Related Application
Field of the Invention
[0002] This invention relates to a graphic arts die and support assembly adapted to be mounted
as a unit on the platen chase of a flat bed graphic arts press or the chase for the
cylinder of a rotary graphic arts press. Each of the dies is fixedly mounted in predetermined
relative relationship on a die carrier or mounting plate serving as a support member
for the dies. A number of arcuate die carrier plates are provided in instances where
the curved die carrier plates and associated curved dies are to be mounted on the
cylinder of a rotary graphic arts press in disposition such that the assembly of die
plates and dies may extend more than 180° around the circumference of the cylinder.
Furthermore, each die may be moved slightly relative to the remaining dies during
set up of the press to bring the design defining surface of each die into exact register
with artwork for the substrate being processed in the press.
[0003] In the case of an assembly of curved die carrier plates and associated curved die
units for rotary graphic arts presses, at least one of the die carrier plates is preferably
provided with a scribed centering line or other marker indicia. The curved plate having
a centering indicia is adapted to be attached to the cylinder of the rotary press
in register with a conventional center line on the press cylinder that is equally
spaced from the ends of the cylinder. The remaining curved die supporting plates may
then be attached to the cylinder based on the position of the registered first attached
plate, so that all of the die supporting plates are in proper registration with the
center line of the cylinder.
Background of the Prior Art
[0004] In conventional stamping, embossing, or die cutting presses, it has long been the
practice to provide an apertured chase for mounting the stamping, embossing or die
cutting dies on a flat bed press or the apertured chase of a rotary press. Fasteners
received in the apertures of the flat bed chase or cylinder chase of a rotary press
engage the edge of the die to hold the dies in selected positions on the flat bed
or rotary press.
[0005] Typical flat bed chases are 22 in. by 28 in., 28 in. by 40 in. or 39 in. by 50 in.
in size. These chases are usually from about 0.625 in. to about 2 in. thick steel
with closely spaced apertures formed in the chase for receiving fasteners such as
toggle devices. Similarly, rotary cylinders for mounting of curved dies generally
are in the 8 in. to 12 in. diameter range and have an apertured sleeve chase for the
rotary press cylinder, in which the sleeve chase has closely spaced fastener receiving
holes. Fasteners are employed to secure a multiplicity of stamping, embossing, or
die cutting dies to the die mounting surface of the apertured chases. Each fastener,
which is preferably a toggle device, is introduced into an aperture in the flat bed
chase or the apertured sleeve chase for the cylinder of a rotary press adjacent to
an edge of a respective die and the toggle device expanded with a tool to bring a
beveled edge of the hold down device into engagement with a complementally beveled
edge of a respective die. Typically as many as six fasteners may be required to secure
a rectangular stamping, embossing, or die cutting die to a flat bed press chase or
rotary press chase. Chases of the type described typically cost many thousands of
dollars. The toggle hold down devices are also relatively expensive and in a typical
die set up, there may be a need for as many as 100 fasteners, depending upon the size
of the flat bed chase or the diameter of the rotary cylinder chase and the number
of dies attached to the flat bed or rotary press.
[0006] Set up, also known as lock-up, of foil stamping, embossing, or die cutting dies on
an apertured chase, whether flat or cylindrical, is very time consuming. Each of the
dies must be oriented on a respective apertured chase in disposition such that the
design image of each die correctly and precisely aligns with image design artwork.
[0007] Lock-up is accomplished by placing the first of a series of foil stamping, embossing,
or die cutting dies on the die support surface of the apertured chase of a flat bed
press, or the apertured sleeve for the cylinder of a rotary press in approximately
the position where the die image will align with design image artwork. Fasteners in
the nature of conventional toggle devices are inserted in the nearest aperture of
the flat bed chase or rotary press chase in a position such that an inclined surface
of each toggle device is against the inclined edge of the die plate. A certain degree
of movement of the die with respect to the chase or cylinder may be accomplished by
adjusting the toggle device contained within a particular aperture in the multi-apertured
chase.
[0008] After the first die plate has been secured to the chase in proper disposition, the
entire securement process must be repeated with the next die plate and continued until
all of the die plates have been attached to the chase. Manifestly, this is a very
expensive procedure from the standpoint of personnel costs, and in certain instances
excessive downtime of the press. The lock-up must be carried out in accordance with
a successive time consuming step-by-step process of attaching a multiplicity of flat
or curved die plates to an apertured chase. In addition, once all of the dies are
mounted on its chase, whether it be flat or cylindrical, adjustment of individual
stamping, embossing or die cutting may be required to bring respective die images
into exact alignment with design image artwork.
[0009] Because of the high labor costs involved in lock-up of multiple die stamping, embossing
or die cutting dies on flat bed or rotary presses, some press operators elect to dedicate
a specific flat or cylindrical chase with dies mounted thereon to a high volume processing
operation. The result is that the operator must acquire and keep on hand a number
of individual chases with dies in place thereon for a particular job. In view of the
high cost of chases and the costs involved in providing a large number of toggle hold
down devices for the dies, locked up dedicated flat or cylindrical chases is an expensive
but often necessary undertaking.
[0010] Cylindrical die supporting plates have been provided for rotary press cylinders,
with a plurality of curved dies being attached to the surface of the cylindrical support
plate. In order to mount the cylindrical die support plate on the press cylinder,
it has been necessary to remove a side plate from the press, which can take as long
as four hours and is an expensive, cumbersome, and time-consuming operation. In addition,
because of the time involved in makeready of a cylindrical die supporting plate assembly,
many press operators have elected to provide a separate cylinder and associated dies
for each job, with the pre-madeup cylinders being interchanged as necessary. The costs
incurred limited this practice to very large runs in order to fully amortize the labor
and equipment expenses.
[0011] Alternatively, curved dies have been fabricated and used in the past on rotary press
cylinders, but the curved dies were limited to a circumferential arc no greater than
180°, so that the dies could be attached to the surface of the cylinder. This requirement
limited the applicability of such arrangement for rotary presses. Given the limitation
of a die no greater than 180° in circumference, press operators have mounted a series
of individual curved die plates on the press cylinder, which did extend more than
180° around the circumference of the cylinder. The dies had to be individually mounted
on the cylinder of the press oriented such that each was in register with respective
images on the substrate brought into contact with the dies. This was recognized to
be so labor intensive and time-consuming that low volume runs were of limited practicality.
Summary of the Invention
[0012] In accordance with the present invention, a press operator, whether using a flat
bed or rotary press, need only provide the engraver with a conventional positive/negative
film, or a digital file of the design art work. The film preferably has a line or
other indicia mark that is used for registration of the die plate of a flat bed press
with the press platen, or the plurality of die plates mounted on the cylindrical chase
of a rotary press. The engraver preferably uses the artwork or a digital file thereof
to program a CNC machine, which then forms a design image in a metal die plate blank,
wherein the design image in the plate conforms to the artwork image. In lieu of CNC
milling of the design image in the die blank, an engraver may hand engrave the design
image using an outline on the blank that was derived from a digitized file of the
design image. The engraver in that instance may use conventional techniques including
a hand tool, a grinder, and the like. Other image forming techniques may be used including
a conventional pantograph, computer actuated laser engraving, or chemical etching
of the design on a die blank that has a resist coating leaving only the area to be
etched open for contact by the etchant solution.
[0013] The CNC machine, containing a file of the design image art work preferably has a
program for preparing a flat or a curved support plate for a multiplicity of the pre-engraved
dies, or multiple arcuate support plates that carry one or more curved dies, and for
providing aligned openings in the die blank and support plate receiving fasteners
which fixedly although adjustably secure the die plates on a respective support member
in disposition, wherein all of the dies on a flat support plate are accurately aligned
with the original artwork design, or allow curved support plates and dies to be positioned
so that the dies are registered with the artwork.
[0014] Thus, the engraver may furnish to its customer a completed flat graphic arts die
assembly ready to be mounted on the apertured chase of a flat bed press or a multiplicity
of curved die carrier plates and arcuate dies that may be mounted on the apertured
cylindrical chase of a rotary press. The press operator is therefore not required
as in the past to meticulously and successively mount a series of foil stamping, embossing,
or die cutting dies on a flat bed chase or rotary press chase. Likewise, dedication
of a flat or cylindrical chase with mounted dies thereon for high volume jobs is no
longer necessary, thus freeing up chases and thereby decreasing the need for additional
chases, and toggles, and significantly reducing makeready of the press for foil stamping,
embossing, or die cutting jobs on flat bed as well as rotary presses.
[0015] In most foil stamping, embossing, and die cutting j obs, a plurality of dies are
provided to stamp, emboss or die cut a multiplicity of design images. Thus, in one
embodiment of the invention, the graphic arts die assembly has a number of individual
dies mounted in spaced relationship one from another on a support member. The support
with the dies thereon is adapted to be mounted as a unit on the chase of a flat bed
or the cylindrical chase of a rotary graphic arts press. The individual dies each
have a design defining surface conforming to design artwork furnished to the engraver
as a positive or negative film or digital file representation of the desired design.
The support member for the dies preferably comprises a relatively thin flat metal
plate, or a semi-cylindrical plate member, each being sized for mounting on a flat
bed chase or a rotary press chase.
[0016] In another embodiment of the invention, a plurality of separate curved die carrier
plates are provided, each of which has an inner face adapted to complementally engage
the cylindrical surface of a rotary press chase. Each of the curved carrier plates
is designed to receive one or more complementally configured curved dies. The separate
die carriers are each of a curvature less than 180° so that the carriers may be mounted
on the rotary press chase without removal of an end plate of the press. Structure
is provided for facilitating registration of all of the curved die carriers with respect
to one another and with a circumferentially oriented center line of the cylindrical
press platen.
[0017] The pre-engraved graphic arts dies are mounted on the die receiving surface of the
die support carrier member in pre-determined relative positions. Each die has at least
two through holes oriented outboard of and in pre-determined relationship with respect
to the design defining surface of a respective die. An upstanding die fastener is
provided on the die receiving surface of the die support member for each of the through
holes with respective fasteners being received in a corresponding through hole. A
releasable connector on each fastener engages a respective die for maintaining each
die in a fixed position on the die support member.
[0018] In a preferred embodiment of the invention, each of the fasteners is a threaded stud
welded to the die receiving surface of the support member. The releasable connectors
are preferably nuts threaded onto a corresponding fastener. The design defining surface
of each die has a cavity therein lined with a respective through hole and configured
to receive a corresponding nut threaded onto each fastener.
[0019] The support plate also may be provided with one or more hold down slots located adjacent
a die. Fastening devices are utilized in association with each hold down slot in disposition
engaging the support member at a location surrounding the slot. The fastening devices
are adapted to be received in aligned apertures in the flat bed press chase or rotary
press cylindrical chase and serve to maintain a central portion of the support member
during use of the graphic arts die assembly in close conformity to the surface of
the supporting chase during the various operating conditions of a flat bed or rotary
press.
[0020] Each die is also preferably provided with at least two alignment apertures therein
outboard of the design defining surface of the die and that align with the respective
orifices in the support member. Thus, by inserting temporary pins or the like in the
apertures of each die and introducing the pins into respective orifices in the support
member, each die may be maintained in its precise predetermined position on the support
plate until the connector nuts are snugged down against the surface of the die plate.
Additionally, the provision of the alignment apertures and orifices permit a die to
be returned to its original position using the alignment pins if the die has been
shifted on or removed from the die support member.
[0021] In a preferred procedure for fabrication of the graphic arts die assembly, the design
to be engraved in the surface of a respective die is digitized and the digital data
used to program a CNC machine. That machine then engraves the design in one surface
of a respective die blank. Alternatively, the design may be hand engraved, engraved
with a pantograph, laser engraved or chemically etched in accordance with conventional
engraving procedures. The program of the CNC machine causes at least two through holes
to be drilled in the die outboard of the engraved design, with the holes being precisely
located with respect to the engraved design image. The locations of the through holes
relative to the design image is digitally stored in the program associated with the
CNC machine. The program for the CNC machine also remembers the digital data relating
to the same or different engraved images on the series of dies to be mounted on a
particular support plate therefor, as well as the relative positions of the through
holes in each die.
[0022] The CNC machine is programed to shave the outer die receiving surface of a respective
support member in order to assure that the surface is precisely parallel with the
opposite surface of the support member which engages the flat bed chase. In the case
of a rotary cylinder chase, rather than using a CNC machine for surfacing of the die
support member, a grinding machine is preferably used to grind the die receiving surface
of the support member and thereby provide a die carrier plate of predetermined, specific
thickness. Alternatively, the die receiving surface of the support member may be shaved
with a CNC machine while the support member is in a flat condition, with the shaved
support member then being bent into circular configuration with a conventional roll
former. The perimeter edge of the support member is laser cut or machined by the CNC
unit in order that the exact location of the edge is maintained in the program memory
for the CNC machine. The CNC unit is further programmed to position and weld threaded
studs on the die receiving surface of the support member in locations to be received
in respective through holes through the dies and to thereby position the dies in precise
relationship one with respect to another and relative to the accurately formed edge
of the support member. After placement of the dies over corresponding studs, nuts
are threaded onto the upper ends of the studs in association with a respective washer,
if needed. Each die is provided with cavities in the design defining surface thereof
for receiving the nuts threaded onto corresponding studs. Temporary pins are preferably
placed through the aligned apertures of the die and respective orifices in the support
member to maintain each die in a precise location until the nuts can be applied to
corresponding studs and turned down into firm locking engagement with the design defining
surface of each die.
[0023] Because the perimeter edge of the support member has been accurately machined and
the dies positioned on the plate in pre-determined relationship to the edge, the completed
die assembly may be mounted on a flat bed press chase using an edge of the support
unit as an alignment guide for the graphic arts die assembly with respect to portions
of substrate or other material to be foil stamped, embossed, or die cut. When being
mounted on a rotary press cylindrical chase, the completed multi-section die assembly
may be mounted on the chase using an edge of each support unit as a guide for alignment
of adjacent die carrier supports. Notches at the same position in the edges of each
of the support units serve as keys for registration of adjacent support carriers,
preferably in conjunction with a spacer tool adapted to be received with opposed aligned
key notches of adjacent support members.
[0024] After use of the graphic arts die assemblies, a single carrier plate supporting a
plurality of dies, or multiple die carrier plates with one or more dies can be quickly
removed from the flat bed press chase or rotary press chase and other pre-prepared
graphic arts die assemblies mounted in place, with minimal makeready being necessary
before full press operation. In those instances where slight adjustment of one or
more of the dies is found necessary, such adjustment may be quickly and easily accomplished
by virtue of the fact that the through holes are slightly larger than the studs therein.
Upon loosening of the nuts on the studs for the particular die, the die may be shifted
as necessary to bring the design image of the die into precise alignment with the
area of the substrate to be foil stamped, embossed, or die cut. Then the nuts can
be re-tightened to maintain the die in its newly established position. On the other
hand, if it is desired to return a shifted die to its original location, that may
be accomplished by loosening the nuts associated with that die, and shifting the die
until pins placed in the alignment apertures align with respective orifices in the
support member thus assuring that the die has been returned to its original location
on the support member.
Description of the Drawings
[0025]
Fig. 1 is a fragmentary perspective view of a graphic arts die assembly in accordance
with a preferred embodiment of this invention;
Fig. 2 is a fragmentary, exploded perspective view of components of the graphic arts
die assembly as shown in Fig. 1;
Fig. 3 is a fragmentary, enlarged plan view of the graphic arts die assembly;
Fig. 4 is a horizontal cross-sectional view taken on an irregular line 4-4 through
Fig. 3;
Fig. 5 is an enlarged perspective view of one of the externally threaded studs welded
to the support member of the assembly as shown in Fig. 1 and Fig. 2;
Fig. 6 is a fragmentary plan view of one corner of the graphic arts die assembly shown
mounted in place on the chase of a flat bed press;
Fig. 7 is a schematic representation of a typical flat bed press and showing one position
of the graphic arts die assembly mounted on the chase of the press;
Fig. 8 is an enlarged vertical cross-sectional view through the platen and die assembly
of Fig. 7;
Fig. 9 is a perspective view of rotary foil stamping, embossing, or die cutting mechanism,
which includes an apertured cylindrical chase on a rotary cylinder and an opposed
anvil roller;
Fig. 10 is a fragmentary, enlarged cross-sectional view of one of the studs mounted
on the apertured cylinder for securing the semi-circular support member and associated
curved die plates to the cylinder;
Fig. 11 is a perspective view of rotary press structure as shown in Fig. 9, but in
this instance mounting a plurality of separate die carriers, which collectively wrap
around the chase of the rotary platen more than 180°;
Fig. 12 is a perspective view of one of the curved dies adapted to be mounted on a
respective die support member as illustrated in Fig. 11;
Fig. 13 is an enlarged, schematic cross-sectional representation of one form of tool
receivable in opposed alignment notches in the edges of respective die support members
that is useful to equally space adjacent die support members mounted on the cylindrical
chase of a rotary press;
Fig. 14 is an enlarged fragmentary plan view of two adjacent curved die support members
having registration notches in opposed edges thereof that are used in association
with the tool of Fig. 13 to register and space adjacent support plates;
Fig. 15 is a schematic vertical cross-sectional view taken substantially on the line
15-15 of Fig. 14 and looking in the direction of the arrows;
Fig. 16 is an enlarged fragmentary vertical cross-sectional view through a rotary
cylindrical platen with curved die support plates and associated dies thereon, with
the support plates being attached to the outer cylindrical surface of the rotary chase;
Fig. 17 is an alternate embodiment of the multiple die support members in which edges
of proximal plates have interlocking tongue and notch structure for aligning adjacent
support plates one with respect to the other;
Fig. 18 is a fragmentary enlarged plan view of one of the support members illustrating
the provision of slots in the support members designed to receive a suitable instrument
for minutely adjusting the position of a die on the support member;
Fig. 19 is a fragmentary vertical cross-sectional view taken substantially along the
line 19-19 of Fig. 18;
Fig. 20 is a fragmentary enlarged plan view of one of the support members similar
to Fig. 18 but illustrating an alternate embodiment of structure for shifting a die
to a minute degree using another form of tool than the tool shown in Fig. 19;
Fig. 21 is a fragmentary vertical cross-sectional view taken substantially along the
line 21-21 of Fig. 20;
Fig. 22 is a perspective view of a tool useful for minutely adjusting the position
of a die on a corresponding support member;
Fig. 23is an enlarged fragmentary plan view of a graphic arts die assembly provided
with a die carrier plate having a number of dies attached to the surface thereof,
and specifically adapted to be mounted on a rotary press cylindrical chase provided
with alternate rows of threaded openings and smooth bored alignment openings;
Figs. 24 and 25 are enlarged vertical cross-sectional views taken substantially on
the lines 24-24 and 25-25 respectively of Fig. 23; and
Figs. 26, 27, and 28 are schematic plan views of a die carrier support member illustrating
the position of registration lines or indicia on the surface thereof that are useful
in facilitating alignment of respective die support plates with a circumferentially
disposed center line mark of a rotary press platen.
Description of a Preferred Embodiments of the Invention
[0026] a. Preferred Embodiment of a Die Carrier Plate for a Plurality of Dies and Adapted
to Be Mounted on a Flat Bed Press Chase or Rotary Press Cylindrical Chase.
[0027] The graphic arts die assembly broadly designated 10 includes, in a preferred embodiment,
a relatively thin flat metal die support member or plate 12. The member 12 has a normally
uppermost die receiving flat surface 16 and an opposed flat, chase engaging surface
30. A number of foil stamping, embossing or die cutting dies 14 are selectively mounted
on the die receiving surface 16 in predetermined relative relationship, one with respect
to the other, and also relative to the perimeter edge 18 of the member 12.
[0028] Each of the dies 14 preferably comprises a flat or curved plate having a design defining
image 20 engraved in the normally uppermost surface 22 of each die 14. The design
image 20 may be formed by hand using suitable hand and/or power operated tools, employing
a conventional pantograph machine, laser engraved, or chemically etched. However,
in a preferred embodiment of this invention, the design image 20 is formed in the
normally uppermost surface 22 of the die 14 utilizing a CNC machine programed to execute
engraving of the die plate 14, thus assuring that the engraved image conforms exactly
to a design image of a positive or negative film representation, or a digital file
of the artwork used for foil stamping, embossing, or die cutting of a substrate sheet
or web, or other material.
[0029] The CNC machine also mills the outer edge 26 of the die 14 to provide either a vertical
or a beveled surface. In addition, the machine edge 26 is in precise disposition with
respect to the design defining engraved image 20, or vice versa.
[0030] The CNC machine also drills at least two, and preferably three through holes 28 through
the thickness of die plate 14, again in precise disposition relative to the engraved
image 20 in the upper surface of the die. Through holes 28 are desirably located in
relative relationship such that when mounted on the support member 12, the plate can
be positioned in only one orientation with reference to the support member 12.
[0031] The CNC machine also is controlled by a program that is functional to prepare the
support member 12. One function of the CNC machine after the support member 12 has
been positioned on the bed of the CNC machine in predetermined disposition, is to
shave the entire upper die receiving surface 16 of member 12 so that surface 16, throughout
its entire area, is in precise parallelism with the opposed chase engaging surface
30 of member 12. The outer surface of a curved die carrier support is preferably ground
to provide a die support plate of predetermined thickness having equally spaced outer
surfaces using a conventional grinding machine. This grinding operation assures that
the plate is of uniform and prescribed thickness throughout the extent thereof. When
the curved die carrier support is fabricated from an initially flat plate, a CNC machine
is used to shave the die receiving surface of the die carrier support, and the shaved
plate is then bent into circular configuration by a conventional roll former. The
program for the CNC machine also is operable to mill the perimeter edge of the member
12 and to store in the program memory the location of the edge with respect to the
exact center point of member 12. In lieu of using the CNC machine to mill a perimeter
age of the member 12, the CNC machine may be programmed to control a laser cutter
that precisely cuts the edge of member 12.
[0032] A third function of the program for the CNC machine is to accurately position and
weld a series of externally welded studs 32 to the die receiving surface 16 of member
12. An example of a suitable capacity discharge stud positioner and welder is available
from Cutlass Fasteners Inc. as its "Cutlass Classic". The stud positioner and fastener
mounted on the spindle of the CNC machine is used to hold each stud, position one
end of a respective threaded stud against the die receiving surface 16 of die support
member 12 in a predetermined position established by the program of the CNC machine,
and to effect welding of the stud to the support member. Welding time for each stud
is normally no more than about 20 seconds. The predetermined location of the studs
is controlled by the program of the CNC machine so that the studs will align with
the through holes 28 of respective dies 14, and so that the dies are positioned such
that the engraved surfaces 20 thereof are aligned with the design of the artwork representation
on the positive or negative film, or digital file of the design. Thus, there is one
stud 32 for each through hole 28, and the axis of each stud 32 is aligned with the
axis of a respective through hole 28. The studs 32 may be of various materials including
suitable synthetic resin compositions, and preferably metals. A most preferred material
is steel with a coating of copper. Each stud 32 may for example have a 10-32 thread.
[0033] The design engraved surface 22 of each die 14 has a counter bored cavity 34 coaxial
with a respective through hole 28. The cavities 34 are of sufficient diameter to clear
an internally threaded nut 36 removably threaded over a respective stud 32 after a
corresponding die plate 14 has been placed on the die receiving surface 16 of support
plate member 12. As is evident from Fig. 4, the nuts 36 are each of limited height
such that when threaded over corresponding studs 32 and brought into engagement with
the plate 14 at the bottom of cavities 34, the uppermost surface of each nut is below
the unengraved surface of the die plate 14. The CNC machine is also programmed to
shave off excess material from the upper end of each of the studs 32 so that the upper
extremity of each stud likewise is below the adjacent upper surface of die plate 14.
The same procedure is used in the case of fabrication of a curved support plate for
a rotary press platen wherein a computer program, except that the program functions
to convert the flat engraved image surfaces into altered cylindrical image surfaces
that correspond to the requisite flat image on a substrate brought into engagement
with the curved die.
[0034] After hand, pantograph, laser or etch engraving of the die blank, or during engraving
of each die plate 14 by the programmed CNC machine and drilling of through holes 28,
the CNC machine also drills at least two alignment apertures 38 in the plate 14 outboard
of the engraved image 20 of the die plate. The support plate program for the CNC machine
drills orifices 40 in the support member 12 that directly align with apertures 38
in a respective die plate 14. Thus, the program for the CNC machine is functional
to locate apertures 38 and corresponding orifices 40 in positions correlated and coordinated
with the design on the film positive, negative or digital file representation of the
design to be foil stamped, embossed or die cut. Similarly, the program that converts
flat surface representations to rotary surface representations is utilized to compensate
for the rotary die surface as opposed to a flat die surface.
[0035] It is preferred that the program for the CNC machine also mill a series of hold down
slots 42 in support member 12 in disposition such that the slots do not underlie one
of the die plates 14 positioned on and secured to support member 12. Each slot is
adapted to receive a toggle device 44 or other equivalent fastener that serves to
firmly hold the portion of the support member 12 surrounding a respective slot firmly
against a flat bed press chase or rotary press chase on which the support plate 12
is mounted, with two fasteners such as toggle devices 44 preferably being provided
at opposite ends of the elongated slots 42. As can be seen from Fig. 6, each toggle
device 44 has an uppermost, eccentrically located disc portion 46 configured to overlie
and engage an adjacent segment of the slot in the support member. The toggle devices
44 are adapted to be received in an adjacent aperture 48 of the chase 50 on which
the assembly 10 is mounted. The body of the toggle device 44 received in a respective
aperture 48 of chase 50 and preferably has end-to-end components as shown in Fig.
8 presenting interengaging beveled surfaces such that when the length of the device
is decreased by turning of a suitable connecting screw to move the components toward
one another, the result is an increase in the effective diameter of the toggle device
so that it is locked in a respective aperture 48 and will not move with respect to
the chase 50. It can also be seen from Fig. 6 that toggle devices 44 are useful to
hold down the perimeter of support member 12 by virtue of the fact that the disc portion
of each toggle device lays over and engages the perimeter edge of support member 12.
[0036] As is evident from Fig. 7, chase 50 is a normally stationary part of, for example,
a flat bed press 52 having a reciprocable platen 54 moveable toward and away from
the chase 50 as sheets to be foil stamped, embossed or die cut are inserted therebetween.
[0037] After engraving, edge milling and drilling of each of the die plates 14, and following
surface shaving, edge and slot milling, and stud welding of the support plate 12,
the individual die plates 14 are placed over respective studs, alignment pins are
introduced into aligned apertures 38 and orifices 40, and nuts 36 are threaded over
respective studs 32 until the nuts are in firm engagement with each die plate 14 at
the bottom of cavities 34. The alignment pins may thereupon be removed from aligned
apertures 38 and orifices 40. The completed graphic arts die assembly 10 is ready
to be shipped to a user. The operator of a flat bed stamping, embossing or die cutting
press may mount the flat assembly 10 shown in Figs. 1-8 of the drawings, directly
on the chase of the flat bed press. The edge 18 of the support member 12 may be used
as a guide for location of the assembly 10 in view of the fact that the edge 18 is
precisely located with respect to the center point of support member 12, with the
individual dies 14 being precisely positioned with respect to that center point of
the support member 12. If adjustment of any of the die plates 14 is required during
makeready of the press because of differences in substrate, processing conditions
such as humidity in the press area affecting the substrate, or other factors often
encountered in processing operations, die adjustment may be easily accomplished without
removing the dies from the support member 12. All that is required is loosening of
nuts 36, incremental shifting of the die plate, followed by re-tightening of nuts
36.
[0038] Rotary press components forming a part of a rotary foil stamping, embossing, or die
cutting press are shown in Fig. 9 and are broadly designated by the numeral 156. The
cylindrical chase 150 mounted on roller 158 has a plurality of apertures 148 similar
to the apertures 48 of chase 50. The chase 150 is in direct opposition and mates with
an anvil roller 160 which may have a blanket roll 162. Conventional intermeshing gears
164 and 166 at the ends of cylinder 158 and roller 160 respectively are provided to
effect rotation of cylinder 158 and roller 160 from a single drive shaft.
[0039] The semi-cylindrical support member 112 of the die assembly 110 is preferably made
from a steel tube. This tube is ground to a desired thickness of for example 0.060
in., after which the CNC program is used to control a laser cutting machine to cut
the final die support member. The semi-cylindrical die support member 112 may also
be fabricated from a flat steel plate that is shaved to desired uniform thickness
and then bent into circular configuration with conventional roll forming equipment.
The support member 112 may be prepared from a tube as described, or constructed from
a flat member that is shaved with a CNC machine. A flat surfaced support member is
then bent with a die former into circular configuration. The curved die plates 114
are also of identical construction to plates 14 with the exception that each die plate
114 is preferably fabricated from a metal cylinder of a diameter generally of the
same diameter as the exterior face of chase 150. A semi-cylindrical segment blank
is cut from a metal cylinder such as brass, copper, steel, magnesium, zinc, or other
engravable material having dimensions slightly larger than the final die plate. If,
for example, the metal cylinder used has a thickness of about ½ in., the thickness
of the segment blank is reduced to approximately ¼ in. by the CNC machine in the same
operation that the design image is formed in the outermost face of the metal blank.
The normally innermost surface of the curved die plate is machined with precision
so that it will closely conform with the outer curved die supporting surface of the
semi-cylindrical support member 112.
[0040] The CNC machine is also programmed to form through holes in each of the die plates
114 similar to the through holes 28 in die plate 14, and to form alignment holes in
each of the die plates 114 outboard of the image defining design surface of each curved
die plate. The through holes in die plates 114 align with orifices in support member
112 similar to orifices 40 in support plate 12. The through holes formed in each die
plate 114 are coaxial with nut clearing cavities 134 in the outer design defining
surface of each die plate 114.
[0041] The CNC machine is programmed to weld a series of studs 132 to the outer design receiving
surface 116 of support plate 112 in disposition such that the studs 132 will be in
coaxial alignment with respective through holes in the die plates 114 when the die
plates are mounted in respective positions on support plate 112.
[0042] As can be observed in Fig. 10, the die receiving surface 116 of the support number
112 may have a circular recess 168 for each stud 132 with the lowermost extremity
of each stud 132 being positioned within a corresponding recess. Welding of studs
132 while inserted into a corresponding recess 168 increases the physical connection
of each stud 132 to the support member 112, so that the studs are better able to withstand
tortional forces imparted to the studs during rotation of the cylinder 158 supporting
chase 150.
[0043] In alternate embodiments of the support plate 112, each stud 132 may be secured to
the support plate 112 by press fitting each stud from the back of the support plate
112 through a complemental opening in support plate 112. The part of the studs 132
extending through member 112 may have enlarged conical heads complementally received
in corresponding conical hole segments of the support member 112 to further increase
the holding power of each stud 132. Cylindrical studs extending through the support
member 112, or the conical headed studs 132 may, if desired, be welded, braised, or
chemically bonded as with an adhesive to the support member 112. The upper extremities
of each of the studs 132 should be shaved if necessary so that the upper end of each
stud does not project above the outer design defining surface of a respective die
plate 114.
[0044] Toggle devices 144, preferably of the same construction as toggle devices 44, are
received in respective slots 142 in support member 112. One toggle device 144 is illustrated
in each of the slots 142 in Fig. 10, as being representative, but it is to be understood
that in preferred construction, two toggle devices 144 will be provided in a respective
slot 142, with the toggle devices 144 being located at corresponding ends of slots
142. To that end, the support member 112 is positioned such that the toggle devices
will be received in a respective aperture in the chase 150. Toggle devices 144 function
in the same manner as toggle devices 44 in slots 42 of support member 12 to hold the
interior portion of support member 112 in firm contact with chase 150. Additional
toggle devices 144 received in respective apertures of chase 150 are used to attach
the peripheral edge of support member 112 to the curved surface of chase 150.
[0045] The individual die plates 114 are placed on curved support member 112 with the studs
132 received in respective through holes in corresponding die plates 114. Pins are
temporarily inserted through the alignment holes in die plates 114 and the alignment
apertures in support member 112. Nuts 136 are threaded on each stud 132 and tightened
against the outer surface of each die plate 114 within respective cavities 134. The
curved die plate and support member assembly is ready to be delivered to a customer
for mounting as a unit on the cylindrical chase 150 of the rotary press. Limited movement
of each of the die plates 114 for final registration of each die plate is permitted
upon loosening of respective nuts 136, and the nuts all retightened after a respective
die plate has been repositioned to a desired registered location.
[0046] The operation of the rotary press is essentially the same as described with respect
to the flat bed press, with the exception that a substrate web is fed to the rotary
press instead of individual sheets being fed to the flat bed press.
[0047] Makeready time for a rotary press set up to foil stamp, emboss or die cut is substantially
reduced as compared with a conventional rotary press because of the provision of a
preshaped curved support member and a preformed semi-circular die plate releasably
and removably affixed to the support members. Significantly less operator time is
required to prepare a rotary press for foil stamping, embossing or die cutting using
the present invention, because the dies are all mounted as a unit on the support member
while being maintained in proper registration relative to one another.
Example
[0048] In accordance with the present invention the support member 12 is preferably a steel
plate in which the die receiving surface 16 has been shaved in a milling machine such
that the plate thickness is from about 0.030 in. to about 0.100 in. thick, more preferably
from about 0.040 in. to about 0.090 in., and most preferably 0.060 in. The thickness
of the die plate 14 should be in the range of from about 0.150 in. to about 0.220
in., more preferably from about 0.160 in. to about 0.210 in. and most preferably about
0.190 in. The overall thickness of assembly 10 is most preferably about 0.250 in.,
in order to comply with industry practice in North America that a foil stamping, embossing
or die cutting plate should be no more than about 0.250 in. thick. In the instance
of foreign press operations, the total overall thickness of assembly 10 should typically
be no more than about 7 mm. in accordance with foreign foil stamping, embossing and
die cutting industry practice. In lieu of being made of steel, the support member
12 may be fabricated from a metal other than carbon steel, e.g. copper, brass, titanium,
or stainless steel. Cladded metal plate material comprising two metal layers, including
respective layers of copper, brass, zinc, and magnesium combined with a different
metal such as steel may be used in which one layer of a metal is utilized with a different
metal. Utilization of a cladded metal plate for fabrication of support member 12 has
the advantage that because of the manner in which cladded metal sheets are produced
by passage of the metal overlying layers between rollers which apply very high pressures
to the laminated plate material. The opposing surfaces of the resultant cladded metal
plate are in very precise parallelism, thus in most instances negating the necessity
of shaving one surface of the plate material used to fabricate the support member.
[0049] Preferably each of the through holes 28 is approximately from about 0.200 in. to
about 0.270 in. and preferably about 0.250 in. in diameter while each stud has a diameter
of about 0.187 in. and is about 0.140 in. in height. The nuts 36 are the diameter
of a standard 3/8 in. nut, have 10-32 threads, and are 0.095 in. thick. Cavities 34
are counter bored to a depth of at least 0.100 in. It is preferred in this respect
that the dimensions of the through holes 28 and studs 32 be correlated such that the
die plate 14 may move in all directions a distance relative to the studs 32 therein
within the range of about 0.010 in. to about 0.050 in., and preferably about 0.030
in.
[0050] The die plate 14 may be any ferrous or non-ferrous metal including copper, zinc,
magnesium, aluminum, steel, brass, or a composite material including thermoplastic
and thermoset resins. Although, copper coated steel studs are preferred, the studs
may also be fabricated of any ferrous or non-ferrous weldable material including stainless
steel or copper. In lieu of welding the individual studs to the support member for
the die plate, the studs may be threaded elements that are press fitted, adhesively
bonded or chemically bonded to the support member 12. Another alternative for studs
32 are posts having means such as a groove in the upper end thereof for receipt of
an annular fastener. Preferably there should be a stud 32 for every four to seven
square inches of an engraved die, with a minimum of two studs per die.
[0051] In the case of a die assembly 110 for use on a rotary press the thickness of the
support member 112, nominally should range from about 0.030 in. to about 0.100 in.,
more preferably from about 0.040 in. to about 0.090 in., and most preferably about
0.060 in. The thickness of the die plate 114 should be from about 0.163 in. to about
0.233 in., more preferably from about 0.173 in. to about 0.233 in. and most preferably
about 0.203 in. The overall thickness of the combination of the support member 112
and a respective die 114 is most preferably about 0.263 in.
[0052] Use by a press operator of the present graphic arts assembly 10 or 112 in lieu of
preexisting lock-up procedures for foil stamping, embossing or die cutting dies individually
mounted directly on a flat bed chase or rotary cylinder chase can reduce lock-up time
by as much as 400% or more, thus decreasing not only makeready time but also significantly
lowering the cost of die lock-up and press makeready. b. Preferred Embodiments of
a Series of Curved Die Carrier Plates for One or More Curved Dies and Adapted to Be
Mounted on a Rotary Press Cylindrical Chase.
[0053] The cylindrical chase 250 illustrated in Fig.11 of the drawings mounted on roller
258 is similar to the chase 150 as shown in Fig. 9, and has a large number of smooth
bored apertures 248 around the circumference of the chase. The chase 250 is adapted
to run in opposition to blanket roll 262 carried by anvil roller 260. Conventional
intermeshing gears 264 and 266 at the ends of roller 258 and roller 260 respectively
effect rotation of cylindrical chase 250 and blanket roll 262 in unison from a single
drive shaft.
[0054] The die support assembly unit 210 comprises a plurality of curved die support plate
members 212 that receive at least one arcuate die 214 complementally attached to the
outer surface of a respective support plate 212. Although the die support plates 212
of Fig. 11 have only one die 214 thereon, it is to be understood that a multiplicity
of dies 214 may be provided on each die support plate 212 depending upon the number
of images in the artwork design. Furthermore, although the die support plates 212
shown in Fig. 11 are of the same width in a direction circumferentially of the chase
250. It is to be understood, though, that the die support plates 212 may each be of
varying circumferential width and longitudinal length, provided that required registration
is maintained between the die support plates 212 and with respect to the chase 250.
[0055] Each of the die support plates 212 are secured to the cylindrical chase 250 in the
same manner as the components for releasably affixing the support plate 112 to the
periphery of chase 150 as shown in Fig. 9. Thus, each die plate 212 is preferably
provided with at least a pair of elongated slots 242 adjacent proximal opposed margins
of respective support plates 212. Fasteners 244, similar to toggle devices 44 and
144, are used to releasably affix the die support plates 212 to cylindrical chase
250. Each of the toggle devices 244 is designed to be received within a corresponding
aperture 248 in chase 250. Although only one toggle device 244 is shown in each of
the slots 242 in Fig. 11, it again is to be understood that in a preferred arrangement,
two toggle devices 244 will be provided for each slot 242, with the toggle devices
244 being located at respective opposite ends of corresponding slots 242. It can be
seen in Fig. 11, that a toggle device 244 is provided in each of the slots 242, while
other toggle devices 244 engage the opposed outermost edges of the die support plates
212.
[0056] Fasteners 244, which are the same as or similar to fasteners 144 and that secure
dies 114 to die support plate 112, are provided for attaching dies 214 to each of
the die support plates 212. It can be seen from Fig. 11 that each of the die plates
214 has a plurality of openings 230 that receive respective studs 232 constructed
and mounted in a manner as described with respect to studs 32 mounted on support plate
12. Nuts 236 are threaded over the outermost ends of studs 232. The artwork template
or film that is used to program the equipment for fabrication of each support plate
212 by drilling holes such as holes 40 illustrated in Fig. 2, that are locating apertures
for positioning of the dies 214 on respective support plates 212. At least two alignment
apertures 238 are provided in each of the die support plates 212 for temporary receipt
of an alignment pin that is adapted to be complementally received in a corresponding
alignment aperture, such as holes 40, formed in each support plate 212. Nuts 236 are
tightened down after each die 214 is oriented in its proper position by use of the
alignment pins, whereupon the pins are removed from the apertures 238 and underlying
holes 40.
[0057] The metal material used and the steps for fabricating support plates 212 and dies
214 are the same as previously described with respect to plates 12 and 112. Thus,
as described with respect to plates 12 and 112, and based on the artwork template
or film provided by the user of the die plate assemblies, the location of the alignment
apertures in support plates 212 and corresponding alignment apertures 238 in support
plates 212 are determined and appropriate holes drilled in the plates 212 and the
dies 214. Similarly, the artwork template or film is used to determine the location
of the openings 230 which receive studs 232 for affixation of the dies 214 to respective
semi-cylindrical support plates 212.
[0058] As shown in Figs. 11 and 14, the margins 268 of each die support plate 212 that are
opposed and adjacent to one another as mounted on the cylindrical chase 250, have
rectangular notches 270 of the same shape and size. From Fig. 11 it can be seen that
there are at least two notches in each margin 268 of the die support plates 212, while
three or more notches 270 may be provided in the longer margins of die support plates
212, depending upon the length of a respective plate 212. Each of the notches 270
defines a rectangular opening 272. The notches 270 in respective edges of the die
support plates 212 are located such that a pair of notches 270 of adjacent die support
plates 212 are adapted to align and cooperate to define a rectangular opening 272
that is adapted to receive the operating end of a spacing and alignment tool 274.
From Figs. 13-15, it can be seen that the tool 274 has an elongated stem 276 that
is rectangular in cross-section. The lowermost end of the stem 276 has two opposed,
unitary, outwardly-directed rectangular projections 278 and 280 that define a spacing
head 282. It is to be seen from Fig. 13, that the head 282 is spaced above the bottom
surface 284 of the stem 276 of stem 274. The length of the stem 274 below head 282
is preferably slightly less than the thickness of the plate 212 so that bottom surface
284 of stem 276 does not contact the face of cylindrical chase 250. It is also preferred
that a plurality of the tools 274 be provided, with a minimum of two tools 274 being
available.
[0059] Fig. 26 is a schematic representation of one of the die support plates 212a illustrated
as a flat plate for simplicity, although it is to be understood that the plate will
be of arcuate configuration as shown in Fig. 11. The plate 212a preferably has a registration
line 286 scribed in what will be the outer surface 212' of the plate. The line 286
is used for alignment of the plate 212a with a similar scribed, circumferentially
extending line or marker in the outer face of cylindrical chase 250 when the plate
212a is attached to chase 250. It is required that only one of the die support plates
212, designated as plate 212a in Fig. 26, be provided with a registration line or
marker.
[0060] The program that fabricates the die support plate 212a and that scribes the line
286 in a predetermined position on the plate 212a, also locates the openings 238 for
alignment of dies 214 on plate 212a, so that when an individual die 214 is attached
to the plate 212a, or in the alternative a plurality of dies are mounted on plate
212a, the dies are thereby registered with the line 286 and similarly with respect
to the center line of the cylindrical chase 250. The remaining die support plates
212 mounted on the cylindrical chase 250 in association with the plate 212a, are aligned
with plate 212 using tools 274 positioned in respective openings 272 defined by opposed
aligned notches 270. Viewing Fig. 11, if the die support plate 212a is the support
plate in the upper left hand quadrant of the four plates, and the die support plate
212a has been secured to the cylindrical chase 250 using toggle devices 244, the die
support plate 212b in the upper right hand quadrant of Fig. 11 is positioned in registration
with plate 212a by placement of the head 282 of each of the tools 274 in a corresponding
opening 272 of aligned notches 270. As previously noted, the tools 274 serve to not
only align the plate 212b with plate 212a, both circumferentially and axially of the
cylindrical chase 250, but also maintain a predetermined space between plate 212a
and plate 212b. This spacing between the adjacent plates 212a and 212b compensates
for expansion of the plates 212 upon heating of the press cylinder, while maintaining
the dies 214 in registration with the images on the substrate passed between the two
cylinders of a press. The plate 212c is aligned with plate 212a using tools 274 in
the manner previously described, whereupon plate 212d is aligned with plates 212b
and 212c, again using tool 274. Each of the plates 212b, 212c, and 212d are secured
to the cylindrical chase 250 with respective toggle devices 244. The sequence of alignment
and attachment of plates 212b, 212c, and 212d to the cylindrical chase 250 may be
changed as desired by the press operator.
[0061] As shown in Fig. 27, the plate 212a may have a pair of registration lines 286a and
286b that are in alignment, in lieu of a single line 286 a shown in Fig. 26. Similarly,
the registration line may be offset from the center of the plate as indicated by the
line 286c in Fig. 28. The only requirement is that the registration line or marker
on the plate 212a be located such that the plate 212a will be positioned in predetermined
relationship to the center line of the cylindrical chase 250 when the plate 212a is
attached to the chase 250.
[0062] In order to assure that plates 212 are all attached to cylindrical chase 250 in proper
positions, one with respect to the other, the edges of plates 212 that are in adjacent
relationship after assembly of the plates 212 on cylindrical chase 250, one adjacent
edge of one of the plates 212 is provided with a projecting polarization tab 288 that
is adapted to be received in a corresponding notch 290 in the opposed edge of a proximal
plate 212, as shown in Fig. 17. It is to be understood in this respect that the tabs
288 and corresponding notches 290 are positioned in locations such that the plates
212 can be placed on cylindrical chase 250 in only one relative assembled orientation.
[0063] In the alternative die support assembly unit 310 illustrated in Figs. 18 and 19,
the die support plate members 312 are each provided with a plurality of rectangular
cutouts 316 located in general surrounding relationship to each die 314 mounted on
the outer surface of a respective support plate member 312. Viewing Fig. 18, it is
to be seen that two cutouts 316 are provided in association with each of the edge
portions 314a, 314b, 314c, and 314d of rectangular die 314. It is to be understood
in this respect that each of the cutouts is located such that a portion of the cutout
underlies a corresponding edge portion of the die 314. Thus, a tool in the nature
of a conventional screwdriver 318 may be used to adjust the position of a die 314
with respect to the underlying die support plate member 312 by inserting the blade
tip 320 of screwdriver 318 in one of the cutouts 316. Each die 314 is initially attached
to the die support plate member 312 using nuts 336 threaded over studs 332, after
pins have been inserted in the apertures 338 and extending into corresponding alignment
openings, such as openings 40, in the underlying support plate member 312. In order
to permit slight lateral adjustment of a die 314 as may be desired using the screwdriver
tool 318 as shown in Fig. 19, the nuts 336 threaded over studs 332 projecting upwardly
from the surface of die plate support member 312 are slightly loosened.
[0064] In a further alternative die and support assembly unit 410 shown in Figs. 20 and
21, a plurality of circular cutouts 416 are provided in the die support plate member
412 in lieu of rectangular cutouts 316 in the die support plate 312. Two cutouts 416
are located outboard of the peripheral edge portions 414a, 414b, 414c, and 414d of
rectangular die 414. It can be seen from Fig. 20 that each of the circular cutouts
416 is positioned in spaced relationship from a corresponding edge portion of die
414. A special tool 418 as depicted in Fig. 22 is provided for shifting die 414 laterally
of a respective die support plate member 412. The tool 418 has a shaft 420 connected
to a handle 422. The outer extremity of shaft 420 is provided with a cylindrical cam
head 424 in which the axis of the head is offset from the axis of shaft 420 causing
the cam surface 426 of head 424 to be eccentric with respect to the shaft axis. A
cylindrical button 428 on the lowermost face 430 of head 424 is of the same diameter
as each cutout 416, and is coaxial with shaft 420. The distance from the axis of button
428, and therefore the axis of shaft 420, to the outermost face of cam surface 426
is somewhat greater than the distance between the center of each cutout 416 and the
adjacent peripheral edge portion 414a-d of die 414 when the die is mounted on support
plate member 412 after having been affixed to plate member 412 through use of pins
inserted into apertures 43 8 aligned with underlying apertures in the die support
plate member 412.
[0065] When it is found necessary to slightly move a die 414 relative to the underlying
die support plate member 412 in order to align the die surface with the image on the
substrate, the nuts 412 are loosened slightly on respective studs 432, the button
portion 428 of eccentric head 424 is inserted in a selected circular cutout 416, and
the tool 418 rotated to bring the surface 426 of head 424 into engagement with a respective
edge portion 414a-d of die 414. Continued rotation of tool 418 serves to slightly
shift die 414.
[0066] The alternative die plate support member and die assembly unit 510 depicted in Figs.
23-25 has die plate support members 512 that are especially adapted for mounting on
a cylindrical chase 550 that differs from chase 250 in that the chase 550 has alternate
rows of smooth bore apertures 548 and threaded apertures 552. It can be seen from
Fig. 23 that the apertures 552 are of smaller diameter than apertures 548 and are
offset from the apertures 548. The apertures 548 and 552 of cylindrical chase 550
are arranged in a matrix X-Y grid pattern where there is a predetermined distance
laterally and vertically between adjacent apertures. Information is entered into a
computer program that is indicative of the X-Y coordinate positions and relative distances
between adjacent apertures.
[0067] That program with information as to the positions and relative spacing of the apertures
548 and 552 is then used to program equipment for fabrication of the individual die
support plate members 512. During that fabrication process, a series of elongated
alignment openings 534 are formed along the edge portion of each of the die plates
512. Although only one alignment opening 534 in each die plate 512 is illustrated
in Fig. 23, it is to be understood that a plurality of the elongated openings 534
are provided across the width of a respective die plate.
[0068] Each die plate 512 also has a plurality of die plate alignment apertures 538 (only
one of which is illustrated in Fig. 23). The positions of the openings 534 and apertures
538 are established by the desired location of each die plate 512 based on the coordinates
of the pattern of smooth bore apertures 548 in the cylindrical chase 550. The openings
534 and apertures 538 receive alignment pins 590 that are received in a corresponding
underlying smooth bore aperture 548 in cylindrical chase 550. This die support plate
alignment procedure is carried out with respect to all of the die support plates 512.
In Fig. 23, the die support plate 512a that is intended to be in closest relationship
to the gripper of the cylindrical chase 550 has the designation "GRIPPER" on the plate
for orientation and identification purposes. It is to be recognized in this respect
that there may be more than one support plate 512a across the width of the cylindrical
chase 550 if desired.
[0069] During fabrication of each support plate 512, each plate is provided with alignment
openings that are designed to align with apertures 548 in respective dies 514 so that
pins inserted in apertures 548 and the underlying openings in a corresponding die
support plate 512 provide for proper positioning of each die plate 514 on its corresponding
support plate 512. After pin alignment of each die 514 on the support plate 512, nuts
536 are tightened on respective studs 532 secured to the plate 512 in order to affix
each die to its support plate.
[0070] The support plates 512 may also be provided with rectangular cutouts 516 similar
to cutouts 316 in plates 312, for minute adjustment of the dies 514 using a tool such
as a screwdriver 318 as previously described with respect to unit 310.
[0071] Support plates 512 are preferably secured to the cylindrical chase 550 by screws
592 that extend through openings 596 therefor in support plate 512 and that thread
into an underlying threaded aperture 552. The plates 512 may optionally be provided
with elongated slots 594, which correspond to the slots 242 in plates 212, allowing
plates 512 to be secured to a cylindrical chase 250 of the type illustrated in Fig.
11 using fasteners such as the toggle devices 244 received in the slots 594. When
each plate 512 is mounted on a cylindrical chase such as chase 250, toggle devices
244 are also used to secure the edges of the plate 550 to the surface of the chase.
Accordingly, plates 512 may be mounted on a conventional cylindrical chase of the
type designated by 250, as well as a cylindrical chase such as 550 having alternate
threaded and smooth bore mounting apertures. This is an advantage because one model
of support plate may be provided for mounting on whatever type of press chase is in
use.
[0072] An important advantage of the support plates 512 is the fact that by using a coordinate
system for mounting the plates 512 on any one of two different types of apertured
cylindrical chases of a rotary press, the computer program used to control fabrication
of each support plate as well as the dies to be mounted on that plate, has all of
the coordinate information necessary to assure that the alignment functions of the
plate as well as the die are maintained for each production job, resulting in efficiency
of fabrication and more accurate products.
1. A graphic arts die assembly adapted to be mounted as a unit on the apertured chase
of a flat bed press or the apertured cylindrical chase of a rotary graphic arts press,
said assembly comprising:
a plurality of dies each having a stamping, embossing or die cut surface and an opposed
mounting surface;
a die support member for the dies, said member having a die receiving surface and
an opposed surface engageable with the chase of a flat bed press or the chase on the
cylinder of a rotary press,
the plurality of graphic arts dies being mounted on said die receiving surface of
the die support member in predetermined relative positions;
a plurality of upstanding die fasteners secured to the die receiving surface of the
die support member, there being at least two fasteners for each die,
each of the dies having a through hole positioned to receive a respective fastener
therein; and
a releasable connector on each fastener engaging a respective die for maintaining
each die in a fixed position on the die support member.
2. An assembly as set forth in claim 1 wherein each of said holes is of a size greater
than the thickness of the fastener received therein, sufficient to allow movement
of each die relative to the fasteners for that die and with respect to the support
member when the connectors of a respective die are released from fixed engagement
with the die.
3. An assembly as set forth in claim 1 wherein each of said fasteners is a threaded stud
and each of the connectors is rotatively threaded onto a respective stud.
4. An assembly as set forth in claim 3 wherein each of said fasteners is a nut threaded
onto a respective stud.
5. An assembly as set forth in claim 3 wherein each of the design defining surfaces of
the dies are provided with a relief cavity aligned with a respective through hole
in each die and sized to receive a connector threaded onto a corresponding stud.
6. An assembly as set forth in claim 5 wherein each of said cavities is of a depth at
least about equal to the thickness of a respective connector threaded onto a corresponding
stud.
7. An assembly as set forth in claim 1 wherein the fasteners received in the through
holes of a respective die are positioned in predetermined relationship with respect
to and outboard of the design defining surface of that die.
8. An assembly as set forth in claim 1 wherein the design defining surface of each die
conforms to the design image of prepared artwork.
9. An assembly as set forth in claim 1 wherein the plurality of dies are mounted on the
support member in disposition conforming the positions of a plurality of design image
artwork.
10. An assembly as set forth in claim 1 wherein said support member has a perimeter edge,
said support member being provided with at least one support member hold down slot
spaced from said edge of the support member for receiving a device engageable with
the support member and the chase of a flat bed press or the chase of a rotary press
on which the support member is mounted to hold the portion of the support member surrounding
the hold down slot in substantial conforming contact with the adjacent area of a respective
chase.
11. An assembly as set forth in claim 10 wherein is provided a plurality of spaced hold
down slots in the support member for receiving respective devices and located such
that the devices maintain the support member in close conforming relationship to the
chase of a flat bed press or the cylindrical chase of a rotary press.
12. An assembly as set forth in claim 1 wherein said support member has a plurality of
recesses, with each recess receiving an end portion of a respective fastener.
13. An assembly as set forth in claim 1 wherein each of the fasteners is a stud affixed
to the die receiving surface of the support member.
14. An assembly as set forth in claim 13 wherein each of said studs is of generally cylindrical
configuration and of greater height than width.
15. An assembly as set forth in claim 13 wherein the studs are located on the die receiving
surface of the support member in predetermined relationship in accordance with digitized
program derived from and conforming to design artwork.
16. An assembly as set forth in claim 1 wherein said through holes in respective dies
are sized relative to the fasteners received therein allowing movement of a respective
die with respect to the support member through a displacement of at least about 0.050
in.
17. An assembly as set forth in claim 1 wherein said support member is from about 0.030
in. to about 0.100 in. thick.
18. An assembly as set forth in claim 1 wherein each of said dies is from about 0.150
in. to about 0.220 in. thick.
19. An assembly as set forth in claim 1 wherein the combined thickness of each die and
the support member is about 0.250 in.
20. An assembly as set forth in claim 1 wherein the combined thickness of each die and
the support member is about 7 mm.
21. An assembly as set forth in claim 1 wherein each of the said dies is from about 0.163
in. to about 0.233 in. thick.
22. An assembly as set forth in claim 1 wherein the combined thickness of each die and
the support member is about 0.263 in.
23. An assembly as set forth in claim 1 wherein each of the dies has at least two apertures
therein and the support member has an orifice therein aligned with each die aperture,
the aligned apertures and orifices being adapted to receive an alignment tool extending
therethrough.
24. An assembly as set forth in claim 1 wherein said support member and each of the dies
are of planar configuration.
25. An assembly as set forth in claim 1 wherein said die receiving surface and said mounting
surface of the support member are parallel throughout the die receiving surface area
of the support member.
26. An assembly as set forth in claim 1 wherein said support member and each of the dies
is of semi-cylindrical, conforming configuration.
27. A method of preparing a graphic arts die assembly adapted to be mounted as a unit
on the apertured chase of a flat bed graphic arts press or the apertured cylindrical
chase of a rotary graphic arts press, said method comprising the steps of:
forming a stamping, embossing or die cutting operating surface in each of a plurality
of dies, each of said operating surfaces conforming to design artwork;
forming at least two through holes in each die located outboard of and in predetermined
disposition relative to the operating surface of a respective die;
providing a die support member for the dies in which the support member has a die
receiving surface and an opposed mounting surface engageable with a flat bed chase
or a rotary cylinder chase;
attaching a plurality of fasteners to the die support member and each located relative
to one another in disposition to be received in a respective through hole of a corresponding
die;
positioning the dies on the support plate with fasteners received in respective holes
in a corresponding die; and
applying a connector to each of the fasteners in disposition releasably engaging a
respective die to fixedly secure each die to the support member.
28. A method as set forth in claim 27 wherein is included the step of successively affixing
the fasteners to the die support surface of the support member.
29. A method as set forth in claim 27 wherein is included the steps of digitizing design
artwork, forming an operating surface on each die in accordance with the digitized
artwork, and locating the through holes in each die and positioning the fasteners
on the support member to conform with the digitized artwork.
30. A method is set forth in claim 27 wherein is included the steps of forming at least
one support member hold down slot in the die support member in disposition spaced
from the perimeter edge of the support member.
31. A method is set forth in claim 27 wherein is included the steps of forming through
holes in the support member larger than the width of respective fasteners, and temporarily
releasing the connectors from fixed engagement with the support member to an extent
to permit shifting of a respective die with respect to the fasteners received in through
holes through that die.
32. A method is set forth in claim 27 wherein is included the steps of forming the support
member and each of the dies in complemental semi-cylindrical configuration for mounting
on a rotary press apertured cylindrical chase of the press.
33. A method as set forth in claim 27 wherein is included the steps of providing an indicia
in the die support member, and locating the fasteners with respect to the location
of the indicia using an X-Y coordinate matrix based on the indicia location.
34. A method as set forth in claim 33 wherein is included the step of fixing each of the
fasteners in a predetermined position, and moving the die support member through a
displacement based on the location of the indicia, and securing each fastener to the
die support member while fixed in said predetermined position.
35. Graphic arts die units adapted to be mounted as an assembly on the apertured chase
of a flat bed press or apertured cylindrical chase of a rotary press, said assembly
comprising:
a plurality of dies each having a stamping, embossing or die cut surface and an opposed
mounting surface;
a plurality of die support plate members for the dies, said plate members having edge
portions, a die receiving surface, and an opposed mounting surface engageable with
the chase of a flat bed press or the chase on the cylinder of a rotary press,
at least one die being mounted on each of the die support plate members in predetermined
disposition with respect to the surface of a corresponding die support member,
each of said die support plate members having an edge portion that is adjacent the
edge portion of at least one other die support member when the graphic arts die units
are assembled in predetermined relative dispositions on a flat bed press chase or
the chase of a rotary press,
said adjacent edge portions of the die support plate members each having notches therein,
each of said notches being located in disposition to align to a corresponding notch
in an opposed edge portion of an adjacent die support plate member,
each pair of opposed notches cooperating to define an opening for removable reception
of a combination alignment and spacing tool.
36. A graphic arts die unit assembly as set forth in claim 35, wherein said notches are
of generally rectangular configuration.
37. A graphic arts die unit assembly as set forth in claim 35, wherein is provided at
least a pair of notches in each of said adjacent edge portions of the die support
plate member.
38. A graphic arts die unit assembly as set forth in claim 35, wherein is provided a polarization
tab on one edge portion of a die support plate member adjacent the edge portion of
another die support plate member, and the adjacent edge portion of said another die
support plate member being provided with a notch located to receive the opposed tab,
the tabs and corresponding notches receiving the tabs being located in different positions
on different die support plate members.
39. A graphic arts die unit assembly as set forth in claim 35, wherein at least one of
said die support plate members is provided with registration indicia thereon adapted
to be aligned with a mark on the chase of a flat bed press or the cylindrical chase
of a rotary press in order to permit registered orientation of the die support plate
member with the mark on the chase of a flat bed press or the cylindrical chase of
a rotary press.
40. A graphic arts die unit assembly as set forth in claim 35, wherein said die plate
support members are provided with at least one cutout adjacent the peripheral edge
portions of each die mounted on the die plate support member, each cutout being configured
to receive the head of a tool in a position such that manual manipulation of the tool
will selectively shift the die relative to the die support plate.
41. A graphic arts die unit assembly as set forth in claim 35, wherein each cutout is
a rectangular opening underlying and projecting outwardly from a respective proximal
peripheral edge portion of the die, each cutout being configured to receive the blade
of a tool.
42. A graphic arts die unit assembly as set forth in claim 35, wherein each cutout is
a circular opening adjacent and spaced from a respective proximal peripheral edge
portion of the die, each cutout opening being located and configured to receive a
cam tool for selective shifting of the proximal die in response to rotation of the
cam tool.
43. A graphic arts die unit assembly as set forth in claim 35 adapted to be mounted on
a rotary press cylindrical chase having alternate rows of smooth bore and threaded
apertures, wherein each of said die support plate members is provided with apertures
therein in disposition to be aligned with smooth bore apertures in the cylindrical
chase for removable receipt of alignment pins, each of said die support plate members
further being provided with openings therein that receive fasteners, which may be
threaded into the threaded apertures in the cylindrical chase for releasably attaching
the die support plate member to the cylindrical chase.
44. A graphic arts die unit assembly as set forth in claim 43, wherein said apertures
and openings in each of the die support plate members are located in dispositions
in accordance with an X-Y coordinate matrix that corresponds to the X-Y coordinate
matrix of the apertures in the cylindrical chase on which the die support plate members
are mounted.
45. A graphic arts die unit assembly as set forth in claim 43, wherein each of said die
support plate members are provided with slots, and a series of fasteners, said slots
being located to permit attachment of the die support plate members to a cylindrical
chase in which all of the apertures in the chase are smooth bored, certain of said
fasteners being adapted to extend through the slots into respective aligned chase
apertures, and other of the fasteners engaging the periphery of each die support member
and adapted to extend into aligned chase apertures.
46. A graphic arts die unit assembly as set forth in claim 35 wherein said support members
and each of the dies are of planar configuration.
47. A graphic arts die unit assembly as set forth in claim 35 wherein said support members
and each of the dies are of curved configuration, the curvature of the dies being
complemental to the curvature of the support members.
48. A graphic arts die unit assembly as set forth in claim 47 wherein the assembly of
curved support members extends through an arc of greater than 180°.
49. A graphic arts die unit assembly as set forth in claim 47 wherein the die support
members are of the same arcuate length.
50. A graphic arts die unit assembly as set forth in claim 47 wherein the die support
members are of different arcuate length.