Method for forming an embossing tool with an optically precise pattern
DCFirst Claim
1. A method of making a thin flexible seamless generally cylindrical embossing tool for continuous embossing of a web of material with an optically precise pattern having sharp angles and flatness of faces in certain detail, comprising the steps of forming at least one master element to the precision optical pattern required;
- assembling a contiguous cluster of master elements, at least one of which has the pattern therein;
replicating the assembled cluster to provide a number of flexible strips of contiguous pattern;
assembling said strips on a cylindrical mandrel and replicating such assembled strips to provide cylindrical segments;
assembling such segments to provide a cylinder of the desired dimensions corresponding to the width of web to be embossed;
replicating such cylinder to provide a seamless master cylinder;
replicating said master cylinder to produce a relatively thick seamless and metallurgically uniform mother cylinder;
replicating said mother cylinder to produce a relatively thin, seamless, flexible, and generally cylindrical metal embossing tool having the precision optical pattern therein.
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Accused Products
Abstract
Cylindrical embossing tools are constructed from one or more masters formed by accurately scribing the face of a substrate along three axes in the face to produce a pattern of tetrahedrons. The plurality of masters, or replicated copies made from a single master, are assembled in a fixture and seamless copies are made by electrodeposition of nickel using various shielding and grinding methods to provide replicated copies of uniform thickness. The replicated copies are assembled and used to form larger electroforms until a generally cylindrical embossing tool of the correct width and circumference is created. Novel processes and apparatus are provided for removing the electroformed cylindrical tool from its mother cylinder.
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Citations
23 Claims
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1. A method of making a thin flexible seamless generally cylindrical embossing tool for continuous embossing of a web of material with an optically precise pattern having sharp angles and flatness of faces in certain detail, comprising the steps of forming at least one master element to the precision optical pattern required;
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assembling a contiguous cluster of master elements, at least one of which has the pattern therein; replicating the assembled cluster to provide a number of flexible strips of contiguous pattern; assembling said strips on a cylindrical mandrel and replicating such assembled strips to provide cylindrical segments; assembling such segments to provide a cylinder of the desired dimensions corresponding to the width of web to be embossed; replicating such cylinder to provide a seamless master cylinder; replicating said master cylinder to produce a relatively thick seamless and metallurgically uniform mother cylinder; replicating said mother cylinder to produce a relatively thin, seamless, flexible, and generally cylindrical metal embossing tool having the precision optical pattern therein. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of preparing a ruled master with a precise optical pattern consisting of more than one ruled line, from a metal element having at least one planar surface, such master to be used in the production of embossing tools, comprising the steps of forming a first groove in a planar surface of a metal element;
- filling said first groove with a synthetic material of appropriate hardness and machinability and permitting said material to cure;
positioning said metal element to a second position offset from said first position;
forming a second groove in said planar surface of said metal element, said second groove intersecting said first groove, and thereafter removing said fill material from the remainder of said first groove. - View Dependent Claims (9, 10, 11)
- filling said first groove with a synthetic material of appropriate hardness and machinability and permitting said material to cure;
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12. A method of preparing a ruled master from a metal element, having at least one planar surface, to be used in the production of embossing tools comprising the steps of:
- forming a first series of uniformly spaced grooves in a planar surface of a metal blank;
filling said first series of grooves with a synthetic material of appropriate hardness and machinability and permitting said material to cure;
rotating said element to a position offset from said first series of grooves;
forming a second series of uniformly spaced grooves in said planar surface of said metal blank, said second series of grooves intersecting said first series of grooves; and
removing said fill material from the remainder of said first series of grooves. - View Dependent Claims (13, 14, 15, 16)
- forming a first series of uniformly spaced grooves in a planar surface of a metal blank;
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17. A method of separating a thin, continuous flexible metal electroform from within a substrate upon which it is formed wherein said substrate and said electroform have relatively small and plural complementary engaging features providing fine detail and interfering relationships when formed which preclude rotational or axial movement relative to one another, comprising the steps of inserting a support within said substrate, said support having one or more selectively operable lifting devices thereon;
- operating said devices to grip the electroform on said substrate and to separate said electroform from said substrate;
collapsing said flexible metal electroform inwardly; and
removing said electroform completely from said substrate. - View Dependent Claims (18, 19, 23)
- operating said devices to grip the electroform on said substrate and to separate said electroform from said substrate;
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20. A method of making a thin flexible seamless generally cylindrical embossing tool for continuous embossing of a web of material with an optically precise pattern, having sharp angles and flatness of faces in certain detail, comprising the steps of forming at least one master element to the precision optical pattern required;
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assembling a contiguous cluster of master elements, at least one of which has the precision pattern therein; replicating the assembled cluster to provide a number of flexible strips of contiguous pattern; assembling said strips on a cylindrical mandrel and replicating such assembled strips to provide cylindrical segments; assembling such segments to provide a cylinder of the desired dimensions corresponding to the width of web to be embossed; replicating such cylinder to provide a thin, flexible seamless master cylinder having the precision optical pattern therein. - View Dependent Claims (21, 22)
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Specification