Background of the Invention
[0001] The present invention relates to a method for making decorative emblems, plaques,
and the like (hereafter generically called "decorative shapes") which have a cured
plastic layer over a decorative surface. More particularly it relates to a method
in which a plurality of individual coated shapes are stamped from a single substrate
without damaging the plastic coat or deforming the shape during the die cutting operation.
[0002] Copending U. S. Application S.N. 054,548 filed July 5, 1979, now U. S. Patent No.
( ) discloses a process for mass producing decorative shapes in which a smooth
coating of a radiation curable polyurethane composition is applied by flow coating
to a foil substrate decorated with a series of designs in the form of individual emblems
or plaques and backcoated with a layer of adhesive. Using a cutting die such as shown
in Fig. 3 individual shapes are stamped from the substrates by pressing the shape
contiguous with the decorative design with a male punch into a female cutting die.
This imparts a domed shape to the decorative emblem. While in some instances this
dome is of aesthetic value, the depth of the dome is difficult to control and the
domed shape is difficult to apply to a flat surface or a surface where the radius
of curvature is substantially different than that of the dome. Furthermore, when a
dome is imparted to the shape as it is die cut, it is difficult to obtain decorative
shapes having a sharply cut vertical edge, occasionally the shape may delaminate,
scratch or chip, and there is some edge deformation and silvering of the foil substrate.
There is also a tendency for the adhesive to ooze from the substrate and contaminate
the mold when it is die cut. All of these drawbacks contribute to a reduction in the
weather resistance of the cut shape.
[0003] A typical decorative shape produced in accordance with the present invention and
the aforementioned U. S. Patent Application is stamped from a laminate including
a sheet of aluminum painted or silk-screened on one side with a decorative insignia
or graphic which is over coated with a layer of cured polyurethane and coated on the
other side with an adhesive composition. The adhesive layer is overlayed with a sheet
of release paper. One example of this laminate is shown in Fig. 1. When the cutting
die strikes this laminar structure, due to the relative softness of the polyurethane
and the adhesive composition in comparison to the aluminum sheet, the coated substrate
moves slightly with the cutting edge of the die. This causes the substrate to bow
under the face of the male punch. Bowing involves the drawbacks mentioned above. In
particular, bowing irreversibly domes the decorative shape and produces a shape with
poor edge characteristics, which is subject to delamination and has poor weather
resistance.
[0004] Thus, there is a need for a method of die cutting shapes having a weather and wear
resistant plastic coating which does not dome or delaminate the shape and which yields
a sharply cut edge and a shape having good weather resistance.
Summary of the Invention
[0005] The present invention provides a method for obtaining essentially flat decorative
emblems, plaques and the like with a sharp vertical edge. In accordance with the invention
individual decorative shapes are die cut from a laminated substrate on which a series
of decorative designs are reproduced, which designs are overcoated with a layer of
cured plastic. The invention uses a cutting die set in which a pressure platform is
resiliently mounted in a female cutting die. The pressure platform prevents the substrate
in the area of the decorative shape from bowing under the punch by sandwiching the
shape between the platform and the punch.
[0006] In accordance with the invention as the cutting die set closes on the substrate,
the pressure platform biases the substrate against the male punch with sufficient
pressure to prevent it from bowing on the face of the male punch. As the press completes
its closure, the male punch forces the substrate into the cutting die by depressing
the pressure platform. The tension in the platform mount is adjustable such that the
platform provides enough resistance to prevent the substrate bowing without otherwise
scratching or deforming the plastic coat.
[0007] At the completion of the cutting cycle, the press opens, and releases the substrate.
The platform under its resilient mounting returns to its pre-cutting position and
insodoing the shape which is now cut from the substrate, is reinserted in the substrate
selvage for carriage to a punching station where the shape is ejected from the substrate
and collected.
[0008] In accordance with one embodiment of the invention, a 2-working station cutting die
set is employed wherein shapes are simultaneously cut and reinserted into the substrate
at one station and punched or ejected from the substrate and collected at the other.
In a preferred embodiment the substrate from which the shapes are cut and ejected
is supported on a resilient table for both operations.
[0009] In accordance with another embodiment of the invention the mouth of the female cutting
die is provided with a steel rule knife. The knife minimizes the cutting force and
delamination, reduces aluminum burring, and provides a sharp vertical edge and also
cleanly cuts adhesive and release paper.
[0010] Other objects and advantages of the invention will be apparent from the following
description, the accompanying drawings and the appended claims.
Brief Description of the Drawings
[0011]
Fig. 1 is sectional view showing the laminar construction of the decorative shapes
produced in accordance with the present invention.
Fig. 2 is a schematic illustration of one example of a coated, laminated substrate
prior to cutting in accordance with the invention.
Figs. 3A and 3B are schematic views in section of a cutting die set and method used
in a prior process.
Figs. 4A and 4B are schematic views in section of a 2-working station cutting die
set and method used in the present invention.
Figs. 5A and 5B are schematic views in section of another cutting die set and method
used of the present invention.
Detailed Description of a Preferred Embodiment
[0012] The present invention is a process for forming decorative shapes such as that illustrated
in cross-section in Fig. 1. A typical shape comprises a substrate 10 which is coated
on the back side with a layer of adhesive 12. To prevent the adhesive from inadvertently
becoming adhered to a surface or collecting dust or lint, and to facilitate handling
the shape is shown with a sheet of release paper 14 releasably laminated to the layer
of adhesive 12. The top or graphic surface 13 of the substrate 10 is preferably provided
with a layer of primer or a subbing layer 16 on which a decorative design or insignia
18 is painted or silk screen printed. This design is overcoated with a clear plastic
layer 20 which beautifies the image and imparts wear and weather resistance to the
object. Plastic coating 20 is optionally overcoated with a further protective film
22 such as a film of polyethylene.
[0013] A composite for mass producing these shapes is shown in Figure 2 wherein an array
of designs 24 is formed on graphic face 25 of a sheet of substrate 26. The design
areas present a laminar construction as in Figure 1, however, for simplicity only
the plastic coat 28 is separately shown and the laminated substrate is generally
designated 26 with the understanding that it represents the laminated substrate structure
as shown in Fig. 1. Alternatives to coating local areas of the substrate are to coat
the entire sheet of substrate 26 or only the individual designs 24 with plastic.
To coat only the design area and not the contiguous surrouding area, the designs may
be formed with an edge, dyke or other shapes defined peripheral edge which halts the
flow of the plastic at the design edge. The simpler technique however is to deposit
an amount of plastic on the design which, when it flows to completion, coats the design
and a small amount of the area which immediately surround it, as shown in Fig. 2.
[0014] The formulation of the layers which make up the above laminate as well as the coating
techniques used to fabricate it are discussed in some detail in the aforementioned
patent application and Serial No. 54,548.
[0015] The substrate upon which the fluent plastic is coated may be a plastic or metal foil,
preferably an aluminum foil 0.003 to 0.020 inch thick. The foil substrate is decorated
with an appropriate design or series of designs. More commonly, a series of designs
in the form of individual emblems or plaque shapes will be applied to the foil sheet.
With a metal foil, the series of designs is preferably applied by silk screen or
lithographic printing then the design is enhanced by embossing select areas; although,
other means for forming the decorative designs may also be used. The foil may be
embossed to give a three dimensional effect to the emblem.
[0016] It is desirable to prime the top surface of the substrate prior to printing. Any
suitable primer may be used, such as a silane primer. The decorated-primed substrate
is then placed upon a vacuum mat which is situated upon a horizontal vacuum table
such as that shown in commonly assigned U. S. Patent No. 4,034,708. Vacuum is drawn
against the bottom surface of the foil through the mat to hold the substrate flat
and horizontal.
[0017] The flow characteristics of the fluent plastic and the liquid wettability of the
substrate are used to control the spread of the plastic so that it is contiguous with
predetermined areas of the foil as well as being uniformly thick. It is also possible
to control the plastic flow by use of sharply defined peripheral sides for the substrate
or defined areas of the substrate as disclosed in Serial No. 54,548.
[0018] Flow coating is a path-wise desposition. That is, a multiple orifice nozzle (or nozzles)
is passed over the decorated-primed surface of the foil at a steady speed as the substrate
is held stationary. The number of orifices used may vary depending on the width
of the path to be laid down. The thickness sought is between approximately 0.020 to
0.040 inch.
[0019] The plastic is preferably a fluent polyurethane of two component parts (polyol and
isocyanate) which are mixed immediately prior to coating and cure upon heating. A
polyurethane of this type is disclosed in commonly assigned U. S. Patent No. 4,100,010.
[0020] Basically, that mixture is one of a polyether polyol component ("A"), which may
be a difunctional, trifunctional and/or tetrafunctional polypropylene glycol containing
a suitable catalyst, and a diisocyanate component ("B") such as an aliphatic diisocyanate.
A catalyst such as a lead or mercury material is used since it promotes a slow cure
at room temperature so as to allow time for full flow of the liquid polyurethane before
setting. As stated in Patent No. 4,100,010, which is specifically incorporated herein
by reference, an example of the diisocyanate is Hylene W from E. I. du Pont de Nemours
and Co., and the polyether polyol may be one or more of the Pluracol materials (P-410
or TP-440) from BASF Wyandotte. It may also be a polyether-polyester polyol combination,
use of the polyester polyol making the cured polyurethane more flexible. The ratio
of components A:B is preferably 50-60:40-50. A polyester polyol or polylactone polyol
could be used in place of the polyether polyol.
[0021] In formulating the particular plastic composition from among those disclosed in
that patent, it is important to use a catalyst which results in a somewhat slow curing
time in order to allow the flow coated liquid plastic to flow sufficiently, i.e.,
to the sharply defined peripheral sides if ones are used, before curing is accomplished.
Otherwise, it may not be possible to obtain a uniform thickness, smooth coating.
[0022] Likewise, the polyurethane may be compounded from among components listed in the
patent as is known to give a more flexible cured plastic. As long as the bond to the
substrate remains strong, it is desirable in this invention to have a somewhat flexible
plastic coat so that the emblem or plaque may be conformed. For example, some decorative
automobile panels are applied to a curved surface. With the present invention, it
is possible to conform the cured plastic coated panel to that surface.
[0023] For most of the types of plastic contemplated, curing will be by irradiation with
infra-red or ultra-violet light. The polyurethane compounds mentioned above are heat
curable and, thus, infra-red lamps are used; although, obviously other heat sources
may also be used. Still, it is desirable to get a through cure, i.e., heat from both
the top and bottom of the coated foil. The preferred vacuum table arrangement of U.
S. Patent No. 4,034,708 makes this possible because of a capability of heating or
cooling it. However, it has been found desirable to use the infra-red lamps themselves
as the heat source for both top and bottom heating. This may be done by using an I.R.
absorptive mat as the vacuum mat. The mat will, then pick up heat from the infra-red
radiation and conduct it back from the bottom through the coated foil.
[0024] After curing, the coated substrate is cooled and removed from the vacuum table. Individual
emblem or plaque shapes are stamped out by a cutting die around the particular emblem
or plaque shape. It has been found that by preventing the coated substrate from bowing
while die cutting the decorative shape it is possible to obtain a shape which is essentially
flat (except in areas where the shape has been pre-embossed to give depth to the decorative
pattern) and which has a sharp vertical edge which resists delamination and provides
good weather and wear resistance. In accordance with the invention the shapes are
cut from the coated, laminated substrate using a die set such as that illustrated
in Figs. 4 or 5. The die sets shown in Figs. 4 and 5 are 2-working station sets wherein
the coated substrate moves from right to left in the figures. It will be clear that
using separate dies for the die cutting and ejecting operations discussed below is
equivalent to the 2-working station die sets illustrated. Furthermore, it will be
evident that the ejecting operation could be performed manually without a die set.
[0025] As background, a conventional cutting die set is shown in Fig. 3A. This die set comprises
a punch holder 40 which is mounted in die cutting relation with a die holder 42. Punch
holder 40 is coupled to a press ram (not shown) by shank 43, and die holder 42 is
clamped or otherwise mounted to the press bed at ears 45. The punch holder 40 and
die holder 42 are aligned by a plurality of guide posts and guide bushings (not shown).
Typically the press is mechanically actuated but a hydraulic press may also be used.
A male punch 46 is mounted on the punch holder 40 with a surrounding stripper plate
44. The plate 44 contiguously frames the male punch 46 and is mounted for resilient
reciprocation on a set of spring-shoulder screw assemblies comprising die springs
49 and 51 carried on shoulder screws or stripper bolts 48 and 50. In Figs. 3A and
3B, two shoulder screws are shown, another pair of shoulder screws, located on the
back side of the stripper plate is not seen in this schematic sectional view. A threaded
connection is provided between the plungers 48 and 50 and the stripper plate 44.
The stripper plate 44 holds the substrate in place during the cutting operation and
cleans any selvage clinging to the punch 46. The position of the stripper plate may
be lowered or raised by inserting a shim under the shoulder or body of the shoulder
screw. To increase spring pressure, a shim may be inserted under the die spring or
a higher pressure die spring can be used.
[0026] Die holder 42 carries a female die 54 having a cutting edge 56, a die face 58 and
a female die cavitiy 60. The female die 54 is positioned on the die holder 42 such
that the female die cavity 60 opens on an outlet passage 62 formed in the holder 42.
[0027] Shapes having a laminar construction such as shown in Fig. 1 are cut from a substrate
by positioning the substrate 26 on the face 58 of the female die 54 with its graphic
side 25 down and its design area in alignment with the mouth or cutting edge 56 of
the die. When the press is closed as shown in Fig. 3B, the substrate 26 is engaged
by the stripper plate 44 and the punch 46. As the punch 46 descends into the die cavity
60, the springs 49 and 51 on the shoulder screws 48 and 50 are compressed and the
area of the substrate contiguous with the design is engaged by the stripper plate
44. Due to the relative softness of the layers on each side of the substrate 26, the
substrate is pulled into the die cavity 60 and bows under the punch 46 as shown by
the bow 68 in Fig. 3B. As the punch 46 completes its descent it finally cuts a shape
70 from the substrate 26 contiguous with the design 66. This shape falls from the
die cavity 60 through the passage 62 in the holder 46 where it is collected. Due to
the bowing which occurs, a dome is imparted to the shape 70 which is shown exiting
the press in Fig. 3B.
[0028] In accordance with the invention, bowing is prevented by holding the substrate flat
on the punch face using a pressure platform which is resiliently mounted in the female
cutting die. Furthermore, because cut shapes can no longer be collected from an opening
in the base of the female cutting die cavity, they are reinserted in the substrate
selvage by the platform after they are cut and ejected by a separate operation which
is conveniently performed at another working station in the die set.
[0029] Referring to Fig. 4A, the die set comprises a punch holder 80, a die holder 82, a
right working station 84 and a left working station 86. In the right station 84, the
shape is cut from and reinserted into the substrate 26. In the left station 86, the
cut shape is ejected from the substrate by a punch. The die set is mounted to the
press ram by shank 85 and fixed to the press bed at ears 87.
[0030] The right station 84 includes a female cutting die 90 which is mounted on the die
holder 82. The female cutting die comprises a die cavity 92 in which a pressure platform
94 is resiliently mounted on a spring and shoulder screw assembly comprising spring
96 and shoulder screw 98. Embodiments are also envisioned in which a plurality of
spring shoulder screw assemblies are used to support the platform depending on the
size of the shape cut. The shoulder screw 98 is threaded and screws into the platform
94. The platform in the die cavity and the tension on the spring 96 can be adjusted
to provided just enough pressure to prevent the substrate from bowing without deforming
the plastic coating over the graphic using shims in a manner analogous to that previously
described for the stripper plate 44 in Fig. 3. In accordance with a preferred embodiment
of the invention, the mouth of the die cavity 92 is equipped with a knife 100.
[0031] Turning to the head portions of the die set, a punch 102 is mounted on the punch
holder 80 and framed by a contiguous stripper plate 104. As in Fig. 3, the stripper
plate 104 is mounted on a set of four spring shoulder screw assemblies wherein two
assemblies are shown in the view with springs 106 carried on shoulder screws 108 which
are threaded at the bottom where they connect to the stripper plate 104. Engagement
of the stripper plate is adjusted as earlier described.
[0032] The left station 86 comprises a second punch 110 mounted on the punch holder 80 and
a female die 112 having a die face 114 which is mounted on the die holder 82 such
that the die cavity 116 opens into a collection passage 120 formed in the die holder
82. Punch 86 is framed by a stripper plate 115 which is mounted for reciprocating
movement on spring-shoulder screw assemblies 115ª and 115
b. Plate 115 functions analogous to plate 104 and holds the substrate flat as the cut
shape is ejected and removes selvage from the punch 110.
[0033] While in this and the embodiment of the invention subsequently discussed below, the
pressure platform 94 is shown resiliently mounted on a spring shoulder screw assembly,
those skilled in the art will understand that the spring shoulder screw assemblies
illustrated herein may be replaced by other types of resilient mounts including rubber
blocks and compressed air or hydraulically actuated cylinders.
[0034] Operation of the die press is shown in Fig. 4b wherein the substrate 26, which typically
has an array of cured plastic coated designs thereon as shown in Fig. 2 is positioned
in the right station 84 with its graphic side 25 facing the punch 102 and its design
contiguous with the cutting edge 100 of the die. The pitch of the designs on the substrate
is such that a second cut design is simultaneously located over the die 112 in the
left station as the first design is cut. Furthermore, the size of the die assemblies
in the right and left working stations usually dictate that a third cut design be
idle between the right and left station as the cutting and ejecting operation proceed.
[0035] Turning first to the cutting operation, as the punch holder 80 closes, the punch
102 engages the substrate 88 and presses it against the pressure platform 94. The
tension in the spring 96 is such that the pressure platform 94 resists the descent
of punch 102 with sufficient tension to prevent the substrate 26 from bowing under
application of the punch 102 without otherwise scratching, compressing or deforming
the design shape 24 or its clear plastic coating 28. The tension spring 96 and the
pressure in platform 94 is adjusted using shims or through the selection of the die
spring, such that the substrate is not distorted by cutting and the cut part is returned
to the selvage for carriage to the ejecting station. If the spring tension is too
much, the part is distorted, if it is too low, it is not returned to the selvage.
[0036] As the punch holder 80 completes its closure, under pressure from punch 102, the
platform 94 is depressed below the upper edge of the knife 100 and the substrate 26
is urged against the knife 100 whereupon a decorative shape 126 is cut from the substrate
26 and forced into the female die cavity 92. As the press closes, the stripper plate
104 engages the portions of the substrate 26 surrounding the shape 126 to prevent
those portions from angling around the knife edge 100 and to assist in obtaining a
sharply cut vertical edge.
[0037] After cutting decorative shape 126 from the substrate 26, the press opens and punch
102 disengages the substrate. As pressure on platform 94 is released, the platform
returns to its original position slightly above the edge of the knife 100 and insodoing
reinserts the shape 126 into the substrate 26. At this time, stripper plate 104 is
still in pressing engagement with the substrate such that the substrate does not cling
to the male punch 102 and the platform 94 is able to reinsert the shape 126 into the
substrate without lifting the substrate off the face of the female cutting die.
[0038] At the same time shapes are cut at the right station 84, shapes which have been resinserted
into the substrate are removed at the left station 86. At the left station 86, the
die press closes such that the second punch 110 forces the cut shape 126 out of the
substrate 88 and into the cavity 116 of the female die 112 from whence the shape 126
falls under its own weight out of the press through the passage 120 where it is collected.
While Fig. 4 illustrates a completely automated system in which decorative shapes
are continuously cut at the right working station and ejected from the substrate at
the left working station with each stroke of the die set, the ejection operation at
the second station can be performed manually. In this case, a cutting die set having
only the right station 84 produces a substrate from which the cutout shapes can be
pushed, for example, by hand.
[0039] Figs. 5A and 5B illustrate another embodiment of the invention. In contrast of the
previous embodiment, in accordance with this embodiment of the invention, the female
cutting die is mounted above the punch and moves into a stationery die punch. Referring
to Fig. 5A, as in the case of the aforementioned embodiment, the die set is a two
working station die set having a cutting station 140 on the right and a punching station
142 on the left. The punching station 142 may be replaced by its manual equivalent.
The cutting station 140 and the punching station 142 share a upper die set holder
144. In the cutting station a female cutting die 146 is mounted on the upper holder
144 in die cutting relation with a male punch 148 mounted on the lower die set holder
150. The upper holder 144 is coupled by shank 152 to a mechanical press (not shown)
by a ram cap, the lower holder 150 is secured to the press bed. Alignment of the upper
and lower holders is typically by guide posts, also not shown. The female die 146
includes a die cavity 154 in which a pressure platform 156 is resiliently mounted
on a spring and shoulder screw assembly comprising a spring 158 carried on a shoulder
screw 160 wherein the shoulder screw has a threaded connection with platform 156.
Of course, a plurality of spring and shoulder screw assemblies may be used instead
of the one shown depending on the design of the shape. Lower holder 150 supports a
resilient table 162 mounted on a set of spring and shoulder screw assemblies 164 each
assembly comprising a spring 166 carried on a shoulder screw 168 which is mounted
by a threaded connection to the table 162. The height of the table 162 and the tension
of the springs can be adjusted using shims as previously discussed. The number of
spring and shoulder screw assemblies supporting the table 162 will vary depending
upon the size and design of the emblem or plaque being cut. In the embodiments shown
six shoulder screws are used - the three seen in the view and three on the backside.
The male punch 148 is mounted on the lower holder 150 through an opening 147 in the
table 162 such that resilient reciprocal movement is permitted between the table
162 and the punch 148 and the table 162 strips any substrate hanging on the punch
148 after cutting.
[0040] To cut the substrate, the substrate 26 is positioned in station 140 with its graphic
side 25 facing the punch 148 and its plastic coated design aligned with the cutting
edge 176 of the die (which is preferably equipped with a steel rule knife as shown).
The upper holder 144 moves the die 146 into engagement with the substrate 26 and the
punch 148 whereupon the pressure platform 156 is engaged and prevents the substrate
from bowing. Upon further descent of the die 146 onto the male punch 148, the pressure
platform 156 is depressed with some depression of the resilient table 162 on the
die holder 150 whereupon the shape is cut from the substrate. As pressure is released,
the resilient table 162 maintains the substrate 26 in contact with the face of the
female die 146 such that the pressure platform 156 can reinsert the shape into the
substrate as it returns to its original undepressed position.
[0041] The left station 142 comprises a male punch 174 mounted on upper holder 144, the
resilent table 162, and a channel 188 which is formed by a channel-forming wall 178
which is slidably received in passage 180 formed in the lower holder 150. In the left
station 142 as the upper holder 144 descends, the substrate is resiliently engaged
between the table 162 and a stripper plate 182 which frames the punch 174 and is mounted
resiliently and adjustably on spring and shoulder screw assemblies 184. The male punch
174 subsequently pushes the cut shape 82 through the opening 176 in table 162 and
into the channel 188 formed by the channel-forming wall 178 from which it falls out
of the press through the passage 180 in the lower holder.
[0042] There has been a tendency for shapes to chip slightly at their periphery as they
are cut and ejected from the substrate in the manner illustrated in Fig. 4. While
this tendency has been quite limited and has not seriously detracted from the commercial
acceptability of the cut shapes, the embodiment illustrated in Fig. 5 minimizes peripheral
chipping. It has been found that the plastic coating 20 (Fig. 2) is radially compressed
as it is cut from the substrate and it expands when pressure is released leaving a
slight overhang at the edge. In accordance with the embodiment of Fig. 5, by ejecting
the cut shape from the side bearing the plastic coating 20, edge chipping is reduced.
[0043] While the methods herein described constitute preferred embodiments of this invention,
it is to be understood that the invention is not limited thereto, and that changes
may be made therein without departing from the scope of the invention claimed.
1. In a method for producing decorative shapes which comprises flow coating a clear,
viscous, fluent plastic onto the top surface of a horizontally supported substrate
having a series of individual designs provided thereon, curing said fluent plastic
and die cutting plastic coated shapes from said substrate contiguous with said designs;
the improvement which comprises:
die cutting said shapes by application of a female cutting die to one surface of said
substrate and a male punch to the other surface of said substrate while preventing
said substrate from bowing,
said female cutting die comprising a die cavity, a pressure platform mounted in said
cavity, and a resilient mounting means supporting said platform, wherein as said substrate
is die cut, said substrate is engaged in the area of said designs between the face
of said punch and said resiliently mounted platform, and said platform applies a sufficient
force to said substrate against said punch that said substrate cannot bow under said
punch as said shape is cut.
2. The method of claim 1 wherein said decorative shapes are cut out using a die set
having a first working station;
said first working station comprising said female cutting die mounted in die cutting
relation with said male punch such that upon the application of pressure to said female
cutting die and/or said male punch, said substrate is engaged between said resiliently
mounted platform and said punch, said platform is depressed, and said shape is cut
from said substrate and pressed into said die cavity, and upon the release of said
pressure, said substrate is disengaged and said resiliently mounted platform reinserts
said shape into said substrate.
3. The method of claim 2 wherein a stripper plate is resiliently mounted about said
punch such that said plate contiguously frames said punch and said plate engages the
portions of said substrate surrounding said shape as said shape is cut from and reinserted
in said substrate.
4. The method of claim 3 wherein said die press includes a second working station,
said second working station comprising means for ejecting said cut and reinserted
shapes from said substrate.
5. The method of claim 4 wherein said second working station comprises a second punch
mounted in die-cutting relation with a support member having an opening formed therein
for receiving said punch and exiting said shapes.
6. The method of claim 5 wherein a stripper plate is resiliently mounted about said
second punch such that said plate contiguously frames said punch and said plate engages
the portions of said substrate surrounding said shape as said shape is ejected from
said substrate.
7. The method of claim 1 wherein the mouth of said female cutting die is equipped
with a steel rule knife.
8. The method of claim 1 wherein said decorative shapes are die cut using a die set
wherein said die set comprises:
a first support member,
a second support member,
a female cutting die mounted on said first support member,
a first punch co-mounted on said first support member with said female cutting die,
a table resiliently mounted on said second support member
resilient mounting means mounting said table on said second support member,
said table having a first opening and a second opening therein,
a second punch mounted on said second support member through said first opening in
said resiliently mounted table,
a passage formed in said second support member and aligned with said second opening
in said resiliently mounted table,
wherein said first and second support members are mounted for reciprocation with said
female cutting die mounted in die-pressing relation with said second punch and said
first punch mounted in die-pressing relation with said second opening in said resilient
table such that upon the application of pressure to said support member, at said female
cutting die said substrate is engaged between said resiliently mounted platform and
said punch with a pressing force which prevents said substrate from bowing without
otherwise deforming said substrate, said platform is depressed and said shape is cut
from said substrate and pressed into said die cavity, and upon releasing said pressure,
said substrate is disengaged by said punch and said resiliently mounted platform reinserts
said shape into said substrate, and
at said first punch, said cut and reinserted shapes are ejected from said substrate
and through said passage in said second support member.
Amended claims in accordance with Rule 86(2) EPC.
1. In a method for producing decorative shapes which includes flow coating a clear,
viscous, fluent plastic onto the top surface of a horizontally supported substrate
having a series of individual designs provided thereon, curing said fluent plastic
and die cutting plastic coated shapes from said substrate contiguous with said designs;
characterised by:
die cutting each of said shapes by application of a female cutting die to one
surface of said substrate and a male punch to the other surface of said substrate,
said female cutting die comprising a die cavity, a steel rule knife edge at the mouth
of said die cavity, a pressure platform mounted in said cavity, and a resilient mounting
means supporting said platform,
while die cutting said shape, holding said shape against the face of said punch
with said platform, and
supplying sufficient force to said shape to prevent said shape from bowing.
2. The method as claimed in claim 1, wherein said decorative shape is die cut out
using a die set having a first working station;
said first working station comprising said female cutting die mounted in die cutting
relation with said male punch such that upon the application of pressure to said female
cutting die and/or said male punch, said substrate is engaged between said resiliently
mounted platform and said punch, said platform is depressed, and said shape is cut
from said substrate and pressed into said die cavity; and following said die cutting,
said method further comprises reinserting said shape into said substrate by said platform.
3. The method as claimed in claim 2, wherein a stripper plate is resiliently mounted
about said punch such that said plate contiguously frames said punch and said plate
engages the portions of said substrate surrounding said shape as said shape is cut
from and reinserted in said substrate.
4. The method as claimed in claim 3, wherein, following said reinserting, said method
further comprises ejecting said shape from said substrate at a second working station,
said second working station comprising means for ejecting said cut and reinserted
shape from said substrate.
5. The method as claimed in claim 4, wherein said second working station comprises
a second punch mounted in die cutting relation with a support member having an opening
formed therein for receiving said punch and exiting said shape.
6. The method as claimed in claim 5, wherein a stripper plate is resiliently mounted
about said second punch such that said plate contiguously frames said punch and said
plate engages the portions of said substrate surrounding said shape as said shape
is ejected from said substrate.
7. The method as claimed in any preceidng claim, wherein said shape has a layer of
an adhesive and a release liner on the surface of the substrate opposite said plastic.
8. The method as claimed in claim 1, wherein said decorative shape is die cut using
a die set wherein said die set comprises:
a first support member,
a second support member,
a female cutting die mounted on said first support member,
a first punch co-mounted on said first support member with said female cutting
die,
a table resiliently mounted on said second support member
resilient mounting means mounting said table on said second support member,
said table having a first opening and a second opening therein,
a second punch mounted on said second support member through said first opening
in said resiliently mounted table,
a passage formed in said second support member and aligned with said second opening
in said resiliently mounted table,
wherein said first and second support members are mounted for reciprocation with said
female cutting die mounted in die-pressing relation with said second punch and said
first punch mounted in die-pressing relation with said second opening in said resilient
table such that upon the application of pressure to said support member, at said female
cutting die said substrate is engaged between said resiliently mounted platform and
said punch with a pressing force which prevents said substrate from bowing without
otherwise deforming said substrate, said platform is depressed and said shape is cut
from said substrate and pressed into said die cavity, and upon releasing said pressure,
said substrate is disengaged by said punch and said resiliently mounted platform reinserts
said shape into said substrate, and
at said first punch, said cut and reinserted shape is ejected from said substrate
and through said passage in said second support member.