WO2025219013A1 - Dispositif et procédé de gaufrage rotatif à sec d'un substrat, et matrice femelle - Google Patents
Dispositif et procédé de gaufrage rotatif à sec d'un substrat, et matrice femelleInfo
- Publication number
- WO2025219013A1 WO2025219013A1 PCT/EP2025/057932 EP2025057932W WO2025219013A1 WO 2025219013 A1 WO2025219013 A1 WO 2025219013A1 EP 2025057932 W EP2025057932 W EP 2025057932W WO 2025219013 A1 WO2025219013 A1 WO 2025219013A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- die
- substrate
- embossing roller
- magnetic
- roller
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
- B44B5/02—Dies; Accessories
- B44B5/026—Dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/07—Embossing, i.e. producing impressions formed by locally deep-drawing, e.g. using rolls provided with complementary profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F19/00—Apparatus or machines for carrying out printing operations combined with other operations
- B41F19/02—Apparatus or machines for carrying out printing operations combined with other operations with embossing
- B41F19/06—Printing and embossing between a negative and a positive forme after inking and wiping the negative forme; Printing from an ink band treated with colour or "gold"
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
- B44B5/0004—Machines or apparatus for embossing decorations or marks, e.g. embossing coins characterised by the movement of the embossing tool(s), or the movement of the work, during the embossing operation
- B44B5/0009—Rotating embossing tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B5/00—Machines or apparatus for embossing decorations or marks, e.g. embossing coins
- B44B5/02—Dies; Accessories
- B44B5/028—Heated dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F2201/00—Mechanical deformation of paper or cardboard without removing material
- B31F2201/07—Embossing
- B31F2201/0771—Other aspects of the embossing operations
- B31F2201/0776—Exchanging embossing tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M1/00—Inking and printing with a printer's forme
- B41M1/24—Inking and printing with a printer's forme combined with embossing
Definitions
- the invention relates to a device for rotary blind embossing of a substrate, a die and a method for rotary blind embossing of a substrate.
- Blind embossing is widely used to finish substrates such as packaging. This process creates a specific pattern, motif, or lettering in the substrate using a matrix and a male die. With relief embossing, the pattern, motif, or lettering is embossed, while with debossing it is embossed into the substrate.
- blind embossing is carried out either as stroke embossing or as cylinder embossing, which is also known as rotary blind embossing.
- rotary blind embossing the substrate to be embossed is guided between an embossing roller and a counter-pressure roller, and depressions and/or elevations are embossed into the substrate using appropriate forms, so-called matrixes and male dies.
- the embossing roller is equipped with matrixes and the counter-pressure roller is equipped with male dies.
- the matrixes and male dies are mounted or attached to the respective rollers in an interchangeable manner.
- the male part forms the so-called male form and the female part the corresponding female form.
- the female part on the The embossing cylinder and the male die on the impression cylinder must be aligned in register with each other so that the overlap area, i.e., the area where the female die meets the male die, is essentially precisely aligned. Precise registration is important both for embossing quality and to prevent damage to the female and/or male dies.
- DE 102018102638 A1 discloses a rotary blind stamping process and device.
- This process utilizes magnetic rollers on which the dies and male dies are magnetically positioned.
- the use of magnetic dies and male dies offers the significant advantage that they can be easily replaced, no residues, such as adhesive, remain on the roller, and short changeover times are achieved compared to screwing or gluing dies and/or male dies.
- the alignment of the magnetic dies and male dies is achieved using an adjustment aid, a so-called window plate.
- the window plate has webs and window areas in which the dies and/or male dies are later positioned. This window plate is first placed on the respective roller and held in place by a magnet.
- the dies and/or male dies which have a steel underside, are then positioned on the magnetic rollers in the window areas.
- the underside of the dies and/or the male dies is then attracted by the magnet in the magnetic roller and held on the surface of the roller.
- the disadvantage of this is that with increasing operating time, the dies and/or the male dies move longitudinally on the roller. This leads to the embossing on the substrate no longer being able to be formed into a print in register. However, it can also lead to the die no longer being congruent or out of register with the male die in the overlapping area. This inevitably leads to damage to the die and/or the patrix and thus also to a deterioration of the stamping result.
- the invention is based on the object of providing an improved method and an improved device for blind embossing a substrate, in particular wherein the register accuracy or
- the positional stability of the die magnetically attached to the embossing roller is improved. Furthermore, the invention is based on the object of providing an improved die for use in a blind embossing device.
- a device for the rotary blind embossing of a substrate comprising a workstation comprising a magnetic embossing roller and a counter-pressure roller, wherein at least one die is magnetically arranged on the magnetic embossing roller and at least one male die is arranged on the counter-pressure roller, wherein the at least one die is multi-layered and has at least a first metal layer made of a ferromagnetic material. It is essential that the at least one die has a foil on the side facing the magnetic embossing roller.
- a die in particular for use in a device according to one of claims 1 to 22, wherein the die is multilayered and has at least a first metal layer made of a ferromagnetic material. It is essential that the die has a foil on its underside.
- a method for rotary blind embossing of a substrate in particular using a device according to one of claims 1 to 22, wherein the method comprises the following steps, in particular in the following order: a) Providing a substrate; b) Arranging at least one die, in particular according to one of claims 23 to 35, on a magnetic embossing roller; c) Arranging at least one male die on a counter-pressure roller; d) Blind embossing the substrate by means of the at least one die and the at least one male die.
- the device for rotary blind embossing of a substrate increases the holding force of the die on the magnetic embossing roller, particularly under tangential stress, by up to 50% or more than 50%, compared to conventional, prior-art dies that are attached to the embossing roller by magnetic force.
- This approximately 50% higher holding force ensures that the at least one die on the embossing roller maintains its position during the processing time or maintains it for longer than conventional dies. This significantly reduces maintenance work.
- it also ensures that the embossing quality remains consistently high throughout the processing cycle.
- the positional stability and/or register stability of the die on the magnetic embossing roller ensures that the at least one male die is not damaged. This also ensures consistent embossing quality.
- Another advantage is that at least one die can be relatively easily removed from the magnetic embossing roller by radially lifting it off the magnetic embossing roller. This solution allows the device to be easily retooled, and the dies can be exchanged for a new embossing series without leaving adhesive residue on the embossing roller or requiring the removal of screws or other fasteners. This also reduces retooling times accordingly.
- Blind embossing is understood here, in particular, to mean relief embossing without the use of ink, in particular a printing ink, and/or without the use of a transfer foil, in particular a hot stamping foil or cold stamping foil.
- a pattern, motif, or lettering is embossed into the substrate, with the pattern, motif, or lettering being raised in particular in the case of embossing, and/or the pattern, motif, or lettering being embossed into the substrate in a debossed manner.
- a die is understood here in particular to mean an embossing tool which has the corresponding relief shape as elevations and/or depressions, wherein the die preferably has the relief shape of the relief embossing to be achieved in a mirrored arrangement, i.e. in an arrangement which is not immediately readable.
- a male die is understood here in particular to mean an embossing tool which has the corresponding relief shape as elevations and/or depressions, wherein the male die preferably has the relief shape of the relief embossing to be achieved in a non-mirrored arrangement, i.e. in a readable arrangement.
- the die and the male die fit together in such a way that the relief embossing is created in a legible form on the substrate.
- the die acts on the substrate from the top side and the male die from the bottom side, with the top side of the substrate representing the viewing side in the substrate's later use.
- the die and the male die can also be arranged in reverse relation to the arrangement described above if, for example, a transparent substrate in the later form of use is to be viewed from the underside of the substrate.
- Register or registration or registration accuracy or registration accuracy is to be understood in particular as the positional accuracy of two or more elements and/or layers relative to one another, here for example the precise arrangement of the embossing and other features applied to the substrate, such as a print, layers applied to the substrate and/or fold lines or crease lines, relative to one another.
- the register accuracy should advantageously be within a predetermined tolerance and be as small as possible.
- the register accuracy of several elements and/or layers relative to one another is expediently an important feature in order to increase process reliability.
- the precise positioning can be achieved in particular by means of sensory, preferably optically detectable registration marks or register marks. These registration marks or register marks can either represent special separate elements or areas or layers or can themselves be part of the elements or areas or layers to be positioned.
- the underside is preferably understood to mean the side of the at least one die which, in the installed state, faces the embossing roller.
- step d) the substrate is blind embossed in such a way that the substrate has at least one elevation and/or depression.
- An elevation and/or depression of the substrate is understood to mean, in particular, a relief form which represents a pattern, motif or writing and which is preferably arranged either raised (embossing) or recessed (debossing) relative to an unprocessed area of the substrate. If the substrate is raised, this is preferably a raised embossing, meaning the pattern, motif, or lettering is embossed into the substrate. If the substrate is recessed, this is preferably a debossing, meaning the pattern, motif, or lettering is embossed into the substrate.
- the at least one elevation and/or depression of the substrate in step d) is created with a height and/or depth of at least 0.01 mm, preferably at least 0.03 mm, more preferably at least 0.1 mm. This allows visually and haptically appealing blind embossing to be created.
- the positioning of the at least one die is carried out by means of a positioning system, whereby the positioning system interacts with the magnetic embossing roller in such a way that the magnetic embossing roller is rotated by a predefined angle of rotation in order to determine the position of the at least one die in the radial direction of the magnetic embossing roller, and subsequently the position of the at least one die in the axial direction of the magnetic embossing roller is determined.
- the at least one die may also be possible for the at least one die to be positioned along a stop in step b) and then magnetically attached to the surface of the magnetic embossing roller.
- the positioning system thus allows multiple dies to be applied to the embossing roller in a space-saving manner. This means that the distance between the individual dies can be significantly reduced by using the positioning system compared to, for example, the use of window panels or other positioning aids.
- the stop preferably specifies the position in which the die is applied to the magnetic embossing roller.
- the die is preferably manually applied to the stop. and then attached to the magnetic embossing roller using the magnet or magnetic force.
- the at least one die may also be possible for the at least one die to be bent before step b) or in step b), in particular so that the curvature of the die substantially corresponds to the curvature of the magnetic embossing roller.
- the at least one die it is possible for the at least one die to be deformed such that the at least one die has a curvature that substantially corresponds to the curvature of the magnetic embossing roller. This adapts the shape of the die to the shape of the magnetic embossing roller, so that the die can be used for rotary blind embossing.
- Rounding is preferably understood here as a radius of curvature, wherein the radius of curvature corresponds in particular to the radius of a circle of curvature, which at a certain point of a curve is the circle that best approximates the curve at this point.
- step b) the at least one die is arranged on the magnetic embossing roller in such a way that the film faces the surface of the magnetic embossing roller.
- the adhesive force of the die on the magnetic embossing roller being significantly increased against approximately tangentially acting forces, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside.
- the film in particular which is formed from a thermoplastic elastomer, clings to both the first metal layer of the die and the outer circumference of the magnetic embossing roller. This reduces air pockets between the die and the magnetic embossing roller, which leads to a "vacuum effect".
- the die has a has increased adhesive force, whereby any displacement of the die during the embossing process and due to the tangential forces occurring during the embossing process is reduced or even completely prevented.
- the positional stability or register accuracy of the at least one die is thus maintained throughout the entire embossing cycle.
- the at least one die can still be easily removed from the magnetic embossing roller by preferably being lifted radially from the magnetic embossing roller. In this case, only the magnetic force of the magnetic embossing roller has to be overcome.
- the effects of the increased adhesive force due to the film on the side of the die facing the surface of the magnetic embossing roller therefore occur only slightly or not at all in the radial direction of the magnetic embossing roller.
- the second sample is a die according to the invention in which a foil is arranged on the underside of the steel layer.
- the two samples each measure 5.0 cm x 10.0 cm and thus cover an area of 50 cm2 . Furthermore, a hole was drilled into each sample, into which the hook of a digital force gauge "SAUTER FC 1 K" was attached using a carabiner.
- the surfaces of the die and the magnet surface were first cleaned and deoiled. The die samples were then placed one after the other on the magnet surface, and the force required to move the die from the magnet surface was measured in the tangential direction using a suitcase scale.
- an average force of 164 N was measured. In contrast, an average force of 257 N was measured for the die according to the invention.
- the measured adhesive force or holding force in the tangential direction of the die according to the invention is over 50% higher than that of conventional dies.
- a further increase in the holding force in the tangential direction can be achieved by selecting suitable other polymer materials.
- the adhesive force per unit area of the at least one die on the magnetic embossing roller is at least 5 N/ cm2 , compared to approximately tangentially acting forces.
- step c) at least one carrier plate is first arranged on the circumference of the counter-pressure roller.
- the carrier plate serves, in particular, to accommodate the at least one male mold. This can be done in different ways, as described below.
- step c) a sheet of maternal cardboard is arranged, in particular glued, on the carrier sheet, and preferably the sheet of maternal cardboard is moistened, and the master board sheet is embossed with the at least one matrix arranged on the magnetic embossing roller to form the at least one male mold in the master board sheet.
- the moistening is preferably carried out by means of a spraying device that applies a light spray to the master board sheet. The moistening softens the master board sheet, and the contour of the matrix can thus be more easily embossed into the master board sheet as a counter-mold.
- step c) during embossing according to the first variant I) the matrix cardboard sheet is compacted, in particular whereby the moisture is pressed out of the matrix cardboard sheet.
- the magnetic embossing roller is heated, in particular with a temperature in the range from 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C, in order to dry the matrix cardboard sheet so that the at least one male part solidifies.
- the at least one male mold may also be provided with a double-sided adhesive tape on its side facing the counter-pressure roller in step c) according to a second variant II).
- the male mold is preferably glued or attached to the counter-pressure roller, in particular the carrier sheet, using the double-sided adhesive tape.
- the male mold can, for example, comprise materials selected individually or in combination from: plastic, silicone, rubber, brass.
- the male part is bonded to the at least one female part by means of an adhesive or adhesive tape or adhesive pieces in a form-fitting manner and then the at least one male part is applied to the counter-pressure roller, in particular by bringing the embossing roller into contact with the counter-pressure roller.
- the adhesive tape facing the counter-pressure roller has a higher adhesive force than the adhesive or the adhesive tape or the adhesive pieces facing the die. This ensures that when the at least one male part is brought into contact with the counter-pressure roller, the at least one male part is firmly attached to the counter-pressure roller and the male part is released from the die.
- any adhesive residues on the upper side of the male part i.e. the side facing the die, are removed. Analogously, adhesive residues on the upper side of the at least one die can also be removed.
- step c) according to a third variant III
- a UV-curable plastic is applied at least partially or over the entire surface of the carrier sheet, which is at least partially pre-crosslinked using a UV pre-curing light source, and then the pre-crosslinked UV-curable plastic is embossed using the at least one matrix, so that at least one male mold is introduced into the pre-crosslinked UV-curable plastic and finally the pre-crosslinked UV-curable plastic is fully cured using a UV final curing light source.
- the viscosity of the UV-curable plastic is increased to such an extent that it retains its shape independently, but is nevertheless deformable to such an extent that it can be deformed by external forces.
- the magnetic embossing roller and the counterpressure roller are driven in opposite directions at corresponding rotational speeds. It is also possible for the magnetic embossing roller and the counterpressure roller to be driven in opposite directions at corresponding rotational speeds.
- the at least one die and the at least one male die preferably engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die, in particular in an overlap region of the at least one die and the at least one male die, is embossed. It is also possible for the at least one die and the at least one male die to be arranged in such a way that they engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die, in particular in an overlap region of the at least one die and the at least one male die, can be embossed.
- the ratio of the diameter of the embossing roller to the diameter of the counter-pressure roller is 1 to 2, preferably 1 to 1.
- the substrate is embossed in such a way that the deviations between the embossments of each cycle are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.
- the procedure shall conveniently further comprise the following step:
- the process further includes at least one of the following steps, which are carried out in one or more additional workstations:
- the device may further comprise one or more additional workstations for printing on the substrate and/or for cold embossing on the substrate and/or for hot embossing on the substrate and/or for blind Braille embossing on the substrate and/or for separating, in particular cutting, the substrate and/or for creasing and/or folding the substrate.
- the one or more additional workstations are arranged before and/or after the workstation comprising the embossing roller and the counterpressure roller.
- Printing is preferably carried out using offset printing, screen printing, gravure printing, letterpress printing, flexographic printing, or inkjet printing. Furthermore, it is preferred if the printing is produced using a printing roller.
- one or more printing inks are advantageously applied to the substrate, in particular according to a printing pattern.
- the substrate is preferably separated by punching, with the substrate being separated, in particular, using a cutting tool and/or punching tool.
- the bendability of the substrate is preferably changed using a pressing tool, in particular by material displacement. Folding is preferably understood as the creation of a sharp folded edge using a tool. According to a further embodiment of the invention, the substrate is preferably processed continuously.
- the substrate is provided as a sheet.
- the sheet can be provided in particular as a stack of sheets, or alternatively, the substrate can be provided as a roll, which is cut into individual sheets, particularly inline, using a roll cross cutter, thus providing the substrate as a sheet.
- the deviations between the embossings on the sheets of the substrate provided as sheet goods are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.
- Sheet of maternal cardboard by means of which at least one matrix is formed or embossed.
- At least one carrier plate is arranged on the circumference of the counter-pressure roller, wherein on the carrier plate
- a matrix carton is arranged in which at least one corresponding male mold is molded to the at least one female mold;
- At least one corresponding male die is arranged to the at least one female die
- a UV-curable plastic is applied over a large area, in which at least one corresponding male mold is molded to the at least one female mold.
- the device may also comprise a positioning system for arranging the at least one die on the embossing roller, wherein the positioning system has a displaceable stop.
- the stop for the exact positioning of at least one die on the magnetic embossing roller.
- the first metal layer has a thickness in the range of 0.05 mm to
- 1.5 mm preferably from 0.1 mm to 1 mm, more preferably from 0.15 mm to 0.5 mm.
- the second metal layer has a thickness in the range of 0.3 mm to
- the matrix comprises an adhesive layer.
- the adhesive layer is preferably arranged between the first metal layer and the second metal layer. It is also advantageous if the adhesive layer is a hot-melt or cold-melt adhesive layer.
- the adhesive layer prefferably be a two-component adhesive (2K adhesive), in particular comprising epoxy resins.
- 2K adhesive a two-component adhesive
- the adhesive layer is a 2K epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.
- the adhesive layer is a double-sided adhesive tape.
- the carrier material of the double-sided adhesive tape is coated on both sides with a pressure-sensitive adhesive (PSA).
- PSA pressure-sensitive adhesive
- Such double-sided adhesive tapes can be purchased, for example, from tesa, Norderstedt, Germany.
- the adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.
- the film is or comprises a plastic film, in particular wherein the film is formed from a thermoplastic elastomer.
- the film is preferably arranged on the side of the die facing the magnetic embossing roller.
- the film thus forms the bottom layer of the die.
- the film advantageously has the effect that the adhesive force of the at least one die on the magnetic embossing roller is significantly increased against approximately tangentially acting forces, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside, which are also magnetically attached to a magnetic embossing roller. It is provided that the adhesive force per area of the at least one die on the magnetic embossing roller against approximately tangentially acting forces is at least 5 N/cm 2 .
- Thermoplastic elastomers are a group of materials that can be processed and recycled like thermoplastics, but have similar properties and performance to thermosetting rubber materials.
- Thermoplastic elastomers preferably have a hardness of 20 Shore A to 65 Shore D.
- Thermoplastic elastomers can preferably be block copolymers or thermoplastic-elastomer compounds.
- Block copolymers are structures that contain two different monomers in a single polymer chain.
- block copolymers are thermoplastic polyurethane, thermoplastic polyester, thermoplastic polyamide, or thermoplastic block copolymer.
- Thermoplastic-elastomer compounds are preferably produced by blending elastomers and thermoplastics in a molten state.
- examples of thermoplastic-elastomer compounds are thermoplastic vulcanizers or thermoplastic polyolefins.
- all thermoplastic elastomer types have two or more polymer phases, one hard and one soft. Upon solidification below the melting temperature, the hard regions of the various chains combine to form hard thermoplastic parts, while the soft regions form elastomeric parts.
- the film has a thickness in a range from 20 pm to 250 pm, in particular from 30 pm to 150 pm.
- the film in particular on the side facing the first metal layer, has a film adhesive layer, which in particular consists of a pressure-sensitive adhesive (pressure sensitive adhesive (PSA).
- PSA pressure sensitive adhesive
- the film adhesive layer can also be multi-layered and/or comprise a hot-melt adhesive and/or a two-component adhesive.
- the film adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.
- the die has a layer structure, in particular in the following order, starting with the layer facing the embossing roller:
- the foil forms the underside of the die
- the second metal layer forms the top side of the die.
- the “top side” refers to the side facing the substrate or the male part.
- the matrix has at least one elevation and/or depression which corresponds in particular to the relief shape to be embossed in positive and/or negative form.
- the at least one elevation of the die has a height of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm, and/or that the at least one depression of the die has a depth of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm.
- the at least one elevation and/or depression of the die has a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, pointed or mixtures of these shapes.
- At least one elevation and/or depression is produced photolithographically.
- matrices can be produced which are characterized by particularly good embossing results, in particular with which fine contours in the form of correspondingly embossed elevations and/or depressions of the substrate can be produced.
- the predetermined shortening factor is determined as a function of the embossing length and/or a printing length, in particular on the substrate. It has been shown that the embossing result can be further improved by such a shortening factor, since this can compensate for a possible distortion or elongation of the relief to be embossed, in particular due to the curvature of the embossing roller and/or the counter-pressure roller on the substrate.
- the defined shape of the at least one elevation and/or depression in the surface of the die is distorted according to a predetermined distortion factor, in particular along a surface normal of the plane spanned by the die.
- the at least one elevation and/or depression it is possible for the at least one elevation and/or depression to exhibit a distortion, in particular along a surface normal of the plane spanned by the die.
- FIG. 1a to 1c show schematically a device and a
- Fig. 2 shows schematically a device for rotary
- Fig. 3 shows schematically a device for rotary
- Fig. 4 shows schematically a section of the device, in particular showing the positioning system
- Fig. 5a shows schematically a sectional view of a die
- Fig. 5b shows a schematic sectional view of a male part
- Fig. 1a to Fig. 1c show schematically a device 1 for rotary blind embossing.
- the device 1 for the rotary blind embossing of a substrate 3 comprises a work station 1a, which comprises a magnetic embossing roller 2a and a counter-pressure roller 2b, wherein at least one matrix 4a is magnetically arranged on the magnetic embossing roller 2a and at least one patrix 4b is arranged on the counter-pressure roller 2b, wherein the at least one matrix 4a is multi-layered and has at least a first metal layer 8 made of a ferromagnetic material and that the at least one matrix 4a has a film 7 on the side facing the magnetic embossing roller 2a.
- the foil 7 on the side of the die 4a facing the magnetic embossing roller 2a advantageously results in the adhesive force of the die 4a on the magnetic embossing roller 2a being significantly increased against approximately tangentially acting forces, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside. This is due in particular to the fact that the foil 7, in particular which is formed from a thermoplastic elastomer, conforms to both the first metal layer 8 of the die 4a and the outer circumference of the magnetic embossing roller 2a.
- the adhesive force per area of the at least one die 4a on the magnetic embossing roller 2a against approximately tangentially acting forces is at least 5 N/cm 2 .
- the die 4a is nevertheless easy to remove from the magnetic embossing roller 2a by preferably radially removing it from the Embossing roller 2a is raised. In this case, only the magnetic force of the magnetic embossing roller 2a must be overcome. The effects of the increased adhesive force caused by the foil 7 on the side of the die 4a facing the surface of the magnetic embossing roller 2a thus occur only slightly or not at all in the radial direction of the magnetic embossing roller 2a.
- a method for the rotary blind embossing of a substrate 3 in the work station 1a comprising a magnetic embossing roller 2a and a counter-pressure roller 2b is carried out, wherein the method comprises the following steps, in particular in the following order: a) Providing a substrate 3; b) Arranging at least one matrix 4a on a magnetic embossing roller 2a; c) Arranging at least one male mold 4b on a counter-pressure roller 2b; d) Blind embossing the substrate 3 by means of the at least one matrix 4a and the at least one male mold 4b.
- the die 4a is already arranged on the magnetic embossing roller 2a.
- the arrangement of the die 4a is described in detail in Fig. 4.
- the die 4a is also already arranged on the counter-pressure roller 2b.
- Fig. 1a thus shows the preparation of the substrate 3.
- the substrate 3 is embossed or blind embossed by means of the die 4a arranged on the magnetic embossing roller 2a and the male die 4b arranged on the counter-pressure roller 2b.
- the substrate 3 is blind embossed in such a way that the substrate 3 has at least one elevation 5a and/or depression 5b.
- An elevation 5a and/or depression 5b of the substrate 3 is understood in particular to mean a relief form which represents a pattern, motif or writing.
- An elevation 5a of the substrate 3 relative to an unprocessed area of the substrate 3 is preferably a raised embossing, so that the pattern, motif or writing is embossed into the substrate 3 in a raised manner.
- a depression 5b of the substrate 3 relative to an unprocessed area of the substrate 3 is preferably a debossing, so that the pattern, motif or writing is embossed into the substrate 3 in a recessed manner.
- the elevation 5a and/or depression 5b shown in Fig. 1c would be mirrored on the plane spanned by the substrate 3, ie the bulge of the substrate 3 would now point downwards and not upwards.
- the at least one elevation 5a and/or depression 5b of the substrate 3 is produced with a height and/or depth of at least 0.01 mm, preferably at least 0.03 mm, more preferably at least 0.1 mm.
- the ratio of the diameter of the magnetic embossing roller 2a to the diameter of the counter-pressure roller 2b is 1 to 1.
- the magnetic embossing roller 2a and the counter-pressure roller 2b may have different diameters.
- the ratio of the diameter of the magnetic embossing roller 2a to the diameter of the counter-pressure roller 2b is 1 to 2.
- the diameter of the magnetic embossing roller 2a is between 100 mm and 450 mm, more preferably between 200 mm and 350 mm, and/or the diameter of the counter-pressure roller 2b is between 200 mm and 800 mm, more preferably between 400 mm and 700 mm.
- the diameter of the magnetic embossing roller 2a is, for example, 300 mm ⁇ 5 mm, preferably 298.4 mm ⁇ 0.02 mm
- the The diameter of the counter-pressure roller 2b is, for example, 600 mm ⁇ 5 mm, preferably 599.4 mm ⁇ 0.02 mm.
- the substrate 3 is preferably provided as a sheet, as shown in Fig. 1a to Fig. 1c. However, it is also possible for the substrate 3 to be provided as a roll for roll-to-roll processing.
- the substrate 3 comprises cellulose and/or plastics.
- the substrate 3 is paper, cardboard, and/or films, in particular plastic films, or hybrid and/or composite materials made of such materials.
- the magnetic embossing roller 2a and the counterpressure roller 2b are preferably driven in opposite directions at corresponding rotational speeds.
- the die 4a and the male die 4b mesh with each other during each rotation such that the substrate 3 located between the die 4a and the male die 4b is embossed, particularly in an overlapping area of the die 4a and the male die 4b.
- Fig. 2 schematically shows a device 1 for rotary blind embossing.
- the device 1 of Fig. 2 differs from the device 1 of Figs. 1a to 1c in that three dies 4a are arranged on the magnetic embossing roller 2a and correspondingly three male dies 4b are arranged on the counter-pressure roller 2b.
- the magnetic embossing roller 2a and/or the counter-pressure roller 2b are equipped with so many dies 4a and/or male dies 4b that a large part of the circumferential surface, or ideally the entire circumferential surface, of the magnetic embossing roller 2a and/or counter-pressure roller 2b is equipped with dies 4a and male dies 4b.
- the magnetic embossing roller 2a and the counter-pressure roller 2b are preferably driven in opposite directions to each other at corresponding rotational speeds, wherein the matrices 4a and the male dies 4b engage with each other during each rotation in such a way that the substrate 3 located between the matrices 4a and the male dies 4b, in particular in an overlapping region of the matrices 4a and the male dies 4b, is embossed.
- Fig. 3 shows a further embodiment of a device 1 for rotary blind embossing of a substrate 3.
- the device 1 according to Fig. 3 essentially corresponds to the device 1 according to Fig. 2, but with the difference that the device 1 according to Fig. 3 comprises a transport device 11, which serves to transport the substrate 3.
- the transport device 11 it is possible for the transport device 11 to comprise a supply roll on which the substrate 3 is wound.
- the transport direction 11 it is also possible for the transport direction 11 to be designed in an arc shape for transporting the substrate 3.
- the device 1 comprises the work station 1b for printing the substrate 3.
- the work station 1b comprises a printing roller.
- Printing is preferably carried out using offset printing, screen printing, gravure printing, flexographic printing, letterpress printing, or inkjet printing.
- it is preferred if the print is produced using a printing roller.
- one or more printing inks are advantageously applied to the substrate 3, in particular according to a screen pattern.
- the device 1 according to Fig. 3 comprises the work station 1a for the rotary blind embossing of the substrate 3.
- the work station 1a for the rotary blind embossing of the substrate 3.
- the device 1 according to Fig. 3 comprises the work station 1c for creasing and/or folding the substrate 3.
- the work station 1c comprises a pressing tool and/or folding tool for producing a sharp crease.
- the bendability of the substrate 3 is preferably changed by means of a pressing tool, in particular by material displacement. Folding is preferably understood to mean the production of a sharp crease using a tool.
- the device 1 further comprises the workstation 1d for separating the substrate 3.
- the workstation 1d comprises a cutting tool.
- the substrate 3 is separated by punching, with the substrate 3 being separated in particular by means of a cutting tool and/or punching tool.
- the substrate 3 is processed continuously.
- the substrate 3 is provided as sheet material.
- the deviations between the embossings on the sheets of the substrate 3 provided as sheet goods less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.
- work station 1b is arranged before work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b.
- Work stations 1c and 1d are arranged after work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b.
- work stations 1a, 1b, 1c, 1d are also conceivable.
- work station 1c it is possible for work station 1c to be arranged before and/or work station 1b after work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b.
- Fig. 4 schematically shows a section of the device 1, in which the positioning system 6 is shown.
- the positioning system 6 serves to arrange the at least one matrix 4a or several matrices 4a on the circumferential surface of the magnetic embossing roller 2a.
- the positioning system 6 is arranged in the immediate vicinity of the magnetic embossing roller 2a.
- the positioning system 6 interacts with the magnetic embossing roller 2a.
- the position of the at least one matrix 4a in the radial direction of the magnetic embossing roller 2a is defined via the angle of rotation of the magnetic embossing roller 2a.
- the positioning system 6 comprises a displaceable stop 6a, wherein the stop 6a specifies the position of the at least one die 4a.
- the stop 6a can be, as shown in Fig. 4, a stop 6a with two arms, whereby the two arms are arranged at a right angle to each other.
- the stop 6a can also be designed differently.
- a die 4a in this case a rectangular die 4a, can then be placed against the stop 6a and positioned accordingly on the magnetic embossing roller 2a and magnetically secured.
- the at least one die 4a is bent accordingly before being attached to the magnetic embossing roller 2a, so that the curvature of the at least one die 4a substantially corresponds to the curvature of the magnetic embossing roller 2a.
- the at least one die 4a is preferably arranged on the magnetic embossing roller 2a such that the film 7 of the at least one die 4a faces the surface of the magnetic embossing roller 2a. This arrangement ensures a high holding or adhesive force of the die 4a on the magnetic embossing roller in the tangential direction, thereby preventing displacement, particularly in the tangential direction, of the at least one die 4a.
- the arrangement of the at least one male die 4b on the counter-pressure roller 2b is subsequently carried out, in particular in register or in exact register with the at least one die 4a.
- At least one carrier plate is initially arranged on the circumference of the counter-pressure roller 2b. It may also be possible for the counter-pressure roller 2b to have at least one carrier plate on its circumferential surface. Furthermore, the counter-pressure roller 2b can be designed such that it has two systems. In this case, each system takes up approximately half of the circumferential surface of the Counterpressure roller 2b. In this case, two carrier plates can be arranged on the counterpressure roller 2b.
- At least one carrier plate can be arranged on the circumference of the counter-pressure roller 2b, wherein on the carrier plate
- a matrix carton is arranged in which at least one corresponding male mold 4b is molded to the at least one female mold 4a;
- At least one corresponding male die 4b is arranged to the at least one female die 4a;
- a UV-curable plastic is applied over a large area, in which at least one corresponding male mold 4b is molded to the at least one female mold 4a.
- a master cardboard sheet is arranged, in particular glued, on the carrier sheet, and preferably the master cardboard sheet is moistened, and the master cardboard sheet is embossed with the at least one die 4a arranged on the magnetic embossing roller 2a in order to form the at least one male part in the master cardboard sheet. Moistening the master cardboard sheet softens it, so that the contour of the at least one die 4a can be transferred to the master cardboard sheet with relatively little force. Moistening is preferably carried out by means of a spray mist.
- the sheet of matrix cardboard is preferably compacted, in particular, the moisture is pressed out of the sheet of matrix cardboard.
- the sheet of matrix cardboard regains stability, and the molded contour of the at least one matrix 4a becomes dimensionally stable.
- the magnetic embossing roller is heated, in particular with a temperature in the range from 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C, in order to dry the matrix cardboard sheet so that the at least one male mold 4b solidifies.
- the at least one male mold 4b can be designed as an individual male mold, or each male mold 4b can be designed as an individual male mold.
- the male mold 4b can, for example, comprise materials selected individually or in combination from: plastic, silicone, rubber, brass. This means that in this embodiment, the shape of the male mold 4b is already incorporated, preferably by means of a laser, photolithography, milling, an additive printing process, such as 3D printing, etc.
- the shape of the male mold 4b is preferably designed as a counter-mold to the at least one female mold 4a.
- the at least one male part 4b is provided with a double-sided adhesive tape on its side facing the counter-pressure roller 2b. Furthermore, the at least one male part 4b is also provided with an adhesive, a double-sided adhesive tape, or adhesive pieces on its side facing the at least one female part 4a. Subsequently, the male part 4b is bonded in a form-fitting manner to the at least one female part 4a. Thereafter, the magnetic counter-pressure roller 2b is brought into contact with the counter-pressure roller 2b, in particular such that the underside of the male part 4b, in particular the side of the male part 4b facing the counter-pressure roller 2b, is brought into contact with the carrier plate of the counter-pressure roller 2b. Due to the double-sided adhesive tape, the at least one male part 4b now adheres to the
- Counter-pressure roller 2b It is preferably provided that the adhesive force of the adhesive pieces, adhesive tapes, or glue applied to the side of the male part 4b facing the counter-pressure roller 2b is stronger than the adhesive force of the side facing the female part 4a. Only in this way can the at least one male part 4b subsequently detach from the female part 4a. Finally, any adhesive residues are removed from both the at least one female mold 4a and the at least one male mold 4b.
- a UV-curable plastic is applied to the carrier sheet at least partially or over its entire surface, which is at least partially pre-crosslinked by means of a UV pre-curing light source, and then the pre-crosslinked UV-curable plastic is embossed by means of the at least one matrix 4a, so that at least one male mold 4b is introduced into the pre-crosslinked UV-curable plastic and finally the pre-crosslinked UV-curable plastic is completely cured by means of a UV final curing light source.
- Fig. 5a shows a schematic cross-sectional view of a die 4a.
- the die 4a is multi-layered.
- the die 4a has the following layer structure, beginning with the side facing the magnetic embossing roller 2a:
- Adhesive layer 9 Adhesive layer 9; second metal layer 10.
- the side facing the magnetic embossing roller 2a is preferably the underside of the die 4a.
- the die 4a has a foil 7 on its underside as shown in Fig. 5a.
- the film 7 is a plastic film.
- the film 7 is or comprises a thermoplastic elastomer.
- a thermoplastic elastomer is a plastic that has properties of both a thermoplastic and a thermoset. This causes the film 7 to adhere to both the first metal layer 8 of the die 4a and the surface of the magnetic Embossing roller 2a, thus creating a kind of "vacuum effect.” This ensures an increased adhesive or holding force of the die 4a on the surface of the magnetic embossing roller 2a relative to a force applied in the tangential direction.
- the film 7 has a film adhesive layer which is formed in particular from a pressure-sensitive adhesive (PSA).
- PSA pressure-sensitive adhesive
- the film adhesive layer can alternatively also be multi-layered and/or have a hot melt adhesive and/or a two-component adhesive.
- the film adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.
- the film adhesive layer is not shown in Fig. 5a.
- the film adhesive layer can preferably be applied during production of the film and is preferably part of the film.
- the first metal layer 8 is formed from a ferromagnetic material.
- the first metal layer 8 comprises a material or combination of materials selected from: iron, steel, ferrites, cobalt, and/or nickel.
- the die 4a shown in Fig. 5a uses a first metal layer 8 made of steel.
- the second metal layer 10 preferably comprises a material or combination of materials selected from: brass, bronze, copper, nickel, zinc, tin, lead, iron, and/or steel.
- the second metal layer 10 is formed, for example, from brass.
- the embossing mold is preferably molded into the second metal layer 10 as a positive or negative mold, in particular comprising elevations 12a and/or depressions 12b.
- the elevation 12a and/or depression 12b can be engraved and/or milled, for example, using a computer-controlled engraving machine and/or a computer-controlled milling machine.
- the relief shape is preferably first defined and designed using a computer. The design can be done manually or using predetermined relief shapes.
- elevations 12a and/or depressions 12b may be produced photolithographically.
- elevations 12a and/or depressions 12b may be created by means of a laser, in particular by laser ablation.
- the material of the matrix 4a is completely removed and/or ablated during the laser ablation.
- the laser is preferably a gas laser, in particular a CO2 laser, and/or a solid-state laser, in particular an Nd:YAG laser.
- the laser power is advantageously at least 20 W, preferably at least 30 W, more preferably at least 100 W. Furthermore, it is advantageous if the wavelength of the laser is between 9.35 pm and 10.25 pm.
- the desired relief shape to be embossed is reduced by a predetermined shortening factor, particularly before the elevations 12a and/or depressions 12b are created in the surface of the female mold 4a and/or male mold 4b.
- the shortening factor is preferably between 0.95 and 1, preferably between 0.9750 and 0.9999, more preferably between 0.98000 and 0.99999, and even more preferably between 0.99000 and 0.9999.
- the predetermined shortening factor is determined as a function of the diameter of the embossing roller 2a and/or the counter-pressure roller 2b. Furthermore, it is possible for the predetermined shortening factor to be determined as a function of the embossing length and/or a printing length, in particular on the substrate 3.
- the elevations 12a and/or depressions 12b are introduced in flat states of the die 4a and the die 4a is subsequently deformed such that the die 4a has a rounding which substantially corresponds to the rounding of the magnetic embossing roller 2a and/or the rounding of the counter-pressure roller 2b.
- an adhesive layer 9 is provided between the first metal layer 8 and the second metal layer 10.
- the adhesive layer 9 is a hot-melt or cold-melt adhesive layer.
- the adhesive layer 9 is a two-component adhesive (2K adhesive), in particular comprising epoxy resins.
- 2K adhesive a two-component adhesive
- the adhesive layer 9 is a 2K Epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.
- the adhesive layer 9 is a double-sided adhesive tape.
- the double-sided adhesive tape is coated on both sides with a pressure-sensitive adhesive (PSA).
- PSA pressure-sensitive adhesive
- Such double-sided adhesive tapes can be obtained, for example, from tesa, Norderstedt, Germany.
- the adhesive layer 9 preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.
- the matrix 4a according to Fig. 5a preferably has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm.
- the die 4a according to Fig. 5a has at least one elevation 12a and/or depression 12b, which in particular corresponds to the relief shape to be embossed in positive and/or negative form.
- the at least one elevation 12a of the die 4a has a height of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm, and/or that the at least one depression 12b of the die 4a has a depth of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm.
- Fig. 5b shows a schematic sectional view of a male mold 4b.
- the male mold 4b is designed as a counter-mold to the female mold 4a shown in Fig. 5a.
- the male mold 4b is single-layered. This can, as described above, be manufactured or designed according to one of the variants I), II) or III).
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- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
L'invention concerne un dispositif (1) pour le gaufrage rotatif à sec d'un substrat (3), le dispositif (1) comprenant un poste de travail (1a) qui comporte un rouleau de gaufrage magnétique (2a) et un rouleau de contre-pression (2b), au moins une matrice femelle (4a) étant installée magnétiquement sur le rouleau de gaufrage magnétique (2a) et au moins une matrice mâle (4b) étant positionnée sur le rouleau de contre-pression (2b), ladite au moins une matrice femelle (4a) étant multicouche et présentant au moins une première couche métallique (8) constituée d'un matériau ferromagnétique, et ladite au moins une matrice femelle (4a) présentant un film (7) sur la face orientée vers le rouleau de gaufrage magnétique (2a).
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102024110784.7 | 2024-04-17 | ||
| DE102024110784.7A DE102024110784B3 (de) | 2024-04-17 | 2024-04-17 | Vorrichtung sowie Verfahren zum rotativen Blindprägen eines Substrats sowie Matrize |
| DE102024125633.8 | 2024-09-06 | ||
| DE102024125633 | 2024-09-06 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2025219013A1 true WO2025219013A1 (fr) | 2025-10-23 |
Family
ID=95155080
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/EP2025/057932 Pending WO2025219013A1 (fr) | 2024-04-17 | 2025-03-24 | Dispositif et procédé de gaufrage rotatif à sec d'un substrat, et matrice femelle |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2025219013A1 (fr) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040035311A1 (en) * | 2000-08-19 | 2004-02-26 | Herbert Moll | Method for positioning a male mould on a counter-pressure cylinder of an embossing station |
| US7717035B1 (en) * | 2007-02-16 | 2010-05-18 | Carey Color, Inc. | Embossing apparatus and method for mounting embossing plates |
| DE102018102638A1 (de) | 2018-02-06 | 2019-08-08 | Hinderer + Mühlich Gmbh & Co. Kg | Verfahren sowie Vorrichtung zum rotativen Blindprägen eines Substrats, eine Matrize und/oder Patrize zur Verwendung in einer Vorrichtung sowie ein Verfahren zur Herstellung einer Matrize und/oder Patrize |
-
2025
- 2025-03-24 WO PCT/EP2025/057932 patent/WO2025219013A1/fr active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20040035311A1 (en) * | 2000-08-19 | 2004-02-26 | Herbert Moll | Method for positioning a male mould on a counter-pressure cylinder of an embossing station |
| US7717035B1 (en) * | 2007-02-16 | 2010-05-18 | Carey Color, Inc. | Embossing apparatus and method for mounting embossing plates |
| DE102018102638A1 (de) | 2018-02-06 | 2019-08-08 | Hinderer + Mühlich Gmbh & Co. Kg | Verfahren sowie Vorrichtung zum rotativen Blindprägen eines Substrats, eine Matrize und/oder Patrize zur Verwendung in einer Vorrichtung sowie ein Verfahren zur Herstellung einer Matrize und/oder Patrize |
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