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Method for forming an embossing tool with an optically precise pattern

DC
  • US 4,478,769 A
  • Filed: 09/30/1982
  • Issued: 10/23/1984
  • Est. Priority Date: 09/30/1982
  • Status: Expired due to Term
First Claim
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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;

  • 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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