Manufacturing container or tube from paper; or other manufacturi – With extruding – drawing – or attenuating
Reexamination Certificate
1998-03-04
2001-02-13
Johnson, Brian L. (Department: 3618)
Manufacturing container or tube from paper; or other manufacturi
With extruding, drawing, or attenuating
C493S058000, C101S295000, C101S211000
Reexamination Certificate
active
06186936
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to a system for embossing paper, such as greeting cards, and more particularly relates to an embossing system having an improved flexible counter for supporting a sheet of paper for pressing by a female die.
BACKGROUND
Embossing systems are used to form an embossment or decoratively raised area on a sheet of paper or cardboard. Such an embossment may serve as a decorative feature on a greeting card, business card, or the like. Conventional embossing systems include matable male and female dies contoured in the shape of the desired embossment. With a sheet (e.g., paper) disposed between the two dies, the male and female dies are pressed together in complementary engagement with each other. The paper is thereby deformed to have an embossment matching the contour of the dies.
In an embossing system with mated dies, expenses are incurred for making both the male and female dies. Additionally, such a system requires regular attention to maintain precise die alignment for repeated mating engagement.
Attempts have been made to eliminate the male die component by instead providing a flexible “counter” to support a paper being pressed by the female die. Unfortunately, known flexible counter systems have not provided suitable embossing results. Basically, known counters include a flexible mat which supports the paper during pressing by female die. Some known counters include a structure that contains all but one side of the mat. These known flexible counters often tear the paper during embossing or result in an unsuitable embossment. Such performance shortcomings may be due to poor deformation behavior or “flow” characteristics of the mat as supported by these known counters.
SUMMARY OF THE INVENTION
The present invention provides improved embossing performance in a system for embossing areas on greeting card material, paper or cardboard products or other items. A flexible counter is provided to support the material being embossed by opposing pressure from a female die. The flexible counter has a resilient mat which resides in a fixed bolster. According to the invention, the bolster is constructed to form recesses which receive bulging deformation of the mat material as the mat is compressed by the opposing die forces. By accommodating bulging of lower portions of the mat, deformation of upper portions of the mat are controlled to reduce stretching behavior of the upper mat surface which supports the sheet, and thereby optimize embossing performance.
According one aspect of the invention, the bolster has a sidewall which extends generally around a periphery of the mat so that an upper portion of the thickness of the mat extends above the sidewall. Another aspect of the invention provides that the bolster has at least one support surface which is adjacent to a recess. The support surface supports a bottom surface of the mat, and the recess receives a bulging portion of the mat as the mat deforms under compression of the embossing die.
In an embodiment, the bolster has a plurality of support surfaces. These support surfaces may be formed by buttons of various shapes, loop-shaped elements or other appropriately-shaped support members. The bolster may also have a fixed floor to which such support members and sidewalls are mounted. The buttons or other support members are preferably spaced apart from each other to form the recesses.
Embodiments of the invention may include additional features found to enhance performance. For example, a friction-reducing film, such as a mylar or urethane film, may be positioned over the mat to separate the mat from the sheet. The friction-reducing film reduces damage to the sheet and aids in removing the sheet from the counter after embossing.
A recess may be provided around a lower periphery of the mat. In an embodiment, such a peripheral recess may be defined by a chamfered interior edge of the sidewall.
An advantage of the present invention is that it provides reliable embossing performance while minimizing damage to the material being embossed.
Another advantage of the present invention is that it permits embossing with a female die, eliminating a need for a mated male die, reducing material expenses.
A related advantage of the present invention is that it eliminates a need to maintain precise die alignment, reducing maintenance effort and associated down time of the system.
Additional features and advantages of the invention are described in, and will be apparent from, the disclosure herein.
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Pp. 287-291 from book entitled “Manufacturing Processes and Materials for Engineers”, Second Edition, Lawrence E. Doyle, Prentice-Hall, Inc., Englewood Cliffs, N.J., © 1961, 1969.
Pages from the Web Site of Urethane Tooling & Engineering Corporation, Scottsdale, Arizona, dated Oct. 18, 1996.
Product Data Sheet for CC010 Countercast Tuff Film from Astor Universal, Lawrence, Kansas, dated May 22, 1996.
Schimke Scott A.
Smith Ronald R.
Augustyn John M.
Hallmark Cards Incorporated
Johnson Brian L.
Leydig , Voit & Mayer, Ltd.
Luby Matthew
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