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CN-122008722-A - Combined detachable coating embossing roller and preparation and maintenance method thereof

CN122008722ACN 122008722 ACN122008722 ACN 122008722ACN-122008722-A

Abstract

The invention discloses a combined detachable coating embossing roller and a preparation and maintenance method thereof, and belongs to the technical field of embossing roller preparation. The embossing roller comprises a roller substrate, wherein the outer circumferential surface of the roller substrate is provided with a groove array, independent coating blocks are inlaid in each groove through interference fit, each coating block consists of an invar alloy substrate with a small thermal expansion coefficient and a wear-resistant coating on the surface of the invar alloy substrate, and patterns are engraved on the outer surface of the coating. The preparation method is characterized in that the roller matrix is heated to expand and then embedded into the coating block, and interference fixation is realized after cooling. The maintenance method comprises the steps of local replacement and integral renovation, wherein the damaged area is locally heated until the damaged area is matched with the damaged area to be loose, then a new block is replaced, and the whole coating block can be removed and replaced in sequence after moving and heating along the roller body during integral renovation. The invention realizes local quick repair and convenient pattern renewing of the embossing roller, and improves the service life and the production flexibility of the roller body.

Inventors

  • WANG CANMING
  • XIN ZHIPENG
  • SONG QIANG
  • SHAO LEI
  • SONG XIAOJIE
  • LIU YI

Assignees

  • 山东科技大学

Dates

Publication Date
20260512
Application Date
20260130

Claims (10)

  1. 1. A combined detachable coating embossing roller comprises a roller substrate and is characterized in that a plurality of square grooves are formed in the outer circumferential surface of the roller substrate to form a groove array, an independent coating block is inlaid and fixed in each groove through interference fit, the coating block comprises a block-shaped base material made of invar alloy and a coating layer coated on the outer surface of the block-shaped base material, embossing patterns are engraved on the outer surface of the coating layer, and the thermal expansion coefficient of the block-shaped base material is smaller than that of the roller substrate.
  2. 2. The combination removable coated embossing roll of claim 1 wherein said invar alloy comprises at least 4J36, 4J32 and 4J9 invar.
  3. 3. The composite removable coated patterned roll of claim 1 wherein the coating is an alloy coating prepared by laser cladding, plasma cladding, or a supersonic flame spraying process.
  4. 4. The combination removable coated embossing roll of claim 1 wherein the alloy coating is 0.5mm thick.
  5. 5. A method for producing a combined removable coated embossing roll as claimed in any one of claims 1 to 4, characterized in that it comprises in particular the following steps: the first step is to prepare a carbon steel-based roller substrate and process an array of grooves for embedding coating blocks on the outer circumferential surface thereof, the machining dimensional tolerance of the grooves being designed as M is the length or width dimension of the groove; preparing a cylinder made of invar alloy, and preparing a functional coating on the outer surface of the cylinder; cutting the invar alloy cylinder with the coating into independent coating blocks matched with the grooves, wherein the sizes of the coating blocks are consistent with the sizes of the grooves, and the machining dimensional tolerance is that ; Heating the roller matrix, expanding the size of the groove by utilizing the thermal expansion of the roller matrix, embedding the coating blocks into the grooves in a one-to-one correspondence manner, and fixing the coating blocks through interference fit after cooling; and fifthly, engraving an embossing pattern on the outer surface of the coating block.
  6. 6. The method of making a combination removable coated patterned roll according to claim 5 wherein step four is assembled using a mobile or segmented dynamic heating process.
  7. 7. The method of making a combination release coated patterned roll according to claim 5 wherein the temperature at which the roll substrate is heated in step four is from 100 ℃ to 200 ℃.
  8. 8. The method of manufacturing a patterned roll of claim 5, wherein the embossing pattern engraving is achieved by laser engraving.
  9. 9. A method of maintenance of a modular removable coated embossing roll as set forth in any one of claims 1-4, comprising partial coating block replacement and integral pattern refurbishment, wherein: The local coating block replacement method comprises the following steps: (1) Locally heating the region of the roller matrix corresponding to the coating block to be replaced; (2) Stopping heating when the temperature of the region reaches a preset value and the interference fit is enough to loosen, taking out the loosened coating block to be replaced by utilizing the local thermal expansion effect of the roller matrix immediately, and embedding a new coating block into a corresponding groove; (3) After the roller matrix is cooled and contracted, the new coating block is fixed through interference fit, and then corresponding embossing patterns are engraved on the surface of the new coating block according to the requirements; The (II) integral pattern renewing method is (1) Heating the roller matrix to remove interference fit between all coating blocks and the grooves, and taking out all old coating blocks; (2) Preparing and assembling a batch of new coating blocks meeting the requirements of new patterns; (3) And engraving a new pattern on the surface of the newly assembled coating block by laser, and finishing the renovation.
  10. 10. The method of maintaining a modular removable coated patterned roll according to claim 9 wherein step (1) is accomplished by moving the scanning heating from one end to the other end in the axial direction of the roll base using an induction heating coil, instantly loosening the coating blocks in the scanned area by interference fit using the difference in thermal expansion coefficient, immediately removing the loosened coating blocks in the area after the induction heating coil has moved, and repeating the process until all the coating blocks are sequentially removed.

Description

Combined detachable coating embossing roller and preparation and maintenance method thereof Technical Field The invention relates to a preparation method of an embossing roller, in particular to a preparation method of a combined embossing roller with a coating on the surface. Background The embossing roller is a special roller product for embossing concave-convex patterns on the surfaces of plastic sheets, films, aluminum foils, leather, hard plates, wallpaper, floor tiles, glass and other materials, and is widely applied to the printing fields of trademarks, stamps, floor patterns, postcards, cards and other products. The traditional roller base material is usually prepared from low-carbon alloy steel or stainless steel, a printing pattern is processed on the surface of the roller by adopting a laser engraving, electric spark machining or chemical etching method, and then the surface is plated with chromium or NiP and other alloy coatings to improve the surface hardness and corrosion resistance. The electroplating process is poor in environmental protection and reduces the definition of the printed pattern. There are also processes for preparing a thick abrasion-resistant coating (not less than 0.5 mm) on a roll surface by adopting plasma spraying, supersonic flame spraying and laser cladding processes, and then engraving patterns. However, the conventional method is to directly process the pattern on the roll surface, once the pattern is locally damaged, the roll is scrapped, and the pattern is required to be removed by secondary processing and prepared again, so that the cost is high. In small lot printing, each pattern requires custom embossing rolls, which also creates significant material and energy waste. To solve the above problems, several removable embossing roll solutions have been proposed in the prior art. For example, patent CN206646277U discloses a detachable embossing roll consisting of a plurality of unit roll bodies, adjacent unit roll bodies are spliced by grooves and corresponding bosses, and detachable engraved aluminum rings are arranged on the surfaces of the unit roll bodies to bear patterns. However, the replaceable unit of the scheme is a macroscopic roller section or a ring-shaped part, so that the microscopic local pattern unit on the embossed surface cannot be independently maintained and replaced, and mechanical structures such as mortise and tenon joints, bolts and the like are relied on. Another patent CN115839007a discloses a nonwoven fabric embossing roll provided with a "quick-change mechanism", wherein the mechanism is provided with a "middle embossing plate" and a "side embossing plate" outside the roll body, and uses mechanical locking structures such as "movable cavity", "push block", "fixed spring", "baffle" and engagement of "fixed slot" and "fixed block" to realize dismounting of the embossing plate. This solution, although allowing the replacement of the plate-like member, relies on an additional set of mechanical locking mechanisms, not based on the characteristics of the material itself. In summary, although the existing detachable scheme improves the partial repeatability of the roller body, the existing detachable scheme has the defects that (1) the replaceable unit is still an integral part (roller section or embossing plate) and cannot realize real local repair, (2) the existing detachable scheme relies on additional mechanical connection or locking mechanisms instead of using the characteristics of materials to realize connection, and (3) the difference of thermal expansion coefficients between the base body and the materials of the replaceable unit is not utilized, so that the existing detachable scheme cannot realize high-precision and high-reliability assembly and disassembly which can be completed without complex mechanisms and only by thermal expansion and cold contraction. Therefore, there is a need for an embossing roller and a method for manufacturing the embossing roller that can realize independent replacement of surface micropattern units, eliminate external mechanical connectors, and make full use of the thermal expansion coefficient difference of mating materials to realize stable interference fit assembly and disassembly. Disclosure of Invention The invention provides a combined type detachable coating embossing roller and a preparation and maintenance method thereof, and aims to overcome the defects that the traditional embossing roller is damaged locally, namely scrapped integrally, and the existing detachable embossing roller is inconvenient to disassemble and assemble due to the fact that a replacement unit of the existing detachable embossing roller is integrated and depends on mechanical connection. The embossing roller has the advantages that the independent coating block structure is embedded on the surface of the base roller, and the interference fit assembly and disassembly are realized by utilizing the difference of the thermal expa