US3573910A - Method of making reproduction art work layouts and printing plates for composite unit record cards - Google Patents

Method of making reproduction art work layouts and printing plates for composite unit record cards Download PDF

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US3573910A
US3573910A US687339A US3573910DA US3573910A US 3573910 A US3573910 A US 3573910A US 687339 A US687339 A US 687339A US 3573910D A US3573910D A US 3573910DA US 3573910 A US3573910 A US 3573910A
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cards
unit record
sheet
composite
punched
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Henry John Guiliani
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Bell and Howell Co
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Bell and Howell Co
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    • GPHYSICS
    • G03PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03FPHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
    • G03F1/00Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof
    • G03F1/90Originals for photomechanical production of textured or patterned surfaces, e.g., masks, photo-masks, reticles; Mask blanks or pellicles therefor; Containers specially adapted therefor; Preparation thereof prepared by montage processes
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06KGRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K1/00Methods or arrangements for marking the record carrier in digital fashion
    • G06K1/12Methods or arrangements for marking the record carrier in digital fashion otherwise than by punching
    • G06K1/126Methods or arrangements for marking the record carrier in digital fashion otherwise than by punching by photographic or thermographic registration

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  • a negative photographic material is accurately photographically scribed and a fully punched conventional unit record card is accurately imaged onto a specific portion thereof.
  • the negative is then developed and a positive template is made therefrom so that the machine readable holes are black.
  • the positive template is then placed on a light box and covered with a sheet of plastic.
  • a series of conventional machine readable unit record cards are specially punched and sprayed with two coats of black paint to make them opaque. These painted cards are then individually taped in place on the plastic over the positive template so that no light passes through the holes of the individually punched black cards.
  • the positive also serves to locate visually readable sheets corresponding to each of the painted cards.
  • a white sheet is then slipped between the individually punched cards and the plastic.
  • Each of the resulting individual layouts is then used as a reproduction art Work layout for a different printing plate in a series of printing plates, which are used to print a series of unique composite cards having printing that is located with a high degree of accuracy.
  • This invention relates to a method of manufacturing uniquely shaped unit record cards and more particularly, to a method of making reproduction art work layouts from which printing plates are made for the manufacture of composite cards having very accurately located machine readable information.
  • the record cards with which this invention is concerned are manufactured in one piece; have non-standard but nevertheless exact dimensions; and have two basic portionsone of which contains visually readable information, and the other of which contains machine readable data.
  • at least the machine readable portions of the composite cards are often intended for use on light sensing types of document reading machines.
  • the printing plates are made so that the machine readable portions of the card are adapted to prevent optical cross-talk as the document is being machine read.
  • unit record cards In some instances it has become desirable to use unit record cards in what would otherwise be considered to be adverse conditions.
  • unit record cards are now being used in connection with computerized automotive testing machines. In these cases the cards must not only be free from cross-talk, but they must be dimensionally stable; relatively non-stretch; quite impervious to gasoline; readily cleanable; and of non-fading quality.
  • a suitable material for such a card is calendered vinyl which has the machine readable portions thereof printed in an ink that is opaque to infra-red radiation.
  • a major problem has been the lack of a commercially practical process for making large. numbers of different cards of this type which have the machine readable data printed thereon with suflicient dimensional accuracy. It is a further object of this invention to provide a commercially practical method of making a plurality of dilierent printing plates for such unit record cards having the required dimensional accuracy.
  • One method of producing such a record card is to first make an artwork layout and then make a printing plate by a photographic process. The cards can then be printed by means of that printing plate.
  • the artwork In order for the printing plate to be sufiiciently accurate, however, the artwork must be extremely precise. If only a single composite card were involved, the problem would be no greater than those of any other accurate printing process.
  • this invention is concerned with large numbers of composite cards, each having different visual and machine readable portions. Consequently, the process of this invention is concerned with hundreds of separate printing platesnot merely one or a few. In other words, the presently available photolithographic techniques have not been satisfactory to economically produce the required variety of such printing plates while at the same. time maintaining the required dimensional accuracy of the thusly printed cards. It is, therefore, another object of this invention to provide a method of producing a wide variety of such printing plates and more particularly to provide a method of making reproduction art work layouts, by means of which the required variety of printing plates can be produced.
  • a photosensitive material receives accurate plural exposures to an accurately scribed line to form a latent image having substantially the. identical overall dimensions as the composite card that it is desired to produce.
  • the same photosensitive sheet is then exposed to a completely punched individual unit record card so that a latent image thereof is accurately located with respect to the scribed lines.
  • These latent images are then developed to form a negative template having clear holes and the negtaive is used to expose a second sheet of photosensitive material.
  • This second sheet is then also developed to form a positive template having black holes.
  • This positive template is placed on a light box and covered with a substantially transparent sheet.
  • a separate unit record card is then punched with the data that it is desired to have appear on each of the final composite record cards.
  • These separate unit record cards are then made substantially completely opaque and individually accurately taped into place on the transparent sheet over the black holes of the previously fabricated positive template so that no light shines through the holes of the individual unit record cards.
  • Artwork for the composite cards corresponding visually readable portion is also located on the transparency over the positive template. In this manner, the transparency has uniquely punched unit record cards and the reproduction proofs with the other artwork, comprises a reproduction art work layout which can be photographed to make a printing plate from which a plurality of composite cards can be printed.
  • Another aspect of the invention relates to the above noted prevention of halos around the composite cards holes.
  • a white, substantially opaque backing or anti-diffusion sheet is slipped between the individually punched unit record cards and the reproduction proofs transparency. This step prevents what appear to be certain diffusive or ditlractive efiects of the transparency, whereby the undesirable halos are eliminated from the composite cards.
  • FIG. 1 is a plan view of a composite unit record card resulting from the method of the invention
  • FIG. 2 is a schematic perspective view of a step and repeat chase located above a line-up table
  • FIG. 3 is a perspective view of a fully punched unit record card
  • FIG. 4 is a fragmentary schematic perspective view of an image of the holes in FIG. 3s unit record card upon a portion of the structure illustrated in FIG. 2;
  • FIG. 5 is a perspective view of a positive template
  • FIG. 6- is a perspective view of an individually punched and blakened machine readable unit record card
  • FIG. 7 is a schematic perspective view of the visually readable portions of a reproduction art work layout
  • FIG. 8 is a fragmentary perspective view of FIG. 6s individually punched unit record card and FIG. 7s visually readable element placed upon a transparent sheet over the positive template of FIG. 5;
  • FIG. 9 is a sectional view taken along the lines 99 in FIG. 8.
  • FIG. 1 One preferred embodiment of the inventions method has been used in connection with the mass production of a series of composite unit re-record cards that are used with computer controlled testing of automobiles.
  • a separate composite card was produced for each different type of automobile. That is, a separate composite card was produced for each different year and model of each different manufacturer so that a total of upwards to 1,000 separate composite cards was required.
  • FIG. 1 a sheet of transparent calendared vinyl 12 has a machine readable portion 14 and a visually readable portion 16 which includes an identification tab 18.
  • the machine readable portion 14 is printed in reverse so that the unprinted portions correspond to the punched holes of a conventional unit record card.
  • the drawings illustrate a unit record card having only 21 bit positions. This, however, is merely for purposes of simplicity of illustration-it being understood that a conventional unit record card would probably have more bit positions, with the most conventional number being 960 bit positions.
  • each composite card had its own unique machine readable portion and a corresponding visually readable portion.
  • each composite card had its own unique machine readable portion and a corresponding visually readable portion.
  • FIG. 2 a preferred embodiment of the inventions method will be described in connection with the production of a set of reproduction proofs for the above described series of composite documents to be used in an automated automotive testing machine.
  • the genesis of the problem is to produce a series of reproduction art work layouts from which individual printing plates can be made for each composite document in the series. This is accomplished by first placing a. photosensitive four-up plate 30 on a line-up table 32 which is accurately movable to the left and right in FIG. 2 by means of a suitable rack and pinion or lead screw mechanism which are illustrated symbolically as element 34. Similarly, the line-up plate is accurately movable fore and aft by means of a structure symbolized as element 30 in FIG. 2.
  • a fine single scribe line 40 is placed on a piece of negative material 42 so that light can pass throughout the line 40, but not the remainder of the sheet 42 which is black.
  • the sheet 42 is then affixed to the underside of a step and repeat chase 44 which is mounted on a conventional structure such as 46 for vertical motion as well as accurate rotary motion in a horizontal plane.
  • a conventional structure such as 46 for vertical motion as well as accurate rotary motion in a horizontal plane.
  • light from an exposure lamp 48 may be used to accurately place an image of the fine scribed line 40 upon any selected portion of the four-up plate 30 which is a negative working material.
  • the plate 30s emulsion is of the type which, upon development, turns clear where exposed to light.
  • the scribed negative 40 is held against the photosensitive plate 30 by means of a conventional vacuum printing frame or the like.
  • the photosensitive plate 30 is exposed to three fore and aft lines 50, 52, and 54 by means of three separate exposures and corresponding step and repeat operations.
  • the chase assembly 44 is then rotated through degrees and three step and repeat operations are used to scribe the photosensitive plate 30 with the three lines 56, 58, and 60.
  • Suitable conventional instrumentation associated with both the line-up table 32 and the step and repeat chase structure 44 is used to accurately spatially locate each of the lines 5060 to within less than 0.001 inch accuracy.
  • the photosensitive film 30 is precisely exposed so as to form latent images of four rectangles 62, 64, 66, and 68.
  • the scribe line 40 is suitably masked and the rectangles are exposed to other scribe lines such as 55, 57, and 59 in rectangle 62. If desired, the plate 30 can also be exposed to additional scribe lines such as those which are dotted into the rectangle 62, for example.
  • a completely punched unit record card 70 (FIG. 3) has holes such as 24a which correspond to holes such as 24 of the composite card in FIG. 1; and in particular hole 25a corresponds to hole 25.
  • This card 70 is accurately imaged and exposed onto the upper left-hand corner of each of the rectangles 6 2, 66 by the step and repeat chase 44. That is, either the card 70 or a sheet of negative material having light passing apertures or holes representing a composite card layout, formed from the card, is mounted in the step and repeat chase 44 so as to accurately image the holes at a particular location in one of the four rectangles (shown dotted in FIG. 2). Thereafter, light from the exposure lamp 48 images the holes at the accurate location.
  • the step and repeat chase is operated in a conventional manner to move the hole image to the same location on the other three rectangles, and the exposure light creates images at these locations in those rectangles. Because the sheet 30 is positive, Working the card 70 is effectively imaged in reverse. That is, upon development, the sheet 30s holes and scribe lines are clear while the remainder of the sheet is black.
  • the utmost of care is taken to insure that the image of the left-hand edge of hole 25a is precisely located with respect to line 52; and that the image of the upper edge of hole 25a is precisely located with respect to line 56.
  • the image of the left side of hole 25a was held to within 0.001 inch of 10.813 inches from line 52 while the image of the top of hole 25a was held to within 0.001 inch of 0.223 inch from line 56.
  • the images in the other rectangles, 64, 66 and 68 are similarly accurately aligned and will not be further described at this time.
  • the illustrated unit record card 70 shows only 21 bit positions, but this number is merely illustrates. Also, the methods preferred embodiment is described as having all of the individual unit record card 70s bit positions punched. The only requirement, however, is that there be a hole corresponding to each of the holes in all of the separate unit record cards of the automobile models for which a composite card is to be produced.
  • the thusly exposed photosensitive material 30 is then developed in a conventional manner to form a negative template which is all black except for the variously imaged holes and lines.
  • the outline of the card 70 does not actually appear, but it is shown dotted in FIG. 4 for purposes of illustration.
  • a second photosensitive sheet is exposed to the negative template to form latent positive images on the second sheet of photosensitive material.
  • the second sheet is then developed to form a positive template 130 as illustrated in FIG. 5.
  • the various elements have been numbered similarly with the previously described figures but having a 1 prefix. Note also that the holes and scribe lines are black while the remainder of the positive template is clear.
  • each of the composite cards with which this invention is concerned is different. That is, each of the 1,000 or so composite cards in the series has both a different punched hole pattern in the machine readable portion thereof and different visually readable information in the right-hand portion thereof. Consequently, if the previously described somewhat conventional steps were used to produce the entire series of the composite cards, it would be necessary to repeat the above time consuming process for each of the composite cards in the series. Moreover, every time that it was desired to change the information in a conposite cards machine readable portion, it would be necessary to re-establsh all of the spatial coordinates that were initially used to make the first sheet 30 in FIG. 4. Again, however, this would be impractically time consuming. Hence, as will now be described, it is at this point that the method of the invention departs from and adds to what has been done before.
  • the positive template 130 which is illustrated schematically in FIG. 5 is used to make reproduction art work layouts for each of the individual composite cards in the series.
  • separate unit record cards are punched to contain the desired machine readable information about each of the automobile models in the series.
  • One such unit record card 114 is illustrated in FIG. 6 and corresponds to the machine readable portion 14 of the composite card 12 which is illustrated in FIG. 1.
  • the data representations that are punched into the conventional unit record card 114 correspond to the desired data for a 1963 six-cylinder Hall automobile having 260 cubic inches displacement and an automatic transmission.
  • Visually readable information about the same model automobile is printed by any suitable means on a separate sheet 116 (FIG. 7), in a preferred method, each of the individual conventional unit record cards is then sprayed with two layers of black paint on all surfaces including those surrounding the holes so as to make it substantially completely opaque except for the punched hole areas.
  • the positive template 130 is then taped onto a light box which is symbolically represented by a lamp 119 in FIG. 8 and a sheet of clear plastic 120 is taped over the template 130.
  • a lamp 119 in FIG. 8 a lamp 119 in FIG. 8
  • a sheet of clear plastic 120 is taped over the template 130.
  • four of the separately punched machine readable cards 114 are very carefully positioned on top of the plastic sheet 120 directly over the image of card 70s hole pattern 170 on the positive template 130 (FIG. 5).
  • FIG. 9 illustrates the positive template in partial cross section through the developed holes 180, 181, and 182 (see also FIG. 5) which are located in an emulsion layer 130a on the template 130.
  • the four visually readable documents 116 corresponding to each of the individal record cards 114 are taped onto the plastic sheet so as to be in accurate registration with the scribe lines 155 and 159 (see FIGS. 5, 8, and 9).
  • the artwork for the tab portion 18 (FIG. 1) was added separately. In that case, the scribe line 157 was used to align the lower portions of the documents 116.
  • the plastic sheet 120 is now lifted off of the positive template and with its machine and visually readable portions 114 and 116, respectively, comprises the reproduction art work layout for four of the composite record cards 12 (FIG. 1). Another sheet of plastic can then be placed over the same positive template and the above steps repeated so as to make reproduction art work layouts for the entire series of composite cards. In this manner, although all of the art work layouts are in substantially exact registration, only one negative template and one positive template are required for the entire series of composite cards.
  • the reproduction art work layouts are photographed by placing them on a vacuum copy board (not shown) and imaging them onto a film which is accurately positioned so that there is no increase or reduction in size during the photographic process.
  • a halo is produced around the holes such as 24 and 25 of FIG. 1s composite card.
  • I have solved this problem by slipping a piece of white substantially opaque or translucent sheet material such as paper 123 between each taped card 114 and the plastic sheet 120 after the layout steps are completed and before the reproduction art Work layouts are photographed.
  • This paper 123 acts as an anti-diffusion sheet and prevents the undesirable halos from forming.
  • reproduction art work layouts are photographed, they are carefully dimensionally checked to be sure that none of the individually punched machine readable cards or the visually readable documents of the positive template having either shrunk or stretched.
  • its negative is again checked for dimensional accuracy against the positive template.
  • the negative is then used to make either a right reading offset printing plate or a reverse reading letter press printing plate, whichever is desired.
  • These printing plates are also checked against the positive template for dimensional accuracy and then used to print the desired number of each of the sheets of four different composite unit record cards. These sheets are then cut and again dimensionally checked against the positive template so as to produce the desired number or highly accurate sets of the series of composite cards.
  • the reproduction art work layouts for the entire series of composite cards have been produced from only a single negative template and a single positive template. In this manner, all of the composite cards have the required degree of accuracy, but the tune consuming steps of scribing lines corresponding to 50-66 and the images 74) have only been carried not once.
  • the negative template serves as a master plate from which subsequent positive templates can be made; and the posiu tive template serves as a master from which subsequent reproduction art work layouts can be made. In this manner, as changes are made to existing models of automobiles or as new models are produced, the required changes in the individual composite cards can be easily accomplished.
  • the above described process is suitable for producing a large plurality of individual composite cards each of which has its edges accuratley aligned with the composite cards machine readable information.
  • the shape and composition of the composite card is relatively limitless whereby an oddly shaped composite card can be effectively punched even though its shape or composition would render it entirely unsuited for being punched in any conventional keypunch type of machine.
  • a method of making a reproduction art work layout comprising the steps of:
  • step of exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed line includes the sub-step of: exposing said first sheet of photo-sensitive material to a first plurality of parallel lines;
  • the method of claim a including the additional step of placing a transparent sheet over said second template prior to accurately superimposing said information unit record card.
  • the method of claim 5 including the additional step of:
  • said first sheet of photo-sensitive material is a positive working material so that after development the exposed portions thereof are clear and said second sheet of photo-sensitive material is a negative working material so that after development of the exposed portions thereof are opaque.
  • a method of making a photographic plate of an art work layout comprising the steps of:
  • said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.
  • step of exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed lines includes the sub-step of:
  • the method of claim 13 including the sub-steps of: punching a first unit record card in accordance with said predetermined hole pattern; utilizing said first unit record card so as to produce said latent image of said predetermined hole pattern on said first sheet of photo-sensitive material; and punching an information unit record card in accordance with a second predetermined pattern wherein each of the punched holes thereof corresponds to a particular hole in said first predetermined pattern.
  • said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.
  • said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.

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Abstract

A PROCESS FOR MAKING REPRODUCTION ART WORK LAYOUTS AND PRINTING PLATES FOR A LARGE PLURALITY OF NON-CONVENTIONAL COMPOSITE UNIT RECORD CARDS EACH OF WHICH HAS A UNIQUE MACHINE READABLE PORTION AND A RELATED VISUALLY READABLE PORTION. A NEGATIVE PHOTOGRAPHIC MATERIAL IS ACCURATELY PHOTOGRAPHICALLY SCRIBED AND A FULLY PUNCHED CONVENTIONAL UNIT RECORD CARD IS ACCURATELY IMAGED ONTO A SPECIFIC PORTION THEREOF. THE NEGATIVE IS THEN DEVELOPED AND A POSITIVE TEMPLATE IS MADE THEREFROM SO THAT THE MACHINE READABLE "HOLES" ARE BLACK. THE POSITIVE TEMPLATE IS THEN PLACED ON A LIGHT BOX AND COVERED WITH A SHEET OF PLASTIC. A SERIES OF CONVENTIONAL MACHINE READABLE UNIT RECORD CARDS ARE SPECIALLY PUNCHED AND SPRAYED WITH TWO COATS OF BLACK PAINT TO MAKE THEM OPAQUE. THESE PAINTED CARDS ARE THEN INDIVIDUALLY TAPED IN PLACE ON THE PLASTIC OVER THE POSITIVE TEMPLATE SO THAT NO LIGHT PASSES THROUGH THE HOLES OF THE INDIVIDUALLY PUNCHED BLACK CARDS. THE POSITIVE ALSO SERVES TO LOCATE VISUALLY READABLE CARDS. THE POSITIVE ALSO SERVES TO LOCATE VISUALLY READABLE SHEETS CORRESPONDING TO EACH OF THE PAINTED CARDS. A WHITE SHEET IS THEN SLIPPED BETWEEN THE INDIVIDUALLY PUNCHED CARDS AND THE PLASTIC. EACH OF THE RESULTING INDIVIDUAL LAYOUTS IS THEN USED AS A REPRODUCTION ART WORK LAYOUT FOR A DIFFERENT PRINTING PLATE IN A SERIES OF PRINTING PLATES, WHICH ARE USED TO PRINT A SERIES OF UNIQUE COMPOSITE CARDS HAVING PRINTING THAT IS LOCATED WITH A HIGH DEGREE OF ACCURACY.

Description

April 6, 1971 H. J. GUILIANI 3,573,910
METHOD 0!" MAKING REPRODUCTION ART WORK LAYOUTS AND PRINTING PLATES FOR COMPOSITE UNIT RECORD CARDS Filed Dec. 1, 1967 3 Sheets-Sheet 1 LNO LOAD B ATTERY VOLT ALL ELEC. OFF MIN. IZAOVOIIS I I I I I I I 22 I I4 I I i I ZSLDWELL AI:4GLE @IDLE 40-45 DEGREES i I I -16 I I i I 40.FUEL FLOW @IDLE AU TO.
=\ Fl 6 I.
FIG.2.
IN V EN TOR.
Henry J. Giuliani ATTORNEY April 6, 1971 H. J. GUILIANI 3,573,910
METHOD OF MAKING REPRODUCTION ART WORK LAYOUTS AND PRINTING PLATES FOR COMPOSITE UNIT RECORD CARDS Filed Dec. 1, 1967 3 Sheets-Sheet 3,
.250 ens.
'INVENTOR. Henry J. Giuliom BY M ATTORNE S Apnl 6, 1971 H. J. GUILIANI 3,573,910
METHOD OF MAKING REPRODUCTION ART WORK LAYOUTS AND PRINTING PLATES FOR COMPOSITE UNIT RECORD CARDS Filed Dec. 1, 1967 3 Sheets-Sheet 5 "9 Fl 6.9. M
ATTORNE S United States Patent METHOD OF MAKING REPRODUCTION ART WORK LAYOUTS AND PRINTiNG PLATES FOR COMPOSITE UNIT RECORD CARDS Henry John Guiiiani, Diamond Bar, Calif., assignor to The Bell and Howell Company, Chicago, Iii. Filed Dec. 1, 1967, Ser. No. 687,339 Int. Cl. G03c 5/04 US. Cl. 96-41 20 Claims ABSTRACT OF THE DISCLOSURE A process for making reproduction art work layouts and printing plates for a large plurality of non-conventional composite unit record cards each of which has a unique machine readable portion and a related visually readable portion. A negative photographic material is accurately photographically scribed and a fully punched conventional unit record card is accurately imaged onto a specific portion thereof. The negative is then developed and a positive template is made therefrom so that the machine readable holes are black. The positive template is then placed on a light box and covered with a sheet of plastic. A series of conventional machine readable unit record cards are specially punched and sprayed with two coats of black paint to make them opaque. These painted cards are then individually taped in place on the plastic over the positive template so that no light passes through the holes of the individually punched black cards. The positive also serves to locate visually readable sheets corresponding to each of the painted cards. A white sheet is then slipped between the individually punched cards and the plastic. Each of the resulting individual layouts is then used as a reproduction art Work layout for a different printing plate in a series of printing plates, which are used to print a series of unique composite cards having printing that is located with a high degree of accuracy.
This invention relates to a method of manufacturing uniquely shaped unit record cards and more particularly, to a method of making reproduction art work layouts from which printing plates are made for the manufacture of composite cards having very accurately located machine readable information.
The record cards with which this invention is concerned are manufactured in one piece; have non-standard but nevertheless exact dimensions; and have two basic portionsone of which contains visually readable information, and the other of which contains machine readable data. In addition, at least the machine readable portions of the composite cards are often intended for use on light sensing types of document reading machines. Hence, to accommodate this intended use, the printing plates are made so that the machine readable portions of the card are adapted to prevent optical cross-talk as the document is being machine read.
In many of the present-day document reading machines with which the above described composite record cards are used, it is a requirement that the machine readable portions of the card be precisely located with respect to the cards edges. Moreover, because the record cards with which this invention is concerned are uniquely shaped, they are not suited for use with standard key-punch types of machines. It is an object of this invention, therefore to provide a method of manufacturing the reproduction art work layouts for such cards whereby the machine readable information is uniquely, but accurately located with respect to the cards edges.
In some instances it has become desirable to use unit record cards in what would otherwise be considered to be adverse conditions. For example, unit record cards are now being used in connection with computerized automotive testing machines. In these cases the cards must not only be free from cross-talk, but they must be dimensionally stable; relatively non-stretch; quite impervious to gasoline; readily cleanable; and of non-fading quality. To this end it has been determined that a suitable material for such a card is calendered vinyl which has the machine readable portions thereof printed in an ink that is opaque to infra-red radiation. A major problem, however, has been the lack of a commercially practical process for making large. numbers of different cards of this type which have the machine readable data printed thereon with suflicient dimensional accuracy. It is a further object of this invention to provide a commercially practical method of making a plurality of dilierent printing plates for such unit record cards having the required dimensional accuracy.
One method of producing such a record card is to first make an artwork layout and then make a printing plate by a photographic process. The cards can then be printed by means of that printing plate. In order for the printing plate to be sufiiciently accurate, however, the artwork must be extremely precise. If only a single composite card were involved, the problem would be no greater than those of any other accurate printing process. But this invention is concerned with large numbers of composite cards, each having different visual and machine readable portions. Consequently, the process of this invention is concerned with hundreds of separate printing platesnot merely one or a few. In other words, the presently available photolithographic techniques have not been satisfactory to economically produce the required variety of such printing plates while at the same. time maintaining the required dimensional accuracy of the thusly printed cards. It is, therefore, another object of this invention to provide a method of producing a wide variety of such printing plates and more particularly to provide a method of making reproduction art work layouts, by means of which the required variety of printing plates can be produced.
It has also been found that otherwise conventional photolithographic techniques produce composite cards having holes with light spots or halos around them. This, of course, renders the composite cards unsatisfactory for use with optical scanning devices. It is another object of the invention, therefore to provide a method of making composite cards that do not have such halos.
In accordance with the principle of the invention, a photosensitive material receives accurate plural exposures to an accurately scribed line to form a latent image having substantially the. identical overall dimensions as the composite card that it is desired to produce. The same photosensitive sheet is then exposed to a completely punched individual unit record card so that a latent image thereof is accurately located with respect to the scribed lines. These latent images are then developed to form a negative template having clear holes and the negtaive is used to expose a second sheet of photosensitive material. This second sheet is then also developed to form a positive template having black holes. This positive template is placed on a light box and covered with a substantially transparent sheet.
A separate unit record card is then punched with the data that it is desired to have appear on each of the final composite record cards. These separate unit record cards are then made substantially completely opaque and individually accurately taped into place on the transparent sheet over the black holes of the previously fabricated positive template so that no light shines through the holes of the individual unit record cards. Artwork for the composite cards corresponding visually readable portion is also located on the transparency over the positive template. In this manner, the transparency has uniquely punched unit record cards and the reproduction proofs with the other artwork, comprises a reproduction art work layout which can be photographed to make a printing plate from which a plurality of composite cards can be printed.
Another aspect of the invention relates to the above noted prevention of halos around the composite cards holes. In accordance with the principle of this aspect of the invention, a white, substantially opaque backing or anti-diffusion sheet is slipped between the individually punched unit record cards and the reproduction proofs transparency. This step prevents what appear to be certain diffusive or ditlractive efiects of the transparency, whereby the undesirable halos are eliminated from the composite cards.
The foregoing and other objects, features and advantages of this invention will be apparent from the following more particular description of a preferred embodiment thereof as illustrated in the accompanying drawings wherein the same reference numerals refer to the same parts throughout the various views. The drawings are not necessarily intended to be to scale, but are presented so as to illustrate the principles of the invention in clear form.
In the drawings:
FIG. 1 is a plan view of a composite unit record card resulting from the method of the invention;
'FIG. 2 is a schematic perspective view of a step and repeat chase located above a line-up table;
FIG. 3 is a perspective view of a fully punched unit record card;
FIG. 4 is a fragmentary schematic perspective view of an image of the holes in FIG. 3s unit record card upon a portion of the structure illustrated in FIG. 2;
FIG. 5 is a perspective view of a positive template;
FIG. 6- is a perspective view of an individually punched and blakened machine readable unit record card;
FIG. 7 is a schematic perspective view of the visually readable portions of a reproduction art work layout;
FIG. 8 is a fragmentary perspective view of FIG. 6s individually punched unit record card and FIG. 7s visually readable element placed upon a transparent sheet over the positive template of FIG. 5; and
FIG. 9 is a sectional view taken along the lines 99 in FIG. 8.
One preferred embodiment of the inventions method has been used in connection with the mass production of a series of composite unit re-record cards that are used with computer controlled testing of automobiles. In that instance, a separate composite card was produced for each different type of automobile. That is, a separate composite card was produced for each different year and model of each different manufacturer so that a total of upwards to 1,000 separate composite cards was required. One card of thus type is illustrated in FIG. 1. Therein, a sheet of transparent calendared vinyl 12 has a machine readable portion 14 and a visually readable portion 16 which includes an identification tab 18. The machine readable portion 14 is printed in reverse so that the unprinted portions correspond to the punched holes of a conventional unit record card. In this respect, the drawings illustrate a unit record card having only 21 bit positions. This, however, is merely for purposes of simplicity of illustration-it being understood that a conventional unit record card would probably have more bit positions, with the most conventional number being 960 bit positions.
In the case of the above noted series of composite unit record cards relating to the testing of automobiles, each composite card had its own unique machine readable portion and a corresponding visually readable portion. For eample, for a series covering 1,000 separate models,
years and makes of automobiles, there would be 1,000 separate composite cards having 1,000 separate machine readable portions each of which has an accompanying, but similarly unique visually readable portion. When these composite documents are passed through a related data processing machine, the edges 20 and 22 are used to register each document in the data processor. But, in order for the processor to properly read the transparent bits such as 24 and 25 of the documents machine readable portion 14, it was found that each of the bits had to be accurately aligned with respect to the edges 20 and 22 to Within a non-cumulative accuracy of 0.003 inch. If only one such. composite document were required, the problems of manufacture would not be so great. Where such large numbers of composite documents are required, however, prior art methods have rendered it virtually impossible to produce all of the cards to within the required degrees of accuracy.
Turning now to the various portions of FIG. 2; a preferred embodiment of the inventions method will be described in connection with the production of a set of reproduction proofs for the above described series of composite documents to be used in an automated automotive testing machine.
The genesis of the problem is to produce a series of reproduction art work layouts from which individual printing plates can be made for each composite document in the series. This is accomplished by first placing a. photosensitive four-up plate 30 on a line-up table 32 which is accurately movable to the left and right in FIG. 2 by means of a suitable rack and pinion or lead screw mechanism which are illustrated symbolically as element 34. Similarly, the line-up plate is accurately movable fore and aft by means of a structure symbolized as element 30 in FIG. 2.
A fine single scribe line 40 is placed on a piece of negative material 42 so that light can pass throughout the line 40, but not the remainder of the sheet 42 which is black. The sheet 42 is then affixed to the underside of a step and repeat chase 44 which is mounted on a conventional structure such as 46 for vertical motion as well as accurate rotary motion in a horizontal plane. In this manner, light from an exposure lamp 48 may be used to accurately place an image of the fine scribed line 40 upon any selected portion of the four-up plate 30 which is a negative working material. This is, the plate 30s emulsion is of the type which, upon development, turns clear where exposed to light. In this respect, during actual exposure of the photosensitive member 30, the scribed negative 40 is held against the photosensitive plate 30 by means of a conventional vacuum printing frame or the like.
In carrying out the first basic step of the process the photosensitive plate 30 is exposed to three fore and aft lines 50, 52, and 54 by means of three separate exposures and corresponding step and repeat operations. The chase assembly 44 is then rotated through degrees and three step and repeat operations are used to scribe the photosensitive plate 30 with the three lines 56, 58, and 60. Suitable conventional instrumentation associated with both the line-up table 32 and the step and repeat chase structure 44 is used to accurately spatially locate each of the lines 5060 to within less than 0.001 inch accuracy. In the manner, the photosensitive film 30 is precisely exposed so as to form latent images of four rectangles 62, 64, 66, and 68. Similarly, the scribe line 40 is suitably masked and the rectangles are exposed to other scribe lines such as 55, 57, and 59 in rectangle 62. If desired, the plate 30 can also be exposed to additional scribe lines such as those which are dotted into the rectangle 62, for example.
A completely punched unit record card 70 (FIG. 3) has holes such as 24a which correspond to holes such as 24 of the composite card in FIG. 1; and in particular hole 25a corresponds to hole 25. This card 70 is accurately imaged and exposed onto the upper left-hand corner of each of the rectangles 6 2, 66 by the step and repeat chase 44. That is, either the card 70 or a sheet of negative material having light passing apertures or holes representing a composite card layout, formed from the card, is mounted in the step and repeat chase 44 so as to accurately image the holes at a particular location in one of the four rectangles (shown dotted in FIG. 2). Thereafter, light from the exposure lamp 48 images the holes at the accurate location. Then, the step and repeat chase is operated in a conventional manner to move the hole image to the same location on the other three rectangles, and the exposure light creates images at these locations in those rectangles. Because the sheet 30 is positive, Working the card 70 is effectively imaged in reverse. That is, upon development, the sheet 30s holes and scribe lines are clear while the remainder of the sheet is black.
It should be noted that the utmost of care is taken to insure that the image of the left-hand edge of hole 25a is precisely located with respect to line 52; and that the image of the upper edge of hole 25a is precisely located with respect to line 56. In one preferred embodiment, for example, the image of the left side of hole 25a was held to within 0.001 inch of 10.813 inches from line 52 while the image of the top of hole 25a was held to within 0.001 inch of 0.223 inch from line 56. The images in the other rectangles, 64, 66 and 68 are similarly accurately aligned and will not be further described at this time.
Again, the illustrated unit record card 70 shows only 21 bit positions, but this number is merely illustrates. Also, the methods preferred embodiment is described as having all of the individual unit record card 70s bit positions punched. The only requirement, however, is that there be a hole corresponding to each of the holes in all of the separate unit record cards of the automobile models for which a composite card is to be produced.
The thusly exposed photosensitive material 30 is then developed in a conventional manner to form a negative template which is all black except for the variously imaged holes and lines. The outline of the card 70 does not actually appear, but it is shown dotted in FIG. 4 for purposes of illustration. Next, a second photosensitive sheet is exposed to the negative template to form latent positive images on the second sheet of photosensitive material. The second sheet is then developed to form a positive template 130 as illustrated in FIG. 5. Therein, the various elements have been numbered similarly with the previously described figures but having a 1 prefix. Note also that the holes and scribe lines are black while the remainder of the positive template is clear.
Up to this point, although highly accurate and time consuming, the process might be described as being somewhat conventional. If the final product were to be a mere reproduction of the image represented in rectangle 162,
it would only be necessary to make a suitable printing plate therefrom and go to press. As noted above, however, each of the composite cards with which this invention is concerned is different. That is, each of the 1,000 or so composite cards in the series has both a different punched hole pattern in the machine readable portion thereof and different visually readable information in the right-hand portion thereof. Consequently, if the previously described somewhat conventional steps were used to produce the entire series of the composite cards, it would be necessary to repeat the above time consuming process for each of the composite cards in the series. Moreover, every time that it was desired to change the information in a conposite cards machine readable portion, it would be necessary to re-establsh all of the spatial coordinates that were initially used to make the first sheet 30 in FIG. 4. Again, however, this would be impractically time consuming. Hence, as will now be described, it is at this point that the method of the invention departs from and adds to what has been done before.
The positive template 130 which is illustrated schematically in FIG. 5 is used to make reproduction art work layouts for each of the individual composite cards in the series. First, however, separate unit record cards are punched to contain the desired machine readable information about each of the automobile models in the series. One such unit record card 114 is illustrated in FIG. 6 and corresponds to the machine readable portion 14 of the composite card 12 which is illustrated in FIG. 1. The data representations that are punched into the conventional unit record card 114 correspond to the desired data for a 1963 six-cylinder Hall automobile having 260 cubic inches displacement and an automatic transmission. Visually readable information about the same model automobile is printed by any suitable means on a separate sheet 116 (FIG. 7), in a preferred method, each of the individual conventional unit record cards is then sprayed with two layers of black paint on all surfaces including those surrounding the holes so as to make it substantially completely opaque except for the punched hole areas.
The positive template 130 is then taped onto a light box which is symbolically represented by a lamp 119 in FIG. 8 and a sheet of clear plastic 120 is taped over the template 130. Next, four of the separately punched machine readable cards 114 are very carefully positioned on top of the plastic sheet 120 directly over the image of card 70s hole pattern 170 on the positive template 130 (FIG. 5).
As noted above, the holes on the positive template are black. This is illustrated FIG. 9 which, among other things, illustrates the positive template in partial cross section through the developed holes 180, 181, and 182 (see also FIG. 5) which are located in an emulsion layer 130a on the template 130. When the individual record card 114 is in exact registration with the positive templates hole pattern, therefore, none of the lamp s light can pass through hole 184 to the eye 121 of a viewer. Consequently, all four of the individual unit record cards are positioned on the plastic sheet so that the viewer sees no light through the cards 114 from the lamp 119. The individual record cards are then taped in that exact registration position.
Next, the four visually readable documents 116 corresponding to each of the individal record cards 114, are taped onto the plastic sheet so as to be in accurate registration with the scribe lines 155 and 159 (see FIGS. 5, 8, and 9). In one preferred embodiment, the artwork for the tab portion 18 (FIG. 1) was added separately. In that case, the scribe line 157 was used to align the lower portions of the documents 116.
The plastic sheet 120 is now lifted off of the positive template and with its machine and visually readable portions 114 and 116, respectively, comprises the reproduction art work layout for four of the composite record cards 12 (FIG. 1). Another sheet of plastic can then be placed over the same positive template and the above steps repeated so as to make reproduction art work layouts for the entire series of composite cards. In this manner, although all of the art work layouts are in substantially exact registration, only one negative template and one positive template are required for the entire series of composite cards.
The reproduction art work layouts are photographed by placing them on a vacuum copy board (not shown) and imaging them onto a film which is accurately positioned so that there is no increase or reduction in size during the photographic process. With respect to this photographic step, and in accordance with another aspect of the invention. I have found that if conventional photographic techniques are used, a halo is produced around the holes such as 24 and 25 of FIG. 1s composite card. I have solved this problem by slipping a piece of white substantially opaque or translucent sheet material such as paper 123 between each taped card 114 and the plastic sheet 120 after the layout steps are completed and before the reproduction art Work layouts are photographed. This paper 123, acts as an anti-diffusion sheet and prevents the undesirable halos from forming.
In addition, before the reproduction art work layouts, are photographed, they are carefully dimensionally checked to be sure that none of the individually punched machine readable cards or the visually readable documents of the positive template having either shrunk or stretched. After each reproduction art Work layout is photographed, its negative is again checked for dimensional accuracy against the positive template. The negative is then used to make either a right reading offset printing plate or a reverse reading letter press printing plate, whichever is desired. These printing plates are also checked against the positive template for dimensional accuracy and then used to print the desired number of each of the sheets of four different composite unit record cards. These sheets are then cut and again dimensionally checked against the positive template so as to produce the desired number or highly accurate sets of the series of composite cards.
It should be appreciated at this point that the reproduction art work layouts for the entire series of composite cards have been produced from only a single negative template and a single positive template. In this manner, all of the composite cards have the required degree of accuracy, but the tune consuming steps of scribing lines corresponding to 50-66 and the images 74) have only been carried not once. Moreover, the negative template serves as a master plate from which subsequent positive templates can be made; and the posiu tive template serves as a master from which subsequent reproduction art work layouts can be made. In this manner, as changes are made to existing models of automobiles or as new models are produced, the required changes in the individual composite cards can be easily accomplished. For example, it is merely necessary to punch a new machine readable card; accurately align it upon a plastic sheet over the positive template with the aid of a magnifying glass or the like; print and align a corresponding visually readable document (116) on the transparent sheet over the positive template; and photolithograph the resulting structure to produce a printing plate from which the new composite documents can be made.
It will also be appreciated by those skilled in the art that the above described process is suitable for producing a large plurality of individual composite cards each of which has its edges accuratley aligned with the composite cards machine readable information. Moreover, the shape and composition of the composite card is relatively limitless whereby an oddly shaped composite card can be effectively punched even though its shape or composition would render it entirely unsuited for being punched in any conventional keypunch type of machine.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departingfrom the spirit and scope of the invention. For example, although the invention has been described in terms of the composite unit record card being comprised of calendared vinyl, this is not necessarily the case. Where it is not necessary that the composite card resist solvents and be cleanable, it is quite practical to practice the steps of the invention so that the composite cards are printed upon conventional card stock Where the holes are printed in magnetic ink, for example. Similarly, I have found it convenient to make several positive template masters from the negative template. One, for example, being stored with the negative template in an atmospherically controlled vault and the others being used for the various dimensional checking steps. This is particularly convenient where the art-work is performed at one location and the printing at another.
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A method of making a reproduction art work layout comprising the steps of:
exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed lines; developing the latent images of said first sheet of photo-sensitive material to form a first template; exposing a second sheet of photo-sensitive material to said first template to form a latent image thereof on said second sheet of photo-sensitive material; developing the latent image on said second sheet of photo-sensitive material to form a second template having opaque areas corresponding to the said predetermined hole pattern and accurately scribed lines; accurately superimposing an information unit record card having punched information apertures over the predetermined hole pattern images formed in said second template so as to prevent the passage of light through the entire area covered by said unit record card; and
placing a sheet translucent material between said second template and said information unit record card. 2. The method of claim 1 wherein the step of exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed line includes the sub-step of: exposing said first sheet of photo-sensitive material to a first plurality of parallel lines;
exposing said first sheet of photo-sensitive material to a second plurality of parallel lines which are mutually perpendicular to said first plurality of parallel lines so as to produce a latent image of at least one substantially rectangular portion on said first sheet of photo-sensitive material; and
exposing said first sheet of photo-sensitive material to the image of a unit record card having said predetermined hole pattern so as to produce a latent image of said predetermined hole pattern in accurate predetermined alignment with the latent images of said first and second plurality of parallel lines.
3. The method of claim 2 including the step of treating said information unit record card so as to make it substantially opaque.
4. The method of claim 3 including the additional step of:
placing a transparent sheet over said second template prior to accurately superimposing said information unit record card.
5. The method of claim 2 including the sub-steps of:
punching a first unit record card in accordance with said predetermined hole pattern;
utilizing said first unit record card so as to produce said latent image of said predetermined hole pattern on said first sheet of photo-sensitive material; and
punching an information unit record card in accordance with a record predetermined pattern wherein each of the punched holes thereof corresponds to a particular hole in said first predetermined pattern.
6. The method of claim 5 including the step of:
treating said information unit record card so as to make it substantially opaque.
7. The method of claim a including the additional step of placing a transparent sheet over said second template prior to accurately superimposing said information unit record card. 8. The method of claim 5 including the additional step of:
placing a transparent sheet over said second template prior to accurately superimposing said information unit record card.
9. The method of claim wherein said first sheet of photo-sensitive material is a positive working material so that after development the exposed portions thereof are clear and said second sheet of photo-sensitive material is a negative working material so that after development of the exposed portions thereof are opaque.
10. A method of making a photographic plate of an art work layout comprising the steps of:
exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed lines; developing the latent images of said first sheet of photosensitive material to form a first template; exposing a second sheet of photo-sensitive material to said first template to form a latent image thereof on said second sheet of photosensitive material; developing the latent image on said second sheet of photo-sensitive material to form a second template having opaque areas corresponding to the said predetermined hole pattern and accurately scribed lines; accurately superimposing an information unit record card having punched information apertures over the predetermined hole pattern images formed in said second template so as to prevent the passage of light through the entire area covered by said unit record card; placing a sheet of translucent material between said second template and said information unit record card;
photographing said second template having said information unit record card superimposed thereon so as to produce a latent image thereof on a third sheet of photo-sensitive material; and
developing the latent image on said third sheet of photo-sensitive material.
11. The method of claim wherein said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.
12. The method of claim 10 including the steps of:
exposing a photo-sensitive printing plate to the developed image on said third sheet; and
developing said photo-sensitive printing plate.
13. The method of claim 10 wherein the step of exposing a first sheet of photo-sensitive material to form a plurality of latent images of a predetermined hole pattern and accurately scribed lines includes the sub-step of:
exposing a first sheet of photo-sensitive material to a second plurality of parallel lines which are mutually perpendicular to said first plurality of parallel lines so as to produce a latent image of at least one substantially rectangular portion on said first sheet of photo-sensitive material; and
exposing said first sheet of photo-sensitive material to the image of a unit record card having said predetermined hole pattern so as to produce a latent image of said predetermined hole pattern in accurate predetermined alignment with the latent images of said first and second plurality of parallel lines.
14. The method of claim 13 including the sub-steps of: punching a first unit record card in accordance with said predetermined hole pattern; utilizing said first unit record card so as to produce said latent image of said predetermined hole pattern on said first sheet of photo-sensitive material; and punching an information unit record card in accordance with a second predetermined pattern wherein each of the punched holes thereof corresponds to a particular hole in said first predetermined pattern.
15. The method of claim 14 wherein said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.
16. The method of claim 14 including the steps of:
exposing a photo-sensitive printing plate to the developed image on said third sheet; and
developing said photo-sensitive printing plate.
17. The method of claim 10 including the sub-steps of:
punching a first unit record card in accordance with said predetermined hole pattern;
utilizing said first unit record card so as to produce said latent image of said predetermined hole pattern on said first sheet of photosensitive material; and, punching an information unit record card in accordance with a second predetermined pattern wherein each of the punched holes thereof corresponds to a particular hole in said first predetermined pattern.
18. The method of claim 17 including the step of treating said information unit record card so as to make it substantially opaque.
19. The method of claim 18 wherein said third sheet of photo-sensitive material is a photo-sensitive printing plate so that the development of the third latent image produces a printing plate.
20. The method of claim 18 including the steps of:
exposing a photo-sensitive printing plate to the developed image on said third sheet; and
developing said photo-sensitive printing plate.
References Cited UNITED STATES PATENTS OTHER REFERENCES Hallstead, H. 1., et al.Photographic Composite Generation. Published in IBM Technical Disclosure Bulletin,
vol. 7, No. 7, December 1964, pp. 628-629.
DAVID KLEIN, Primary Examiner U.S. Cl. X.R.
mg UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,573,910 D t d April 6, 1971 Inventor-( HENRY J. GIULIANI It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:
The spelling of the inventor's name in the heading of the patent is changed from "GUILIANI" t0 GIULIANI Signed and sealed this 19th day of October 1971 (SEAL) Attest:
EDWARD M.FLETCHER.JR. ROBERT GOTTSCHALK Attesting Officer Acting Commissioner of Paton
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4229099A (en) * 1978-12-22 1980-10-21 Watkins Ronald C Method and apparatus for burning or dodging preselected portions of an image formed on photographic paper

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4229099A (en) * 1978-12-22 1980-10-21 Watkins Ronald C Method and apparatus for burning or dodging preselected portions of an image formed on photographic paper

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