This is because, in the case of a sheet such as wallpaper, generally, as shown in FIG. 9, the spatial frequency distribution of the height data 24 has peaks at low to medium frequencies and high frequencies. .

  That is, the height data 24 includes, as components, a height change caused by the deflection of the document 3 and the texture unevenness formed on the document surface, and the former height change is a low to medium frequency component, and the latter. The concavo-convex shape appears predominantly as a high frequency component. As shown in FIG. 9, since the height change caused by the deflection of the document 3 has a relatively wide frequency band, in the range B where the value of the blur radius r is medium, the height changes even if the blur radius r is changed. The difference H does not vary greatly and is substantially constant. On the other hand, since the uneven shape of the texture is narrowly distributed in the high frequency region, in the range A where the value of the blur radius r is small, the height data 24 changes greatly only by changing the blur radius r slightly, and as a result, the height difference H is changed. It fluctuates greatly. In addition, in the range C where the value of the blur radius r is large, the deflection shape in the medium frequency region is gradually removed from the height data 24 without being removed as the blur radius r increases, so that the fluctuation of the height difference H also increases. .

  In the present embodiment, in order to remove the deflection shape and the like from the height data 24, the height difference H is approximately constant with respect to the change in the blur radius r before and after the approximate line 41 in FIG. One blur radius r in the range B is calculated. This is because the deflection shape or the like of the document 3 appears as a spatial frequency in the range B between the range A and the range C.

The range B in which the height difference H is substantially constant with respect to the change in the blur radius r is, for example, as shown in FIG. 10A, the blur radius r with respect to the relational expression H = f (r). The first-order derivative dH / dr is calculated, and the average value μ and the standard deviation σ regarding the fluctuation is used to define the range of the blur radius r that satisfies the following expression (1).
μ−σ <dH / dr <μ + σ (1)

In the present embodiment, in order to calculate one appropriate blur radius r, a second-order differential d ² H / dr ² with respect to the blur radius r is calculated for the relational expression H = f (r) as shown in FIG. 10B. To do. Then, the value of the blur radius r ₀ such that the value is 0 is obtained, and this is set as an appropriate blur radius r. As a method of calculating the blur radius r ₀ , a blur radius value that minimizes the value of the first-order differential dH / dr may be obtained.

(S4: Blur processing of height data)
The height data processing apparatus 1 finally performs the blur processing of the height data 24 with the appropriate blur radius r calculated in S3. As a result, the bending shape or the like of the document 3 is removed. As the blurring process, the same process as described in S2 can be used.

  FIG. 11 is a diagram showing this blurring process. By blurring the original height data, which appears as the left and right deflection shape shown on the left, with an appropriate blurring radius, the deflection shape is removed as shown on the right, and the fine uneven shape of the texture is shown. Height data in which (a pattern in which a high position and a low position are repeated in a checkerboard pattern) remains is obtained. On the other hand, when the blur radius is small or large, the fine concavo-convex shape of the texture is deteriorated or the bent shape cannot be completely removed.

(3. Embossed plate production and wallpaper production)
The height data 24, which has been corrected as described above and from which the bent shape or the like has been removed, is used in the manufacture of an embossed plate, whereby a texture uneven shape is formed on the surface of the embossed plate. This will be described with reference to FIG.

  The embossing plate manufacturing apparatus 9 </ b> A in FIG. 12 uses the height data 24 to perform an embossed engraving with a textured uneven shape on the embossed plate cylinder. As shown in the figure, the embossed plate manufacturing apparatus 9 </ b> A includes a computer 91, an engraving machine 93, a support base 101, and a rotation drive unit 104.

  The computer 91 corrects the height data 24 by the method described above as the height data processing apparatus 1 and controls the engraving machine 93 based on the corrected height data 24.

  The engraving machine 93 is an embossed plate manufacturing means including an engraving machine control unit 931, a driving unit 932, and an engraving blade (cutting blade) 933.

  The engraving machine control unit 931 drives the drive unit 932 according to the height data 24 input from the computer 91, and the depth direction with respect to the plate surface of the embossing plate cylinder 100 supported by the support bases 101, 101. The embossing cylinder 100 is moved in the direction of the rotation axis (direction AA in the figure). The rotation driving unit 104 rotates the embossed plate cylinder 100 supported by the support bases 101 and 101 around the direction of the rotation axis AA in accordance with an instruction input from the computer 91.

  Accordingly, the engraving machine 93 engraves the metal or resin embossed plate cylinder 100 at a depth according to the height data 24 to form a textured uneven shape.

  The engraving machine 93 may be of a type using a laser or the like instead of the engraving blade 933. In this case, the engraving machine 93 may use a scanning unit, a laser oscillator, and an optical unit in place of the driving unit 932 and the engraving blade 933 in FIG. In the same manner as described above, the laser beam having an output value based on the height data 24 is irradiated through the optical unit while moving the embossing cylinder 100 or the optical unit. This also makes it possible to form a textured uneven shape on the embossed cylinder 100.

  On the other hand, the embossed plate manufacturing apparatus 9B shown in FIG. 13 forms an uneven shape of the texture on the embossed plate cylinder using an etching method based on the height data 24.

  The embossed plate manufacturing apparatus 9B includes a pattern exposure device 96, a corrosion device 98, a support base 101, and a rotation drive unit 104 in addition to the computer 91 similar to the above. An embossed cylinder 200 coated with a resist layer is attached to the support base 101.

  The pattern exposure apparatus 96 includes a scanning unit 961, a laser oscillator 962, and an optical unit 963, and constitutes an embossed plate manufacturing unit together with the corrosion apparatus 98.

  The pattern exposure device 96 drives the scanning unit 961 according to the height data 24 input from the computer 91 to move the optical unit in the direction of the rotation axis of the embossed cylinder 200 and controls the laser oscillator 962 to obtain the height data 24. Modulate the output value accordingly.

  Here, the height data 24 is binarized using a predetermined gradation value as a threshold value, and control is performed so that the laser is turned ON / OFF with the threshold value as a boundary. Thereby, a laser beam is irradiated to a predetermined position of the embossed plate cylinder 200 coated with the resist layer, and an exposure process for forming a pattern including an exposed portion and a non-exposed portion is performed. As the resist layer, either a positive resist or a negative resist can be used. In the case of a positive resist, the resist layer in the exposed area is gelled by the exposure process. In the case of a negative resist, the resist layer in the exposed portion is cured by the exposure process.

  After the exposure processing is completed, the embossing plate cylinder 200 is developed and washed with a developing device (not shown), and an exposed portion (in the case of a positive resist) or a non-exposed portion (in the case of a negative resist) of the resist layer is removed. Then, a resist layer pattern is formed.

  Thereafter, when a corrosive liquid is applied to the embossed plate cylinder 200 by the corrosive device 98, the metal surface portion exposed by the removal of the resist layer is corroded and recessed, and an uneven shape corresponding to the pattern is formed. Subsequently, a cleaning process is performed to remove the remaining resist layer.

  Thereafter, the resist layer is again coated on the surface of the embossed cylinder 200, and the above processing is repeated while changing the above threshold value. By performing this process a plurality of times, it is possible to form a plurality of concavo-convex shapes on the surface of the embossing plate cylinder 200, thereby forming a texture concavo-convex shape. An appropriate value may be set in advance as the threshold value.

  Further, as a means for forming a resist layer pattern by a laser beam, it is necessary to draw directly on the embossed cylinder 200 coated with the resist layer (burn out the resist layer) and to remove the resist layer by development processing or cleaning processing. There are laser plate machines that do not, and are often used. The configuration of the embossed plate manufacturing apparatus in this case is the same as that of the embossed plate manufacturing apparatus 9B described above except that a developing device or the like is not required.

  At this time, the pattern exposure apparatus 96 performs the same control as described above, irradiates a predetermined position of the embossing plate cylinder 200 coated with the resist layer with a laser beam, burns and removes the resist layer in the exposed portion, and removes the resist layer. Form a pattern. As a laser oscillated by the laser oscillator 962, a YAG laser or a fiber laser can be used.

  Thereafter, the same corrosion treatment as described above is performed to form an uneven shape corresponding to the pattern on the embossed plate, and then the remaining resist layer is removed by the cleaning treatment. By repeating the resist layer coating, the exposure process, the corrosion process, and the cleaning process a plurality of times while changing the threshold value, irregularities having different depths can be formed on the surface of the embossed plate cylinder 200.

  The embossed plate manufacturing apparatus 9 </ b> C in FIG. 14 manufactures a photomask 97 based on the height data 24, and etches the embossed plate cylinder 200 using the photomask 97, thereby forming a textured uneven shape.

  The embossed plate manufacturing apparatus 9C includes a pattern exposure device 96, corrosion devices 98 and 98a, an embossed plate exposure device 99, a support base 101, and a rotation drive unit 104 in addition to the computer 91 similar to the above. An embossed cylinder 200 coated with a resist layer is attached to the support base 101.

  Here, the pattern exposure device 96 and the corrosion device 98 are used in the manufacturing stage of the photomask 97, and the embossed plate is manufactured by the embossing plate exposure device 99 and the corrosion device 98a using the photomask 97. That is, these devices constitute embossed plate manufacturing means.

  In the photomask 97, a light shielding film 972 is formed on a substrate 973, and a resist layer 971 is further coated thereon. With respect to the photomask 97 in such a state, the pattern exposure apparatus 96 performs exposure control according to the threshold value of the height data 24 in the same manner as described with reference to FIG. And a non-exposed portion. Thereafter, development and washing are performed to remove an unnecessary resist layer to form a resist layer pattern. In the portion where the resist layer is removed, the light shielding film 972 is exposed.

  Subsequently, when a corrosive liquid is applied by the corrosive device 98, the exposed portion of the light shielding film 972 is removed by corrosion. Thereafter, when the remaining resist layer is removed by the cleaning process, a photomask 97 in which the pattern of the light shielding film 972 is formed on the substrate 973 is manufactured.

  The required number of photomasks 97 are manufactured while changing the threshold value, and each is used for exposure to the embossing plate cylinder 200. That is, the embossed plate cylinder 200 coated with the resist layer is covered with a photomask 97 and exposed by an embossed plate exposure apparatus 99, whereby an exposure portion according to the pattern of the light shielding film 972 formed on the photomask 97 and A non-exposed portion is formed.

  Subsequently, as in the example of FIG. 13, development and cleaning processes are performed to remove unnecessary resist layers and form a resist layer pattern. Thereafter, when corrosion and cleaning processes are performed using a corrosive device 98a or a cleaning device (not shown), as described above, irregularities are formed on the surface of the embossed plate cylinder 200, and the remaining resist layer is removed.

  The surface of the embossed plate cylinder 200 is changed by replacing the photomask 97 and repeating the processes of resist layer coating, exposure, development, cleaning (removal of unnecessary resist layer), corrosion, and cleaning (removal of remaining resist layer). A plurality of concavo-convex shapes can be formed, and a texture concavo-convex shape can be formed.

  According to these embossed plate manufacturing apparatuses 9A, 9B, and 9C, it is possible to form textured uneven shapes on the embossed plate cylinders 100 and 200 based on the height data 24. Further, a sheet such as wallpaper can be manufactured by embossing a desired sheet using the embossed cylinders 100 and 200. The material of the sheet is determined according to the application, and for example, paper, resin, synthetic leather, or the like can be used.

  As described above, the change in height of the height data 24 caused by the deflection of the document 3 has a relatively wide frequency band. Therefore, when the blur radius r is in a range corresponding to such a frequency band, the blur is generated. Even if the radius r is changed, the height difference H does not vary greatly and becomes substantially constant. Therefore, in this embodiment, by adopting the blur radius r in such a range and correcting the height data 24, the deflection shape of the document 3 in the height data 24 can be automatically removed on the computer, and the user This reduces the burden of trial and error, and can easily remove the bent shape with high accuracy. By producing an embossed plate based on the height data 24 after removing the bent shape and the like, and embossing the sheet surface using the manufactured embossed plate, the influence of the bent shape and the like is reduced and the design is excellent. Sheets such as wallpaper can be manufactured efficiently.

[Second Embodiment]
Next, a second embodiment of the present invention will be described. The second embodiment is a different example in the method of calculating an appropriate blur radius r in S3 of FIG. Since other than that is the same as that of 1st Embodiment, description is abbreviate | omitted.

  The second embodiment is an example in which, in the above relational expression, the upper limit value of the range in which the height difference H is substantially constant with respect to the change in the blur radius r before and after is calculated, and the height difference H increases. The starting blur radius r is calculated.

  In the second embodiment, the curvature is used to calculate one appropriate blur radius r in S3. That is, as shown in FIG. 15A, the curvature radius R is obtained for the approximate line 41 representing the relational expression H = f (r), and the curvature 1 / R is maximized as shown in FIG. 15B. The blur radius rmax is calculated as an appropriate blur radius r.

  In the second embodiment, an appropriate blur radius r can be calculated based on the curvature of the approximate line 41, and the same effect as in the first embodiment can be obtained. On the other hand, in the first embodiment, an appropriate blurring radius can be calculated from the inflection point of the relational expression H = f (r). Which method is used to calculate an appropriate blurring radius depends on the sheet characteristics, the deflection shape, and the like. The selection may be made according to other characteristics.

  The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to such examples. It will be apparent to those skilled in the art that various changes or modifications can be conceived within the scope of the technical idea disclosed in the present application, and these naturally belong to the technical scope of the present invention. Understood.

1: Height data processing device 2: Three-dimensional scanner 3: Documents 9A, 9B, 9C: Embossed plate manufacturing device 21: Height difference calculating means 22: Suitable distance calculating means 23: Height data correcting means 24: Height data

Claims (7)

The height data for embossed plate production, which is image data indicating the height information as gradation values, obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, from the gradation value of each pixel, the pixel The corrected height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the height, and the height difference that is the difference between the maximum value and the minimum value of the corrected height data is obtained. A difference calculating means;
In the relational expression showing the relationship between the distance and the height difference obtained by calculating the height difference for a plurality of the distances, the height difference is substantially constant with respect to the change in the distance before and after. A suitable distance calculating means for obtaining the distance;
Height data correcting means for creating the corrected height data when the predetermined distance is the distance calculated by the appropriate distance calculating means;
A height data processing apparatus comprising:   The height data processing apparatus according to claim 1, wherein the appropriate distance calculation unit calculates the distance such that a second-order differential value of the relational expression is zero. Computer
The height data for embossed plate production, which is image data indicating the height information as gradation values, obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, from the gradation value of each pixel, the pixel The corrected height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the height, and the height difference that is the difference between the maximum value and the minimum value of the corrected height data is obtained. A difference calculating step;
In the relational expression showing the relationship between the distance and the height difference obtained by calculating the height difference for a plurality of the distances, the height difference is substantially constant with respect to the change in the distance before and after. A suitable distance calculating step for obtaining the distance;
Height data correction step for creating the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step;
The height data processing method characterized by performing. On the computer,
The height data for embossed plate production, which is image data indicating the height information as gradation values, obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, from the gradation value of each pixel, the pixel The corrected height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the height, and the height difference that is the difference between the maximum value and the minimum value of the corrected height data is obtained. A difference calculating step;
In the relational expression showing the relationship between the distance and the height difference obtained by calculating the height difference for a plurality of the distances, the height difference is substantially constant with respect to the change in the distance before and after. A suitable distance calculating step for obtaining the distance;
Height data correction step for creating the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step;
A program for running On the computer,
The height data for embossed plate production, which is image data indicating the height information as gradation values, obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, from the gradation value of each pixel, the pixel The corrected height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the height, and the height difference that is the difference between the maximum value and the minimum value of the corrected height data is obtained. A difference calculating step;
In the relational expression showing the relationship between the distance and the height difference obtained by calculating the height difference for a plurality of the distances, the height difference is substantially constant with respect to the change in the distance before and after. A suitable distance calculating step for obtaining the distance;
Height data correction step for creating the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step;
A recording medium on which a program for executing the program is recorded. Computer
The height data for embossed plate production, which is image data indicating the height information as gradation values, obtained by three-dimensionally scanning a document having a concavo-convex shape on the surface, from the gradation value of each pixel, the pixel The corrected height data is created by subtracting the average gradation value of the pixels within a predetermined distance from the height, and the height difference that is the difference between the maximum value and the minimum value of the corrected height data is obtained. A difference calculating step;
In the relational expression showing the relationship between the distance and the height difference obtained by calculating the height difference for a plurality of the distances, the height difference is substantially constant with respect to the change in the distance before and after. A suitable distance calculating step for obtaining the distance;
Height data correction step for creating the corrected height data when the predetermined distance is the distance calculated in the appropriate distance calculation step;
Run
Embossed plate manufacturing means
An embossed plate manufacturing method characterized in that, based on the corrected height data calculated in the height data correcting step, an embossed plate having a concavo-convex shape indicated by the corrected height data formed on the surface by an engraving or etching technique. The sheet | seat manufacturing method characterized by embossing a sheet | seat surface using the embossing plate manufactured by the embossing plate manufacturing method of Claim 6 .