WO 2005/009668 PCT/US2004/022896 METHOD FOR MAKING A THIN DIE TO BE USED IN A PRESS CROSS-REFERENCES TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application No. 60/488,570 5 (Attorney Docket No. 021919-001700US) filed July 17, 2003 and is herein incorporated by reference for all purposes. FIELD OF THE DISCLOSURE [0002] Disclosed is a thin die adapted to be used in a press and, more particularly, 10 disclosed is a thin die adapted to be used in a press, a system including a thin die and a press, and a method for making a thin die adapted to be used in a press. BACKGROUND OF THE DISCLOSURE [00031 Dies and sheet cutting presses are used to cut various patterns out of sheet 15 materials. The presses may take the form of a platen die press or a roller die press. The presses are designed to apply uniform pressure to a die to cut through a sheet or a plurality of sheets simultaneously. Dies also may be used for embossing images onto sheet materials. Typically, the sheets are placed between the die and a cutting pad, with the steel rule and the die extending through the sheets and slightly into the cutting pad when pressure 20 is applied to the die. Die presses are used commercially, as well as by consumers. Typically, a variety of shapes are provided by the various dies available. For example, typical dies include shapes that range from the letters in the alphabet, numbers, and various other shapes, such as moons, stars, animals, trees, and various other shapes. [00041 Typically, the dies include a base material, such as plywood or plastic, that houses 25 a steel rule that is formed to the desired cutting shape. A rubber material is then glued to the plywood or plastic base so that the rubber extends above the height of the sharpened edge of the bent steel rule shape, so that the rubber protects the steel rule and acts as an ejector means to eject the cut sheet material from the steel rule after the cutting process.
WO 2005/009668 PCT/US2004/022896 BRIEF SUMMARY OF THE DISCLOSURE [0005] Disclosed is a thin die adapted to be used in a press. The die disclosed herein includes a base or backing portion that provides rigidity to the die assembly. The base includes an indentation defining a border around the peripheral edge of the base. A thin die 5 is housed in the indentation of the base and the thin die is adhered to the indentation of the base by an adhesive. The thin die is positioned in the indentation of the base so that raised portions of the thin die are facing away from the indentation in the base to allow the thin die to cut into and emboss a sheet material. Ejection foam is adhered to the raised portion side of the thin die by an adhesive so that the ejection foam protects the raised portion of the thin 10 die and provides an ejection means of the cut out shape of the sheet material. [00061 Also disclosed is a die and press system utilizing the thin die disclosed herein. Included in the system is a die press, which may be a platen die press or a roller die press. The die press includes a cutting pad that allows the die to cut through the sheet material and into the cutting pad, if a platen die press is used. The system further includes a thin die 15 adapted to be used with a die press. The thin die includes a base portion, a thin die portion, and an ejection foam portion, wherein the base portion and the ejection foam portion sandwich the thin die portion so that the thin die is located in an indentation located in the base and is adhered to the base by an adhesive. Further, the ejection foam portion is adhered to the thin die portion so as to protect raised portions of the thin die portion. The 20 ejection foam protects the raised portions of the thin die portion and acts as an ejection means to eject the cut shapes from the sheet material. [0007] Also disclosed herein is a method of making a thin die, wherein the method includes the steps of providing a steel material, chemical etching away a portion of the steel material so as to leave at least one raised portion on one surface of the steel material to 25 provide a shape in the steel material. The process further includes adhering the steel material to a base portion so that the raised portion of the steel material is exposed on one side. Further, an ejection foam is adhered to the cutting side of the steel material to protect the raised portions of the steel die and to act as an ejection means to eject the cut shape from a sheet material used in a cutting process. 30 [00081 In another aspect of the disclosure, a method of making a thin die is disclosed wherein a second etching process is incorporated after stripping the laminating film off of 2 WO 2005/009668 PCT/US2004/022896 the raised or cutting portion of the die. The second etching step typically lasts from 10 to 25 seconds, and more preferably from 15 to 20 seconds, depending upon the steel being chemically etched and the strength and composition of the chemical etching solution. The secondary etching step removes the sharp edges from the cutting surface to provide a 5 sharper cut when the thin die is used. BRIEF DESCRIPTION OF THE DRAWINGS [00091 The disclosure will now be described in greater detail with reference to the embodiment illustrated in the accompanying drawings, in which like elements bear like 10 reference numerals and wherein: [00101 Fig. 1 illustrates a perspective view of a thin die according to the present disclosure; [00111 Fig. 2 illustrates a cross-sectional view taken from line 2-2 of Fig. 1 according to the present disclosure; 15 [0012] Fig. 3 illustrates a bottom-view of the thin die according to the present disclosure; [0013] Fig. 4 illustrates a system utilizing a platen or roller press and a thin die according to the present disclosure; [00141 Fig. 5 illustrates the process of making a thin die according to the present disclosure; 20 [0015] Fig. 6 illustrates a top view of the thin die with the ejection foam removed; [0016] Fig. 7 illustrates a side profile view of the raised or cutting edge of the die portion with the laminating film left on the raised cutting portion, this is what the die portion looks like after the etching step but before the stripping of the laminating film; and [00171 Fig. 8 illustrates the finished die portion after the laminating film has been 25 removed and after the die portion has been exposed to a secondary etching process to remove the sharp edges from the raised cutting portion of the die. DETAILED DESCRIPTION OF THE DISCLOSURE [0018] Disclosed is a thin die that is adapted to be used in a die press, such as a platen die 30 press or a roller die press. As shown in Fig. 1, disclosed is a thin die, such as a chemical 3 WO 2005/009668 PCT/US2004/022896 etched die assembly 100. The die assembly 100 includes a base portion 102 and an ejection foam portion 104. As will be further described below, the ejection foam portion 104 has a shape 106 that follows the contour of a raised portion of the thin die portion of the assembly. The shapes 106 are defined by shape borders 108. The shape borders 108 define 5 the shapes 106 in the ejection foam 104 and are created during the first use of the chemical etched die assembly 100, which the first use may be done at the factory to test the die or may be accomplished by the user of the die assembly 100. The ejection foam portion 104 includes an ejection foam border 110 that follows a border 112 of the base portion. [0019] Fig. 2 is a cross-sectional side-view taken from line 2-2 of Fig. 1. Fig. 2 illustrates 10 how the portions are assembled to comprise the final assembly configuration of the die assembly 100. The base portion 102 includes a base portion indentation 202 to define the base portion peripheral border 112. The chemical etched die 206 includes a relatively flat portion 207 and an opposite raised portion as defined by 208 and lower portions 210. The flat portion 207 of the chemical etched die 206 is adhered to the base indentation 202 so that 15 the chemical etched die 206 is located in and surrounded by the base portion peripheral border 112. A layer of adhesive 204 adheres the chemical etched die flat portion 207 to the base indentation 202. This adhesive 204 may be a foam adhesive, a spray adhesive or any other means to adhere the flat portion 207 of the chemical etched die to the base indentation portion 202. 20 [0020] The ejection foam portion 104 is adhered to the lower portions 210 of the chemical etched die 206. The ejection foam portion 104 is adhered to the lower portions 210 to the chemical etched die 206 by an adhesive 212. The adhesive 212 may be a foam adhesive, spray adhesive, or any other means to adhere the ejection foam portion 104 to the lower portions 210 of the chemical etched die 206. The close-up view shown in Fig. 2A, 25 illustrates one exemplary embodiment wherein the ejection foam adhesive 212 is limited to the lower portions 210 of the chemical etched die 206. In this embodiment, this configuration prevents the ejection foam material 104 from binding or interfering with the raised portion, or cutting surface 208 of the chemical etched die 206. In the alternative, the adhesive is adhered to the lower portions 210, as well as the raised cutting portions 208. In 30 this embodiment, when the first use or cut of the die occurs, the raised portion 208 of the die simply cuts through the adhesive and the ejection foam. The height of the raised or cutting portion of the die portion is .021 inches, with the base of the die portion being .010 inches. The base of the raised or cutting portion of the die portion is approximately .021 inches 4 WO 2005/009668 PCT/US2004/022896 wide at the bottom and is approximately .004 inches wide at the top, with a cutting flat surface of approximately .002 inches wide. Of course these dimensions are exemplary only and not intended to limit the claims. For example, the top of the raised cutting portion could range anywhere from .001 inches to .005 inches, for example without crushing the material 5 to be cut. [00211 Fig. 3 illustrates the bottom of the chemical etched die assembly 100, wherein only the base portion 102 is viewed. The base portion 102 includes a back-side 300. The back side 300 includes a back-side indentation 302. The back-side indentation 302 allows for a label 304 with identifying indentia 306 to be located in the back-side indentation 302. As 10 shown in Fig. 3A, which is a cross-sectional view taken from line 3A-3A from Fig. 3. The depth of the back-side indentation 302 is greater than the height of label 304 so that the forces transferred through the die assembly 100 are uniform across the die assembly 100 when the die assembly 100 is used with a die press. This is represented in Fig. 3A wherein the depth of the back-side indentation 302 is identified by d and the height of the label 304 15 is identified by h, wherein d > h. [0022] As shown in Fig. 4, the thin die disclosed herein may be used with a platen die press 402 with a cutting pad 404 and an optional adaptor 406. In the alternative, the thin die 100 disclosed herein may be used with a roller press 406. Sheet material 408, which may comprise paper, plastic, leather, or a variety of other materials, is placed between the thin 20 die 100 and the cutting pad 404. Pressure is applied to the thin die 100 through the platen press 402 so that the raised portion for the cutting portion 208 of the chemical etched die portion 206 is forced into and through the sheet material 408 and into the cutting pad 404 so that the desired shape is cut out of the sheet material 408. In the alternative, chemical etched die embosses the shape of the raised portion of the die into the sheet material 408. In 25 this embodiment, the raised portion 208 is not as sharp so as to not cut through the sheet material 408 when pressure is applied to the die from the press. [00231 If a roller press 406 is used with the thin die 100 disclosed herein, sheet material 408 and the thin die is fed through the rollers of the roller press 406 so that pressure is exerted to the thin die 100 and to the sheet material 408 so that the desired shape is cut out 30 of the sheet material 408. If a roller press 406 is utilized, the rollers may include a rubber or other resilient layer so that the raised portion or cutting portion 208 of the chemical etched 5 WO 2005/009668 PCT/US2004/022896 die 206 does not become damaged when being fed through the rollers of the roller press 406. 100241 Also disclosed herein is a method for making a thin die assembly 100, as disclosed herein. Fig. 5 illustrates the method of making the thin die, which includes the steps of 5 providing a sheet of flat stock material that may be a spring steel with a 45 high hardness or HRC rating. The steel material is cleaned to remove dirt and oils from the steel surfaces. The steel material is also degreased to remove the grease from the steel sheet stock material. The steel sheet stock is then water rinsed to remove any degreasing material on the steel surfaces. The steel material then may be acid rinsed to further remove any grease or other 10 particles on the surfaces of the steel material. The steel material is then again water rinsed to remove any remaining acid chemicals on the steel surfaces. The steel material is then scrubbed with a scrubbing roller. The scrubbing roller may be made of a nylon material. The steel material is then rinsed again and the steel material is then dried. The steel material is then dusted to remove any dust on the steel surfaces. Next, the steel surfaces that 15 are not to be chemical etched away, are laminated with a dry film. The dry film may be a dry film with a specification of a YQ-30SD. The dry film is applied upon to the steel surfaces at a temperature of 115 0 C at a pressure of 70 pounds per square inch or psi. The laminated film is exposed to make the image and/or the word into a negative on the steel surface, with the negative result being on the steel surface being exposed with a strong light. 20 This developing process is completed at a temperature 12'C and a pressure of -720 mmHg. The laminate is developed by the steps of removing the dry film without exposing the dry film, to get the image and the word located on a surface of the steel material. A developing solution includes a chemical known as NaCO 3 at a 1% solution, and at a temperature of 30'C, and at a pressure of 1.5kg/cm 2 and with a contact time of 50 seconds of the 25 developing solution with the laminated steel material. The steel material is then water rinsed and blow dried. [0025] Next, the steel material is chemical etched without the dry film in with a chemical solution of FeCL 3 to get the image and/or the word on the steel material. It is this step that creates the raised or cutting portions 208 and the lower portion 210. It is the lower portion 30 210 that is etched away, while the raised portion or cutting portion 208 remains at the original thickness of the steel material. The etching process includes a chemical known as FeCL 3 41%, with a specific gravity of 1.41, HCL 31% with a specific gravity of 1.151, and PC-420 with a specific gravity of 1.288. Further, this is conducted at a temperature of 6 WO 2005/009668 PCT/US2004/022896 48'C, and a pressure of 3.Okg\cm 2 and with the steel material being exposed to this chemical solution approximately 15 to 30 minutes long, and more preferably 15 to 25 minutes long. [00261 Next, steel material with the resulting chemical etched away surfaces is water 5 rinsed and blow dried. Next, the dry laminated film is stripped away from the raised or cutting portion 208 with a chemical known as NaOH at 5%, at a temperature of 48*C and at a pressure of 2.Okg\cm2 and at a contact time of 60 seconds. The steel material has the near net shape as shown in Fig. 7 before the laminated film is stripped away from the cutting portion 208. At this point, in one embodiment, the steel material is then exposed to a 10 secondary etching step after the dry laminated film has been stripped away from the raised or cutting portion 208. The secondary etching process may last anywhere between 10 to 30 seconds, and more preferably lasts 15 to 20 seconds long, depending upon the composition of the metal being etched and the composition of the chemical etching solution. Fig. 8 illustrates the steel material after the dry laminated film has been removed from the raised 15 or cutting portion 208 and after the steel material has been exposed to the secondary etching process. More specifically, the secondary etching process removes edges 501 and 503 shown in Fig. 7. The resulting shape is a die that has a raised cutting portion 208 of approximately .021 inches wide and approximately .031 inches in overall height, but the height is not limited to this dimension. The width of the top of the raised portion 208 is 20 approximately .004 inches, and more specifically, the flat cutting surface is approximately .002 inches wide at the top of the raised or cutting portion 208, but could be .001 to .005 inches wide. 100271 Next, the steel material with the etched net shape is exposed to a chemical etch process again, without any dry laminated film located over the raised or cutting portion 208. 25 This takes away any sharp edges from the raised or cutting portion 208 and further defines the raised or cutting portion 208. This step is known as a second etching step. In this step, the steel material with the near net shape is exposed to the etching chemicals for approximately 20 to 25 seconds; however, this length of time is exemplary only and is a function of the thickness of the chemical etched die and the strength and composition of the 30 chemical etching materials. 100281 Next, the steel material is pressure rinsed and blow dried, and then an antioxidant may be applied to the steel material. The antioxidant must not interfere with the adhesion of 7 WO 2005/009668 PCT/US2004/022896 the rejection foam onto the steel material or the adhesion of the steel material onto the base portion 102. Next, the resulting steel material, otherwise known as the chemical etched die portion 206, is applied to the base portion 102, and then the ejection foam material 104 is applied to the cutting side of the chemical etched die 206. The sponge material that is used 5 may be known as PORON, a cellular urethane foam, part number 470130-25025-04, from Rogers Corporation, Woodstock, CT. In the alternative, the sponge material may be of the neoprene family and, more particularly, a synthetic neoprene, such as chloroprene rubber, otherwise known as CR foam. CR foam is a durable and relatively inexpensive foam since it is synthetic. 10 [00291 The steel sheet stock that is provided may allow a plurality of chemical etched dies 206 to be etched from one piece of sheet stock. Therefore, a plurality of chemical etched dies 206 may be machined from piece of sheet stock, with the separation of the individual dies from the sheet stock being accomplished in the etching step. [00301 Although this disclosure has been shown and described with respect to detailed 15 embodiments, those skilled in the art will understand that various changes in form and detail may be made without departing from the scope of the present disclosure, for example, in one embodiment, the steel material is shipped in rolls for ease of shipping. The steel material is unrolled and cut into specific sizes to maximize the sheet yield depending upon the size of the dies to be etched from the sheets. The steel sheets are then flattened by 20 sending the steel sheets through rollers and then the steel sheets are cleaned. The material is then cleaned and then the laminating dry film is applied to the surfaces and the material is then rinsed prior to the anti-oxidation step. The chemical etching assembly line may include a number of etching sections for providing the operator an opportunity to check quality of the pieces between each etching section or module. Further, a chemical etching 25 regeneration system, such as the one available from Japan Aqua Co., Ltd. located in Osaka, Japan helps to control the chemical composition to the desired rates during the etching process. 8