JPS6212038B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an embossing plate used in a wiping method and a valley printing method, and a method for manufacturing the same.

Wiping or valley printing methods are used to produce decorative sheets with wood grain and the like. In these methods, after embossing a thermoplastic resin sheet with an embossing plate having convex portions on the surface (wiping method) or at the same time as the embossing treatment (valley printing method), the formed recesses are filled with colorant or Print.

The embossed plates conventionally used for the wiping method and valley printing method include the photo etching method,
Those with unevenness formed by engraving or electroforming are used. However, the embossing plate obtained by photoetching or engraving has a relatively monotonous uneven structure, which is not desirable in terms of design. On the other hand, the embossing plate obtained by electroforming is superior in that it has faithful tone reproducibility, but it has limitations on originals, is difficult to form on a cylindrical plate cylinder, and is difficult to form on a cylindrical plate cylinder. Also, it is not possible to create or correct the tone manually, it is extremely difficult to process the seams between one embossed image and the next, the process is complicated, the manufacturing time is long, and the manufacturing cost is high. , its application to decorative sheets with wood grain patterns is almost never put to practical use. Engraving plates in which only the conduit is extracted based on the electroforming method have been widely put into practical use, and although the reproducibility of only the conduit shape is good, it cannot be expected to be in sync with minute surface shapes and gradation changes.

SUMMARY OF THE INVENTION In view of the above-mentioned circumstances, an object of the present invention is to provide an embossing plate capable of providing an embossed image with an excellent sense of substance and in which the uneven pattern and gradation are synchronized. Another object of the present invention is to provide a method for manufacturing the above-mentioned embossing plate by a combination of an image processing method, an engraving method, and an electrodeposition method.

That is, the embossing plate of the present invention is formed by forming a metal protrusion on a metal substrate, the lower part of which is buried in the metal substrate, and the metal protrusion has a relatively large protrusion relative to the shape and area of the recess of the original. It is characterized by having fine halftone dot-like protrusions having an area and density that change depending on the gradation of the original. Further, the method for manufacturing an embossing plate according to the present invention, which provides such an embossing plate, is characterized by including the following steps.

(b) creating a secondary original having image information including the shape and area of the concave portion of the starting original as well as the gradation of the starting original; (b) the step of creating a secondary original having image information including the shape and area of the recess of the starting original; Based on the image information of the secondary original, a relatively large recess corresponding to the shape and area of the recess of the starting original and a fine dot-shaped recess having an area and density that vary depending on the gradation of the starting original are engraved. (c) A step of selectively electrodepositing metal on the exposed portion of the substrate to form convex portions of electrodeposited metal.

Hereinafter, the present invention will be specifically described with reference to Examples.

1 and 2 are partial cross-sectional views showing the conceptual structure of an embodiment of the embossing plate of the present invention, respectively.

Referring to FIG. 1, this embossing plate has metal protrusions 2a and 2b on a metal substrate 1, the lower portions of which are buried in the metal substrate 1. It consists of a relatively large convex portion 2a corresponding to the gradation of the document, and a fine dot-like convex portion 2b having an area and density that change depending on the gradation of the original. Also the second
The embossed version shown in the figure has a protective layer 3 consisting of a chrome plating layer etc. covering the metal convex parts of the embossed version shown in Fig. 1.
was formed.

The production of the embossing plate according to the present invention is carried out in the following manner, taking, for example, a wood grain embossing plate as an example.

First, a starting manuscript made of, for example, an actual wood-grained board is photographed, and the most recessed parts of the original, such as conduits, or parts where the recesses should be particularly emphasized are photographically extracted and/or manually drawn. Create a positive that emphasizes the recesses. This positive is an intermediate document containing image information including the shape and area of the concave portion of the document, which is further modulated by hand-drawn image information as necessary. Next, the same original is photographed to create a positive having the desired gradation. This positive is an intermediate document that expresses the texture and color changes of the wood grain board as changes in density. At the stage of creating these intermediate manuscripts, it goes without saying that negative-positive reversal can be performed as necessary, and adjustments to tone and pattern as well as seam processing for seamless platemaking using cylindrical plate materials can also be performed as necessary. .

Next, the above intermediate manuscripts are photographically combined to create a secondary manuscript. This secondary document contains image information obtained by modulating the shape area of the concave portion of the starting document by changes in gradation of the document, hand-drawn information, etc. as density changes.

On the other hand, as shown in FIG. 3, a plate material having a resin film 4 formed on a metal base material 1 is prepared. This plate material preferably has a cylindrical shape suitable for seamless plate making, and FIG. 3 and the following figures should be understood as partial cross-sectional views of the surface layer viewed from the lateral direction. The material of the base material 1 must be electrically conductive, and copper, nickel, iron, aluminum, etc. are preferably used. The resin forming the resin film 2 satisfies the requirements of being non-conductive, having excellent suitability for coating, having excellent abrasion resistance, and having excellent suitability for engraving with an engraving needle. For example, polyvinyl cinnamate (for example, TPR204, 201 manufactured by Tokyo Ohka Kogyo Co., Ltd.), polyester, epoxy, urethane, and other resins are used. The resin film 4 is formed by applying a liquid resin or a resin solution using a spray, ring, roll coater, etc., drying it, and then hardening it by baking or ultraviolet irradiation.
It is formed to a thickness of ~5 μm.

The thus obtained plate material as shown in FIG. 3 is engraved in correspondence with the above-mentioned secondary manuscript, and as shown in FIG. 2), and a fine dot-like concave portion 5b is formed whose area and density vary depending on the gradation of the document. More specifically, the recess 5a reproduces the recess such as a conduit part of a wood grain board as it is or with some modification, and even if the recess is not formed in the original, it can be further reproduced according to the change in shading of the original. Although they are fine, fine halftone dot-like recesses 5b are added, which have a large area and a high density in the high concentration area, and a small area and low density in the low concentration area.

The above-mentioned engraving is preferably carried out using an electronic engraving machine commercially available under the trade names of Helio Chrysiograph (manufactured by Hell AG, West Germany), Skyanagraver, Scanyzer, Elgrama, and the like. This electronic engraving machine has a scanning section for optically scanning a document, an electronic calculation section for processing image information from the scanning section, and an engraving section for actually engraving with an engraving needle made of diamond or the like. It is something. This electronic engraving machine engraves the secondary original while rotating the plate cylinder. The engraving needle is inserted deeply or shallowly into the plate material depending on the density of the corresponding part of the secondary manuscript, thereby creating relatively large recesses 5a and fine recesses 5b corresponding to the gradation of the original and the shape and area of the recesses. It is formed on the metal base material 1 through the resin film 4. Also, one of the important advantages of using such an electronic engraving machine is that the dimensions are precisely matched in both the circumferential direction and the width direction, so when forming the recess in the cylinder,
It is possible to produce a completely seamless embossing plate.

Next, the exposed recesses 5a and 5b of the metal base material 1
Metal is deposited by electrodeposition (electroplating).
As the electrodeposited metal, a metal having good adhesion to the metal constituting the base material 1, such as copper or nickel, is used. These electrodeposition conditions and the like are well known to those skilled in the art, so there is no need to explain them in detail. As a result, metal convex portions 2a and fine mesh-like metal convex portions 2b having relatively large areas are formed corresponding to the concave portions 5a and 5b. The height of the convex portions 2a and 2b formed can be adjusted arbitrarily by changing the electrodeposition time, but generally ranges from 10 to 100 μm.

The product thus formed and illustrated in FIG. 5 itself corresponds to an embodiment of the embossing plate of the present invention. However, in order to emphasize the convex portions 2a and 2b, the resin film 4 is removed, for example, by peeling or melting, resulting in the structure shown in FIG. Furthermore, for the purpose of improving wear resistance, oxidation resistance, etc. and arbitrarily changing the surface condition (gloss) of the plate material, it is preferable to form a protective layer 3 made of, for example, a chrome layer or the like by, for example, electrodeposition.

The obtained embossing plate shown in FIG. 1, FIG. 2, or FIG.
7b, and to give a wood grain-like decorative board, for example, apply black or dark brown paint, and wipe the surface to apply paint to the bottom of the recess 7 according to the area and depth of the recess 7. A decorative surface with a change in color tone is provided by a large amount or a small amount of 8 remaining. In addition, in order to apply the known valley printing method, a paint having a desired color is supplied via an anilox roller only to the convex portions of the embossed plate, which has been heated to an appropriate level, and is heated separately. At the same time as it presses against the material to be embossed made of thermoplastic resin or the like, the paint adhering to the convex portion is transferred. As a result, the paint adheres to the recesses formed in the material to be embossed according to the shape of the recesses, and a decorative surface with a synchronized feel and extremely rich in design is obtained, which has both unevenness and color tone changes. . A protective layer made of a thermoplastic or thermosetting resin layer is further formed on the decorative surface, if necessary.

In the above, the most basic aspect of the method for manufacturing an embossing plate according to the present invention has been explained. However, the method of the present invention can also be implemented with modifications, for example as shown below.

That is, it is also possible to combine the writing of an image onto a metal substrate serving as a plate material with the known direct printing/developing method. In this case, a photosensitive resin is used for the resin forming the resin film 2, and only the portions on the printing plate where it is desired to form particularly high sharp convex portions are photographed using the photographic process described above. A resist is optically formed using a known direct baking/developing method, and only the convex portions of the substrate metal are exposed.

After that, input only the intermediate document on which you want to create minute textures, color changes, etc. into the electronic engraving machine,
The photosensitive resin film is engraved according to the method described in the present invention to expose the substrate in registration with the image already written by the direct baking/developing method, and a convex portion is formed through an electrodeposition process. is also possible.

In this case, the lower part of the convex part made of the image written by the direct printing/developing method is in close contact with the metal plate, and the lower part made of the image written by the electronic engraving machine is a fine mesh embedded in the metal plate. It is higher than the point-like convex part, and has the characteristic of having fine lines and sharp edges.

In addition, it is not necessary to create a secondary manuscript completely photographically as described above, but after obtaining an intermediate manuscript using the photographic method, the image information from this is processed by the electronic calculation section of the electronic engraving machine. You can also create a secondary manuscript.

Further, instead of the electronic engraving machine, a laser engraving machine or an electron beam engraving machine having an electronic calculation section for image information processing can be used as well.

As described above, according to the present invention, an image processing method,
By employing a combination of the engraving method and the electrodeposition method, the following effects can be obtained.

(b) When embossing is performed using the embossing plate obtained in the present invention, clear recesses similar to those seen in conventional photo etching methods are formed in areas where recesses should be emphasized, such as conduit sections of wood grain decorative boards. On the other hand,
The gradation required for a decorative surface is reproduced by a collection of fine halftone dots with changes in area and density, just like those seen on the surface of a gravure plate, and when combined with the wiping method and valley printing method, it is possible to achieve extremely high design quality. A decorative sheet with high quality can be obtained.

(b) Since a photoengraving method can be used to create the secondary manuscript, it is not only simpler than the electroforming method, but there are no restrictions on the dimensions of the manuscript or plate material, and it is compatible with camera work and hand-drawing methods. By combining these, tonal effects are possible, and manufacturing costs are low.

(c) By engraving the recesses on the plate material using an electronic engraving machine, it is possible to precisely match the dimensions in both the circumferential direction and the width direction, resulting in completely seamless embossing with excellent gradation reproducibility. A plate can be manufactured.

[Brief explanation of the drawing]

Figures 1 and 2 are sectional views of an embodiment of the embossing plate of the present invention, respectively, and Figures 3 to 5 show intermediate steps in the production of the embossing plate according to the method of the present invention, viewed from the thickness direction of the plate material. The sectional view shown in FIG. 6 is a perspective sectional view of a decorative sheet obtained using the embossing plate of the present invention. 1... Metal base material, 2a... Relatively large metal protrusion,
2b...Fine dotted metal convex portions, 3...Protective layer, 4...Resin film, 5a...Relatively large recesses, 5b...Fine dotted concave portions, 6...Decorative sheet base material, 7a, 7b...Decorative sheet concavities , 8...Colored paint.

Claims (1)

[Scope of Claims] 1 A metal protrusion is formed on a metal substrate, the lower part of which is buried in the metal substrate, and the metal protrusion is a relatively large protrusion corresponding to the shape and area of the recess of the document. and fine halftone dot-like convex portions having an area and density that vary depending on the gradation of the original. 2. The embossing plate according to item 1, which has a protective layer covering the metal convex portion. 3. A method for manufacturing an embossed plate characterized by including the following steps: (a) a step of creating a secondary manuscript having image information including the shape and area of the concave portion of the starting manuscript and the gradation of the starting manuscript; (b) A relatively large recess corresponding to the shape and area of the recess of the starting original is formed on a metal substrate formed by forming a resin film on the metal substrate based on the image information of the secondary original, and a recess corresponding to the gradation of the starting original is formed on the metal substrate. (c) selectively electrodepositing metal on the exposed portions of the substrate to form convex portions of electrodeposited metal; Process. 4. In step (a), the shape and area of the concave portion and the gradation of the starting manuscript are individually taken out photographically and further synthesized to create a secondary manuscript.
Section method. 5. The method described in item 4 above, in which a secondary manuscript is created by overlapping and compositing images that are manually added to the parts to be further emphasized. 6. The method according to any of the above items 3 to 5, in which the engraving in step (b) is performed using an electronic engraving machine. 7. The above-mentioned third plate in which the plate material forms a cylindrical plate cylinder.
Any method from Section 6 to Section 6.