EP3749523B1 - Method and device for rotary blind embossing of a substrate - Google Patents

Description

The invention relates to a method for rotary blind embossing of a substrate and a device for rotary blind embossing of a substrate.

Blind embossing is popular for refining substrates such as packaging. Here, a specific pattern, motif or writing is created in the substrate using a matrix and a male mold. With embossing, the pattern, motif or writing is embossed into the substrate, with deep embossing it is embossed into the substrate. Blind embossing typically uses large stamps or plates to emboss the pattern, motif or writing into the substrate. In order to be able to produce a variety of types and strengths of deformations, such as steep edges, different angles or simultaneously embossed and embossed elements, a stroke embossing process or a stroke embossing device is often used, as the desired variety of deformations can be achieved with high quality can. During lifting embossing, the deformation takes place in a lifting movement, in particular by the pressure transmitted by the embossing tool. Although a large number of deformations can be produced with this method, the disadvantage is that a maximum of around 8000 sheets per hour can be processed using the common stroke embossing methods or stroke embossing devices. Furthermore, the personnel and/or mechanical effort required for lifting embossing is increased, since the substrate to be embossed must be individually inserted and aligned in the lifting embossing device for the embossing process.

From the WO 2007/028557 A1 a method for producing a matrix or male mold is also known. Furthermore, from the DE 100 40 683 A1 a method for positioning a male die on a counter-pressure roller of an embossing station is known.

The invention is based on the task of providing an improved method and an improved device for blind embossing a substrate.

This object is solved by a method for rotary blind embossing of a substrate according to claim 1. This object is further solved by a device for rotary blind embossing of a substrate according to claim 10.

It has been shown here that the method for rotary blind embossing of a substrate and the device for rotary blind embossing of a substrate can significantly increase the number of sheets processed compared to stroke embossing methods or stroke embossing devices, while at the same time achieving an embossing result that is qualitatively comparable to stroke embossing becomes. This can result in significant cost savings. The personnel and machine costs are further reduced because Rotary blind embossing process is preferably carried out continuously and therefore, for example, manual insertion of the substrate into the embossing device is eliminated. Furthermore, particularly when using the method in combination with further process steps, such as punching, creasing or printing, in a common continuous process, on the one hand the processing speed is further increased and on the other hand a high registration accuracy, for example between printing and embossing, is achieved, since the rotary Process can be combined with other rotary processes such as punching, creasing or printing. With such an inline combination, the mechanical and personnel effort and thus the costs can be further reduced.

Blind embossing is understood to mean, in particular, relief embossing without the use of a color, in particular a printing ink, and/or without the use of a transfer foil, in particular a hot stamping foil or cold stamping foil. Preferably, a pattern, motif or writing is embossed into the substrate, particularly in the case of embossing, the pattern, motif or writing is embossed in a raised manner and/or in the case of deep embossing, the pattern, motif or writing is embossed recessed into the substrate.

A die is here understood to mean, in particular, an embossing tool which has the corresponding relief shape as elevations and/or depressions, the die preferably having the relief shape of the relief embossing to be achieved in a mirrored arrangement, i.e. not an immediately readable arrangement.

A male die is understood to mean, in particular, an embossing tool which has the corresponding relief shape as elevations and/or depressions has, wherein the male die preferably has the relief shape of the relief embossing to be achieved in a non-mirrored arrangement, ie in a readable arrangement.

The die and male die fit together in particular in such a way that the relief embossing is created in a readable form in the substrate. For this purpose, the die preferably acts on the substrate from the top and the male die from the underside, with the top side of the substrate representing the viewing side in the later use form of the substrate.

In particular, the die and male die can also be arranged inverted to the previously described arrangement if, for example, a transparent substrate in the later use form is to be viewed from the underside of the substrate.

Register or register or register accuracy or register accuracy is in particular a positional accuracy of two or more elements and / or layers relative to one another, here for example the positionally accurate arrangement of the embossing and other features applied to the substrate, such as a print, layers and layers applied to the substrate /or fold or crease lines, to be understood relative to each other. The register accuracy should advantageously be within a predetermined tolerance and be as low as possible. At the same time, the register accuracy of several elements and/or layers to one another is expediently an important feature in order to increase process reliability. The precise positioning can be carried out in particular by means of sensory, preferably optically detectable, registration marks or register marks. These registration marks or Register marks can either represent special separate elements or areas or layers or can themselves be part of the elements or areas or layers to be positioned.

Further advantageous embodiments of the invention are described in the subclaims.

It is advantageous if in step b) the substrate is blind embossed in such a way that the substrate has at least one elevation and/or depression.

An elevation and/or depression of the substrate is understood to mean, in particular, a relief shape which represents a pattern, motif or writing and which is preferably arranged either elevated (embossed) or recessed (debossed) relative to an unprocessed area of the substrate.

If the substrate is raised, it is preferably an embossing, so that the pattern, motif or writing is embossed into the substrate. A recess in the substrate is preferably a deep embossing, so that the pattern, motif or writing is embossed recessed into the substrate.

It is further advantageous if the at least one elevation and/or depression of the substrate in step b) has a height and/or depth of at least 0.02 mm, preferably at least 0.05 mm, more preferably at least 0.1 mm, even more preferably at least 0.5 mm is produced. This allows visually and haptically appealing blind embossing to be created.

The method preferably further comprises the following steps, which are carried out in particular before step a) and/or step b): - Fixing the at least one die on the embossing roller and/or the at least one male die on the counter-pressure roller by means of a fixing device. It is thus possible for the at least one die to be firmly fixed on the embossing roller and/or the at least one male die to be fixed on the counter-pressure roller by means of a fixing device. The fixing device is expediently a pin, bolt or screw. It is also advantageous if the embossing roller and/or the counter-pressure roller has a plurality of holes into which the fixing device can be inserted. In this way it can be achieved that the matrix and/or male mold can be fixed at locations predefined by the large number of holes.

Furthermore, it is also possible that the at least one die is introduced directly into the surface of the embossing roller as at least one elevation and/or depression and/or that the at least one male die is introduced directly into the surface of the counter-pressure roller as at least one elevation and/or depression is. The die and/or the male die can therefore in particular be a solid tool, which in particular is designed to be completely solid in one piece or at least in the area of the embossing tools to be partially solid in one piece. This provides a mechanically extremely stable embossing roller with an inserted die and a mechanically extremely stable counter-pressure roller with an inserted male die, which is particularly useful when the device is converted a few times to relief shapes that are to be embossed differently or for relief shapes that are to be embossed uniformly.

It is also possible that the at least one die is introduced as at least one elevation and/or depression into the surface of an embossing cylinder, which is detachably arranged on the embossing roller and/or that the at least one male die is introduced as at least one elevation and/or depression the surface of a counter-pressure cylinder is introduced, which is detachably arranged on the counter-pressure roller. In this way, a quick changeover can be achieved, especially in comparison to a full tool, since only the embossing cylinder and/or the impression cylinder need to be replaced.

According to a further exemplary embodiment of the invention, the embossing roller and/or the counter-pressure roller is designed to be magnetic or magnetic, in particular the embossing roller and/or the counter-pressure roller is designed as a magnetic cylinder. This ensures that the device can be set up quickly and easily.

According to the invention, the device has a positioning aid with at least one window area, the positioning aid being arranged on the embossing roller and/or the counter-pressure roller and the at least one die and/or male die being arranged in the at least one window area of the positioning aid.

According to the invention, the method further comprises the following steps, which are carried out in particular before step a) and/or step b): - Providing a positioning aid comprising at least one window area; - Arranging the positioning aid on the embossing roller and/or the counter-pressure roller; - Arranging the at least one die and/or male mold in the at least one window area of the positioning aid.

This makes it possible for the die and/or male die to be arranged in predetermined positions, which are determined by the window areas of the positioning aid, whereby, on the one hand, a quick and therefore cost-effective setup of the device is possible, since, for example, the comparatively rough positioning is essentially is predetermined by the window areas and, on the other hand, a particularly precise adjustment of the die and / or male die within the window areas is still possible in order to be able to compensate for tolerances. Furthermore, a variety of relief shapes, for example the simultaneous use of embossing and deep embossing, can be realized in this way, since only the die and/or male die have to be exchanged with the corresponding relief shapes within the window areas and any relief shapes can also be combined with one another, especially in the individual window areas can be.

The term area here is understood to mean, in particular, a defined area which, when viewed, is taken up perpendicular to a plane spanned by the positioning aid. For example, the positioning aid, in particular in the flat state, has one or more window areas, with each of the window areas occupying a defined area when viewed perpendicular to a plane spanned by the positioning aid.

The following describes, among other things, preferred embodiments of the positioning aid:
The positioning aid expediently has two or more window areas, in particular the two or more window areas being arranged according to a one- or two-dimensional grid.

Furthermore, it is expedient if the outline of the at least one window area of the positioning aid essentially corresponds to the outline of the at least one die and/or male die.

The term outline here is understood to mean, in particular, the contours or outer contours of the window area or the male and/or female die, which, when viewed, are taken perpendicular to a plane spanned by the positioning aid or the female and/or female die.

Advantageously, the at least one window area of the positioning aid is larger than the at least one die and/or male die, in particular the distance from each edge of the at least one window area to the at least one die and/or male die is at least 0.1 mm, preferably 0.2 mm, even more preferably 0.3 mm. This ensures, on the one hand, that the essential positioning of the die and/or male die is correct and, on the other hand, that the female die and/or male die continues to be within the distance from each edge of the respective window area to that of the die and/or male die respectively arranged within the window area can be arranged adjustable, in particular with precise registration, in order to be able to compensate for tolerances, for example.

The positioning aid preferably comprises metals, in particular copper, nickel, chromium, iron, zinc, tin, lead or alloys of such metals.

It is also possible for the positioning aid to be magnetic or to be designed magnetically. In this way, a simple and quick arrangement of the positioning aid on the preferably magnetically designed embossing roller and/or the preferably magnetically designed counter-pressure roller can be achieved.

It is also advantageous if the positioning aid has a thickness of at least 0.25 mm, preferably at least 0.5 mm, more preferably at least 0.75 mm.

Furthermore, it is possible that the positioning aid has an increased thickness in an area around the at least one window area compared to the remaining thickness of the positioning aid, in particular that the positioning aid in an area around the at least one window area is preferably at least 0.1 mm has a thickness increased by at least 0.2 mm, more preferably by at least 0.3 mm, compared to the remaining thickness of the positioning aid. It has been shown here that the increased thickness of the positioning aid around the window areas can increase the stability and thus improve the embossing result, in particular since displacements and/or mechanical movements of the die and/or male die are preferably prevented or reduced due to the higher mechanical stability become.

It is also possible for the area around the at least one window area to have a width of at least 0.2 mm, preferably at least 0.5 mm, more preferably at least 1.5 mm.

Furthermore, it is possible if the positioning aid has a width of at least 250 mm, preferably at least 500 mm, more preferably at least 750 mm, and a length of at least 500 mm, preferably at least 750 mm, more preferably at least 1000 mm, and /or that the at least one window area has a width of at least 5 mm, preferably at least 10 mm, more preferably at least 20 mm, and a length of at least 10 mm, preferably at least 20 mm, more preferably at least 100 mm.

It makes sense if the positioning aid is tensioned on the embossing roller and/or the counter-pressure roller, in particular if the positioning aid is tensioned on the embossing roller and/or the counter-pressure roller in such a way that the positioning aid has a curve which essentially corresponds to the diameter of the embossing roller and/or or corresponds to the diameter of the counter-pressure roller. It is also possible for the positioning aid to be tensioned onto the embossing roller and/or the counter-pressure roller, in particular for the positioning aid to be tensioned onto the embossing roller and/or the counter-pressure roller in such a way that the positioning aid has a curve which essentially corresponds to the diameter of the embossing roller and/or corresponds to the diameter of the counter-pressure roller.

Rounding here is preferably understood to mean a radius of curvature, the radius of curvature in particular being the radius of a circle of curvature, which, at a certain point on a curve, is the circle that best approximates the curve at this point.

Preferably, the positioning aid and/or the embossing roller and/or the counter-pressure roller has a clamping device for this purpose. The clamping device of the positioning aid expediently has holes by means of which the positioning aid can be fastened to the embossing roller and/or the counter-pressure roller, for example using pins or screws. The positioning aid preferably completely encompasses the embossing roller and/or the counter-pressure roller. However, it is also possible for the positioning aid to only partially span the embossing roller and/or the counter-pressure roller. For example, it is possible for the positioning aid to span half of the embossing roller and/or the counter-pressure roller, so that the positioning aid would form a semicircle. Other partial loops such as a three-quarter circle or a quarter circle are also conceivable.

It is also possible for the embossing roller and/or the counter-pressure roller to have several positioning aids that completely or only partially surround the embossing roller and/or the counter-pressure roller. For example, two positioning aids can each span half of the embossing roller and/or the counter-pressure roller. However, any other subdivisions and/or distribution of several positioning aids on the embossing roller and/or the counter-pressure roller can also be carried out.

According to a further exemplary embodiment of the invention, the at least one die and the embossing roller and/or the at least one The male die and the counter-pressure roller each represent two different components of the device, in particular the at least one die and/or male die is applied to the surface of the embossing roller and/or the counter-pressure roller in the at least one window area of the positioning aid. This makes it possible to set up and/or rearrange the device quickly and easily, since only the die and/or male die, which is small compared to the embossing roller and/or the counter-pressure roller, need to be replaced. Particularly in combination with a positioning aid, the device can be set up quickly and precisely to the desired embossed relief shapes.

Below, among other things, preferred embodiments of the die and/or male die as well as the arrangement or design of the die and/or male die in the device for rotary blind embossing are described. The use of the die and/or male die in the method and/or the device for rotary blind embossing is also described:
Preferably, the at least one die and/or male die is deformed in such a way that the at least one die and/or male die has a curve which essentially corresponds to the diameter of the embossing roller and/or essentially corresponds to the diameter of the counter-pressure roller. It is also possible for the at least one die and/or male die to be deformed before being arranged in the at least one window area of the positioning aid in such a way that the at least one die and/or male die has a rounding which essentially corresponds to the diameter of the embossing roller and /or corresponds to the diameter of the counter-pressure roller. It is also possible for the die and/or male die to be rounded, in particular for the female die and/or male die to be deformed in such a way that the female die and/or male die has a curve which essentially corresponds to the diameter of an embossing roller and/or the diameter of a counter-pressure roller on which the die and/or male die is arranged.

This results in an adaptation of the shape of the die and/or male die to the shape of the embossing roller and/or counter-pressure roller, so that the die and/or male die can be used in the rotary process.

It is advantageous if the die and/or male die has at least one elevation and/or depression, which corresponds in particular to the relief shape to be embossed in positive and/or negative form. It is also possible for the at least one elevation and/or depression to represent a pattern, motif or writing. For example, a pattern may be a graphically designed outline, a figurative representation, an image, a symbol, a logo, a portrait, and the like. A font can be, for example, an alphanumeric character, a text and the like.

It is further advantageous that the at least one increase in the die and/or the male die has a height of a maximum of 5.0 mm, preferably a maximum of 3.0 mm, more preferably a maximum of 1.0 mm, even more preferably a maximum of 0 .5 mm, and/or that the at least one recess of the die and/or the male die has a depth of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of maximum 0.5 mm.

It is possible that the at least one elevation and/or depression of the matrix and/or the male mold has a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, prismatic-flat, pointed or mixtures of these shapes.

Furthermore, it is possible for the at least one elevation and/or depression of the matrix and/or patrix to be designed in several stages, in particular sculptured, in terms of its height and/or depth.

Sculpted is preferably understood to mean a relief form that represents or forms a sculpture, a motif, a pattern or a writing. Preferably, the at least one elevation and/or depression of the die and/or male die has at least one side flank, the angle between the at least one side flank and a line running parallel to the surface of the female die and/or male die being between 0° and 180°, preferably between 45° and 135°, more preferably between 80° and 100°, even more preferably between 85° and 95°.

Furthermore, it is expedient if the at least one elevation and/or depression has such a round shape that the shape of the elevation and/or depression is essentially defined by a circular section, in particular with a radius between 0.1 mm and 2.5 mm. preferably between 0.3 mm and 0.7 mm. The shape of the elevation and/or depression can also be essentially elliptical, with the smaller radius of the ellipse having a dimension between 0.1 mm and 2.5 mm, preferably between 0.3 mm and 0.7 mm.

Advantageously, the at least one die is magnetically attached to the embossing roller and/or the at least one male die is magnetically attached to the counter-pressure roller. This makes it possible for the matrix and/or male mold can be arranged quickly and easily on the embossing roller and/or the counter-pressure roller.

According to a further exemplary embodiment of the invention, the at least one die is arranged on the embossing roller and the at least one male die is arranged on the counter-pressure roller in such a way that the holding force with which the at least one die is arranged on the embossing roller is higher, preferably by a factor of 1 .5 to 5 is higher, more preferably by a factor of 2.5 to 3.5 higher, than the holding force with which the at least one male part is arranged on the counter-pressure roller. It is also possible for the at least one die to be arranged on the embossing roller and the at least one male die to be arranged on the counter-pressure roller in such a way that the holding force with which the at least one die is arranged on the embossing roller is higher, preferably by a factor of 1 .5 to 5 is higher, more preferably by a factor of 2.5 to 3.5 higher, than the holding force with which the at least one male part is arranged on the counter-pressure roller.

The holding force was measured in particular in the longitudinal direction of the die or male die. In particular, the measuring force was transmitted via 50 mm wide TESA adhesive tape 4651 glued to the surface of the female or male die and a hanging tab on the adhesive tape with a length of approx. 100 mm and thus a distance from the sample. With this measuring method, the measuring force acts particularly tangentially to the roll surface. In particular, the static friction force is determined as the maximum force using an electronic spring force balance (ALLURIS FMI100C5/500 N). Advantageously, the roller surface as well as the surface of the die or male die have each been cleaned and deoiled.

This ensures that the male part is arranged less firmly in comparison to the female part. The male part is therefore arranged in particular “looser” than the female part. It has been shown here that by means of such a relatively lower holding force of the male mold on the counter-pressure roller compared to the female mold on the embossing roller, embossings of comparable quality can still be achieved, in particular with the stroke embossing process, since the male mold in particular has advantageous degrees of freedom due to the lower holding force in such a way that this can assume the ideal position in relation to the matrix forming the counterpart. In particular, the male “looks” for the ideal position, so to speak. This advantageously enables self-adjustment, which delivers a high-quality embossing result. Furthermore, such automatic self-adjustment or positioning of the male mold relative to the female die significantly reduces the effort required to set up and/or reorient the device, since the ideal positioning or alignment is essentially brought about automatically by the defined lower holding force of the male die compared to the female die becomes. Particularly in combination with the positioning aid, a high-quality embossing result is produced, since the male die then snaps into the ideal position relative to the die, as described above, with excessive play in the male die due to the limitation of the window area of the positioning aid which the male part is arranged is prevented.

According to the invention, the at least one die and/or male die can be adjusted in the at least one window area of the positioning aid by means of an adjusting aid. So it is also according to the invention if, when arranging the at least one die and/or male die in the at least one window area of the positioning aid, the at least one die and/or male part is adjusted by means of an adjustment aid in which at least one window area is adjusted.

The adjustment aid expediently consists, for example, of one or more metal sheets, in particular of one or more gauge blocks and/or one or more spigots, which are inserted in particular into the space between the die and/or male die and the edge of the window area. The gap is preferably created by the fact that the at least one window area is larger than the at least one die and/or male die. In particular, the gap corresponds to the distance from each edge of the at least one window area to the at least one die and/or male die. This makes it possible to adjust the die and/or male die, in particular to compensate for tolerances, so that a precisely registered embossing result can be achieved.

Further according to the invention, the adjustment aid is arranged such that the at least one die and/or male die is movable, in particular flexible, at least in one direction.

The adjustment aid is advantageously arranged in such a way that the die and/or male die is movable, in particular flexible, in a direction parallel to the feed direction of the substrate. However, it is also possible for the adjustment aid to be arranged in such a way that the at least one die and/or male die is movable, in particular flexible, in a direction perpendicular to the feed direction of the substrate. Preferably, the at least one die and/or male die is arranged movably, in particular flexibly, in an intermediate space which corresponds to the distance from each edge of the at least one window area to the at least one female die and/or male die.

It is therefore possible for the adjustment aid to be arranged on one or two, in particular two opposite sides of the window area. For example, the adjustment aid is arranged on those sides of the window area which run parallel to the longitudinal axis or to the transverse axis of the positioning aid. The adjustment aid is preferably arranged on the sides of the window area that are parallel to the direction of rotation or running direction of the embossing roller and/or counter-pressure roller. However, it is also possible for the adjustment aid to be arranged on the sides of the window area that are perpendicular to the direction of rotation or running direction of the embossing roller.

This makes it possible for at least one die and/or male die to still have play in at least one direction despite the use of an adjustment aid, so that the self-adjustment described above is made possible at least in one direction.

It is expedient if the at least one die and/or male die is fastened in the at least one window area of the positioning aid by means of a fastening device. It is thus possible that when arranging the at least one die and/or male die in the at least one window area of the positioning aid, the at least one female die and/or male die is fastened in the at least window area by means of a fastening device. The fastening device is preferably a clamp.

It also makes sense if the die and/or male die comprises metals, in particular brass or other copper alloys, and/or plastics, in particular photopolymers.

Advantageously, the die and/or male die is designed in multiple layers, in particular the die and/or male die comprises a first layer, preferably a first metal layer, a second layer, preferably a second metal layer, and an adhesive layer. It has been shown that particularly good embossing results can be achieved by designing the die and/or male die in this way.

Preferably, the first layer is a first metal layer, in particular a brass layer, and the second layer is a second metal layer, in particular a steel layer.

The first layer is preferably a first metal layer and/or the second layer is a second metal layer, wherein the first and/or second metal layer comprises brass, bronze, copper, nickel, zinc, tin, lead, iron or steel .

The first layer is expediently a first metal layer made of a non-magnetic or weakly magnetic material, in particular copper and/or zinc. So it is possible that the first layer is a brass layer.

The second layer is preferably a second metal layer made of ferromagnetic materials, in particular comprising iron, ferrites, cobalt and/or nickel. So it is possible that the second layer is a steel layer.

It is therefore possible for the first layer to be a first metal layer made of a non-magnetic or weakly magnetic material and for the second layer to be a metal layer made of a magnetic, in particular strongly magnetic, material. For example, the first layer may be a brass layer and the second layer may be a steel layer.

Advantageously, the second layer, in particular the second metal layer, is magnetic. This makes it possible to easily arrange the die and/or male die on the embossing roller and/or the counter-pressure roller.

It is expedient if the second layer, in particular the second metal layer, of the matrix is thicker, preferably by a factor between 1.2 and 3.5, more preferably by a factor between 1.2 and 2.5, thicker than that second layer, in particular the second metal layer, of the male part. It is also possible for the second layer, in particular the second metal layer, of the die to be at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.15 mm, thicker than the second layer, in particular second metal layer, the male part.

This can ensure that the holding force with which the at least one die is arranged on the embossing roller is higher than the holding force with which the at least one male die is arranged on the counter-pressure roller. With regard to the further advantages of such a design, reference is made to the above statements.

The die and the male die preferably have the same materials and/or the same layer structure, in particular the female die and the male die, in particular the first layers, made of metal, in particular brass.

Furthermore, it is also possible for the first layer, in particular the first metal layer, of the die and the male die to be made of the same metal, preferably brass. Furthermore, it makes sense if the layer of the die and/or male die that has at least one depression and/or elevation is made of the same metal, preferably brass.

It has been shown that high-quality embossing results can be achieved in this way, in particular that fine contours of the relief shapes to be embossed can also be produced in the embossing.

It is also preferred that the die and male die have different materials, in particular that the female die has metal, in particular brass, and the male die has plastic, in particular a photopolymer, rubber or rubber.

It is also preferred if the first layers of the matrix and the male matrix have different materials. It is thus possible for the first layer of the matrix to be made of metal, in particular of brass, and the first layer of the male mold to be made of plastic, in particular of a photopolymer, rubber or rubber. It is also possible for the first layer of the male mold to be made from a rubber printing blanket.

In this way it can be achieved that, for example, the male part and/or the first layer of the male part can be manufactured cheaply and easily from a rubber, while at the same time a good embossing result is achieved, especially since the softer male mold adapts to the relief shape of the harder female mold, which is made of metal, for example.

The thickness of the first layer is preferably between 0.5 mm and 2.5 mm, preferably between 0.75 mm and 2 mm, more preferably between 1 mm and 1.75 mm and/or the thickness of the second layer is between 0.05 mm and 1.5 mm, preferably between 0.1 mm and 1 mm, more preferably between 0.15 mm and 0.5 mm.

It is also advantageous if the adhesive layer is a hot glue or cold glue layer.

It is also possible for the adhesive layer to be a two-component adhesive (2K adhesive), in particular comprising epoxy resins. The adhesive layer is preferably a 2-component, epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.

It is also advantageous if the adhesive layer is a double-sided adhesive tape. The double-sided adhesive tape is preferably coated on both sides with a pressure - sensitive adhesive (PSA). Such double-sided adhesive tapes can be obtained, for example, from tesa, Norderstedt, Germany.

It also makes sense if the adhesive layer preferably has a layer thickness between 0.01 mm and 0.75 mm, preferably between 0.05 mm and 0.5 mm, more preferably between 0.05 mm and 0.25 mm.

However, it is also possible for the female mold and/or male mold to be designed in one layer. Preferably, the single-layer matrix and/or male mold is magnetic. Advantageously, the single-layer matrix and/or male mold is made of a magnetic, in particular strongly magnetic, material. The single-layer die and/or male die preferably comprises ferromagnetic materials, in particular comprising iron, ferrites, cobalt and/or nickel.

It is therefore possible for the single-layer die and/or male die to be made of steel. The die and/or male die can therefore in particular be a single-layer steel die and/or male die.

Even with a single-layer die and/or male die, it is advantageous if the die is thicker than that, preferably by a factor between 1.2 and 3.5, more preferably by a factor between 1.2 and 2.5 Patrician. Here too, it is possible for the die to be at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.15 mm thicker than the male die. With regard to the advantages of such a design, reference is made to the above statements.

It is also advantageous if the die has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm, and / or the male die has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm.

It is particularly useful when producing the die and/or male die that the at least one elevation and/or depression is engraved and/or milled, in particular by means of a computer-controlled engraving machine and/or a computer-controlled milling machine.

It is also possible for the at least one elevation and/or depression to be produced photolithographically.

Furthermore, it is possible for the at least one elevation and/or depression to be generated by means of a laser, in particular by laser ablation.

It has been shown here that, particularly when producing the die and/or male die using a computer-controlled engraving machine and/or milling machine, matrices and/or male dies can be produced which are characterized by particularly good embossing results, in particular with which fine contours in the form of corresponding embossed elevations and / or depressions of the substrate can be created.

Furthermore, it is particularly advantageous when producing the die and/or male die that the method further comprises the following step, which is carried out in particular before the step of producing the at least one elevation and/or depression in the surface of the female die and/or male die: Reducing the defined shape of the at least one elevation and/or depression in the surface of the die and/or male die by a predetermined shortening factor, the shortening factor being in particular between 0.95 and 1, preferably between 0.9750 and 0.9999, more preferably between 0.98000 and 0.99999, even more preferably between 0.99000 and 0.9999. Advantageously, the predetermined shortening factor is determined depending on the diameter of the embossing roller and/or the counter-pressure roller. It is also possible for the predetermined shortening factor to be determined depending on the embossing length and/or a print length, in particular on the substrate. This has shown that The embossing result can be further improved by such a shortening factor, since this can compensate for possible distortion or lengthening of the relief to be embossed, in particular due to the curvature of the embossing roller and/or the counter-pressure roller on the substrate.

Furthermore, it is advantageous if the defined shape of the at least one elevation and/or depression in the surface of the die and/or male die is distorted according to a predetermined distortion factor, in particular along a surface normal of the plane spanned by the female die and/or male die. It is therefore possible for the at least one elevation and/or depression to have a distortion, in particular along a surface normal of the plane spanned by the die and/or male die.

Preferably, areas of the at least one die and/or male die that are not intended to emboss the substrate are removed or exposed. In particular, the male die is removed or exposed in such a way that the so-called base of the female die is not embossed into the substrate. Here, the male part is preferably removed or released by at least 0.2 mm, more preferably by at least 0.3 mm, even more preferably by at least 0.4 mm.

Below, among other things, further preferred embodiments of the method and the device for rotary blind embossing of a substrate are described:
Furthermore, it is possible for the method to further comprise the following step, which is carried out in particular before step a) and/or step b): - Insertion of at least one compensation layer between the at least a die and the embossing roller and/or the at least one male die and the counter-pressure roller. It is also possible for at least one compensation layer to be arranged between the at least one die and the embossing roller and/or the at least one male die and the counter-pressure roller. This allows the height of the matrix and/or the male mold to be adjusted in a defined manner, for example to enable height compensation.

It is also possible for the ratio of the diameter of the embossing roller to the diameter of the counter-pressure roller to be 1 to 2, preferably 1 to 1.

Preferably, the embossing roller and the counter-pressure roller are driven in opposite directions to one another at corresponding rotational speeds. It is also possible for the embossing roller and the counter-pressure roller to be driven in opposite directions to one another with corresponding rotational speeds.

Here, the at least one die and the at least one male die preferably engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die is embossed, in particular in an overlap area of the at least one die and the at least one male die. It is also possible for the at least one die and the at least one male die to be arranged in such a way that they engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die, in particular in an overlap area of the at least one die and at least one male die can be embossed.

It is further advantageous that the substrate is embossed in such a way that the deviations between the embossings of each cycle are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

The method expediently further comprises the following step: - feeding the substrate to the work station comprising the embossing roller and the counter-pressure roller.

It also makes sense if the method further comprises at least one of the following steps, which are carried out in one or more further work stations: - printing on the substrate; - cutting the substrate; - Grooving and/or folding the substrate. It is also possible for the device to further comprise one or more further work stations for printing on the substrate and/or for cutting the substrate and/or for creasing and/or folding the substrate. Preferably, the one or more further work stations are arranged before and/or after the work station comprising the embossing roller and the counter-pressure roller.

Printing is preferably carried out using offset printing, screen printing, gravure printing, letterpress printing or inkjet printing. It is further preferred if the pressure is generated by means of a printing roller. During printing, one or more printing inks are advantageously applied to the substrate, in particular according to a printing grid. Preferably, the substrate is separated by punching, in particular the substrate being separated by means of a cutting tool and/or punching tool. When grooving, the bending ability of the substrate is preferably changed by means of a spinning tool, in particular by material displacement. Under folds is preferably understood as the production of a sharp folding edge with the help of a tool.

According to a further exemplary embodiment of the invention, the substrate is preferably processed continuously.

It is also advantageous that, particularly in step a), the substrate is provided as sheet material.

It is further preferred here if the deviations between the embossings on the sheets of the substrate provided as sheet goods amount to less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

Furthermore, it is possible for the method and/or the device to produce more than 8,000 sheets per hour, preferably more than 10,000 sheets per hour, more preferably more than 12,000 sheets per hour, even more preferably more than 14,000 sheets per hour Sheet material provided substrate can be processed.

Fig. 1a bis Fig. 1c

zeigen schematisch eine Vorrichtung sowie ein Verfahren zum rotativen Blindprägen

Fig. 2

zeigt schematisch eine Vorrichtung zum rotativen Blindprägen

Fig. 3

zeigt schematisch eine Vorrichtung zum rotativen Blindprägen

Fig. 4

zeigt schematisch ein Verfahren zum rotativen Blindprägen

Fig. 5

zeigt schematisch eine Vorrichtung zum rotativen Blindprägen

Fig. 6a bis Fig. 6d

zeigen schematisch Schnittdarstellungen von Prägewalzen und/oder Gegendruckwalzen

Fig. 7a bis Fig. 7e

zeigen schematisch Positionierungshilfen in Draufsicht

Fig. 7f bis Fig. 7i

zeigen schematisch Schnittdarstellungen des vergrößerten Ausschnitts der Fig. 7c

Fig. 8a bis Fig. 8c

zeigen schematisch Schnittdarstellungen von Matrizen und/oder Patrizen

Fig. 9a und Fig.9b

zeigen schematisch Schnittdarstellungen von Matrizen und/oder Patrizen

Fig. 10a bis Fig. 10g

zeigen schematisch Schnittdarstellungen von Reliefformen

Fig. 11a bis Fig. 11e

zeigen schematisch Schnittdarstellungen von Reliefformen

Fig. 12a bis Fig. 12d

zeigen schematisch Schnittdarstellungen von Reliefformen

Fig. 13a und Fig. 13b

zeigen Verfahren zur Herstellung einer Matrize und/oder Patrize

In the following, exemplary embodiments of the invention are explained using the accompanying figures, which are not true to scale.

Fig. 1a to Fig. 1c

show schematically a device and a method for rotary blind embossing

Fig. 2

shows schematically a device for rotary blind embossing

Fig. 3

shows schematically a device for rotary blind embossing

Fig. 4

shows schematically a method for rotary blind embossing

Fig. 5

shows schematically a device for rotary blind embossing

Fig. 6a to Fig. 6d

show schematic sectional views of embossing rollers and/or counter-pressure rollers

Fig. 7a to Fig. 7e

show schematic positioning aids in a top view

Fig. 7f to Fig. 7i

show schematic sectional views of the enlarged section of the Fig. 7c

Fig. 8a to Fig. 8c

show schematic sectional views of matrices and/or patrixes

Fig. 9a and Fig.9b

show schematic sectional views of matrices and/or patrixes

Fig. 10a to Fig. 10g

show schematic sectional views of relief shapes

Fig. 11a to Fig. 11e

show schematic sectional views of relief shapes

Fig. 12a to Fig. 12d

show schematic sectional views of relief shapes

Fig. 13a and Fig. 13b

show methods for producing a die and/or male die

Fig. 1a to Fig. 1c show schematically a device 1 for rotary blind embossing.

The device 1 for rotary blind embossing of a substrate 3 comprises a work station 1a, which in turn comprises an embossing roller 2a and a counter-pressure roller 2b, a die 4a being arranged on the embossing roller 2a and a male die 4b being arranged on the counter-pressure roller 2b.

Blind embossing is understood to mean, in particular, relief embossing without the use of a color, in particular a printing ink, and/or without the use of a transfer foil, in particular a hot stamping foil or cold stamping foil. Preferably a pattern, motif or a Writing is embossed into the substrate 3, with the pattern, motif or writing being embossed, particularly in the case of embossing, and/or the pattern, motif or writing being embossed recessed into the substrate 3 in the case of deep embossing.

By means of the in Fig. 1a Device 1 shown is, as in the Fig. 1a to Fig. 1c shown, a method for rotary blind embossing of the substrate 3 is carried out in the work station 1a comprising an embossing roller 2a and a counter-pressure roller 2b, the method comprising the following steps, which are carried out in particular in the following order: a) providing the substrate 3; b) Blind embossing of the substrate 3 by means of the die 4b arranged on the embossing roller 2a and the male die 4b arranged on the counter-pressure roller 2b.

As in Fig. 1a shown, the substrate 3 is provided in a first step. Then, as in Fig. 1b shown, the substrate 3 is embossed or blind embossed by means of the die 4a arranged on the embossing roller 2a and the male die 4b arranged on the counter-pressure roller 2b.

As in Fig. 1c shown, it is an advantage if in the in Fig. 1b step shown, the substrate 3 is blind embossed in such a way that the substrate 3 has at least one elevation 5a and / or depression 5b.

An elevation 5a and/or depression 5b of the substrate 3 is understood to mean, in particular, a relief shape which represents a pattern, motif or writing. An elevation 5a of the substrate 3 relative to an unprocessed area of the substrate 3 is preferably an embossing, so that the pattern, motif or writing is embossed into the substrate 3. At a depression 5b of the substrate 3 relative to one The unprocessed area of the substrate 3 is preferably a deep embossing, so that the pattern, motif or writing is embossed deep into the substrate 3. For example, in the case of debossing, the in Fig. 1c The elevation 5a and/or depression 5b shown is mirrored on the plane spanned by the substrate 3, ie the bulge of the substrate 3 would now point downwards and not upwards.

It is further advantageous if the at least one elevation 5a and/or depression 5b of the substrate 3 is produced with a height and/or depth of at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.5 mm .

As in Fig. 1a to Fig. 1c shown schematically, the ratio of the diameter of the embossing roller 2a to the diameter of the counter-pressure roller 2b is 1 to 1. However, it is also possible for the embossing roller 2a and the counter-pressure roller to have different diameters. It is also possible for the ratio of the diameter of the embossing roller 2a to the diameter of the counter-pressure roller 2b to be 1 to 2. Preferably, the diameter of the embossing pressure roller is between 100 mm and 450 mm, preferably between 200 mm and 350 mm, and/or the diameter of the counter-pressure roller is between 200 mm and 800 mm, preferably between 400 mm and 700 mm. It is thus possible for the diameter of the embossing roller to be, for example, 300 mm ± 5 mm, preferably 298.4 mm ± 0.02 mm, and/or the diameter of the counter-pressure roller, for example 600 mm ± 5 mm, preferably 599.4 mm ± 0, 02 mm.

The substrate 3 is, as in Fig. 1a to Fig. 1c shown, preferably provided as sheet material. However, it is also possible for the substrate 3 to be provided as roll goods for roll-to-roll processing.

Preferably, the substrate 3 comprises pulp and/or plastics. The substrate 3 is advantageously paper, cardboard and/or films, in particular plastic films, or hybrid and/or composite materials made from such materials.

The substrate 3 is expediently fed to the work station 1a comprising the embossing roller 2a and the counter-pressure roller 2b. This is done, for example, by means of a transport device which has corresponding rollers with which the substrate 3 is transported to the desired position in the work station 1a, i.e. the substrate 3 is advanced accordingly.

As in Fig. 1a to Fig. 1c indicated by the arrows, the embossing roller 2a and the counter-pressure roller 2b are preferably driven in opposite directions to one another at corresponding rotational speeds. Here, the die 4a and the male die 4b advantageously engage with each other during each revolution in such a way that the substrate 3 located between the female die 4a and the male die 4b is embossed, in particular in an overlap area of the female die 4a and the male die 4b.

By means of the in Fig. 1a to Fig. 1c In the device shown, it is possible for the substrate 3 to be embossed in such a way that the deviations between the embossings of each cycle are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

With regard to the arrangement of the die 4a on the embossing roller 2a and the male die 4b on the counter-pressure roller 2b as well as the design of the die 4a and the male die 4b, reference is made to the statements below.

Fig. 2 shows schematically a device 1 for rotary blind embossing. The device of Fig. 2 differs from device 1 of the Fig. 1 a to Fig. 1c in that three matrices 4a are arranged on the embossing roller 2a and three male molds 2b are arranged on the counter-pressure roller 2b.

Here, too, the embossing roller 2a and the counter-pressure roller 2b are preferably driven in opposite directions to one another at rotational speeds corresponding to one another, with the matrices 4a and the male molds 4b engaging with one another during each revolution in such a way that the substrate 3, in particular, located between the matrices 4a and the male molds 4b in an overlap area of the matrices 4a and the patrixes 4b.

The device 1 also has the Fig. 2 in contrast to the device of Fig. 1a to Fig. 1c , a positioning aid 7. The positioning aid 7 is in Fig. 2 only arranged on the embossing roller 2a.

The positioning aid 7 has recesses in the form of window areas in the areas in which the matrices 4a are arranged on the embossing roller 2a, into which the matrices 4a can be inserted. Advantageously, before embossing the substrate 3, the positioning aid comprising the window areas is first provided. The positioning aid 7 is then arranged on the embossing roller 2a and the matrices 4a are preferably arranged on the embossing roller 2a in the window areas of the positioning aid 7.

With regard to the further design of the positioning aid 7 and the arrangement of the die 4a on the embossing roller 2a, reference is made to the statements below.

Fig. 3 shows schematically a device 1 for rotary blind embossing. The device of Fig. 3 differs from the device of the Fig. 2 in that a positioning aid 7 is arranged both on the embossing roller 2a and on the counter-pressure roller 2b. The positioning aid 7 arranged on the counter-pressure roller also has recesses in the form of window areas in the areas in which the male molds 4b are arranged on the counter-pressure roller 2b, into which the male molds 4b can be inserted. Advantageously, before embossing the substrate 3, the positioning aid comprising the window areas is first provided. The positioning aid 7 is then arranged on the counter-pressure roller 2b and the male molds 4b in the window areas of the positioning aid 7 are preferably arranged on the counter-pressure roller 2b.

With regard to the further design of the positioning aid 7 and the arrangement of the male mold 4b on the counter-pressure roller 2b, reference is made to the statements below.

The device 1 also has the Fig. 3 in contrast to device 1 of the Fig. 2 Compensating layers 8, which are arranged between the male molds 4b and the counter-pressure roller 2b.

Such compensation layers preferably have a layer thickness of at least 0.01 mm, preferably 0.02 mm, more preferably 0.03 mm.

Using such compensation layers, a defined height compensation of the embossing, i.e. trimming, is possible. It is also possible for the compensation layers to be arranged between the matrices 4a and the embossing roller 2a.

Fig. 4 shows schematically a method for rotary blind embossing. The method includes steps 10a to 10e.

In the method, a substrate 3 is first provided in step 10a.

In a further step 10b, the substrate 3 is printed. Printing is preferably carried out using offset printing, screen printing, gravure printing, letterpress printing or inkjet printing. It is further preferred if the pressure is generated by means of a printing roller. During printing, one or more printing inks are advantageously applied to the substrate 3, in particular according to a grid.

In a further step 10c, the substrate 3 is blind embossed using a die 4a arranged on an embossing roller 2a and a male die 4b arranged on a counter-pressure roller 2b. With regard to blind embossing, please refer to the above statements. The substrate 3 is expediently fed to the embossing roller 2a and the counter-pressure roller 2b in a defined manner, in particular with precise registration.

Register or register or register accuracy or register accuracy is in particular a positional accuracy of two or more elements and / or layers relative to one another, here for example the positionally accurate arrangement of the embossing and other features applied to the substrate, such as a print, layers and layers applied to the substrate /or fold or crease lines, to be understood relative to each other. The register accuracy should in particular be within a specified tolerance and be as low as possible. At the same time, the register accuracy of several elements and/or layers to one another is expediently an important feature in order to increase process reliability. The precise positioning can be carried out in particular by means of sensory, preferably optically detectable, registration marks or register marks. These registration marks or register marks can either represent special separate elements or areas or layers or can themselves be part of the elements or areas or layers to be positioned.

In a further step 10d, the substrate 3 is grooved and/or folded. When grooving, the bending ability of the substrate 3 is preferably changed by means of a spinning tool, in particular by material displacement. Folding is preferably understood to mean producing a sharp fold edge using a tool.

In a further step 10e, the substrate 3 is separated. The substrate 3 is preferably separated by punching, in particular the substrate 3 being separated by means of a cutting tool and/or punching tool.

Steps 10a to 10e are preferably carried out in different work stations of a device.

It makes sense here if the substrate 3 is preferably processed continuously.

It is also advantageous if the substrate 3 is provided as sheet material. It is further preferred here if the deviations between the embossings on the sheets of the substrate 3 provided as sheet goods amount to less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

Furthermore, it is possible for the method to produce more than 8,000 sheets per hour, preferably more than 10,000 sheets per hour, more preferably more than 12,000 sheets per hour, even more preferably more than 14,000 sheets per hour, of the substrate 3 provided as sheet goods. are processed.

Fig. 5 shows schematically a device 1 for rotary blind embossing.

The device 1 in Fig. 5 comprises a transport device 11, which is used to transport the substrate 3. For example, it is possible for the transport device 11 to comprise a supply roll on which the substrate 3 is wound. Alternatively, it is also possible for the transport direction 11 to be designed in an arc shape for transporting the substrate 3.

The device 1 further comprises the work station 1b for printing on the substrate 3. The work station preferably comprises a printing roller.

With regard to printing on the substrate 3, reference is made to the above statements.

The device 1 further comprises the work station 1a for rotary blind embossing of the substrate 3. With regard to the design of the work station 1a and the rotary blind embossing, reference is also made here to the above statements.

The device further comprises the work station 1c for creasing and/or folding the substrate 3. The work station 1c preferably comprises a pressing tool and/or folding tool for producing a sharp folding edge. With regard to the grooving and/or folding of the substrate 3, reference is also made to the above statements.

The device further comprises the work station 1d for cutting the substrate 3. Advantageously, the work station 1d comprises a cutting tool. Regarding the cutting of the substrate 3, reference is also made to the above statements.

As in Fig. 5 shown, the work station 1b is arranged in front of the work station 1a comprising the embossing roller 2a and the counter-pressure roller 2b. The work stations 1c and 1d are arranged after the work station 1a comprising the embossing roller 2a and the counter-pressure roller 2b. However, other orders of the workstations are also conceivable. For example, it is possible for the work station 1c to be arranged before and/or the work station 1b after the work station 1a, comprising the embossing roller 2a and the counter-pressure roller 2b.

It is further advantageous if, by means of the device 1, more than 8,000 sheets per hour, preferably more than 10,000 sheets per hour, more preferably more than 12,000 sheets per hour, even more preferably more than 14,000 sheets per hour, of the substrate 3 provided as sheet material , are processed.

Fig. 6a to Fig. 6d show schematic sectional views of embossing rollers 2a and/or counter-pressure rollers 2b.

As in Fig. 6a shown, it is possible that the die 4a is introduced directly as at least one elevation and/or depression into the surface of the embossing roller 2b and/or that the at least one male die 4a is introduced directly as at least one elevation and/or depression into the surface of the counter-pressure roller 2b is introduced. The die 4a and/or the male die 4b can therefore in particular be a solid tool, which in particular is designed to be completely solid in one piece or at least in the area of the embossing tools to be partially solid in one piece. With such solid tools, the relief shapes to be embossed are therefore introduced directly into the surface of the solid cylinder forming the embossing roller 2a and/or counter-pressure roller 2b. The introduction is preferably carried out by etching, engraving and/or using a laser, in particular using laser ablation.

It is also further, as in Fig. 6b shown possible that the die 4a and/or the male die 4b are fixed on the embossing roller 2a and/or the counter-pressure roller 2b by means of a fixing device 6. The fixing device 6 is preferably a pin, bolt or screw. It is also advantageous if the embossing roller 2a and/or the counter-pressure roller 2b has a plurality of holes into which the fixing device 6 can be introduced. In this way it can be achieved that the die 4a and/or male die 4b can be fixed at locations predefined by the large number of holes. However, the fixation can also be done using a clamp. It is also possible for the die 4a and/or the male die 4b to be fixed by clamping or tensioning on the embossing roller 2a and/or the counter-pressure roller 2b.

It is also possible for the embossing roller 2a and/or the counter-pressure roller 2b to be magnetic or to be designed magnetically. It is also possible for the embossing roller 2a and/or the counter-pressure roller 2b to be a magnetic cylinder. Here, the die 4a and/or the male die 4b can preferably be fixed magnetically on the embossing roller 2a and/or counter-pressure roller 2b.

As in Fig. 6c shown, it is also possible that the die 4a is introduced as an elevation and/or depression in the surface of an embossing cylinder 12a, which is detachably arranged on the embossing roller 2a and/or that the male die 4b as an elevation and/or depression in the surface of a counter-pressure cylinder 12b is introduced, which is detachably arranged on the counter-pressure roller 2b.

Here too, it is possible for the embossing cylinder 12a and/or the counter-pressure cylinder 12b to be clamped and/or tensioned onto the embossing roller 2a and/or the counter-pressure roller 2b. The embossing cylinder 12a and/or the counter-pressure cylinder 12b is preferably magnetically applied to the embossing roller 2a and/or the counter-pressure roller 2b, in particular the embossing roller 2a and/or the counter-pressure roller 2b being magnetic. Alternatively The embossing cylinder 12a and/or the impression cylinder 12b can also be designed to be magnetic.

As in Fig. 6d shown, it is advantageous if the die 4a and/or the male die 4b are arranged on the embossing roller 2a and/or the counter-pressure roller 2b with the aid of a positioning aid 7. As in Fig. 6d shown, in particular several matrices 4a and / or male molds 4b can be arranged on the embossing roller 2a and / or the counter-pressure roller 2b with the help of the positioning aid 7 or applied to the embossing roller 2a and / or the counter-pressure roller.

The positioning aid 7 has recesses in the form of window areas in the areas in which the matrices 4a and/or patrixes 4b are arranged on the embossing roller 2a and/or the counter-pressure roller, into which the matrices 4a and/or patrixes 4b can be inserted . The device thus advantageously has a positioning aid 7 with window areas, the positioning aid 7 being arranged on the embossing roller 2a and/or the counter-pressure roller 2b and the matrices 4a and/or male molds 4b being arranged in the window areas of the positioning aid.

The positioning aid 7 is preferably tensioned on the embossing roller 2a and/or the counter-pressure roller 2b, in particular the positioning aid 7 is tensioned on the embossing roller 2a and/or the counter-pressure roller 2b in such a way that the positioning aid 7 has a curve which essentially corresponds to the diameter of the embossing roller 2a and/or the diameter of the counter-pressure roller 2b corresponds.

Rounding here is preferably understood to mean a radius of curvature, the radius of curvature corresponding in particular to the radius of a circle of curvature, which at a certain point on a curve is the circle that best approximates the curve at this point. For example, the diameter of the embossing roller 2a and/or the counter-pressure roller 2b represents a circle of curvature, the radius of which is then essentially the radius of curvature of the positioning aid 7.

Preferably spans, as in Fig. 6d shown, the positioning aid 7 completes the embossing roller 2a and/or the counter-pressure roller 2b. However, it is also possible for the positioning aid 7 to only partially span the embossing roller 2a and/or the counter-pressure roller 2b. For example, it is possible for the positioning aid 7 to span half of the embossing roller 2a and/or the counter-pressure roller 2b, so that the positioning aid 7 in Fig. 6d would form a semicircle. Other partial loops such as a three-quarter circle or a quarter circle are also conceivable.

It is also possible for the embossing roller 2a and/or the counter-pressure roller 2b to have several positioning aids 7, which completely or only partially span the embossing roller 2a and/or the counter-pressure roller 2b. For example, two positioning aids 7 can each span half of the embossing roller 2a and/or the counter-pressure roller 2b. However, any other subdivisions and/or distributions of several positioning aids 7 on the embossing roller 2a and/or the counter-pressure roller 2b can also be carried out.

Preferably, the positioning aid 7 and/or the embossing roller 2a and/or the counter-pressure roller 2b has a clamping device, by means of which in particular the positioning aid 7 can be tensioned on the embossing roller 2a and/or the counter-pressure roller 2b. The clamping device of the positioning aid expediently has holes by means of which the positioning aid can be fastened to the embossing roller and/or the counter-pressure roller, for example using pins or screws.

Here too, it is particularly useful for arranging the positioning aid 7 on the embossing roller 2a and/or the counter-pressure roller 2b if the embossing roller 2a and/or the counter-pressure roller 2b is magnetic or is designed to be magnetic, in particular if the embossing roller 2a and / or the counter-pressure roller 2b is a magnetic cylinder. As a result, the positioning aid 7 can be arranged magnetically on the embossing roller 2a and/or the counter-pressure roller 2b. It is also possible for the positioning aid 7 itself to be magnetic.

Fig. 7a to Fig. 7e show schematically positioning aids 7 in a top view.

As in Fig. 7a shown, the positioning aid preferably has a plurality of window areas 7a, the several window areas 7a being arranged according to a grid.

The term “area” is understood to mean, in particular, a defined area which, when viewed, is taken up perpendicular to a plane spanned by the positioning aid 7. For example, the positioning aid 7, in particular in the flat state, has one or more window areas 7a, each of the window areas 7a occupying a defined area when viewed perpendicular to a plane spanned by the positioning aid 7.

Furthermore, it is possible for the positioning aid 7 to have a width 7c of at least 250 mm, preferably of at least 500 mm, more preferably of at least 750 mm, and a length 7d of at least 500 mm, preferably at least 750 mm, more preferably of at least 1000 mm , and/or that the at least one window region 7a has a width 7ab of at least 5 mm, preferably at least 10 mm, more preferably at least 20 mm, and a length 7al of at least 10 mm, preferably at least 20 mm, more preferably at least 100 mm.

In the Fig. 7a Positioning aid 7 shown has, for example, a width 7c of 752 mm and a length 7d of 1020 mm. Furthermore, the window areas 7a in FIG Fig. 7a Positioning aid 7 shown has a width 7ab of 40 mm and a length 7al of 150 mm. Next are the window areas 7a in FIG Fig. 7a shown positioning aid 7 rotated relative to the outer edges of the positioning aid 7, in particular rotated by less than 2 °, preferably by less than 1 °. However, it is also possible for the window areas 7a not to be rotated relative to the outer edges of the positioning aid 7.

The positioning aid preferably comprises 7 metals, in particular copper, nickel, chromium, iron, zinc, tin, lead or alloys of such metals. At the in Fig. 7a The positioning aid 7 shown is a positioning aid 7 made of steel.

It is also possible for the positioning aid 7 to be magnetic or to be designed magnetically.

The in Fig. 7a Positioning aid 7 shown has a clamping device 7b. The clamping device 7b of the positioning aid 7a expediently has holes by means of which the positioning aid 7a can be fastened or tensioned on the embossing roller 2a and/or the counter-pressure roller 2b, for example by means of pins or screws.

In the Fig. 7b Positioning aid 7 shown corresponds to that in Fig. 7a Positioning aid 7 shown with the difference that the window areas 7a in Fig. 7b Positioning aid shown are square. Furthermore, the window areas 7a are not rotated relative to the outer edges of the positioning aid 7. With regard to the further design of the positioning aid 7, reference is made to the above statements.

In the Fig. 7c Positioning aid 7 shown corresponds to that in Fig. 7a shown positioning aid 7 with the difference that matrices 4a and/or male molds 4b are arranged in the window areas 7a, with matrices 4a being used in particular when the positioning aid 7 is arranged on the embossing roller 2a and male molds 4b being used in particular when the Positioning aid 7 is arranged on the counter-pressure roller 2b.

As in Fig. 7c shown, it is expedient if the outline of the respective window area 7a of the positioning aid 7 essentially corresponds to the outline of the die 4a and/or male die 4b arranged therein.

The term outline here is understood to mean in particular the contours or outer contours of the window area 7a or the male part 4a and/or female part 4b, which, when viewed perpendicular to a plane spanned by the positioning aid 7 or the die 4a and/or male die 4b, are taken up.

Regarding the in Fig. 7c 13 shown, reference is made to the statements below.

In the Fig. 7d Positioning aid 7 shown corresponds to that in Fig. 7b shown positioning aid 7 with the difference that in the window areas 7a matrices 4a and / or male molds 4b are arranged, the elevations and / or depressions, which correspond in particular to the relief shapes to be embossed in positive and / or negative form, in Fig. 7d are shown schematically as text. However, it is also possible to use other fonts as relief shapes to be embossed. Patterns or motifs can also be used as relief shapes to be embossed or combinations of patterns, motifs or fonts.

In the Fig. 7e Positioning aid 7 shown includes the window areas 7a, in which differently designed matrices 4a and / or male molds 4b are arranged. As in Fig. 7e shown, the relief shapes to be embossed can be selected from a variety of shapes. It is therefore possible for the elevations and/or depressions, which correspond in particular to the relief shapes to be embossed in positive and/or negative form, to represent a pattern, motif or writing. For example, a pattern may be a graphically designed outline, a figurative representation, an image, a symbol, a logo, a portrait, and the like. A font can be, for example, an alphanumeric character, a text and the like. Combinations of these patterns, motifs and fonts can also be used as relief shapes to be embossed.

Fig. 7f to Fig. 7i show schematically a sectional view of the enlarged section of the Fig. 7c .

As in Fig. 7f shown, the positioning aid 7 preferably has a thickness 7e of at least 0.25 mm, preferably of at least 0.5 mm, more preferably of at least 0.75 mm. In the Fig. 7f Positioning aid 7 shown has a thickness 7e of 0.25 mm.

The positioning aid 7 also points out, as in Fig. 7f shown, in an area 16 around the window area 7a, preferably an increased thickness 7f compared to the remaining thickness of the positioning aid 7. In particular, the positioning aid 7 in the area 16 around the window area 7a has an increased thickness of at least 0.1 mm, preferably at least 0.2 mm, compared to the remaining thickness of the positioning aid 7. In the Fig. 7f The positioning aid 7 shown has a thickness 7f of 0.5 mm in the area 16, for example.

It is also possible for the area 16 around the window area 7a to have a width of at least 0.2 mm, preferably at least 0.5 mm, more preferably at least 1.5 mm. The area 16 points around the window area 7a Fig. 7f a width of 1.5 mm.

Next is in the window area 7a, as in Fig. 7f shown, a die 4a is arranged. The die 4a here includes the layers 17a, 17b and 17c. With regard to the layers 17a, 17b and 17c and the design of the die 4a, reference is made to the statements below.

Furthermore, the window area 7a of the positioning aid 7 is expediently larger than the die 4a and/or male die 4b arranged in the window area 7a. The distance from each edge of the window area 7a to the die 4a and/or male die 4b is preferably at least 0.1 mm, preferably 0.2 mm, even more preferably 0.3 mm.

Fig. 7g corresponds Fig. 7f with the difference that a male mold 4b is arranged in the window area 7a instead of a female mold 4a. The male mold 4b here includes the layers 17a, 17b and 17c. With regard to the layers 17a, 17b and 17c and the design of the male mold 4b, reference is made to the statements below.

Fig. 7h corresponds Fig. 7f with the difference that the male part 4b can be adjusted in the window area 7a of the positioning aid 7 by means of an adjusting aid 9a.

The adjusting aid 9a expediently consists, for example, of one or more sheets, in particular of one or more gauge blocks and/or one or more spigots, which are inserted in particular into the space between the male part 4b and the edge of the window area 7a. Because the window area 7a is preferably larger than the male mold 4b, the gap is created into which the adjusting aid 9a is preferably inserted. In particular, the gap corresponds to the distance from each edge of the window area 7a of the male mold 4b. It is also possible that the matrix 4a Fig. 7f in the window area 7a of the positioning aid 7 can be adjusted by means of an adjusting aid 9a.

Preferably, the adjustment aid 9a is arranged such that the at least one die 4a and/or male die 4b is arranged to be movable, in particular flexible, at least in one direction. The adjustment aid 9a is advantageously arranged in such a way that the die 4a and/or male die 4b is arranged to be movable, in particular flexible, in a direction parallel to the feed direction of the substrate 3. However, it is also possible for the adjustment aid 9a to be arranged in such a way that the at least one die 4a and/or male die 4b is arranged to be movable, in particular flexible, in a direction perpendicular to the feed direction of the substrate 3. Preferably, the at least one die 4a and/or male die 4b is arranged movably, in particular flexibly, in an intermediate space which corresponds to the distance from each edge of the at least one window area 7a to the at least one female die 4a and/or male die 4b.

It is therefore possible for the adjustment aid 9a to be arranged on one or two, in particular two opposite sides of the window area 7a. For example, the adjustment aid 9a is arranged on those sides of the window area 7a which run parallel to the longitudinal axis or to the transverse axis of the positioning aid 7. The adjustment aid 9a is preferably arranged on the sides of the window area 7a that are parallel to the direction of rotation or running direction of the embossing roller 2a and/or counter-pressure roller 2b. However, it is also possible for the adjustment aid 9a to be arranged on the sides of the window area 7a that are perpendicular to the direction of rotation or running direction of the embossing roller 2a and/or counter-pressure roller 2b.

By means of the adjustment aid, the position of the die 4a and/or the male die within the respective window area 7a can preferably be precisely determined or the degrees of freedom of the female die 4a and/or the male die 4b can be determined for the self-adjustment described above.

Fig. 7i equals to Fig. 7h with the difference that the male part 4b is fastened in the window area 7a of the positioning aid 7 by means of a fastening device 9b. The fastening device 9a is preferably a clamp. It is also possible that the matrix 4a Fig. 7f in the window area 7a of the positioning aid 7 is fastened by means of a fastening device 9b.

Below the positioning aid 7 and the die 4a and/or male die 4b, the embossing roller 2a and/or the counter-pressure roller 2b is arranged, which is in the Fig. 7f to Fig. 7i is not shown. In particular, the die 4a and/or male die 4b is therefore applied in the window area 7a of the positioning aid 7 to the surface of the embossing roller 2a and/or the counter-pressure roller 2b. Preferably, the die 4a and the embossing roller 2a and/or the male die 4b and the counter-pressure roller 2b each represent two different components of the device, so that in particular a quick and easy setup and/or rearrangement of the device can be achieved, since only the ones in comparison small die 4a and/or male die 4b must be exchanged for the embossing roller 2a and/or the counter-pressure roller 2b.

Advantageously, the die 4a is magnetically attached to the embossing roller 2a and/or the male die 4b is magnetically attached to the counter-pressure roller 2b, so that in particular the simple and quick setup and/or realignment can be further improved.

The die 4a is preferably arranged on the embossing roller 2a and the male die 4b on the counter-pressure roller 2b in such a way that the holding force with which the die 4a is arranged on the embossing roller 2a is higher, preferably by a factor of 1.5 to 5 higher, more preferably by a factor of 2.5 to 3.5 higher is, as the holding force with which the male mold 4a is arranged on the counter-pressure roller 2b.

This ensures that the male part 4a is arranged less firmly in comparison to the female part 4b. The male mold 4b is therefore arranged in particular “looser” than the female mold 4a. It has been shown here that by means of such a relatively lower holding force of the male mold 4b on the counter-pressure roller 2b compared to the female mold 4a on the embossing roller 2a, qualitatively comparable embossing can still be achieved, in particular with the stroke embossing process, since the male mold 4b in particular has degrees of freedom due to the lower holding force in such a way that it can assume the ideal position in relation to the matrices 4a forming the counterpart. As described above, the degrees of freedom can preferably be restricted and/or released using the adjustment aid 9a.

Fig. 8a to Fig. 8c show schematic sectional views of matrices 4a and/or patrixes 4b.

In the Fig. 8a shown matrix 4a and that in Fig. 9b Male mold 9b shown are advantageously designed in multiple layers. The die 4a and the male die 4b include in particular the layers 17a and 17b as well as the adhesive layer 17c.

The layer 17a has the elevations 18a and/or depressions 18b, which correspond in particular to the relief shapes to be embossed in positive and/or negative form. It is also possible that the elevations and/or depressions represent a pattern, motif or writing. A pattern can, for example, be a graphically designed outline, a figurative representation Be an image, a symbol, a logo, a portrait and the like. A font can be, for example, an alphanumeric character, a text and the like. With regard to the various relief shapes to be embossed or embossable, please refer to the statements below.

It is also advantageous if the elevations 18a have a height of a maximum of 5.0 mm, preferably a maximum of 3.0 mm, more preferably a maximum of 1.0 mm, even more preferably a maximum of 0.5 mm and/or if the depressions of the male die have a depth of a maximum of 5.0 mm, preferably a maximum of 3.0 mm, more preferably a maximum of 1.0 mm, even more preferably a maximum of 0.5 mm.

The layer 17a is preferably a metal layer made of brass, bronze, copper, nickel, zinc, tin, lead, iron or steel. At the in Fig. 8a and Fig. 8b Metal layer 17a shown is a layer made of brass.

The layer 17b is preferably a metal layer made of ferromagnetic materials, in particular comprising iron, ferrites, cobalt or nickel. It is also possible that layer 17b is a steel layer. At the in Fig. 8a and Fig. 8b Layer 17b shown is a layer made of steel.

Layer 17a is preferably a metal layer made of a non-magnetic or weakly magnetic material and layer 17b is a metal layer made of a magnetic, in particular strongly magnetic, material. So it is possible that layer 17a is one Brass layer and layer 17b is a steel layer. Layer 17b in particular is advantageously magnetic.

The thickness of the layer 17a is preferably between 0.5 mm and 2.5 mm, preferably between 0.75 mm and 2 mm, more preferably between 1 mm and 1.75 mm.

Advantageously, the thickness of the layer 17b is between 0.05 mm and 1.5 mm, preferably between 0.1 mm and 1 mm, more preferably between 0.15 mm and 0.5 mm.

At the in Fig. 8a In the matrix 4a shown, the thickness of the layer 17a is, for example, 0.5 mm and the thickness of the layer 17b is, for example, 0.25 mm. At the in Fig. 8b In the male mold shown, the thickness of the layer 17a is, for example, 0.8 mm and the thickness of the layer 17b is, for example, 0.15 mm.

Layers 17a and 17b are as in Fig. 8a and Fig. 8b shown, preferably firmly connected by means of an adhesive layer 17c. The adhesive layer 17c is advantageously a hot glue or cold glue layer. It is therefore possible that the adhesive layer 17c is a two-component adhesive (2K adhesive), in particular comprising epoxy resins. The adhesive layer 17c is expediently a 2K epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.

The adhesive layer 17c is preferably a double-sided adhesive tape, which is coated in particular on both sides with a pressure-sensitive adhesive ( PSA ). Such Double-sided adhesive tapes can be obtained, for example, from tesa, Norderstedt, Germany.

Furthermore, the adhesive layer 17c preferably has a layer thickness between 0.01 mm and 0.75 mm, preferably between 0.05 mm and 0.5 mm, more preferably between 0.05 mm and 0.25 mm. At the in Fig. 8a In the die 4a shown, the thickness of the adhesive layer 17c is, for example, 0.05 mm and in the case in Fig. 8b In the male mold 4b shown, the thickness of the adhesive layer 17c is also 0.05 mm, for example.

The die 4a and the male die 4b preferably have the same materials and/or the same layer structure, in particular the female die 4a and the male die 4b, in particular the elevations 18a and/or depressions 18b, which in particular correspond to the relief shapes to be embossed in positive and / or correspond to negative form, having layers of the die 4a and the male die 4b, made of metal, in particular made of brass. So it is also possible that the layer 17a of the female mold 4a and the male mold 4b are made of the same metal, preferably brass.

It is expedient if the layer 17b, in particular the steel layer, of the die 4a is thicker, preferably by a factor of 1.2 to 3.5, more preferably by a factor of 1.2 to 2.5, than the layer 17b , in particular steel layer, the male part 4b. It is also possible for the layer 17b, in particular the steel layer, of the die 4a to be at least 0.05 mm, preferably at least 0.1 mm, more preferably 0.15 mm, thicker than the layer 17b, in particular the steel layer, the patrix 4b. Through such different thicknesses of the layer 17b of the die 4a and the male die 4b, it can be achieved that the holding force with which the die 4a, in particular magnetically, is maintained the embossing roller 2a is arranged is higher than the holding force with which the male mold 4b is arranged, in particular magnetically, on the counter-pressure roller 2b.

Furthermore, it is also possible for the die 4a and/or male die 4b, in particular the layer 17a of the female die 4a and/or the male die 4b, to comprise plastics, in particular photopolymers. So it is also possible that the die 4a and/or the male die 4b, in particular the layer of the die 4a and/or which has the elevations 18a and/or depressions 18b, which in particular correspond to the relief shapes to be embossed in positive and/or negative form, or the male part 4b is made of a plastic, in particular of a photopolymer.

It is also possible for the die 4a and male die 4b, in particular the layer 17a of the female die 4a and the male die 4b, to have different materials. It is thus possible for the die 4a, in particular the layer 17a of the die 4a, to be made of metal, in particular brass, and the male die 4b, in particular the layer 17a of the male die 4b, to be made of plastic, in particular a photopolymer, rubber or rubber is. It is also possible that the layers of the die 4a and the male die 4b having the elevations 18a and/or depressions 18b, which in particular correspond to the relief shapes to be embossed in positive and/or negative form, are formed from different materials, in particular that the The layer of the die having elevations 18a and/or depressions 18b is made of metal, in particular brass, and the layer of the male die 4b having the elevations 18a and/or depressions 18b is made of plastic, in particular a photopolymer.

Such a die 4b is in Fig. 8c shown. In the Fig. 8b Die shown includes layers 17a, 17b and 17c. The layer 17a is a layer made of plastic, in particular a photopolymer. With regard to the design of the adhesive layer 17c and the layer 17b, reference is made to the above statements.

However, it is also possible for the die 4a and/or male die 4b to be designed in one layer. Preferably, the single-layer die 4a and/or male die 4b is magnetic. The single-layer die 4a and/or male die 4b is advantageously formed from a magnetic, in particular strongly magnetic, material. The single-layer die 4a and/or male die 4b preferably comprises ferromagnetic materials, in particular comprising iron, ferrites, cobalt and/or nickel.

It is therefore possible for the single-layer die 4a and/or male die 4b to be made of steel. The die 4a and/or male die 4b can therefore in particular be a single-layer steel die and/or male die.

Even with a single-layer die 4a and/or male die 4b, it is advantageous if the die 4a is thicker, preferably thicker by a factor between 1.2 and 3.5, more preferably by a factor between 1.2 and 2.5 is as the patrix 4b. Here too, it is possible for the die 4a to be at least 0.05 mm, preferably at least 0.1 mm, more preferably at least 0.15 mm thicker than the male die 4b.

Preferably, the die 4a has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm, and/or the male die 4b has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm, on.

Fig. 9a and Fig.9b show schematic sectional views of matrices 4a and/or patrixes 4b.

Fig. 9a shows a die 4a, the die 4a being deformed in such a way that the die 4a has a curve which essentially corresponds to the diameter of an embossing roller 2a on which the die 4a is arranged. In the Fig. 9a Die 4a shown preferably has the multi-layer structure of the one shown in Fig. 8a shown matrix 4a, which, however, is not shown graphically here for simplicity.

Fig. 9b shows one of the matrix 4a Fig. 9a corresponding male mold 4b, wherein the male mold 4b is deformed in such a way that the male mold 4b has a rounding which essentially corresponds to the diameter of the counter-pressure roller 2b on which the male mold 4b is arranged.

The curves are preferably produced by bending, in particular by free bending, die bending, swivel bending or roll rounding.

Fig. 10a to Fig. 10g, Fig. 11a to Fig. 11e as well as Fig. 12a to Fig. 12d show schematic sectional views of relief shapes.

The ones in the Fig. 10a to Fig. 10g, Fig. 11a to Fig. 11e as well as Fig. 12a to Fig. 12d Relief shapes shown can be produced using the rotary blind embossing method and the rotary blind embossing device. As stated above, the die 4a and the male die 4b have, depending on the desired relief shape to be embossed, elevations 18a and/or depressions 18b, which correspond in particular to the relief shapes to be embossed in positive and/or negative form.

So are in the Fig. 10a to Fig. 10g Single-stage relief shapes are shown in cross section, which are embossed, ie the relief shapes are embossed into the substrate 3 in particular according to embossing. Fig. 10a shows a raised round relief shape, Fig. 10b a raised round relief shape with outline, Fig. 10c a raised, flat relief shape with an angular transition, Fig. 10d a raised flat-edged relief shape with outline, Fig. 10e a raised relief shape with a rounded transition, Fig. 10f a raised prismatic relief shape with a pointed apex line and Fig. 10g a raised prismatic relief shape with a flat apex line.

Next are in the Fig. 11a to Fig. 11e Single-stage relief shapes are shown in cross section, which are recessed, ie the relief shapes are embossed into the substrate 3 in particular according to a deep embossing. Fig. 11a shows a recessed round relief shape, Fig. 11b a recessed round relief shape with an angular transition, Fig. 11c a deepened flat relief shape with a rounded transition, Fig. 11d deepened prismatic relief shape with a pointed apex line and Fig. 11e a recessed prismatic relief shape with a flat apex line.

Furthermore, in the Fig. 12a to Fig. 12d multi-stage relief shapes shown in cross section, which are raised or combined raised and deepened. are carried out, ie the relief shapes are embossed into the substrate 3 in particular according to an embossing or according to an embossing and a deep embossing. Fig. 12a shows a raised multi-level relief shape, Fig. 11b a raised sculpted relief form, Fig. 11c a multi-level combined raised and recessed relief shape and Fig. 11d also a multi-stage combined raised and recessed relief form. It is also possible, for example, to create multi-stage, recessed relief shapes. Further Further combinations of multi-level, combined raised and recessed relief shapes are conceivable.

Sculpted is preferably understood to mean a relief form that represents or forms a sculpture, a motif, a pattern or a writing.

By means of the method for rotary blind embossing and by means of the device for rotary blind embossing, the in the Fig. 10a to Fig. 10g, Fig. 11a to Fig. 11e as well as Fig. 12a to Fig. 12d Relief shapes shown are produced in high quality and quantity, with high quality being understood in particular to mean an embossing result comparable to the stroke embossing process.

According to the in the Fig. 10a to Fig. 10g, Fig. 11a to Fig. 11e as well as Fig. 12a to Fig. 12d In the relief shapes shown, the die 4a and the male die 4b have, depending on the desired relief shape to be embossed, the corresponding elevations 18a and/or depressions 18b, which correspond in particular to the relief shapes to be embossed in positive and/or negative form.

It is thus possible for the elevations 18a and/or depressions 18b of the die 4a and/or the male die 4b to have a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, prismatic-flat, pointed or mixtures of these shapes.

It is also possible for the elevation 18a and/or recess 19b of the female mold 4a and/or male mold 4b to be designed in several stages, in particular sculptured, in terms of its height and/or depth.

Fig. 13a and Fig. 13b show methods for producing a die 4a and/or male die 4b.

As in Fig. 13a shown, it is possible for the elevation 18a and/or depression 18b to be engraved and/or milled using a computer-controlled engraving machine and/or using a computer-controlled milling machine 19. For this purpose, the relief shape is preferably first defined and designed with the help of a computer 20. The design can be done manually or using predetermined relief shapes. A data set containing the relief shape is then preferably generated based on this design and the data set is transmitted to the computer-controlled engraving machine and/or milling machine 19. The elevations and/or depressions are then engraved and/or milled into the die 4a and/or male die 4b, particularly depending on the data set.

Alternatively, it is also possible for the elevations 18a and/or depressions 18b to be produced photolithographically.

Next it is as in Fig. 13b shown, it is also possible that the elevations 18a and / or depressions 18b are generated by means of a laser 20, in particular by laser ablation.

During laser ablation, the material of the matrix 4a and/or the male mold 4b is preferably completely removed and/or ablated.

The laser 20 is preferably a gas laser, in particular a CO ₂ laser, and/or a solid-state laser, in particular an Nd:YAG laser. Advantageously, the laser power is at least 20 W, preferably at least 30 W, more preferably at least 100 W. It is also advantageous if the wavelength of the laser 20 is between 9.35 μm and 10.25 μm.

The laser beam 22 is preferably directed along the die 4a and/or the male die by means of deflectable mirrors, in particular by means of a laser scanning module, so that the desired elevations 18a and/or depressions 18b are generated. The beam diameter of the laser 21 in the focal point is in particular between 0.01 mm and 1 mm, preferably between 0.01 mm and 0.2 mm.

Furthermore, it is particularly advantageous when producing the die 4a and/or male die 4b if the desired relief shape to be embossed is reduced by a predetermined reduction factor, in particular before the elevations 18a and/or depression 18b are created in the surface of the female die 4a and/or male die 4a become. Preferably, the reduction factor is in particular between 0.95 and 1, preferably between 0.9750 and 0.9999, more preferably between 0.98000 and 0.99999, even more preferably between 0.99000 and 0.9999. Advantageously, the predetermined shortening factor is determined depending on the diameter of the embossing roller and/or the counter-pressure roller. It is also possible for the predetermined shortening factor to be determined depending on the embossing length and/or a print length, in particular on the substrate. At the in the Fig. 13a and Fig. 13b In the manufacturing method shown, the predetermined reduction factor for the die 4a is 0.99440 and for the male die 4b is 0.99800 with a diameter of the embossing roller 2a of 300 mm and a diameter of the counter-pressure roller of 600 mm.

Preferably, areas of the at least one die 4a and/or male die 4b, which are not intended to emboss the substrate 3, are removed or exposed. In particular, the male part 4b is removed or exposed in such a way that the so-called base of the female part 2a is not embossed into the substrate 3. Here, the male mold 4b is preferably removed or exposed by at least 0.2 mm, more preferably by at least 0.3 mm, even more preferably by at least 0.4 mm.

Preferably, the elevations 18a and/or depressions 18b are introduced in the flat states of the die 4a and/or the male die 4b and the female die 4a and/or the male die 4b are then deformed in such a way that the female die 4a and/or the male die 4b has a rounding, which essentially corresponds to the diameter of the embossing roller 2a and/or the diameter of the counter-pressure roller 2b. It is also possible for the layer 17b to be applied in a further step using the adhesive layer 17c, with the layer 17b preferably already having a corresponding curve.

Reference symbol list

1

contraption

1a, 1b, 1c, 1d

Workstations

2a

embossing roller

2 B

counter-pressure roller

3

Substrate

4a

die

4b

Patrician

5a

Increasing the substrate

5b

Deepening of the substrate

6

Fixation device

7

Positioning aid

7a

Window area

7ab

Width of the window area

7al

Length of the window area

7b

Clamping device

7c

Width of the positioning aid

7d

Length of the positioning aid

7e

Thickness of the positioning aid

7f

increased thickness of the positioning aid

8th

Compensating layer

9a

Adjustment aid

9b

Fastening device

10a, 10b, 10c, 10d, 10e

Procedural steps

11

Transport facility

12a

Embossing cylinder

12b

Impression cylinder

13

Detail

14

motive

16

Area

17a

first metal layer

17b

second metal layer

17c

adhesive layer

18a

Increasing the matrix/patrix

18b

Deepening of the matrix/patrix

19

Engraving machine, milling machine

20

computer

21

Laser

22

laser beam

Claims (15)

1. Method for rotary blind embossing of a substrate (3) in a work station (1a), comprising an embossing roller (2a) and a counterpressure roller (2b), wherein the method comprises the following steps:

   a) preparation of the substrate (3);

   b) blind embossing of the substrate (3) by means of at least one die (4a) arranged on the embossing roller (2a) and at least one punch (2b) arranged on the counterpressure roller (2b);

   and wherein the method comprises the following steps;

   - preparation of a positioning aid (7) comprising at least one window region (7a);

   - arrangement of the positioning aid (7) on the embossing roller (2a) and/or the counterpressure roller (2b);

   - arrangement of the at least one die (4a) and/or punch (4b) in the at least one window region (7a) of the positioning aid (7),

   characterised in that,
   during the arrangement of the at least one die (4a) and/or punch (4b) in the at least one window region (7a) of the positioning aid (7), the at least one die (4a) and/or punch (4b) are adjusted by the means of an adjustment aid (9a) in the at least one window region (7a), and the adjustment aid (9a) is arranged in such a way that the at least one die (4a) and/or punch (4b) is moveable at least in one direction.
2. Method according to claim 1,
   characterised in that,
   the method further comprises the following steps, which in particular are carried out before step a) and/or step b):

   - fixing the at least one die (4a) on the embossing roller (2a) and/or the at least one punch (4b) on the counterpressure roller (2b) by means of a fixing device (6).
3. Method according to one of the preceding claims,
   characterised in that,

   during the arrangement of the at least one die (4a) and/or punch (4b) in the at least one window region (7a) of the positioning aid (7), the at least one die (4a) and/or punch (4b) is fixed by means of a fastening device (9b) in the window region (7a), and/or

   the at least one die (4a) and/or punch (4b) is shaped before the arrangement in the at least one window region (7a) of the positioning aid (7) in such a way that the at least one die (4a) and/or punch (4b) has a curve which substantially corresponds to the diameter of the embossing roller (2a) and/or the diameter of the counterpressure roller (2b), and/or the positioning aid (7) is stretched onto the embossing roller (2a) and/or the counterpressure roller (2b), in particular the positioning aid (7) is stretched onto the embossing roller (2a) and/or the counterpressure roller (2b) in such a way that the positioning aid (7) has a curve which substantially corresponds to the diameter of the embossing roller (2a) and/or the diameter of the counterpressure roller (2b).
4. Method according to one of the preceding claims,
   characterised in that,
   the at least one die (4a) is fixed on the embossing roller (2a) magnetically and/or the at least one punch (4b) is fixed on the counterpressure roller (2b) magnetically.
5. Method according to one of the preceding claims,
   characterised in that,
   the at least one die (4a) is arranged on the embossing roller (2a) and the at least one punch (4b) is arranged on the counterpressure roller (4b) in such a way that the holding force with which the at least one die (4a) is arranged on the embossing roller (2a) is higher, preferably higher by a factor of 1.5 to 5, more preferably by a factor of 2.5 to 3.5 times higher than the holding force with which the at least one punch (4b) is arranged on the counterpressure roller (2b).
6. Method according to one of the preceding claims,
   characterised in that,
   the embossing roller (2a) and the counterpressure roller (2b) are driven with corresponding rotational speeds inversely to each other.
7. Method according to claim 6,
   characterised in that,
   the at least one die (4a) and the at least one punch (4b) engage with each other upon each revolution in such a way that the substrate (3) located between the at least one die (4a) and the at least one punch (4b), in particular in an overlapping region of the at least one die (4a) and the at least one punch (4b), is marked, in particular that the substrate (3) is marked in such a way that the deviations between the markings of each revolution is less than 2%, preferably less than 1%, further preferably less than 0.05%.
8. Method according to one of the preceding claims,
   characterised in that,
   the method further comprises at least one of the following steps, which are carried out in one or more further work stations (1b, 1c, 1d):

   - printing the substrate (3);

   - severing the substrate (3);

   - creasing and/or folding the substrate (3).
9. Method according to one of the preceding claims,
   characterised in that,
   in step a), the substrate (3) is prepared as sheet material, in particular the deviation between the markings on the sheets of the substrate (3) prepared as sheet material are less than 2%, preferably less than 1%, further preferably less than 0.05%, and/or by means of the method, more than 8,000 sheets per hour, preferably more than 10,000 sheets per hour, further preferably more than 12,000 sheets per hour, more further preferably more than 14,000 sheets per hour of the substrate (3) formed as a sheet material, are prepared.
10. Device (1) for rotary blind embossing of a substrate (3), wherein the device comprises a work station (1a) which comprises an embossing roller (2a) and a counterpressure roller (2b), and wherein at least one die (4a) is arranged on the embossing roller (2a) and at least one punch (4b) is arranged on the counterpressure roller (2b), and wherein the device (1) has a positioning aid (7) having at least one window region (7a), wherein the positioning aid (7) is arranged on the embossing roller (2a) and/or the counterpressure roller (2b) and the at least one die (4a) and/or punch (4b) is arranged in the at least one window region (7a) of the positioning aid (7),
    characterised in that,
    the positioning aid (7) further comprises an adjustment aid (9a), the at least one die (4a) and/or punch (4b) is adjustable in the at least one window region (7a) of the positioning aid (7a) by means of the adjustment aid (9a), and the adjustment aid (9a) is arranged in such a way that the at least one die and/or punch are moveable at least in one direction.
11. Device (1) according to claim 10,
    characterised in that
    the at least one die (4a) is introduced as at least one elevation (18a) and/or depression (18b) into the surface of an embossing cylinder (12a) which is arranged on the embossing roller (2a), and/or the at least one punch (4b) is introduced as at least one elevation (18a) and/or depression (18b) into the surface of a counterpressure cylinder (12b) which is arranged on the counterpressure roller (2b).
12. Device (1) according to one of claims 10 or 11,
    characterised in that,

    the positioning aid (7) comprises metals, in particular copper, nickel, chromium, iron, zinc, lead or alloys of such metals, and/or

    the positioning aid (7) is formed magnetically.
13. Device (1) according to one of claims 10 to 12,
    characterised in that,

    the positioning aid (7) has an elevated thickness (7f) in a region (16) around the at least one window region (7a), in comparison to the remaining thickness (7e) of the positioning aid (7), in particular the positioning aid (7) has an elevated thickness (7f) in a region (16) around the at least one window region (7a) of at least 0.1 mm, preferably at least 0.2 mm, further preferably at least 0.3 mm, in comparison to the remaining thickness (7e) of the positioning aid (7), and/or

    the positioning aid (7) has a width (7c) of at least 250 mm, preferably of at least 500 mm, further preferably of at least 750 mm, and a length (7d) of at least 500 mm, preferably of at least 750 mm, further preferably of at least 1000 mm, and/or the at least one window region (7a) has a width (7ab) of at least 5 mm, preferably at least 10 mm, more preferably of at least 20 mm, and a length (7al) of at least 10 mm, preferably at least 20 mm, more preferably of at least 100 mm.
14. Device (1) according to one of claims 10 to 13,
    characterised in that,
    the at least one die (4a) is arranged on the embossing roller (2a) and the at least one punch (4b) is arranged on the counterpressure roller (2b) in such a way that the holding force with which the at least one die (4a) is arranged on the embossing roller (2a) is higher, preferably by a factor of 1.5 to 5 higher, more preferably by a factor of 2.5 to 3.5 times higher, than the holding force with which the at least one punch (4b) is arranged on the counterpressure roller (2b).
15. Device (1) according to one of claims 10 to 14,
    characterised in that,

    the ratio of the diameter of the embossing roller (2a) to the diameter of the counterpressure roller (2b) is 1 to 2, preferably 1 to 1, and/or

    the apparatus (1) further comprises one or more additional work stations (1b, 1c, 1d) for printing the substrate (3) and/or for severing the substrate (3) and/or for creasing and/or folding the substrate (3).

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