Long plastic layer with embossing in register with pattern and rolling method and device therefor
A long plastic layer with an embossing in register with a pattern, a rolling method and a device are described herein. The method comprises a feeding step of feeding a plastic layer into oppositely rolling rollers; and a rolling step of hot rolling an embossing on the plastic layer. A feeding tension of the plastic layer is adjusted according to a longitudinal deviation between the embossing and the pattern in the rolling step. The device comprises a first feeding device, an oppositely rolling rollers control device, a detecting device, and a tension controller disposed on the first feeding device. According to the long plastic layer with the embossing in register with the pattern manufactured by the method, the embossing on the plastic layer is in register with the pattern on the plastic layer. The present invention provides the method, the device and the long plastic layer with the embossing in register with the pattern processed using the method, implementing the embossing rolled on the plastic layer in register with the pattern on the plastic layer and having high production efficiency, low cost and less energy consumption.
1. A rolling method for producing a long plastic layer with an embossing in register with a pattern, comprising:
a feeding step of feeding a plastic layer to be rolled into oppositely rolling rollers by a feeding roller, the plastic layer being printed with repeating unit patterns; and
a rolling step of hot rolling an embossing on the plastic layer;
in the feeding step, a front side of the plastic layer being adjacent to an embossing roller formed by one of the oppositely rolling rollers, and an embossed pattern disposed around an outer surface of a cylinder of the embossing roller corresponding to a pattern of one unit pattern on the plastic layer,
wherein a longitudinal deviation of the embossing is adjusted in the rolling step, an adjusting step comprises:
detecting the longitudinal deviation between the pattern on the plastic layer and the embossed pattern on the embossing roller by sensing a position of a preset part in each unit pattern on the already stretched plastic layer after the feeding roller and prior to entering the oppositely rolling rollers, and detecting a position of a corresponding part directly on the embossing roller corresponding to the preset part prior to embossing, and
adjusting a feeding tension of the plastic layer according to the longitudinal deviation, so as to adjust a stretching length of the plastic layer between the feeding roller in the feeding step and the oppositely rolling rollers in the rolling step before rolling and thereby embossing, so that the longitudinal deviation in subsequent rolling is reduced until the embossed pattern is longitudinally in register with the pattern on the plastic layer during rolling,
wherein the registering of the embossing on the plastic layer and the pattern on the plastic layer is realized during the rolling by the embossing roller; and
wherein the feeding roller only feeds the plastic layer into the oppositely rolling rollers;
wherein the method further comprises the step of controlling the heating temperature of the oppositely rolling rollers by a control device, the control device controlling a hot medium flowing into the oppositely rolling rollers.
2. The rolling method for producing the long plastic layer according to claim 1 , wherein the adjusting step comprises detecting a position of a preset part on each unit pattern of the plastic layer and detecting a position of a corresponding part on the embossing roller corresponding to the preset part at the same time; when the preset part is detected to be ahead of the corresponding part, increase the feeding tension of the plastic layer to increase the stretching length of the plastic layer before rolling, so as to reduce an ahead value of the preset part in subsequent rolling until a deviation between the preset part and the corresponding part is zero, so that the embossing controlled on the plastic layer is longitudinally in register with the pattern on the plastic layer;
and when the preset part is detected to be lagging behind the corresponding part, decrease the feeding tension of the plastic layer to decrease the stretching length of the plastic layer before rolling, so as to increase a lagged value of the preset part in the subsequent rolling until the deviation between the preset part and the corresponding part is zero, so that the embossing hot-rolled on the plastic layer is longitudinally in register with the pattern on the plastic layer.
3. The rolling method for producing the long plastic layer according to claim 1 , wherein a heating temperature in the rolling step ranges from 85° C. to 250° C.
4. The rolling method for producing the long plastic layer according to claim 1 , wherein in the rolling step, the longitudinal deviation of the embossing is measured by a distance difference or a time difference between a detected preset part on each unit pattern of the plastic layer and a detected corresponding part on the embossing roller corresponding to the preset part.
5. The rolling method for producing the long plastic layer according to claim 1 , wherein during the process of adjusting the longitudinal deviation of the embossing in the rolling step, a lateral deviation of the pattern is adjusted, and when a lateral deviation is detected to be existing between the pattern on the plastic layer and the embossed pattern on the embossing roller, the plastic layer or the embossing roller is moved along a lateral direction, so that the pattern on the plastic layer is in register with the embossed pattern around the outer surface of the cylinder of the embossing roller on the lateral direction.
6. A rolling method for producing a long plastic layer with an embossing in register with a pattern, comprising:
a feeding step of feeding a plastic layer to be rolled into oppositely rolling rollers by a feeding roller, the plastic layer being printed with repeating unit patterns; and
a rolling step of hot rolling an embossing on the plastic layer;
in the feeding step, a front side of the plastic layer being adjacent to an embossing roller formed by one of the oppositely rolling rollers, and an embossed pattern disposed around an outer surface of a cylinder of the embossing roller corresponding to a pattern of one unit pattern on the plastic layer,
wherein a longitudinal deviation of the embossing is adjusted in the rolling step, an adjusting step comprises:
detecting the longitudinal deviation between the pattern on the plastic layer and the embossed pattern on the embossing roller by sensing a position of a preset part in each unit pattern on the already stretched plastic layer after the feeding roller and prior to entering the oppositely rolling rollers, and detecting a position of a corresponding part directly on the embossing roller corresponding to the preset part prior to embossing, and
wherein said detecting is of a distance difference or a time difference of signals detected by a first sensor for detecting the position of a preset part and a second sensor for detecting the position of a corresponding part, and
adjusting a feeding tension of the plastic layer according to the longitudinal deviation, so as to adjust a stretching length of the plastic layer between the feeding roller in the feeding step and the oppositely rolling rollers in the rolling step before rolling and thereby embossing, so that the longitudinal deviation in subsequent rolling is reduced until the embossed pattern is longitudinally in register with the pattern on the plastic layer during rolling,
wherein the registering of the embossing on the plastic layer and the pattern on the plastic layer is realized during the rolling by the embossing roller; and
wherein the feeding roller only feeds the plastic layer into the oppositely rolling rollers;
wherein the method further comprises the step of controlling the heating temperature of the oppositely rolling rollers by a control device controlling a hot medium flowing into the oppositely rolling rollers.
7. The rolling method for producing the long plastic layer according to claim 6 , wherein a heating temperature in the rolling step ranges from 85° C. to 250° C.
8. The rolling method for producing the long plastic layer according to claim 1 , wherein the adjusting the feeding tension only uses mechanical tensioning to adjust the feeding tension.
9. The rolling method for producing the long plastic layer according to claim 1 , said feeding step of feeding a plastic layer comprises unwinding said plastic layer from a roll mounted on a feeding axle, wherein said feeding axle is provided with a tension controller, wherein said adjusting a feeding tension of the plastic layer is at least performed by means of adjusting said tension controller of said feeding axle.
10. The rolling method for producing the long plastic layer according to claim 6 , said feeding step of feeding a plastic layer comprises unwinding said plastic layer from a roll mounted on a feeding axle, wherein said feeding axle is provided with a tension controller, wherein said adjusting a feeding tension of the plastic layer is at least performed by means of adjusting said tension controller of said feeding axle.
11. The rolling method for producing the long plastic layer according to claim 1 , comprising a single pair of oppositely rolling rollers, the oppositely rolling rollers configured to emboss the plastic layer.
12. The rolling method for producing the long plastic layer according to claim 1 , further comprising the step of arranging a spread length of the embossed pattern disposed around the outer surface of a cylinder of the embossing roller is 1.0 to 1.5 times of a length of the one unit pattern on the plastic layer before stretching.
13. The rolling method for producing the long plastic layer according to claim 6 , further comprising the step of arranging a spread length of the embossed pattern disposed around the outer surface of a cylinder of the embossing roller is 1.0 to 1.5 times of a length of the one unit pattern on the plastic layer before stretching.