Description

Nickel Emboss Roller and Manufacturing Method thereof Technical Field

[1] The present invention relates to an emboss roller for transferring a particular pattern to an object, and more particularly, to a nickel emboss roller and method of manufacturing the same, in which the emboss roller is manufactured through a nickel plating, thereby improving the quality and the durability of the product. Background Art

[2] In general, an emboss roller is used to transfer patterns or designs, which exist naturally or are created artificially, to an object. Such an emboss roller is generally manufactured of steel, but, as the steel-made emboss roller is susceptible to rust and the like, it is usually manufactured of material resistant to rust, when it is used in a wet place. In this regard, a silicone emboss roller is exemplary for such rollers due to easiness of manufacture. However, the silicone emboss roller can be used to a particular object in terms of the material. That is, as the basic material of the silicone emboss roller is rubber, it is used restrictively to an artificial leather using PVC or PU material among the synthetic leathers due to the limitation of physical property of the rubber.

[3] Accordingly, it has been required to develop an emboss roller which can be used to an object made of various materials. In this regard, a plating roller using nickel has been developed, although the realization state of the pattern of the plating roller is decreased in comparison with the silicone emboss roller. That is, such a plating roller is called a fillable type nickel plating roller which is manufactured by plating nickel on the surface of the silicone emboss roller. With regard to the nickel plating roller, it has been expected to be used for a long time because the state of the deep plating is good, and the abrasion resistance is superior to that of the rubber as the material of the nickel roller is metal.

[4] However, in case of the filling type nickel plating roller, thermal conductivity was low due to structural features, breakdown of the roller has frequently occurred at the time of the transfer work using the pressure, and the durability has failed to come up to the expectations too. Disclosure of Invention Technical Problem

[5] Accordingly, the present invention has been made to solve the above problems

occurring in the prior art, and it is an object of the present invention to provide a nickel emboss roller and method of manufacturing the same, in which the emboss roller is constructed such that a nickel emboss pipe is manufactured using a silicone tube and then an iron core is inserted into the nickel emboss pipe, thereby improving the quality and the durability of the product.

[6] Also, another object of the present invention is to provide a nickel emboss roller and method of manufacturing the same, which makes it easy to machine an inner peripheral surface of a nickel emboss pipe by forming a soft plating layer on the inner peripheral surface thereof.

[7] Furthermore, another object of the present invention is to provide a method for manufacturing a nickel emboss roller and a nickel emboss roller manufactured thereof, in which a plating layer of a metal identical to that of an inner peripheral surface of a nickel emboss pipe is formed on an outer peripheral surface of an iron core engaged with the nickel emboss pipe, so that the nickel emboss pipe is not separated from the iron core at the time of hot embossing or cold embossing using the emboss roller.

[8] In addition, another object of the present invention is to provide a method for manufacturing a nickel emboss roller and a nickel emboss roller manufactured thereof, which do not use an iron core and do not require machining of the inside of an inner peripheral surface of the nickel plating roller by forming a nickel plating layer thick. Technical Solution

[9] In order to accomplish the above objects, according to the present invention, there is provided a method for manufacturing a nickel emboss roller which comprises the steps of: preparing a silicone tube engraved with patterns to be used; inserting an iron core into the silicone tube and then coating silicone on the silicone tube and curing the coated silicone tube while rotating the iron core; separating emboss silicone tube and inserting an iron core into the inside thereof; assembling the iron core into a mold and filling a filler between an inner wall of the mold and an inner peripheral surface of the silicone tube; performing a nickel plating on an inner peripheral surface of the silicone tube after removing the iron core; and separating the mold, the filler, and the silicone tube to thereby obtain an engraved cylindrical nickel emboss pipe.

[10] Also, the method for manufacturing a nickel emboss roller of the present invention further comprises the steps of: smoothly machining an inner peripheral surface of the cylindrical nickel emboss pipe ; directly assembling an iron core into the cylindrical nickel emboss pipe; and fitting a shrink fitting ring onto the iron core after cutting both ends of the cylindrical nickel emboss pipe.

[11] Furthermore, the nickel emboss roller of the present invention comprises: a cylindrical nickel emboss pipe manufactured by the above method; an iron core directly assembled to an inner peripheral surface of the cylindrical nickel emboss pipe; and a shrink fitting ring shrink- fitted onto the iron core at both end sides of the cylindrical nickel emboss pipe for preventing the movement of the cylindrical nickel emboss pipe.

[12] Also, the nickel emboss roller of the present invention is characterized in that both ends of the nickel emboss pipe and a front end of the shrink fitting ring are cut slantly so that the shrink fitting ring can be fitted onto both ends of the nickel emboss pipe.

[13] In addition, according to the present invention, there is also provided a method for manufacturing a nickel emboss roller which comprises the steps of: preparing a silicone tube engraved with patterns to be used; inserting an iron core into the silicone tube and then coating silicone on the silicone tube and curing the coated silicone tube while rotating the iron core; separating emboss silicone tube and inserting an iron core into the inside thereof; assembling the iron core into a mold and filling a filler between an inner wall of the mold and an inner peripheral surface of the silicone tube; performing a nickel plating to form the nickel plating thickly on an inner peripheral surface of the silicone tube after removing the iron core; performing a secondary plating with soft hetero metal on the inner peripheral surface of the silicone tube after the nickel plating has been progressed to a predetermined degree; and separating the mold, the filler, and the silicone tube to thereby obtain an engraved cylindrical nickel emboss pipe.

[14] IVbreover, t he method for manufacturing a nickel emboss roller of the present invention further comprises the steps of: smoothly machining the inner peripheral surface of the cylindrical nickel emboss pipe; directly assembling the iron core into the cylindrical nickel emboss pipe; and fitting a shrink fitting ring onto the iron core after cutting both ends of the cylindrical nickel emboss pipe.

[15] Also, according to the method for manufacturing a nickel emboss roller of the present invention, it is characterized in that an outer peripheral surface of the iron core is plated with a metal material identical to that of the inner peripheral surface of the nickel emboss pipe.

[16] In addition, a nickel emboss roller of the present invention comprises: a cylindrical nickel emboss pipe having a plating layer formed of hetero metal at an inner peripheral surface of the cylindrical nickel emboss pipe manufactured by the manufactured by the above method ; an iron core directly assembled on an inner peripheral surface of the

cylindrical nickel emboss pipe; and a shrink fitting ring shrink-fitted onto the iron core at both ends of the cylindrical nickel emboss pipe for preventing the movement of the cylindrical nickel emboss pipe.

[17] IVbreover, according to the emboss roller of the present invention, it is characterized in that an outer peripheral surface of the iron core is provided with a plating layer formed by plating a metal material identical to that of the plating layer of the inner peripheral surface of the nickel emboss pipe.

[18] Also, according to the present invention, there is provided a method for manufacturing a nickel emboss roller of the present invention which comprises the steps of: preparing a silicone tube engraved with patterns to be used; inserting an iron core into the silicone tube and then coating silicone on the silicone tube and curing the coated silicone tube while rotating the iron core; separating the emboss silicone tube and inserting an iron core into the inside thereof; assembling the iron core into a mold and filling a filler between an inner wall of the mold and an inner peripheral surface of the silicone tube; performing a nickel plating to form the nickel plating thickly on an inner peripheral surface of the silicone tube after removing the iron core; separating the mold, the filler, and the silicone tube to thereby obtain an engraved cylindrical nickel emboss roll; and cut-machining the inner peripheral surface of both ends of the cylindrical nickel emboss roll.

[19] Also, the nickel emboss roller of the present invention comprises a cylindrical nickel emboss roll manufactured by the above method; and support shaft portions engaged to the inside of both ends of the cylindrical nickel emboss roll. Advantageous Effects

[20] Therefore, according to the nickel emboss roller and method for manufacturing the same of the present invention, it is possible to obtain the clean design at the time of forming the product because the nickel plating layer becomes an emboss surface, and to improve the construction of the nickel emboss roller.

[21] Also, according to the nickel emboss roller and method for manufacturing the same of the present invention, since the nickel emboss roller is manufactured by inserting the iron core into the nickel emboss pipe, it is possible to improve the quality of the product at the time of hot embossing and cold embossing due to excellent durability and improved thermal conductivity of the product.

[22] Furthermore, according to the nickel emboss roller and method for manufacturing the same of the present invention, it becomes easy to machine the inner peripheral surface of the nickel emboss pipe by forming a secondary plating layer made of soft metal on

the inner peripheral surface of the nickel emboss pipe.

[23] ϊVbreover, according to the nickel emboss roller and method for manufacturing the same of the present invention, since the outer peripheral surface of the iron core is plated by a metal identical to that of the secondary plating layer formed on the inner peripheral surface of the nickel emboss roller, the inner peripheral surface of the nickel emboss roller and the outer peripheral surface of the iron core expand and contract identically so that the iron core is not easily separated from the nickel emboss roller. Description of Drawings

[24] FIG. 1 is a flow chart diagram showing a method for manufacturing a nickel emboss roller according to the present invention;

[25] FIG. 2 is a view showing a process of manufacturing a nickel emboss roller of the present invention;

[26] FIG. 3 is a constructional view showing a first embodiment of the nickel emboss roller of the present invention;

[27] FIG. 4 is a detail view of 'A' in FIG. 3;

[28] FIG. 5 is a constructional view showing a second embodiment of the nickel emboss roller of the present invention;

[29] FIG. 6 is a constructional view showing a third embodiment of the nickel emboss roller of the present invention;

[30] FIG. 7 is a flow chart diagram showing another embodiment of the method for manufacturing a nickel emboss roller according to the present invention;

[31] FIG. 8 is constructional view showing a nickel emboss roller according to the method of FIG. 7. Mode for Invention

[32] Hereinafter, a nickel emboss roller and method for manufacturing the same of the present invention will be described in detail with reference to the appended drawings.

[33] In the present invention, FIG. 1 is a flow chart diagram showing a method for manufacturing a nickel emboss roller according to the present invention, FIG. 2 is a view showing a process of manufacturing a nickel emboss roller of the present invention, FIG. 3 is a constructional view showing a first embodiment of the nickel emboss roller of the present invention, FIG. 4 is a detail view of 'A' in FIG. 3, FIG. 5 is a constructional view showing a second embodiment of the nickel emboss roller of the present invention, FIG. 6 is a constructional view showing a third embodiment of the nickel emboss roller of the present invention, FIG. 7 is a flow chart diagram showing another embodiment of the method for manufacturing a nickel emboss roller according

to the present invention, and FIG. 8 is constructional view showing a nickel emboss roller according to the method of FIG. 7.

[34] The method for manufacturing a nickel emboss roller according to the present invention, comprises the steps of: preparing a silicone tube 1 engraved with patterns to be used; inserting an iron core 2 into the silicone tube 1 and then coating silicone 3 on the silicone tube and curing the coated silicone tube while rotating the iron core 2; separating the emboss silicone tube 3 and inserting an iron core 4 into the inside thereof; assembling the iron core 4 into a mold 5 and filling a filler 6 between an inner wall of the mold 5 and an inner peripheral surface of the silicone tube 3; performing a nickel plating 7 on an inner peripheral surface of the silicone tube 3 after removing the iron core 4; separating the mold 5, the filler 6, and the silicone tube 3 to thereby obtain an engraved cylindrical nickel emboss pipe 10; machining an inner peripheral surface of the cylindrical nickel emboss pipe 10 smoothly; directly assembling an iron core 20 into the cylindrical nickel emboss pipe 10; and, fitting a shrink fitting ring 30 onto the iron core 20 after cutting both ends of the cylindrical nickel emboss pipe 10.

[35] Herein, it is preferable that the iron core 20 is forcibly inserted so that it can have an outer diameter larger by 0-0.5 mm than an inner diameter of the cylindrical nickel emboss roller.

[36] The nickel emboss roller manufactured by the method according to the above method for manufacturing a nickel emboss roller, comprises a cylindrical nickel emboss pipe 10; an iron core 20 directly assembled to an inner peripheral surface of the cylindrical nickel emboss pipe 10; and a shrink-fitting ring 30 provided by a shrink fitting into the iron core 20 at both end sides of the cylindrical nickel emboss pipe 10 for preventing the movement of the cylindrical nickel emboss pipe 10.

[37] In this instance, it is preferable to cut both ends of the nickel emboss pipe 10 and a front end of the shrink fitting ring 30 slant, so that the shrink fitting ring 30 can be fitted onto both ends of the nickel emboss pipe 10, and the inclination angle of the cutting of the nickel emboss pipe 10 is made to be less than 50 ° .

[38] Meanwhile, the method for manufacturing a nickel emboss roller according to the present invention can comprise the steps of: preparing a silicone tube 1 engraved with patterns to be used; inserting an iron core 2 into the silicone tube 1 and then coating silicone 3 on the silicone tube and curing the coated silicone tube while rotating the iron core 2; separating the emboss silicone tube 3 and inserting an iron core 4 into the inside thereof; assembling the iron core 4 into a mold 5 and filling a filler 6 between an inner wall of the mold 5 and an inner peripheral surface of the silicone tube 3;

performing a nickel plating 7 on an inner peripheral surface of the silicone tube 3 after removing the iron core 4; performing a secondary plating 8 with soft different kind of metal after the nickel plating has progressed to a predetermined degree; separating the mold 5, the filler 6, and the silicone tube 3 to thereby obtain an engraved cylindrical nickel emboss pipe 10; machining an inner peripheral surface of the cylindrical nickel emboss pipe 10 smoothly; directly assembling an iron core 20 into the cylindrical nickel emboss pipe 10; and, fitting a shrink fitting ring 30 onto the iron core 20 after cutting both ends of the cylindrical nickel emboss pipe 10.

[39] Herein, with regard to the different kind of metal, soft metal such as copper or zinc, which is easy of machining, can be used. Also, an outer peripheral surface of the iron core 20 can be plated with metal material identical to that of the inner peripheral surface of the nickel emboss pipe 10. In this instance, it is natural to choose the iron core 20 to have an outer diameter larger than an inner diameter of the cylindrical nickel emboss pipe 10 by 0-0.5 mm .

[40] The nickel emboss roller manufactured through the above method comprises a cylindrical nickel emboss pipe 10 provided with a plating layer 15 formed by different kind of metal on an inner peripheral surface; an iron core 20 directly assembled into an inner peripheral surface of the cylindrical nickel emboss pipe 10; and a shrink fitting ring 30 which is shrink-fitted onto the iron core 20 at both end sides of the cylindrical nickel emboss pipe 10 for preventing the movement of the cylindrical nickel emboss pipe 10. Incidentally, the outer peripheral surface of the iron core 20 can be provided with a plating layer 25 formed of metal material identical to that of the plating layer 15 of the inner peripheral surface of the nickel emboss pipe 10.

[41] It is preferable to cut both ends of the nickel emboss pipe 10 and a front end of the shrink fitting ring 30 slant, so that the shrink fitting ring 30 can be fitted onto both ends of the nickel emboss pipe 10, and the inclination angle of the cutting of the nickel emboss pipe 10 is made to be less than 50 ° .

[42] According to the nickel emboss roller and the manufacturing method thereof of the present invention as described above, it is possible to improve the durability of the emboss roller and to expect improvement of the quality of the product using the same because the emboss roller using a nickel of high hardness can be manufactured.

[43] In the first embodiment of the method for manufacturing the nickel emboss roller, a silicone tube 1 with engraved patterns to be used is manufactured and prepared at first, an iron core 2 is inserted into the silicone tube 1, and then silicone is coated on the tube and cured while rotating the iron core 2. Then, a structure of covering the

engraved silicone tube 1 with an emboss silicone tube 3 is obtained, so that an iron core 4 is inserted into the inside of the emboss silicone tube 3 after separating the emboss silicone tube 3 from the engraved silicone tube 1.

[44] Then, the iron core 4 is assembled into a mold 5 and a filler 6 is filled between an inner wall of the mold 5 and an outer peripheral surface of the silicone tube 3. As a result, the silicone tube 3 is secured to the mold 5 by means of the filler 6 so that the shape of the silicone tube becomes to be unchanged when the iron core 4 is removed. The iron core 4 is removed when the back up of the filler 6 is completed, and nickel plating solution is injected into a space made by the removal of the iron core, so that it is possible to carry out the nickel plating on the inner peripheral surface of the silicone tube 3.

[45] Thereafter, the mold 5, the filler 6, and the silicone tube 3 are separated to acquire the engraved cylindrical nickel emboss pipe 10. Since a plating surface of the obtained cylindrical nickel emboss pipe 10 is not smooth, it is required to perform machining of the plating surface of the cylindrical nickel emboss pipe 10. Then, an iron core 20 is directly assembled to the cylindrical nickel emboss pipe 10, and both ends of the cylindrical nickel emboss pipe 10 are cut within a degree of 50 D , and a shrink fitting ring 30 is fitted onto the iron core 20 to thereby complete the manufacture of the nickel emboss roller.

[46] Herein, since the iron core 20 has an outer diameter larger by 0-0.5 mm than an inner diameter of the cylindrical nickel emboss pipe 10, the iron core 20 is forcibly fit into the nickel emboss pipe 10 so that they can be jointed firmly.

[47] In FIG.3, there is shown the nickel emboss roller manufactured by the method described above, and the thickness of the nickel plating constituting the cylindrical nickel emboss pipe is determined based on the deepness of the pattern.

[48] Meanwhile, with regard to the cylindrical nickel emboss pipe 10, since it is difficult to machine the nickel plating on the inner peripheral surface thereof, secondary plating of the soft hetero metal is performed on the inside of the nickel plating surface to facilitate the machining. That is, the inner peripheral surface of the nickel emboss pipe 10 is secondary plated with the soft metal such as copper or zinc, so that it is possible to machine the inner peripheral surface of the nickel emboss pipe 10 smoothly. In FIG. 5, there is shown the nickel emboss roller manufactured by the method described above, since the secondary plating layer 25 made by plating soft metal is formed on the inside of the nickel plating surface, it is advantageous because it is easy to machine the inner peripheral surface of the nickel emboss pipe 10 for inserting the iron core 20.

[49] Incidentally, if the nickel emboss pipe 10 is formed with the secondary plating layer

15 made of soft metal at the inner peripheral surface, since the thermal expansion coefficients of the secondary plating layer 15 and the iron core 20 inserted into it are different, the nickel emboss pipe 10 can be separated from the iron core 20 when the product is performed by the hot embossing or cold embossing using the nickel emboss roller. Accordingly, it is possible to form the plating layer 25 made of metal identical to that of the secondary plating layer 15 formed at the inner peripheral surface of the nickel emboss pipe 10.

[50] In FIG. 6, there is shown a nickel emboss roller manufactured through such manufacturing method, and if an outer peripheral surface of the iron core 20 is formed with the plating layer 25 made of the same metal as that of the secondary plating layer 15 formed at the inner peripheral surface of the nickel emboss pipe 10, an outer peripheral portion of the iron core 20 and an inner peripheral portion of the nickel emboss pipe 10 are become to expand and contract identically at the time of the formation using the nickel emboss roller, so that separation of the iron core 20 from the nickel emboss pipe 10 cannot be occurred.

[51] Meanwhile, when the iron core 20 is directly assembled into the nickel emboss pipe

10 as described above, it is necessary to machine the inner peripheral surface of the nickel emboss pipe 10 smoothly to insert the iron core 20. However, it is not easy to machine the inner peripheral surface of the nickel emboss pipe, in consideratrion of the feature of nickel. Accordingly, it is required to manufacture the nickel emboss roller without using the iron core 20.

[52] The method for manufacturing the nickel emboss roller comprises the steps of: preparing a silicone tube 1 engraved with patterns to be used; inserting an iron core 2 into the silicone tube 1 and then coating silicone 3 on the silicone tube and curing the coated silicone tube while rotating the iron core 2; separating the emboss silicone tube 3 and inserting an iron core 4 into the inside thereof; assembling the iron core 4 into a mold 5 and filling a filler 6 between an inner wall of the mold 5 and an inner peripheral surface of the silicone tube 3; performing a nickel plating 7 to form the nickel plating thickly on an inner peripheral surface of the silicone tube 3 after removing the iron core 4; separating the mold 5, the filler 6, and the silicone tube 3 to thereby obtain an engraved cylindrical nickel emboss roll 100; cut-machining the inner peripheral surface of both ends of the cylindrical nickel emboss roll 100; and engaging support shaft portions 200 at both ends of the cylindrical nickel emboss roll 100.

[53] Herein, the nickel plating layer is formed to be 7-15 mm thick if a width of the

emboss roller is about 16D0 mm , and if the width of the nickel emboss roller is as large as 2 to 3m, it is formed to be more than 20 mm . As a matter of fact, it can be formed to be less than 7 mm , if the width of the emboss roller is as small as Im.

[54] As shown in FIG. 8, the nickel emboss roller manufactured through the above described method comprises a cylindrical nickel emboss roll 100 engraved with a pattern at an outer peripheral surface and formed by plating a nickel to be more than a predetermined thickness; and support shaft portions 200 engaged to both inner sides of the cylindrical nickel emboss roll 100.

[55] The above described method for manufacturing the nickel emboss roller is adapted to carry out the function of the iron core by the nickel emboss roll 100 itself without using separate iron core. In this regard, the support shaft portions 200 are engaged to both ends of the nickel emboss roll 100 to rotate it. Accordingly, it is advantageous that it is not required to manufacture a separate iron core and to machine the inside of the inner peripheral surface of the nickel emboss roll 100.

[56] As described above, the present invention has been described with reference to the preferred embodiment. However, the scope of the present invention is not restricted to the identified embodiment as described above. Also, it is to be understood that the present invention can be properly modified and changed by those skilled in the art within the scope and spirit of the present invention as represented by the appended claims. Industrial Applicability

[57]