EMBOSSING MEANS
Field of the invention
The invention relates to a method for producing an embossing member according to the preamble of the appended claim 1. The invention also relates to an embossing member according to the preamble of the appended claim 7.
Background of the invention
The invention relates indirectly to the production of diffractive micro- structures, such as holograms, by embossing.
The embossing member corresponding to the microstructure to be produced is typically made on a thin nickel sheet by a method com¬ prising, for example, electron litography or optical exposure combined with electrochemical deposition. In this way, an embossing member or a "shim" is produced, by which diffractive microstructures can be pro- duced by pressing onto the plasticized surface of a substrate, such as for example hot plastic.
The embossing member is preferably a cylinder placed on a roll. The cylinder is made of a sheet by bending and welding. The welded seam produces a corresponding visible mark during the embossing. The mark is visually distracting in the final product.
Attempts can be made to fade out the welded seam for example by grinding it, but also other solutions have been developed to fade out the seam. One such solution is disclosed in US patent document 6,651 ,338 teaching a method for masking the seam of the outer sur¬ face of the cylinder by laser welding. In said method, a smooth filling is welded by laser welding onto the seam of the cylinder to fade out the seam. In practice, this method is very demanding in order to leave no bulge or groove at the seam.
Summary of the invention
Now, a method has been invented which makes it possible to produce the embossing member by a simple method leaving no groove or seam that would produce a visually distracting mark on the surface of the substrate.
To attain this purpose, the method according to the invention is primar¬ ily characterized in what will be presented in the characterizing part of the independent claim 1. The embossing member according to the invention, in turn, is primarily characterized in what will be presented in the characterizing part of the independent claim 7. The other, depend¬ ent claims will present some preferred embodiments of the invention.
In the method according to the invention, the printing surface of the embossing member is made of one or two metal sheets. The surface of at least one of these sheets is provided with one or more printing zones located on the printing surface of the embossing member. Said printing zone is used for producing a diffractive pattern on the substrate at the printing stage. In the method, at least a first and a second edge of the metal sheet are welded together from the side opposite to the printing surface.
In one advantageous embodiment of the method, the first and second ends of the sheet structure are joined together in such a way that the ends are substantially in the same plane during the joining. Thus, if the ends are straight, a preferably l-shaped weld groove is formed between the ends.
In another advantageous embodiment of the invention, the first and second ends of the sheet structure are joined together by laser weld¬ ing. For the laser welding, it is possible to use, for example, a Nd:YAG laser, a CO2 laser or a diode laser.
In one embodiment of the invention, the space between the first and second edges forms a welded seam with a substantially V-shaped
cross-section, which will be called a weld hereinbelow and which becomes narrower from the side opposite to the printing surface towards the printing surface. In other words, the weld is wider on the side from which the laser beam is introduced in the target, and the opposite side of the weld is narrower, respectively. The weld does not necessarily extend to the same level with the printing surface, but a narrow groove may be formed in it. According to the invention, the width of the groove on the side of the microstructure to be produced may be, for example in one embodiment, in the order of 0.2 mm. The aim is, however, to minimize the width of the groove, wherein in some embodiments, the groove is significantly narrower, for example less than 0.05 mm. A narrow groove does not produce a visually distracting mark on the surface of the substrate.
In one method according to the invention, the cylindrical mantle of the embossing member is made of a sheet structure, such as a nickel sheet, whose first surface is provided with zones for producing a diffractive pattern on the substrate. The first and second ends of the sheeet structure are joined together by welding in such a way that the first surface constitutes the outer surface of the mantle, that is, the printing surface. The ends of the sheet structure are joined together by welding them together from the side opposite to the first side, that is, the inside of the mantle. The joining is preferably made by using laser welding, such as a pulsed Nd:YAG laser or a diode laser.
In another method according to the invention, the embossing member may be made by cutting pieces of a desired shape from a sheet with a microstructure, and laser welding the pieces smoothy by a narrow weld to a larger sheet or a cylinder which has been previously provided with respective cut openings. According to the invention, it is possible to produce an embossing member corresponding to the desired shape of the microstructured areas in a fast and inexpensive way. For producing the desired embossing member, one only needs to store a few types of sheets with a microstructure.
The method according to the invention eliminates the work stages needed in prior art solutions for smoothing out or masking the weld.
The method according to the invention makes it possible to produce the embossing member in a fast and cost-efficient way. The manufac¬ ture of the embossing member by prior art methods of exposure and deposition is expensive and may take several weeks.
The aim is to produce the embossing member in such a way that the root end of the weld groove is filled up to the same level as the surface of the sheet on the side of the microstructure. In some cases, however, the weld may be left incomplete, wherein a groove is formed. Accord¬ ing to one embodiment of the invention, the width of the groove on the side of the microstructure is so small that it does not produce a visually distracting mark on the surface of the substrate.
Description of the drawings
In the following, the invention will be described in more detail with reference to the appended principle drawings, in which
Fig. 1 shows a detail of the invention,
Fig. 2 shows a printing zone forming a diffractive pattern,
Figs 3 to 9 show an embodiment according to the invention,
Fig. 10 shows another embodiment according to the invention, and
Fig. 11 shows a cross-section along line A-A in Fig. 10.
For the sake of clarity, the figures only show the details necessary for understanding the invention. The structures and details that are not necessary for understanding the invention but are obvious for anyone
skilled in the art have been omitted from the figures in order to empha¬ size the characteristics of the invention. The dimensions of the figures have also been chosen in such a manner that the basic idea of the invention is as apparent as possible in the figures. Thus the real dimensions may differ from those shown in the figures.
Detailed description of the invention
Figure 1 shows a part of the cylindrical mantle 1 of an embossing member. The figure shows a sheet structure 2, such as a nickel sheet, whose first surface 3 is provided with printing zones 5 for producing a diffractive pattern on a substrate. The mantle 1 is made by bringing a first edge 6 and a second edge 7 close to each other and by joining the edges together by welding in such a way that the first surface 3 forms the outer surface 3 of the mantle, that is, the printing surface 3.
As seen from Fig. 1 , the space between the first edge 6 and the sec¬ ond edge 7 comprises a weld 8b having a substantially V-shaped cross-section. In practice, the weld 8b is formed wider on the side from which it is welded; that is, the weld becomes wider from the root of the weld towards the surface of the weld. In the figure, said weld 8b becomes narrower from the side 4 opposite to the printing surface, towards the printing surface 3. In other words, the weld 8b is wider inside 4 the cylinder than on the outer surface 3. The aim is to make the weld 8b in such a way that the end of the weld joint preparation 8 on the side of the printing surface 3 is filled up to the same level as the surface of the sheet 2 on the side of the printing surface 3. In some cases, however, the weld 8b does not necessarily extend to the same level as the printing surface 3, but a narrow groove 8a may be formed in it. According to one embodiment of the invention, the width of the groove 8a on the side of the printing surface 3 is as small as possible. For example, the width of the groove 8a may be 0.01 to 0.4 mm. A narrow groove 8a does not produce a visually distracting mark on the surface of the substrate.
Figure 2 shows, in principle, a printing zone 5 for producing a diffractive pattern on a substrate. In the figure, the printing zone 5 is illustrated as being planar, but its shape is naturally dependent on the shape of the embossing member. The embossing patterns of the printing zone 5 are placed on the side of the printing surface 3 of the sheet structure 2.
Figures 3 to 9 show, in principle, a stage relating to the invention for forming the cylindrical mantle 1 of the embossing member of a single metal sheet 2. For the sake of clarity, the figures do not show the printing zones, but these are placed on the outer surface 3 of the mantle. In Fig. 3, the metal sheet 2 is bent in such a way that the edges
6, 7 are placed against each other on substantially the same plane, forming a narrow joint preparation 8 in the seam 10. Figure 4 shows the seam 10 of Fig. 3 in an enlargement. As seen from the figure, the edges 6, 7 of the sheet 2 should be arranged as close to each other as possible to form an abutting joint. In practice, however, a small joint preparation 8 is always left between the edges 6, 7.
In Fig. 5, a laser beam 9 is introduced inside the mantle 1 and is, in the example, directed to the joint 10 formed by the edges 6, 7, that is, to the weld groove formed by the joint preparation 8 between the edges 6,
7. The edges 6, 7 of the ends of the sheets 3 are joined together by welding them together from the side 4 opposite to the outer surface 3, that is, from inside the mantle. The joining is preferably performed by using laser welding, such as a Nd:YAG laser, a CO2 laser or a diode laser.
Figure 6 shows the seam 10 of Fig. 5 in an enlarged view. As seen from Fig. 6, the weld groove, that is, the joint preparation 8 between the edges 6, 7, is formed by welding to become narrower from the side 4 opposite to the printing surface towards the printing surface 3.
Figures 7 and 8, in turn, show the welded mantle 1. In the figure, the joint preparation 8 is partly filled by the welding, forming a weld 8b. The weld does not need to fill the joint preparation 8 completely, but an unfilled groove 8a may be left in the part of the groove on the side of
the printing surface 3. Said groove 8a is preferably so narrow that it does not produce a visually distracting mark on the surface of the substrate. However, it is advantageous to form the weld 8b in such a way that its part on the side of the printing surface 3 is substantially on the same level with the edges 6, 7 of the sheet 2.
In the above example shown in Figs. 3 to 8, the ends 6, 7 of the sheet 2 to be welded together were on the same level at the welding stage. Keeping the seam 10 to be joined planar makes it easier to join the edges 6, 7. After the welding, the mantle 1 may be brought to a desired shape, for example to form a cylindrical structure with a circular cross- section. Such a shape of the mantle 1 is shown in Fig. 9.
In some embodiments, it is also possible to bend the metal sheet 2 to a desired circular shape before the welding and to join the edges 6, 7 by welding from inside the mantle 1. In one embodiment, the edges 6, 7 are bevelled before the joining, wherein a substantially l-shaped joint preparation 8 can be made between the edges in the seam 10, even though the sheet 2 is bent to a cylindrical shape.
In another method shown in Figs. 10 and 11 , the embossing member is made by joining smaller printing sheets 2b to a larger printing sheet 2a. In the example, pieces 2b of a desired shape are cut from a sheet with a microstructure. These smaller pieces 2b are laser welded to the lar- ger sheet 2a (which may also be for example cylindrical and) which has been previously provided with corresponding cut openings. The weld¬ ing is performed from the side 4 opposite to the printing surface. The welds 8b between the different pieces 2a, 2b have a substantially V-shaped cross-section. Said welds 8b become narrower from the side 4 opposite to the printing surface towards the printing surface 3. According to the invention, the width of the possible groove 8a on the side of the printing surface 3 is as small as possible. For example, the width of the groove 8a may be 0.01 to 0.4 mm. A narrow groove 8a does not produce a visually distracting mark on the surface of the substrate. The formed structure may be used as a printing plate, or a
cylindrical structure or another structure may be formed of it. The sheets 2a and 2b may be either equal or different in thickness.
By combining, in various ways, the modes and structures disclosed in connection with the different embodiments of the invention presented above, it is possible to produce various embodiments of the invention in accordance with the spirit of the invention. Therefore, the above- presented examples must not be interpreted as restrictive to the inven¬ tion, but the embodiments of the invention may be freely varied within the scope of the inventive features presented in the claims herein- below.