U.S. patent application number 11/552480 was filed with the patent office on 2007-03-08 for method of making a thin die to be used in a press.
This patent application is currently assigned to Ellison Educational Equipment, Inc.. Invention is credited to David L. Hughes.
Application Number | 20070051204 11/552480 |
Document ID | / |
Family ID | 34102774 |
Filed Date | 2007-03-08 |
United States Patent
Application |
20070051204 |
Kind Code |
A1 |
Hughes; David L. |
March 8, 2007 |
METHOD OF MAKING A THIN DIE TO BE USED IN A PRESS
Abstract
Disclosed is a thin die adapted to be used in a press and a die
press system utilizing the thin die and a die press, such as a
platen die press or a roller die press. The die disclosed herein
includes a base or backing portion that provides rigidity to the
die assembly. The base includes an indentation defining a border
around the peripheral edge of the base. A thin die is housed in the
indentation of the base. The thin die is positioned in the
indentation and adhered using an adhesive, such that the raised
portions of the thin die are facing away from the indentation in
the base. Ejection foam is adhered to the raised portion side of
the thin die by an adhesive so that the ejection foam protects the
raised portion of the thin die and ejects a cut shape out of the
sheet material.
Inventors: |
Hughes; David L.; (Rancho
Santa Margarita, CA) |
Correspondence
Address: |
TOWNSEND AND TOWNSEND AND CREW, LLP
TWO EMBARCADERO CENTER
EIGHTH FLOOR
SAN FRANCISCO
CA
94111-3834
US
|
Assignee: |
Ellison Educational Equipment,
Inc.
Lake Forest
CA
|
Family ID: |
34102774 |
Appl. No.: |
11/552480 |
Filed: |
October 24, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10893104 |
Jul 16, 2004 |
|
|
|
11552480 |
Oct 24, 2006 |
|
|
|
60488570 |
Jul 17, 2003 |
|
|
|
Current U.S.
Class: |
76/107.8 ;
76/107.1 |
Current CPC
Class: |
B23P 15/24 20130101;
B23P 15/406 20130101; B26F 1/44 20130101; B26D 7/1818 20130101;
B26F 1/384 20130101; B26F 2001/4472 20130101; B26F 2001/4436
20130101 |
Class at
Publication: |
076/107.8 ;
076/107.1 |
International
Class: |
B21K 5/20 20060101
B21K005/20 |
Claims
1. A method of making a thin die, comprising the steps of:
providing a steel material; chemical etching a near net shape in
one side of the steel material so that the steel material has a
first flat side and a second side that includes a raised cutting
portion; fixing the steel material into an indentation of a base so
that the first flat side of the steel material is adhered to the
base; and adhering an ejection foam to the second side of the steel
material so that the ejection foam covers the chemical etched
shape.
2. The method of making a thin die according to claim 1, further
comprising exposing the steel material to a secondary etching step
after etching the near net shape.
3. The method of making a thin die according to claim 2, wherein
the chemical etching step is approximately 15 to 30 minutes long,
and more preferably 15 to 25 minutes long.
4. The method of making a thin die according to claim 2, wherein
the secondary etching step is approximately 10 to 30 seconds long
and, more preferably, is approximately 15 to 20 seconds long.
5. The method of making a thin die according to claim 1, wherein
chemical etching the near net shape comprises chemical etching the
raised cutting portion to be approximately 0.001 inches to
approximately 0.008 inches wide.
6. The method of making a thin die according to claim 2, further
comprising adhering a laminated film to the steel material to
define the raised portion prior to chemical etching.
7. The method of making a thin die according to claim 6, further
comprising removing the laminated film prior to exposing the steel
material to the secondary etching step.
8. The method of making a thin die according to claim 2, wherein
the method includes a rinsing step after the secondary etching
step.
9. A method of making a thin die, comprising the steps of:
providing a steel material; chemical etching a near net shape in
one side of the steel material so that the steel material has a
first flat side and a second side that includes a raised cutting
portion; exposing at least the second side of the steel material to
a secondary etching step; fixing the steel material into an
indentation of a base so that the first flat side of the steel
material is adhered to the base; adhering an ejection foam to the
second side of the steel material so that the ejection foam covers
the chemical etched shape; and applying identifying indicia to a
side of the base opposite the steel material.
10. A method of making a thin die, comprising the steps of:
chemical etching a near net shape in one side of a die material to
produce a die portion having a first flat side and a second side
that includes a raised portion; and fixing the die portion into an
indentation of a base so that the first flat side of the die
portion is attached to the base within the indentation.
11. The method of claim 10, wherein fixing the die portion into the
indentation comprises fixing the die portion within the indentation
such that the die portion is substantially surrounded by a
peripheral border.
12. The method of claim 10, wherein fixing the die portion into the
indentation comprises adhering the first flat side of the die
portion to a surface of the indentation of the base.
13. The method of claim 10, wherein the die material comprises
steel material.
14. The method of claim 10, wherein chemical etching the near net
shape in one side of the die material comprises: laminating a dry
film to the die material; exposing the dry film to light to produce
an image on the die material; developing the dry film; removing a
portion of the exposed dry film from the die material; chemical
etching the die material; and stripping remaining dry film from the
die material.
15. The method of claim 10, wherein chemical etching the near net
shape in one side of the die material comprises: laminating a dry
film to the die material; chemical etching the die material;
stripping dry film from the die material; and performing a
secondary etch on the die material.
16. The method of claim 10, further comprising applying an
antioxidant to the die portion.
17. The method of claim 10, further comprising applying an
identifying label to a back-side indentation of the base, the
back-side indentation of the base on a surface of the base opposite
the indentation.
18. The method of claim 10, further comprising applying identifying
indicia to a surface of the base opposite the indentation.
19. The method of claim 10, further comprising adhering an ejection
foam to the second side of the die portion so that the ejection
foam covers at least a portion of the chemical etched shape.
20. The method of claim 10, wherein the net shape comprises a
raised embossing portion.
21. The method of claim 10, wherein fixing the die portion into the
base comprises fixing the die portion into a plastic base.
22. A method of making a thin die, comprising: chemical etching a
near net shape in one side of a die material to produce a die
portion having a first flat side and a second side that includes a
raised portion; fixing the die portion into an indentation of a
base so that the first flat side of the die portion is attached to
the base within the indentation; and applying identifying indicia
to a surface of the base opposite the indentation.
23. The method of claim 22, wherein applying the identifying
indicia comprises applying an identifying label to the surface of
the base opposite the indentation.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 10/893,104, filed on Jul. 16, 2004 (Attorney Docket No.
021919-001720US) which claims the benefit of U.S. Provisional
Application No. 60/488,570, filed on Jul. 17, 2003 (Attorney Docket
No. 021919-001700US), each of which is hereby incorporated by
reference herein in its entirety.
FIELD OF THE DISCLOSURE
[0002] Disclosed is a thin die adapted to be used in a press and,
more particularly, disclosed is a thin die adapted to be used in a
press, a system including a thin die and a press, and a method for
making a thin die adapted to be used in a press.
BACKGROUND OF THE INVENTION
[0003] Dies and sheet cutting presses are used to cut various
patterns out of sheet materials. The presses may take the form of a
platen die press or a roller die press. The presses are designed to
apply uniform pressure to a die to cut through a sheet or a
plurality of sheets simultaneously. Dies also may be used for
embossing images onto sheet materials. Typically, the sheets are
placed between the die and a cutting pad, with the steel rule and
the die extending through the sheets and slightly into the cutting
pad when pressure is applied to the die. Die presses are used
commercially, as well as by consumers. Typically, a variety of
shapes are provided by the various dies available. For example,
typical dies include shapes that range from the letters in the
alphabet, numbers, and various other shapes, such as moons, stars,
animals, trees, and various other shapes.
[0004] Typically, the dies include a base material, such as plywood
or plastic, that houses a steel rule that is formed to the desired
cutting shape. A rubber material is then glued to the plywood or
plastic base so that the rubber extends above the height of the
sharpened edge of the bent steel rule shape, so that the rubber
protects the steel rule and acts as an ejector means to eject the
cut sheet material from the steel rule after the cutting
process.
BRIEF SUMMARY OF THE INVENTION
[0005] Disclosed is a thin die adapted to be used in a press. The
die disclosed herein includes a base or backing portion that
provides rigidity to the die assembly. The base includes an
indentation defining a border around the peripheral edge of the
base. A thin die is housed in the indentation of the base and the
thin die is adhered to the indentation of the base by an adhesive.
The thin die is positioned in the indentation of the base so that
raised portions of the thin die are facing away from the
indentation in the base to allow the thin die to cut into and
emboss a sheet material. Ejection foam is adhered to the raised
portion side of the thin die by an adhesive so that the ejection
foam protects the raised portion of the thin die and provides an
ejection means of the cut out shape of the sheet material.
[0006] Also disclosed is a die and press system utilizing the thin
die disclosed herein. Included in the system is a die press, which
may be a platen die press or a roller die press. The die press
includes a cutting pad that allows the die to cut through the sheet
material and into the cutting pad, if a platen die press is used.
The system further includes a thin die adapted to be used with a
die press. The thin die includes a base portion, a thin die
portion, and an ejection foam portion, wherein the base portion and
the ejection foam portion sandwich the thin die portion so that the
thin die is located in an indentation located in the base and is
adhered to the base by an adhesive. Further, the ejection foam
portion is adhered to the thin die portion so as to protect raised
portions of the thin die portion. The ejection foam protects the
raised portions of the thin die portion and acts as an ejection
means to eject the cut shapes from the sheet material.
[0007] Also disclosed herein is a method of making a thin die,
wherein the method includes the steps of providing a steel
material, chemical etching away a portion of the steel material so
as to leave at least one raised portion on one surface of the steel
material to provide a shape in the steel material. The process
further includes adhering the steel material to a base portion so
that the raised portion of the steel material is exposed on one
side. Further, an ejection foam is adhered to the cutting side of
the steel material to protect the raised portions of the steel die
and to act as an ejection means to eject the cut shape from a sheet
material used in a cutting process.
[0008] In another aspect of the disclosure, a method of making a
thin die is disclosed wherein a second etching process is
incorporated after stripping the laminating film off of the raised
or cutting portion of the die. The second etching step typically
lasts from 10 to 25 seconds, and more preferably from 15 to 20
seconds, depending upon the steel being chemically etched and the
strength and composition of the chemical etching solution. The
secondary etching step removes the sharp edges from the cutting
surface to provide a sharper cut when the thin die is used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure will now be described in greater detail with
reference to the embodiment illustrated in the accompanying
drawings, in which like elements bear like reference numerals and
wherein:
[0010] FIG. 1 illustrates a perspective view of a thin die
according to the present disclosure;
[0011] FIG. 2 illustrates a cross-sectional view taken from line
2-2 of FIG. 1 according to the present disclosure;
[0012] FIG. 2a illustrates a close-up view of a raised portion of a
cutting die.
[0013] FIG. 3 illustrates a bottom-view of the thin die according
to the present disclosure;
[0014] FIG. 3a illustrates a cross sectional view taken along line
3a-3a from FIG. 3.
[0015] FIG. 4 illustrates a system utilizing a platen or roller
press and a thin die according to the present disclosure;
[0016] FIG. 5 illustrates the process of making a thin die
according to the present disclosure;
[0017] FIG. 6 illustrates a top view of the thin die with the
ejection foam removed;
[0018] FIG. 7 illustrates a side profile view of the raised or
cutting edge of the die portion with the laminating film left on
the raised cutting portion, this is what the die portion looks like
after the etching step but before the stripping of the laminating
film; and
[0019] FIG. 8 illustrates the finished die portion after the
laminating film has been removed and after the die portion has been
exposed to a secondary etching process to remove the sharp edges
from the raised cutting portion of the die.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Disclosed is a thin die that is adapted to be used in a die
press, such as a platen die press or a roller die press. As shown
in FIG. 1, disclosed is a thin die, such as a chemical etched die
assembly 100. The die assembly 100 includes a base portion 102 and
an ejection foam portion 104. As will be further described below,
the ejection foam portion 104 has a shape 106 that follows the
contour of a raised portion of the thin die portion of the
assembly. The shapes 106 are defined by shape borders 108. The
shape borders 108 define the shapes 106 in the ejection foam 104
and are created during the first use of the chemical etched die
assembly 100, which the first use may be done at the factory to
test the die or may be accomplished by the user of the die assembly
100. The ejection foam portion 104 includes an ejection foam border
110 that follows a border 112 of the base portion.
[0021] FIG. 2 is a cross-sectional side-view taken from line 2-2 of
FIG. 1. FIG. 2 illustrates how the portions are assembled to
comprise the final assembly configuration of the die assembly 100.
The base portion 102 includes a base portion indentation 202 to
define the base portion peripheral border 112. The chemical etched
die 206 includes a relatively flat portion 207 and an opposite
raised portion as defined by 208 and lower portions 210. The flat
portion 207 of the chemical etched die 206 is adhered to the base
indentation 202 so that the chemical etched die 206 is located in
and surrounded by the base portion peripheral border 112. A layer
of adhesive 204 adheres the chemical etched die flat portion 207 to
the base indentation 202. This adhesive 204 may be a foam adhesive,
a spray adhesive or any other means to adhere the flat portion 207
of the chemical etched die to the base indentation portion 202.
[0022] The ejection foam portion 104 is adhered to the lower
portions 210 of the chemical etched die 206. The ejection foam
portion 104 is adhered to the lower portions 210 of the chemical
etched die 206 by an adhesive 212. The adhesive 212 may be a foam
adhesive, spray adhesive, or any other means to adhere the ejection
foam portion 104 to the lower portions 210 of the chemical etched
die 206. The close-up view shown in FIG. 2a, illustrates one
exemplary embodiment wherein the ejection foam adhesive 212 is
limited to the lower portions 210 of the chemical etched die 206.
In this embodiment, this configuration prevents the ejection foam
material 104 from binding or interfering with the raised portion,
or cutting surface 208 of the chemical etched die 206. In the
alternative, the adhesive is adhered to the lower portions 210, as
well as the raised cutting portions 208. In this embodiment, when
the first use or cut of the die occurs, the raised portion 208 of
the die simply cuts through the adhesive and the ejection foam. The
height of the raised or cutting portion of the die portion is 0.021
inches, with the base of the die portion being 0.010 inches. The
base of the raised or cutting portion of the die portion is
approximately 0.021 inches wide at the bottom and is approximately
0.004 inches wide at the top, with a cutting flat surface of
approximately 0.002 inches wide. Of course these dimensions are
exemplary only and not intended to limit the claims. For example,
the top of the raised cutting portion could range anywhere from
0.001 inches to 0.005 inches, for example without crushing the
material to be cut.
[0023] FIG. 3 illustrates the bottom of the chemical etched die
assembly 100, wherein only the base portion 102 is viewed. The base
portion 102 includes a back-side 300. The back-side 300 includes a
back-side indentation 302. The back-side indentation 302 allows for
a label 304 with identifying indicia 306 to be located in the
back-side indentation 302. As shown in FIG. 3a, which is a
cross-sectional view taken from line 3a-3a from FIG. 3. The depth
of the back-side indentation 302 is greater than the height of
label 304 so that the forces transferred through the die assembly
100 are uniform across the die assembly 100 when the die assembly
100 is used with a die press. This is represented in FIG. 3a
wherein the depth of the back-side indentation 302 is identified by
d and the height of the label 304 is identified by h, wherein
d>h.
[0024] As shown in FIG. 4, the thin die disclosed herein may be
used with a platen die press 402 with a cutting pad 404 and an
optional adaptor 406. In the alternative, the thin die 100
disclosed herein may be used with a roller press 406. Sheet
material 408, which may comprise paper, plastic, leather, or a
variety of other materials, is placed between the thin die 100 and
the cutting pad 404. Pressure is applied to the thin die 100
through the platen press 402 so that the raised portion for the
cutting portion 208 of the chemical etched die portion 206 is
forced into and through the sheet material 408 and into the cutting
pad 404 so that the desired shape is cut out of the sheet material
408. In the alternative, chemical etched die embosses the shape of
the raised portion of the die into the sheet material 408. In this
embodiment, the raised portion 208 is not as sharp so as to not cut
through the sheet material 408 when pressure is applied to the die
from the press.
[0025] If a roller press 406 is used with the thin die 100
disclosed herein, sheet material 408 and the thin die is fed
through the rollers of the roller press 406 so that pressure is
exerted to the thin die 100 and to the sheet material 408 so that
the desired shape is cut out of the sheet material 408. If a roller
press 406 is utilized, the rollers may include a rubber or other
resilient layer so that the raised portion or cutting portion 208
of the chemical etched die 206 does not become damaged when being
fed through the rollers of the roller press 406.
[0026] Also disclosed herein is a method for making a thin die
assembly 100, as disclosed herein. FIG. 5 illustrates the method of
making the thin die, which includes the steps of providing a sheet
of flat stock material that may be a spring steel with a 45 high
hardness or HRC rating. The steel material is cleaned to remove
dirt and oils from the steel surfaces. The steel material is also
degreased to remove the grease from the steel sheet stock material.
The steel sheet stock is then water rinsed to remove any dcgrcasing
material on the steel surfaces. The steel material then may be acid
rinsed to further remove any grease or other particles on the
surfaces of the steel material. The steel material is then again
water rinsed to remove any remaining acid chemicals on the steel
surfaces. The steel material is then scrubbed with a scrubbing
roller. The scrubbing roller may be made of a nylon material. The
steel material is then rinsed again and the steel material is then
dried. The steel material is then dusted to remove any dust on the
steel surfaces. Next, the steel surfaces that are not to be
chemical etched away, are laminated with a dry film. The dry film
may be a dry film with a specification of a YQ-30SD. The dry film
is applied upon to the steel surfaces at a temperature of
115.degree. C. at a pressure of 70 pounds per square inch or psi.
The laminated film is cxposed to make the image and/or the word
into a negative on the steel surface, with the negative result
being on the steel surface being exposed with a strong light. This
developing process is completed at a temperature 12.degree. C. and
a pressure of -720 mmHg. The laminate is developed by the steps of
removing the dry film without exposing the dry film, to get the
image and the word located on a surface of the steel material. A
developing solution includes a chemical known as NaCO.sub.3 at a 1%
solution, and at a temperature of 30.degree. C., and at a pressure
of 1.5 kg/cm.sup.2 and with a contact time of 50 seconds of the
developing solution with the laminated steel material. The steel
material is then water rinsed and blow dried.
[0027] Next, the steel material is chemical etched without the dry
film in with a chemical solution of FeCL.sub.3 to get the image
and/or the word on the steel material. It is this step that creates
the raised or cutting portions 208 and the lower portion 210. It is
the lower portion 210 that is etched away, while the raised portion
or cutting portion 208 remains at the original thickness of the
steel material. The etching process includes a chemical known as
FeCL.sub.3 41%, with a specific gravity of 1.41, HCL 31% with a
specific gravity of 1.151, and PC-420 with a specific gravity of
1.288. Further, this is conducted at a temperature of 48.degree.
C., and a pressure of 3.0 kg\cm.sup.2 and with the steel material
being exposed to this chemical solution approximately 15 to 30
minutes long, and more preferably 15 to 25 minutes long.
[0028] Next, steel material with the resulting chemical etched away
surfaces is water rinsed and blow dried. Next, the dry laminated
film is stripped away from the raised or cutting portion 208 with a
chemical known as NaOH at 5%, at a temperature of 48.degree. C. and
at a pressure of 2.0 kg\cm.sup.2 and at a contact time of 60
seconds. The steel material has the near net shape as shown in FIG.
7 before the laminated film is stripped away from the cutting
portion 208. At this point, in one embodiment, the steel material
is then exposed to a secondary etching step after the dry laminated
film has been stripped away from the raised or cutting portion 208.
The secondary etching process may last anywhere between 10 to 30
seconds, and more preferably lasts 15 to 20 seconds long, depending
upon the composition of the metal being etched and the composition
of the chemical etching solution. FIG. 8 illustrates the steel
material after the dry laminated film has been removed from the
raised or cutting portion 208 and after the steel material has been
exposed to the secondary etching process. More specifically, the
secondary etching process removes edges 501 and 503 shown in FIG.
7. The resulting shape is a die that has a raised cutting portion
208 of approximately 0.021 inches wide and approximately 0.031
inches in overall height, but the height is not limited to this
dimension. The width of the top of the raised portion 208 is
approximately 0.004 inches, and more specifically, the flat cutting
surface is approximately 0.002 inches wide at the top of the raised
or cutting portion 208, but could be 0.001 to 0.005 inches
wide.
[0029] Next, the steel material with the etched net shape is
exposed to a chemical etch process again, without any dry laminated
film located over the raised or cutting portion 208. This takes
away any sharp edges from the raised or cutting portion 208 and
further defines the raised or cutting portion 208. This step is
known as a second etching step. In this step, the steel material
with the near net shape is exposed to the etching chemicals for
approximately 20 to 25 seconds; however, this length of time is
exemplary only and is a function of the thickness of the chemical
etched die and the strength and composition of the chemical etching
materials.
[0030] Next, the steel material is pressure rinsed and blow dried,
and then an antioxidant may be applied to the steel material. The
antioxidant must not interfere with the adhesion of the ejection
foam onto the steel material or the adhesion of the steel material
onto the base portion 102. Next, the resulting steel material,
otherwise known as the chemical etched die portion 206, is applied
to the base portion 102, and then the ejection foam material 104 is
applied to the cutting side of the chemical etched die 206. The
sponge material that is used may be known as PORON, a cellular
urethane foam, part number 470130-25025-04, from Rogers
Corporation, Woodstock, Conn. In the alternative, the sponge
material may be of the neoprene family and, more particularly, a
synthetic neoprene, such as chloroprene rubber, otherwise known as
CR foam. CR foam is a durable and relatively inexpensive foam since
it is synthetic.
[0031] The steel sheet stock that is provided may allow a plurality
of chemical etched dies 206 to be etched from one piece of sheet
stock. Therefore, a plurality of chemical etched dies 206 may be
machined from piece of sheet stock, with the separation of the
individual dies from the sheet stock being accomplished in the
etching step.
[0032] Although this disclosure has been shown and described with
respect to detailed embodiments, those skilled in the art will
understand that various changes in form and detail may be made
without departing from the scope of the present disclosure, for
example, in one embodiment, the steel material is shipped in rolls
for ease of shipping. The steel material is unrolled and cut into
specific sizes to maximize the sheet yield depending upon the size
of the dies to be etched from the sheets. The steel sheets are then
flattened by sending the steel sheets through rollers and then the
steel sheets are cleaned. The material is then cleaned and then the
laminating dry film is applied to the surfaces and the material is
then rinsed prior to the anti-oxidation step. The chemical etching
assembly line may include a number of etching sections for
providing the operator an opportunity to check quality of the
pieces between each etching section or module. Further, a chemical
etching regeneration system, such as the one available from Japan
Aqua Co., Ltd. located in Osaka, Japan helps to control the
chemical composition to the desired rates during the etching
process.
* * * * *