Device and method for the rotary blind embossing of a substrate, and female die

Abstract

The invention relates to a device (1) for the rotary blind embossing of a substrate (3), wherein the device (1) comprises a workstation (1a) which comprises a magnetic embossing roller (2a) and a counter-pressure roller (2b), at least one female die (4a) is magnetically installed on the magnetic embossing roller (2a) and at least one male die (4b) is positioned on the counter-pressure roller (2b), the at least one female die (4a) is multi-layered and has at least one first metal layer (8) made of a ferromagnetic material, and the at least one female die (4a) has a film (7) on face facing the magnetic embossing roller (2a).

Description

[0001] Device and method for rotary blind embossing of a substrate and die

[0002] The invention relates to a device for rotary blind embossing of a substrate, a die and a method for rotary blind embossing of a substrate.

[0003] Blind embossing is widely used to finish substrates such as packaging. This process creates a specific pattern, motif, or lettering in the substrate using a matrix and a male die. With relief embossing, the pattern, motif, or lettering is embossed, while with debossing it is embossed into the substrate. Typically, blind embossing is carried out either as stroke embossing or as cylinder embossing, which is also known as rotary blind embossing. With rotary blind embossing, the substrate to be embossed is guided between an embossing roller and a counter-pressure roller, and depressions and / or elevations are embossed into the substrate using appropriate forms, so-called matrixes and male dies. For this purpose, the embossing roller is equipped with matrixes and the counter-pressure roller is equipped with male dies. Depending on the motif to be embossed, the matrixes and male dies are mounted or attached to the respective rollers in an interchangeable manner.The male mold forms the so-called male shape, and the female mold the corresponding female shape. The female mold on the embossing cylinder and the male mold on the impression cylinder must be aligned in register with each other so that the overlap area, i.e., the area where the female mold meets the male mold, is essentially precisely aligned. Accurate positioning is important for the embossing quality and, secondly, to prevent damage to the female and / or male molds.

[0004] For example, DE 102018102638 A1 discloses a rotary blind stamping process and device. This process utilizes magnetic rollers on which the dies and male dies are magnetically positioned. The use of magnetic dies and male dies offers the significant advantage that they can be easily replaced, no residues, such as adhesive, remain on the roller, and short changeover times are achieved compared to screwing or gluing dies and / or male dies. The alignment of the magnetic dies and male dies is achieved using an adjustment aid, a so-called window plate. The window plate has webs and window areas in which the dies and / or male dies are later positioned. This window plate is first placed on the respective roller and held in place by a magnet.The dies and / or male dies, which have a steel underside, are then positioned in the window areas on the magnetic rollers. The underside of the dies and / or male dies is then attracted by the magnet in the magnetic roller and held on the surface of the roller. The disadvantage of this, however, is that with increasing operating time, the dies and / or male dies move longitudinally on the roller. This leads to the embossing on the substrate no longer being able to be formed into a print in register. However, it can also lead to the die being no longer congruent or in register with the male die in the overlap area. This inevitably leads to damage to the die and / or male die and thus also to a deterioration in the embossing result.

[0005] The invention is based on the object of providing an improved method and an improved device for blind embossing a substrate, in particular wherein the register accuracy or

[0006] The positional stability of the die magnetically attached to the embossing roller is improved. Furthermore, the invention is based on the object of providing an improved die for use in a blind embossing device.

[0007] This object is achieved by a device for the rotary blind embossing of a substrate, wherein the device comprises a workstation comprising a magnetic embossing roller and a counter-pressure roller, wherein at least one die is magnetically arranged on the magnetic embossing roller and at least one male die is arranged on the counter-pressure roller, wherein the at least one die is multi-layered and has at least a first metal layer made of a ferromagnetic material. It is essential that the at least one die has a foil on the side facing the magnetic embossing roller.

[0008] This object is further achieved by a die, in particular for use in a device according to one of claims 1 to 22, wherein the die is multilayered and has at least a first metal layer made of a ferromagnetic material. It is essential that the die has a foil on its underside.

[0009] This object is also achieved by a method for the rotary blind embossing of a substrate, in particular using a device according to one of claims 1 to 22, wherein the method comprises the following steps, in particular in the following order: a) providing a substrate; b) arranging at least one matrix, in particular according to one of claims 23 to 35, on a magnetic embossing roller; c) arranging at least one male die on a counter-pressure roller; d) blind embossing the substrate by means of the at least one matrix and the at least one male die.

[0010] It has been shown that the device for rotary blind embossing of a substrate, as well as the die and method for rotary blind embossing of a substrate, increase the holding force of the die on the magnetic embossing roller, particularly under tangential stress, by up to 50% or more than 50%, compared to conventional, prior-art dies that are attached to the embossing roller by magnetic force. This approximately 50% higher holding force ensures that at least one die on the embossing roller maintains its position during the processing time or maintains it for longer than conventional dies. This significantly reduces maintenance work. Furthermore, it also ensures that the embossing quality remains consistently high throughout the processing cycle.At the same time, the positional stability and / or registration of the die on the magnetic embossing roller ensures that the at least one male die is not damaged. This also ensures consistent embossing quality. Another advantage is that the at least one die can be relatively easily removed from the magnetic embossing roller by radially lifting it away from the magnetic embossing roller. This solution allows the device to be easily converted and the dies can be exchanged for a new embossing series without leaving adhesive residue on the embossing roller or without having to loosen screws or other fastening devices. This also reduces changeover times accordingly.Blind embossing is understood here, in particular, to mean relief embossing without the use of ink, in particular a printing ink, and / or without the use of a transfer foil, in particular a hot stamping foil or cold stamping foil. Preferably, a pattern, motif, or lettering is embossed into the substrate, with the pattern, motif, or lettering being raised in particular in the case of embossing, and / or the pattern, motif, or lettering being embossed into the substrate in a debossed manner.

[0011] A matrix is ​​understood here in particular to mean an embossing tool which has the corresponding relief shape as elevations and / or depressions, wherein the matrix preferably has the relief shape of the relief embossing to be achieved in a mirrored arrangement, ie in an arrangement which is not immediately readable.

[0012] A male die is understood here in particular to mean an embossing tool which has the corresponding relief shape as elevations and / or depressions, wherein the male die preferably has the relief shape of the relief embossing to be achieved in a non-mirrored arrangement, ie in a readable arrangement.

[0013] The die and the male die fit together in such a way that the relief embossing is created in a legible form on the substrate. Preferably, the die acts on the substrate from the top side and the male die from the bottom side, with the top side of the substrate representing the viewing side in the substrate's later use.

[0014] The die and patrix can in particular also be arranged upside down to the arrangement described above, for example if a transparent substrate is to be viewed from the underside of the substrate in its later use. Register or registration or register accuracy or registration accuracy is to be understood in particular as the positional accuracy of two or more elements and / or layers relative to one another, here for example the precise positional arrangement of the embossing and other features applied to the substrate, such as a print, layers applied to the substrate and / or fold lines or crease lines, relative to one another. The register accuracy should advantageously lie within a predetermined tolerance and be as small as possible. At the same time, the register accuracy of several elements and / or layers relative to one another is expediently an important feature in order to increase process reliability.Precise positioning can be achieved, in particular, using sensor-based, preferably optically detectable, fiducials or register marks. These fiducials or register marks can either represent specific, separate elements, regions, or layers, or they can themselves be part of the elements, regions, or layers to be positioned.

[0015] The underside is preferably understood to mean the side of the at least one die which, in the installed state, faces the embossing roller.

[0016] Further advantageous embodiments of the invention are described in the subclaims.

[0017] It is advantageous in step d) that the substrate is blind embossed in such a way that the substrate has at least one elevation and / or depression.

[0018] An elevation and / or depression of the substrate is understood in particular to mean a relief form representing a pattern, motif, or writing and which is preferably arranged either raised (embossing) or recessed (debossing) relative to an unprocessed area of ​​the substrate. An elevation of the substrate is preferably a raised embossing, so that the pattern, motif, or writing is embossed into the substrate in a raised manner. A depression of the substrate is preferably a debossing, so that the pattern, motif, or writing is embossed into the substrate in a recessed manner.

[0019] Furthermore, it is advantageous if the at least one elevation and / or depression of the substrate in step d) is created with a height and / or depth of at least 0.01 mm, preferably at least 0.03 mm, more preferably at least 0.1 mm. This allows visually and haptically appealing blind embossing to be created.

[0020] Preferably, in step b), the arrangement of the at least one die is carried out by means of a positioning system, in which the positioning system interacts with the magnetic embossing roller in such a way that the magnetic embossing roller is rotated by a predefined angle of rotation in order to determine the position of the at least one die in the radial direction of the magnetic embossing roller, and that the position of the at least one die in the axial direction of the magnetic embossing roller is subsequently determined. It may also be possible for the at least one die to be placed along a stop in step b) and then magnetically fastened to the surface of the magnetic embossing roller. The positioning system thus allows several dies to be applied to the embossing roller in a space-saving manner. This meansThe distance between the individual dies can be significantly reduced by using the positioning system, compared to, for example, window plates or other positioning aids. The stop preferably specifies the position in which the die is applied to the magnetic embossing roller. The die is preferably manually placed against the stop and then attached to the magnetic embossing roller using the magnet or magnetic force.

[0021] It may also be possible for the at least one die to be bent before step b) or in step b), in particular so that the curvature of the die substantially corresponds to the curvature of the magnetic embossing roller. In particular, it is possible for the at least one die to be deformed such that the at least one die has a curvature that substantially corresponds to the curvature of the magnetic embossing roller. This adapts the shape of the die to the shape of the magnetic embossing roller, so that the die can be used for rotary blind embossing.

[0022] Rounding is preferably understood here as a radius of curvature, wherein the radius of curvature corresponds in particular to the radius of a circle of curvature, which at a certain point of a curve is the circle that best approximates the curve at this point.

[0023] In particular, it is possible that in step b) the at least one die is arranged on the magnetic embossing roller such that the film faces the surface of the magnetic embossing roller. This advantageously results in the adhesive force of the die on the magnetic embossing roller being significantly increased against approximately tangentially acting forces, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside. This is due in particular to the fact that the film, in particular which is formed from a thermoplastic elastomer, conforms to both the first metal layer of the die and the outer circumference of the magnetic embossing roller. This reduces air pockets between the die and the magnetic embossing roller, resulting in a "vacuum effect."In other words, this means that the die has an increased adhesive force in the tangential direction, whereby any displacement of the die during the embossing process and due to the tangential forces occurring during the embossing process is reduced or even completely prevented. Thus, the positional stability or registration accuracy of the at least one die is maintained throughout the entire embossing cycle. Furthermore, the at least one die can still be easily removed from the magnetic embossing roller by preferably lifting it radially from the magnetic embossing roller. In doing so, only the magnetic force of the magnetic embossing roller needs to be overcome. The effects of the increased adhesive force due to the foil on the side of the die facing the surface of the magnetic embossing roller therefore occur only slightly or not at all in the radial direction of the magnetic embossing roller.

[0024] Furthermore, corresponding comparative tests were carried out in which, for the sake of simplicity, a flat die was carried out on a flat magnetic surface which is similar in composition to the magnetic embossing roller. This simplification was made because with this test setup the force can always be applied in the tangential direction. With a curved surface, on the other hand, the force would only be applied at a single point or in a single line in the tangential direction. At all other points, forces in the radial direction would also occur in addition to forces in the tangential direction. Two die samples were prepared for the test. The first sample is a state-of-the-art die, i.e. the underside of the die is made of steel. The second sample is a die according to the invention in which a foil is arranged on the underside of the steel layer.The film used in the comparative test is a polypropylene film with an adhesive coating, designated "PP CLEAR TC 30 / RP37 / HD-FSC" ("PP Clear" = biaxially oriented, transparent, glossy polypropylene film with a thickness of 30 μm; "TC 30" = topcoat / print coating; "RP37" = with water-based dispersion acrylate adhesive (PSA) coating; "HD-FSC" = with removable glassine backing paper to protect the dispersion acrylate adhesive (PSA) coating before the film is applied) from UPM Raflatac. The two samples each measure 5.0 cm x 10.0 cm and thus cover an area of ​​50 cm. 2Furthermore, a hole was drilled into each sample, into which the hook of a digital force measuring device "SAUTER FC 1 K" was hooked using a carabiner. For the test, the surfaces of the die and the magnetic surface were first cleaned and deoiled. Then, one after the other, the die samples were placed on the magnetic surface and the force required to move the die from the magnetic surface was measured in the tangential direction using the suitcase scale. For the conventional die according to the prior art, an average force of 164 N was measured. In contrast, an average force of 257 N was measured for the die according to the invention. Thus, the measured adhesive force or holding force in the tangential direction of the die according to the invention is over 50% higher than for conventional dies.A further increase in the holding force in the tangential direction can be achieved by selecting other suitable polymer materials. Preferably, the holding force per area of ​​the at least one die on the magnetic embossing roller is at least 5 N / cm against approximately tangentially acting forces. 2 amounts.

[0025] In particular, it can be provided that in step c), at least one carrier plate is first arranged on the circumference of the counter-pressure roller. The carrier plate serves, in particular, to accommodate the at least one male mold. This can be done in different ways, as described below.

[0026] For example, it can be provided that in step c) according to a first variant I), a master cardboard sheet is arranged, in particular glued, on the carrier sheet, and preferably the master cardboard sheet is moistened, and the master cardboard sheet is embossed with the at least one matrix arranged on the magnetic embossing roller in order to form the at least one male mold in the master cardboard sheet. The moistening is preferably carried out by means of a spraying device that applies a light spray mist to the master cardboard sheet. The moistening softens the master cardboard sheet, and the contour of the matrix can thus be more easily embossed into the master cardboard sheet as a counter-mold.

[0027] It is also possible that in step c) during embossing according to the first variant I) the matrix cardboard sheet is compacted, in particular whereby the moisture is pressed out of the matrix cardboard sheet.

[0028] It can also be provided that in step c) during embossing according to the first variant I), the magnetic embossing roller is heated, in particular with a temperature in the range from 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C, in order to dry the matrix cardboard sheet so that the at least one male part solidifies.

[0029] Alternatively, it may also be possible for the at least one male mold to be provided with a double-sided adhesive tape on its side facing the counter-pressure roller in step c) according to a second variant II). The male mold is preferably glued or attached to the counter-pressure roller, in particular the carrier sheet, using the double-sided adhesive tape. The male mold can, for example, comprise materials selected individually or in combination from: plastic, silicone, rubber, brass.

[0030] It is preferably provided that in step c) according to the second variant II) the male part is bonded in a form-fitting manner to the at least one female part by means of an adhesive or adhesive tape or adhesive pieces and then the at least one male part is applied to the counter-pressure roller, in particular by bringing the embossing roller into contact with the counter-pressure roller. It is preferably provided that the adhesive tape facing the counter-pressure roller has a higher adhesive force than the adhesive or adhesive tape or adhesive pieces facing the female part. This ensures that when the at least one male part is brought into contact with the counter-pressure roller, the at least one male part is firmly attached to the counter-pressure roller and the male part is released from the female part. Furthermore, it is provided that any adhesive residues on the upper side of the male part, i.e. the side facing the female part, are removed.Similarly, adhesive residues on the top side of at least one matrix can also be removed.

[0031] Alternatively, it may also be possible that in step c) according to a third variant III) a UV-curable plastic is applied at least partially or over the entire surface of the carrier sheet, which is at least partially pre-crosslinked using a UV pre-curing light source, and then the pre-crosslinked UV-curable plastic is embossed using the at least one matrix, so that at least one male mold is introduced into the pre-crosslinked UV-curable plastic and finally the pre-crosslinked UV-curable plastic is fully cured using a UV final curing light source. By pre-crosslinking the UV-curable plastic, the viscosity of the UV-curable plastic is increased to such an extent that it retains its shape independently, but is nevertheless deformable to such an extent that it can be deformed by external forces. This ensures that the contour of the at least one matrix is ​​imprinted as a counter-mold in the UV-curable plastic.Once the contour has been embossed, the UV-curable plastic is fully cured. From this point on, the UV-curable plastic can no longer be deformed without causing breakage or destruction of the UV-curable plastic. Preferably, the magnetic embossing roller and the counterpressure roller are driven in opposite directions at corresponding rotational speeds. It is also possible for the magnetic embossing roller and the counterpressure roller to be driven in opposite directions at corresponding rotational speeds.

[0032] In this case, the at least one die and the at least one male die preferably engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die, in particular in an overlap region of the at least one die and the at least one male die, is embossed. It is also possible for the at least one die and the at least one male die to be arranged in such a way that they engage with each other during each revolution in such a way that the substrate located between the at least one die and the at least one male die, in particular in an overlap region of the at least one die and the at least one male die, can be embossed.

[0033] In particular, it is provided that the ratio of the diameter of the embossing roller to the diameter of the counter-pressure roller is 1 to 2, preferably 1 to 1.

[0034] It is further advantageous that the substrate is embossed in such a way that the deviations between the embossments of each cycle are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

[0035] The procedure shall conveniently further comprise the following step:

[0036] - Feeding the substrate to the workstation comprising the magnetic embossing roller and the counterpressure roller. Furthermore, it is useful if the method further comprises at least one of the following steps, which are carried out in one or more additional workstations:

[0037] - Printing the substrate;

[0038] - Cold stamping of the substrate;

[0039] - Hot stamping of the substrate;

[0040] - Braille blind embossing of the substrate;

[0041] - Separating, in particular cutting, the substrate;

[0042] - Creasing and / or folding the substrate.

[0043] It is also possible for the device to further comprise one or more additional workstations for printing the substrate and / or for cold embossing the substrate and / or for hot embossing the substrate and / or for blind Braille embossing the substrate and / or for separating, in particular cutting, the substrate and / or for creasing and / or folding the substrate. Preferably, the one or more additional workstations are arranged before and / or after the workstation comprising the embossing roller and the counterpressure roller.

[0044] Printing is preferably carried out using offset printing, screen printing, gravure printing, letterpress printing, flexographic printing, or inkjet printing. Furthermore, it is preferred if the printing is produced using a printing roller. During printing, one or more printing inks are advantageously applied to the substrate, in particular according to a printing pattern. The substrate is preferably separated by punching, with the substrate being separated, in particular, using a cutting tool and / or punching tool.

[0045] During grooving, the bendability of the substrate is preferably changed using a pressing tool, in particular by material displacement. Folding is preferably understood as the creation of a sharp folded edge using a tool. According to a further embodiment of the invention, the substrate is preferably processed continuously.

[0046] It is also advantageous, particularly in step a), that the substrate is provided as a sheet. The sheet can be provided in particular as a stack of sheets, or alternatively, the substrate can be provided as a roll, which is cut into individual sheets, particularly inline, using a roll cross cutter, thus providing the substrate as a sheet.

[0047] Furthermore, it is preferred if the deviations between the embossings on the sheets of the substrate provided as sheet goods are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

[0048] Furthermore, it is possible that by means of the method and / or the device more than 8000 sheets per hour, preferably more than 10000 sheets per hour, more preferably more than 12000 sheets per hour, even more preferably more than 15000 sheets per hour, of the substrate provided as sheet material are processed.

[0049] Preferably, the magnetic embossing roller comprises a permanent magnet and / or is designed as a magnetic cylinder. This allows for simple and rapid loading of the magnetic embossing roller with at least one die or multiple dies.

[0050] It may also be possible for the magnetic embossing roller to be temperature-controlled, in particular wherein the magnetic embossing roller has a temperature in the range from 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C. Temperature control is particularly advantageous when, as mentioned above, the at least one male mold is embedded in a matrix cardboard or

[0051] Sheet of maternal cardboard by means of which at least one matrix is ​​formed or embossed.

[0052] In particular, it is possible for the counter-pressure roller to have a permanent magnet and / or for the counter-pressure roller to be designed as a magnetic cylinder. This allows, for example, a carrier plate to be easily arranged or attached to the counter-pressure cylinder.

[0053] It can also be provided that at least one carrier plate is arranged on the circumference of the counter-pressure roller, wherein on the carrier plate

[0054] I) a matrix carton is arranged in which at least one corresponding male mold is molded to the at least one female mold; or

[0055] II) at least one corresponding male die is arranged to the at least one female die; or

[0056] III) a UV-curable plastic is applied over a large area, in which at least one corresponding male mold is molded to the at least one female mold.

[0057] This makes it possible, for example, for the at least one male part to be made of a softer material, selected individually or in combination from plastic, silicone, rubber, or brass, than the at least one female part. This preferably achieves a good stamping result, particularly since the softer male part adapts to the relief shape of the harder female part, which is made of metal, for example.

[0058] It may also be possible for the device to comprise a positioning system for arranging the at least one die on the embossing roller, wherein the positioning system has a movable stop. Preferably, the stop serves to precisely position the at least one die on the magnetic embossing roller.

[0059] It may also be possible for the positioning system to be located in close proximity to the magnetic embossing roller and to interact with the magnetic embossing roller.

[0060] Advantageously, it is provided that the position of the at least one die in the radial direction of the magnetic embossing roller can be defined via the angle of rotation of the magnetic embossing roller and the position of the at least one die in the axial direction of the magnetic embossing roller can be defined via the position of the stop.

[0061] It may also be possible for the at least one female die and / or the at least one male die to have at least one elevation and / or depression, which in particular corresponds to the relief shape to be embossed in positive and / or negative form. Furthermore, it is possible for the at least one elevation and / or depression to represent a pattern, motif, or writing. A pattern can be, for example, a graphically designed outline, a figurative representation, an image, a symbol, a logo, a portrait, and the like. Writing can be, for example, an alphanumeric character, a text, and the like.

[0062] It is furthermore advantageous that the at least one elevation of the at least one female die and / or of the at least one male die has a height of at most 5.0 mm, preferably of at most 3.0 mm, more preferably of at most 1.0 mm, even more preferably of at most 0.5 mm, and / or that the at least one depression of the at least one female die and / or of the at least one male die has a depth of at most 5.0 mm, preferably of at most 3.0 mm, more preferably of at most 1.0 mm, even more preferably of at most 0.5 mm. It is possible for the at least one elevation and / or depression of the at least one female die and / or of the at least one male die to have a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, prismatic-flat, pointed or mixtures of these shapes.

[0063] Furthermore, it is possible that the at least one elevation and / or depression of the at least one female mold and / or the at least one male mold is designed in several stages, in particular sculptured, in its height and / or depth.

[0064] "Sculpted" preferably refers to a relief form that represents or forms a sculpture, a motif, a pattern, or writing. Preferably, the at least one elevation and / or depression of the at least one female die and / or the at least one male die has at least one side flank, wherein the angle between the at least one side flank and a line running parallel to the surface of the at least one female die and / or the at least one male die is between 0° and 180°, preferably between 45° and 135°, more preferably between 80° and 100°, and even more preferably between 85° and 95°.

[0065] Furthermore, it is expedient if the at least one elevation and / or depression has a round shape such that the shape of the elevation and / or depression is essentially defined by a circular segment, in particular with a radius between 0.1 mm and 2.5 mm, preferably between 0.3 mm and 0.7 mm. The shape of the elevation and / or depression can also be essentially elliptical, with the smaller radius of the ellipse having a dimension between 0.1 mm and 2.5 mm, preferably between 0.3 mm and 0.7 mm.

[0066] It is also advantageous if the at least one female die has a thickness in a range from 0.1 mm to 5 mm, preferably from 0.5 mm to 3 mm, and / or the at least one male die has a thickness in a range from 0.1 mm to 5 mm, preferably from 0.5 mm to 3 mm.

[0067] In particular, it is possible for the first metal layer to comprise a material or combination of materials selected from: iron, ferrites, cobalt, and / or nickel. Preferably, the first metal layer may be steel.

[0068] Preferably, the first metal layer has a thickness in the range of 0.05 mm to

[0069] 1.5 mm, preferably from 0.1 mm to 1 mm, more preferably from 0.15 mm to 0.5 mm.

[0070] It can also be provided that the die comprises a second metal layer, in particular wherein the second metal layer comprises a material or combination of materials selected from: brass, bronze, copper, nickel, zinc, tin, lead, iron, and / or steel. The second metal layer is preferably the layer facing the substrate or the at least one male die. The elevations and / or depressions are preferably incorporated into the second metal layer. The second metal layer is preferably made of brass.

[0071] Preferably, the second metal layer has a thickness in the range of 0.3 mm to

[0072] 2.5 mm, preferably from 0.5 mm to 2 mm, more preferably from 1 mm to 1.2 mm.

[0073] It is preferably provided that the first metal layer is made of steel and the second metal layer is made of brass.

[0074] It is advantageous if the matrix comprises an adhesive layer. The adhesive layer is preferably arranged between the first metal layer and the second metal layer. Furthermore, it is advantageous if the adhesive layer is a hot-melt or cold-melt adhesive layer.

[0075] It is also possible for the adhesive layer to be a two-component adhesive (2K adhesive), in particular comprising epoxy resins. Preferably, the adhesive layer is a 2K epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.

[0076] Furthermore, it is also advantageous if the adhesive layer is a double-sided adhesive tape. Preferably, the carrier material of the double-sided adhesive tape is coated on both sides with a pressure-sensitive adhesive (PSA). Such double-sided adhesive tapes can be purchased, for example, from tesa, Norderstedt, Germany.

[0077] Furthermore, it is useful if the adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.

[0078] It is preferably provided that the film is or comprises a plastic film, in particular wherein the film is formed from a thermoplastic elastomer. As already mentioned above, the film is preferably arranged on the side of the die facing the magnetic embossing roller. In particular, the film thus forms the bottom layer of the die. The film advantageously has the effect that the adhesive force of the at least one die on the magnetic embossing roller with respect to approximately tangentially acting forces is significantly increased, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside, which are also magnetically attached to a magnetic embossing roller. It is preferably provided that the adhesive force per area of ​​the at least one die on the magnetic embossing roller with respect to approximately tangentially acting forces is at least 5 N / cm 2 amounts.

[0079] Thermoplastic elastomers (TPE) are a group of materials that can be processed and recycled like thermoplastics, but have similar properties and performance to thermosetting rubber materials. Thermoplastic elastomers preferably have a hardness of 20 Shore A to 65 Shore D.

[0080] Thermoplastic elastomers can preferably be block copolymers or thermoplastic-elastomer compounds. Block copolymers are structures that contain two different monomers in a single polymer chain. Examples of block copolymers are thermoplastic polyurethane, thermoplastic polyester, thermoplastic polyamide, or thermoplastic block copolymer. Thermoplastic-elastomer compounds are preferably produced by blending elastomers and thermoplastics in a molten state. Examples of thermoplastic-elastomer compounds are thermoplastic vulcanizers or thermoplastic polyolefins. Preferably, all thermoplastic elastomer types have two or more polymer phases, one hard and one soft. Upon solidification below the melting temperature, the hard regions of the various chains combine to form hard thermoplastic parts, while the soft regions form elastomeric parts.

[0081] In particular, it is provided that the film has a thickness in a range from 20 pm to 250 pm, in particular from 30 pm to 150 pm.

[0082] It is preferably provided that the film, in particular on the side facing the first metal layer, has a film adhesive layer, which is formed in particular from a pressure-sensitive adhesive (PSA). Alternatively, the film adhesive layer can also be multi-layered and / or comprise a hot-melt adhesive and / or a two-component adhesive. Furthermore, it is expedient if the film adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.

[0083] In particular, it is provided that the die has a layer structure, in particular in the following order, starting with the layer facing the embossing roller:

[0084] - foil;

[0085] - optional foil adhesive layer;

[0086] - first metal layer;

[0087] - adhesive layer;

[0088] - second metal layer.

[0089] In other words, this means that the foil forms the underside of the die, and the second metal layer forms the top side of the die. The "top side" refers to the side facing the substrate or the male part.

[0090] It can also be provided that the matrix has at least one elevation and / or depression which corresponds in particular to the relief shape to be embossed in positive and / or negative form.

[0091] It is preferably provided that the at least one elevation of the die has a height of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm, and / or that the at least one depression of the die has a depth of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm. In particular, it is provided that the at least one elevation and / or depression of the die has a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, pointed or mixtures of these shapes.

[0092] It can also be provided that the die is rounded, in particular that the die is deformed such that the die has a curvature that essentially corresponds to the curvature of a magnetic embossing roller on which the die is arranged. For this purpose, it can be provided that the die is bent accordingly before being attached to the magnetic embossing roller.

[0093] It is particularly expedient during the production of the at least one die that the at least one elevation and / or depression is engraved and / or milled, in particular by means of a computer-controlled engraving machine and / or a computer-controlled milling machine.

[0094] It is also possible that at least one elevation and / or depression is produced photolithographically.

[0095] Furthermore, it is possible that the at least one elevation and / or depression is produced by means of a laser, in particular by laser ablation.

[0096] It has been shown that, in particular when producing the at least one die by means of a computer-controlled engraving machine and / or milling machine, dies can be produced which are characterized by particularly good embossing results, in particular with which fine contours in the form of correspondingly embossed elevations and / or depressions of the substrate can be produced.Furthermore, it is advantageous, in particular during the production of the matrix, that the method further comprises the following step, which is carried out in particular before the step of producing the at least one elevation and / or depression in the surface of the matrix: - reducing the defined shape of the at least one elevation and / or depression in the surface of the matrix by a predetermined shortening factor, wherein the shortening factor is in particular between 0.95 and 1, preferably between 0.9750 and 0.9999, more preferably between 0.98000 and 0.99999, even more preferably between 0.99000 and 0.9999. Advantageously, the predetermined shortening factor is determined as a function of the diameter of the magnetic embossing roller and / or the counter-pressure roller. It is also possible for the predetermined shortening factor to be determined as a function of the embossing length and / or a printing length, in particular on the substrate.It has been shown that the embossing result can be further improved by such a shortening factor, since this can compensate for a possible distortion or elongation of the relief to be embossed, in particular due to the curvature of the embossing roller and / or the counter-pressure roller on the substrate.

[0097] Furthermore, it is advantageous if the defined shape of the at least one elevation and / or depression in the surface of the die is distorted according to a predetermined distortion factor, in particular along a surface normal of the plane spanned by the die. Thus, it is possible for the at least one elevation and / or depression to exhibit a distortion, in particular along a surface normal of the plane spanned by the die.

[0098] In the following, exemplary embodiments of the invention are explained with the aid of the enclosed figures, which are not to scale. Fig. 1a to 1c schematically show a device and a

[0099] Process for rotary blind embossing;

[0100] Fig. 2 shows schematically a device for rotary

[0101] blind embossing;

[0102] Fig. 3 shows schematically a device for rotary

[0103] blind embossing;

[0104] Fig. 4 shows schematically a section of the device, in particular showing the positioning system;

[0105] Fig. 5a shows schematically a sectional view of a die;

[0106] Fig. 5b shows a schematic sectional view of a male part;

[0107] The figures illustrate various examples of embodiments of the invention. Identical or equivalent components have been provided with the same reference symbols. Where the embodiments illustrated in the figures have common features, these common features have been omitted from being described multiple times to avoid repetition. The respective differences between the embodiments are described in relation to the figures. It goes without saying that a person skilled in the art can modify individual embodiments or combine individual features of these embodiments within the scope of the claims.

[0108] Fig. 1a to Fig. 1c schematically show a device 1 for rotary blind embossing. The device 1 for rotary blind embossing of a substrate 3 comprises a workstation 1a, which comprises a magnetic embossing roller 2a and a counter-pressure roller 2b, wherein at least one matrix 4a is magnetically arranged on the magnetic embossing roller 2a and at least one patrix 4b is arranged on the counter-pressure roller 2b, wherein the at least one matrix 4a is multi-layered and has at least a first metal layer 8 made of a ferromagnetic material and that the at least one matrix 4a has a film 7 on the side facing the magnetic embossing roller 2a.

[0109] The foil 7 on the side of the die 4a facing the magnetic embossing roller 2a advantageously results in the adhesive force of the die 4a on the magnetic embossing roller 2a being significantly increased against approximately tangentially acting forces, in particular by up to 50% or more than 50%, compared to conventional dies with a steel underside. This is due in particular to the fact that the foil 7, in particular which is formed from a thermoplastic elastomer, conforms to both the first metal layer 8 of the die 4a and the outer circumference of the magnetic embossing roller 2a. This reduces air pockets between the die 4a and the magnetic embossing roller 2a, resulting in a "vacuum effect."In other words, this means that the die 4a has an increased adhesive force in the tangential direction, which reduces or even completely prevents any displacement of the die 4a during the stamping process and due to the tangential forces occurring during the stamping process. Thus, the positional stability or

[0110] Register accuracy of the die 4a is maintained throughout the entire embossing cycle. Preferably, the adhesive force per area of ​​the at least one die 4a on the magnetic embossing roller 2a against approximately tangentially acting forces is at least 5 N / cm 2Furthermore, the die 4a is still easy to remove from the magnetic embossing roller 2a by lifting it, preferably radially, from the embossing roller 2a. In doing so, only the magnetic force of the magnetic embossing roller 2a needs to be overcome. The effects of the increased adhesive force due to the film 7 on the side of the die 4a facing the surface of the magnetic embossing roller 2a thus occur only slightly or not at all in the radial direction of the magnetic embossing roller 2a.

[0111] By means of the device 1 shown in Fig. 1a, as shown in Fig. 1a to Fig. 1c, a method for the rotary blind embossing of a substrate 3 in the work station 1a comprising a magnetic embossing roller 2a and a counter-pressure roller 2b is carried out, wherein the method comprises the following steps, in particular in the following order: a) Providing a substrate 3; b) Arranging at least one matrix 4a on a magnetic embossing roller 2a; c) Arranging at least one male mold 4b on a counter-pressure roller 2b; d) Blind embossing the substrate 3 by means of the at least one matrix 4a and the at least one male mold 4b.

[0112] In the embodiment shown in Fig. 1a, the die 4a is already arranged on the magnetic embossing roller 2a. The arrangement of the die 4a is described in detail in Fig. 4. Furthermore, in Fig. 1a, the die 4a is also already arranged on the counter-pressure roller 2b. Fig. 1a thus shows the preparation of the substrate 3. Subsequently, as shown in Fig. 1b, the substrate 3 is embossed or blind embossed by means of the die 4a arranged on the magnetic embossing roller 2a and the male die 4b arranged on the counter-pressure roller 2b.

[0113] As shown in Fig. 1c, it is advantageous if, in the step shown in Fig. 1b, the substrate 3 is blind embossed in such a way that the substrate 3 has at least one elevation 5a and / or depression 5b. An elevation 5a and / or depression 5b of the substrate 3 is understood in particular to be a relief form which represents a pattern, motif or writing. An elevation 5a of the substrate 3 relative to an unprocessed area of ​​the substrate 3 is preferably a raised embossing, so that the pattern, motif or writing is embossed in a raised manner into the substrate 3. A depression 5b of the substrate 3 relative to an unprocessed area of ​​the substrate 3 is preferably a debossing, so that the pattern, motif or writing is embossed in a debossed manner into the substrate 3. For example, in the case of a debossing, the elevation 5a and / or depression 5b shown in Fig. 1c would be mirrored on the plane spanned by the substrate 3, i.e.the bulge of the substrate 3 would now point downwards and not upwards.

[0114] Furthermore, it is advantageous if the at least one elevation 5a and / or depression 5b of the substrate 3 is produced with a height and / or depth of at least 0.01 mm, preferably at least 0.03 mm, more preferably at least 0.1 mm.

[0115] As shown schematically in Fig. 1a to Fig. 1c, the ratio of the diameter of the magnetic embossing roller 2a to the diameter of the counter-pressure roller 2b is 1 to 1. However, it is also possible for the magnetic embossing roller 2a and the counter-pressure roller 2b to have different diameters. Thus, it is also possible for the ratio of the diameter of the magnetic embossing roller 2a to the diameter of the counter-pressure roller 2b to be 1 to 2. Preferably, the diameter of the magnetic embossing roller 2a is between 100 mm and 450 mm, more preferably between 200 mm and 350 mm, and / or the diameter of the counter-pressure roller 2b is between 200 mm and 800 mm, more preferably between 400 mm and 700 mm. Thus, it is possible that the diameter of the magnetic embossing roller 2a is, for example, 300 mm ± 5 mm, preferably 298.4 mm ± 0.02 mm, and / or the diameter of the counterpressure roller 2b is, for example, 600 mm ± 5 mm, preferably 599.4 mm ± 0.02 mm.

[0116] The substrate 3 is preferably provided as a sheet, as shown in Fig. 1a to Fig. 1c. However, it is also possible for the substrate 3 to be provided as a roll for roll-to-roll processing.

[0117] Preferably, the substrate 3 comprises cellulose and / or plastics. Advantageously, the substrate 3 is paper, cardboard, and / or films, in particular plastic films, or hybrid and / or composite materials made of such materials.

[0118] As indicated by the arrows in Fig. 1a to Fig. 1c, the magnetic embossing roller 2a and the counterpressure roller 2b are preferably driven in opposite directions at corresponding rotational speeds. Advantageously, the die 4a and the male die 4b mesh with each other during each rotation such that the substrate 3 located between the die 4a and the male die 4b is embossed, particularly in an overlapping area of ​​the die 4a and the male die 4b.

[0119] By means of the device 1 shown in Fig. 1 a to Fig. 1 c, it is possible for the substrate 3 to be embossed in such a way that the deviations between the embossings of each revolution are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

[0120] Regarding the arrangement of the die 4a on the magnetic embossing roller 2a and the male die 4b on the counter-pressure roller 2b as well as the design of the die 4a and the male die 4b, please refer to the explanations below for Fig.

[0121] 4. Fig. 2 schematically shows a device 1 for rotary blind embossing. The device 1 of Fig. 2 differs from the device 1 of Fig. 1a to Fig. 1c in that three matrices 4a are arranged on the magnetic embossing roller 2a and correspondingly three male dies 4b are arranged on the counter-pressure roller 2b. It is conceivable, among other things, that the magnetic embossing roller 2a and / or the counter-pressure roller 2b are equipped with so many matrices 4a and / or male dies 4b that a large part of the circumferential surface or, ideally, the entire circumferential surface of the magnetic embossing roller 2a and / or counter-pressure roller 2b is equipped with matrices 4a or male dies 4b.

[0122] Also in the embodiment according to Fig. 2, the magnetic embossing roller 2a and the counter-pressure roller 2b are preferably driven in opposite directions to each other at corresponding rotational speeds, wherein the matrices 4a and the male dies 4b engage with each other during each rotation in such a way that the substrate 3 located between the matrices 4a and the male dies 4b, in particular in an overlapping region of the matrices 4a and the male dies 4b, is embossed.

[0123] Fig. 3 shows a further embodiment of a device 1 for rotary blind embossing of a substrate 3. The device 1 according to Fig. 3 essentially corresponds to the device 1 according to Fig. 2, but with the difference that the device 1 according to Fig. 3 comprises a transport device 11, which serves to transport the substrate 3. For example, it is possible for the transport device 11 to comprise a supply roll on which the substrate 3 is wound. Alternatively, it is also possible for the transport direction 11 to be designed in an arc shape for transporting the substrate 3.

[0124] The device 1 further comprises the workstation 1b for printing the substrate 3. The workstation 1b preferably comprises a printing roller. Printing is preferably carried out using offset printing, screen printing, gravure printing, flexographic printing, letterpress printing, or inkjet printing. Furthermore, it is preferred if the print is generated using a printing roller. During printing, one or more printing inks are advantageously applied to the substrate 3, in particular according to a screen pattern.

[0125] Furthermore, the device 1 according to Fig. 3 comprises the work station 1a for the rotary blind embossing of the substrate 3. With regard to the design of the work station 1a and the rotary blind embossing, reference is also made to the above explanations.

[0126] Furthermore, the device 1 according to Fig. 3 comprises the work station 1c for creasing and / or folding the substrate 3. Preferably, the work station 1c comprises a pressing tool and / or folding tool for producing a sharp crease. During the creasing process, the bendability of the substrate 3 is preferably changed by means of a pressing tool, in particular by material displacement. Folding is preferably understood to mean the production of a sharp crease using a tool.

[0127] The device 1 further comprises the workstation 1d for separating the substrate 3. Advantageously, the workstation 1d comprises a cutting tool. Preferably, the substrate 3 is separated by punching, with the substrate 3 being separated in particular by means of a cutting tool and / or punching tool.

[0128] Preferably, it is useful if the substrate 3 is processed continuously.

[0129] It is also advantageous if the substrate 3 is provided as sheet material.

[0130] Furthermore, it is preferred if the deviations between the embossings on the sheets of the substrate 3 provided as sheet goods are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

[0131] As shown in Fig. 3, work station 1b is arranged before work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b. Work stations 1c and 1d are arranged after work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b. However, other sequences of work stations 1a, 1b, 1c, 1d are also conceivable. For example, it is possible for work station 1c to be arranged before and / or work station 1b after work station 1a, comprising the magnetic embossing roller 2a and the counterpressure roller 2b.

[0132] Furthermore, it is advantageous if more than 8000 sheets per hour, preferably more than 10000 sheets per hour, more preferably more than 12000 sheets per hour, even more preferably more than 15000 sheets per hour, of the substrate 3 provided as sheet material are processed by means of the device 1 or by means of the method.

[0133] Fig. 4 schematically shows a section of the device 1, in which the positioning system 6 is shown. The positioning system 6 serves to arrange the at least one die 4a or several dies 4a on the circumferential surface of the magnetic embossing roller 2a. As shown in Fig. 4, the positioning system 6 is arranged in the immediate vicinity of the magnetic embossing roller 2a. Furthermore, the positioning system 6 interacts with the magnetic embossing roller 2a. The position of the at least one die 4a in the radial direction of the magnetic embossing roller 2a is defined via the angle of rotation of the magnetic embossing roller 2a.

[0134] The positioning system 6 further comprises a movable stop 6a, wherein the stop 6a specifies the position of the at least one die 4a. The stop 6a can, as shown in Fig. 4, be a stop 6a with two arms, wherein the two arms are arranged at a right angle to each other. Depending on the shape of the die 4a, the stop 6a can also be designed differently. As shown in Fig. 4, a die 4a, in this case a rectangular die 4a, can then be placed against the stop 6a and positioned accordingly on the magnetic embossing roller 2a and magnetically fastened.

[0135] Preferably, it is provided that the at least one die 4a is bent accordingly before being attached to the magnetic embossing roller 2a, so that the curvature of the at least one die 4a substantially corresponds to the curvature of the magnetic embossing roller 2a.

[0136] Furthermore, the at least one die 4a is preferably arranged on the magnetic embossing roller 2a such that the film 7 of the at least one die 4a faces the surface of the magnetic embossing roller 2a. This arrangement ensures a high holding or adhesive force of the die 4a on the magnetic embossing roller in the tangential direction, thereby preventing displacement, particularly in the tangential direction, of the at least one die 4a.

[0137] It is preferably provided that, based on the arrangement of the at least one die 4a on the magnetic embossing roller 2a, the arrangement of the at least one male die 4b on the counter-pressure roller 2b is subsequently carried out, in particular in register or in exact register with the at least one die 4a.

[0138] For this purpose, it is preferably provided that at least one carrier plate is initially arranged on the circumference of the counter-pressure roller 2b. It may also be possible for the counter-pressure roller 2b to have at least one carrier plate on its circumferential surface. Furthermore, the counter-pressure roller 2b can be designed such that it has two systems. Each system takes up approximately half of the circumferential surface of the counter-pressure roller 2b. In this case, two carrier plates can thus be arranged on the counter-pressure roller 2b.

[0139] For the arrangement of the at least one male die 4b, at least one carrier plate can be arranged on the circumference of the counter-pressure roller 2b, wherein on the carrier plate

[0140] I) a matrix carton is arranged in which at least one corresponding male mold 4b is molded to the at least one female mold 4a; or

[0141] II) at least one corresponding male die 4b is arranged to the at least one female die 4a; or

[0142] III) a UV-curable plastic is applied over a large area, in which at least one corresponding male mold 4b is molded to the at least one female mold 4a.

[0143] According to the first variant I), it is preferably provided that a master cardboard sheet is arranged, in particular glued, on the carrier sheet, and preferably the master cardboard sheet is moistened, and the master cardboard sheet is embossed with the at least one die 4a arranged on the magnetic embossing roller 2a in order to form the at least one male part in the master cardboard sheet. Moistening the master cardboard sheet softens it, so that the contour of the at least one die 4a can be transferred to the master cardboard sheet with relatively little force. Moistening is preferably carried out by means of a spray mist.

[0144] During embossing according to the first variant I), the master cardboard sheet is preferably compacted, in particular with the moisture being pressed out of the master cardboard sheet. As a result, the master cardboard sheet regains stability, and the molded contour of the at least one die 4a becomes dimensionally stable. Furthermore, it can be provided that the magnetic embossing roller is heated, in particular to a temperature in the range of 25°C to 50°C, preferably 30°C to 45°C, particularly preferably 35°C to 40°C, in order to dry the master cardboard sheet, so that the at least one male die 4b solidifies.

[0145] Alternatively, according to the second variant II), the at least one male mold 4b can be designed as an individual male mold, or each male mold 4b can be designed as an individual male mold. The male mold 4b can, for example, comprise materials selected individually or in combination from: plastic, silicone, rubber, brass. This means that in this embodiment, the shape of the male mold 4b is already incorporated, preferably by means of a laser, photolithography, milling, an additive printing process, such as 3D printing, etc. The shape of the male mold 4b is preferably designed as a counter-mold to the at least one female mold 4a.

[0146] For attachment to the counter-pressure roller 2b, the at least one male part 4b is provided with a double-sided adhesive tape on its side facing the counter-pressure roller 2b. Furthermore, the at least one male part 4b is also provided with an adhesive, a double-sided adhesive tape, or adhesive pieces on its side facing the at least one female part 4a. Subsequently, the male part 4b is positively bonded to the at least one female part 4a. Thereafter, the magnetic counter-pressure roller 2b is brought into contact with the counter-pressure roller 2b, in particular such that the underside of the male part 4b, in particular the side of the male part 4b facing the counter-pressure roller 2b, is brought into contact with the carrier plate of the counter-pressure roller 2b. Due to the double-sided adhesive tape, the at least one male part 4b now adheres to the

[0147] Counterpressure roller 2b. It is preferably provided that the adhesive force of the adhesive pieces, adhesive tapes, or adhesive applied to the side of the male part 4b facing the counterpressure roller 2b is stronger than the adhesive force of the side facing the female part 4a. Only in this way can the at least one male part 4b subsequently detach from the female part 4a. Finally, any adhesive residues are removed from both the at least one female part 4a and the at least one male part 4b.

[0148] In a further embodiment according to variant III), it can be provided that a UV-curable plastic is applied to the carrier sheet at least partially or over its entire surface, which is at least partially pre-crosslinked by means of a UV pre-curing light source, and then the pre-crosslinked UV-curable plastic is embossed by means of the at least one matrix 4a, so that at least one male mold 4b is introduced into the pre-crosslinked UV-curable plastic and finally the pre-crosslinked UV-curable plastic is completely cured by means of a UV final curing light source.

[0149] Fig. 5a shows a schematic cross-sectional view of a die 4a. As can be seen in Fig. 5a, the die 4a is multi-layered. The die 4a has the following layer structure, beginning with the side facing the magnetic embossing roller 2a:

[0150] Foil 7; first metal layer 8;

[0151] Adhesive layer 9; second metal layer 10.

[0152] The side facing the magnetic embossing roller 2a is preferably the underside of the die 4a. Thus, the die 4a has a foil 7 on its underside as shown in Fig. 5a.

[0153] The film 7 is preferably a plastic film. Preferably, the film 7 is or comprises a thermoplastic elastomer. As already described above, a thermoplastic elastomer is a plastic that has the properties of both a thermoplastic and a thermoset. This causes the film 7 to adhere both to the first metal layer 8 of the die 4a and to the surface of the magnetic embossing roller 2a, thus creating a kind of "vacuum effect." This ensures increased adhesion or holding force of the die 4a on the surface of the magnetic embossing roller 2a relative to a force applied in the tangential direction.

[0154] It is preferably provided that the film 7 has a film adhesive layer which is formed in particular from a pressure-sensitive adhesive (PSA). The film adhesive layer can alternatively also be multi-layered and / or have a hot melt adhesive and / or a two-component adhesive. Furthermore, it is expedient if the film adhesive layer preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm. For better illustration, the film adhesive layer is not shown in Fig. 5a. The film adhesive layer can preferably be applied during production of the film and is preferably part of the film.

[0155] The first metal layer 8 is formed from a ferromagnetic material. Preferably, the first metal layer 8 comprises a material or combination of materials selected from: iron, steel, ferrites, cobalt, and / or nickel. The die 4a shown in Fig. 5a uses a first metal layer 8 made of steel.

[0156] The second metal layer 10 preferably comprises a material or combination of materials selected from: brass, bronze, copper, nickel, zinc, tin, lead, iron, and / or steel. In the die 4a shown in Fig. 5a, the second metal layer 10 is formed, for example, from brass. The embossing mold is preferably molded into the second metal layer 10 as a positive or negative mold, in particular comprising elevations 12a and / or depressions 12b. The elevation 12a and / or depression 12b can be engraved and / or milled, for example, using a computer-controlled engraving machine and / or a computer-controlled milling machine. For this purpose, the relief shape is preferably first defined and designed with the aid of a computer. The design can be carried out manually or using predetermined relief shapes.Subsequently, based on this design, a data set containing the relief shape is preferably generated, and the data set is transferred to the computer-controlled engraving machine and / or milling machine. Subsequently, the elevations 12a and / or depressions 12b are engraved and / or milled into the die 4a, particularly depending on the data set.

[0157] Alternatively, it is also possible for the elevations 12a and / or depressions 12b to be produced photolithographically.

[0158] Furthermore, it is also possible for the elevations 12a and / or depressions 12b to be created by means of a laser, in particular by laser ablation. Preferably, the material of the matrix 4a is completely removed and / or ablated during the laser ablation.

[0159] The laser is preferably a gas laser, in particular a CO2 laser, and / or a solid-state laser, in particular an Nd:YAG laser. The laser power is advantageously at least 20 W, preferably at least 30 W, more preferably at least 100 W. Furthermore, it is advantageous if the wavelength of the laser is between 9.35 pm and 10.25 pm.

[0160] Preferably, the laser beam is guided along the die 4a by means of deflectable mirrors, in particular by means of a laser scanning module, so that the desired elevations 12a and / or depressions 12b are created. The beam diameter of the laser at the focal point is in particular between 0.01 mm and 1 mm, preferably between 0.01 mm and 0.2 mm.

[0161] Furthermore, it is advantageous, particularly during the production of the die 4a and / or the male die 4b, if the desired relief shape to be embossed is reduced by a predetermined shortening factor, particularly before the elevations 12a and / or depressions 12b are created in the surface of the die 4a and / or the male die 4b. The shortening factor is preferably between 0.95 and 1, preferably between 0.9750 and 0.9999, more preferably between 0.98000 and 0.99999, and even more preferably between 0.99000 and 0.9999. Advantageously, the predetermined shortening factor is determined as a function of the diameter of the embossing roller 2a and / or the counter-pressure roller 2b. Furthermore, it is possible for the predetermined shortening factor to be determined as a function of the embossing length and / or a printing length, in particular on the substrate 3.

[0162] Preferably, the elevations 12a and / or depressions 12b are introduced in flat states of the die 4a and the die 4a is subsequently deformed such that the die 4a has a rounding which substantially corresponds to the rounding of the magnetic embossing roller 2a and / or the rounding of the counter-pressure roller 2b.

[0163] As shown in Fig. 5a, an adhesive layer 9 is provided between the first metal layer 8 and the second metal layer 10.

[0164] Furthermore, it is advantageous if the adhesive layer 9 is a hot-melt or cold-melt adhesive layer.

[0165] It is also possible for the adhesive layer 9 to be a two-component adhesive (2K adhesive), in particular comprising epoxy resins. Preferably, the adhesive layer 9 is a 2K epoxy-based adhesive system, such as Araldit from Huntsman, Salt Lake City, Utah, USA.

[0166] Furthermore, it is also advantageous if the adhesive layer 9 is a double-sided adhesive tape. Preferably, the double-sided adhesive tape is coated on both sides with a pressure-sensitive adhesive (PSA). Such double-sided adhesive tapes can be obtained, for example, from tesa, Norderstedt, Germany.

[0167] Furthermore, it is useful if the adhesive layer 9 preferably has a layer thickness in a range from 0.01 mm to 1.0 mm, preferably from 0.05 mm to 0.5 mm, more preferably from 0.06 mm to 0.25 mm.

[0168] The die 4a according to Fig. 5a preferably has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm.

[0169] Furthermore, the die 4a according to Fig. 5a has at least one elevation 12a and / or depression 12b, which in particular corresponds to the relief shape to be embossed in positive and / or negative form.

[0170] It is preferably provided that the at least one elevation 12a of the die 4a has a height of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm, and / or that the at least one depression 12b of the die 4a has a depth of a maximum of 5.0 mm, preferably of a maximum of 3.0 mm, more preferably of a maximum of 1.0 mm, even more preferably of a maximum of 0.5 mm.

[0171] Fig. 5b shows a schematic sectional view of a male mold 4b. The male mold 4b is designed as a counter-mold to the female mold 4a shown in Fig. 5a. As can be seen in Fig. 5b, the male mold 4b is formed as a single layer. As described above, this can be manufactured or formed according to one of the variants I), II), or III).

[0172] List of reference symbols

[0173] I Device

[0174] 1a, 1b, 1c, 1d workstations

[0175] 2a magnetic embossing roller

[0176] 2b Counterpressure roller

[0177] 3 Substrat

[0178] 4a matrix

[0179] 4b Male part

[0180] 5a Increase in substrate

[0181] 5b Deepening of the substrate

[0182] 6 Positioning system

[0183] 6a stop

[0184] 7 Slide

[0185] 8 first metal layer

[0186] 9 adhesive layer

[0187] 10 second metal layer

[0188] II Transport device

[0189] 12a Raising the die / patrix

[0190] 12b Deepening of the matrix / patrix

Claims

A nc r e m e n ts 1 . Device (1) for rotary blind embossing of a substrate (3), wherein the device (1) comprises a work station (1 a) which comprises a magnetic embossing roller (2a) and a counter-pressure roller (2b), wherein at least one die (4a) is magnetically arranged on the magnetic embossing roller (2a) and at least one patrix (4b) is arranged on the counter-pressure roller (2b), wherein the at least one The die (4a) is multi-layered and has at least one first metal layer (8) made of a ferromagnetic material, characterized in that the at least one die (4a) has a film (7) on the side facing the magnetic embossing roller (2a).

2. Device (1) according to claim 1, characterized in that the magnetic embossing roller (2a) has a permanent magnet and / or that the magnetic embossing roller (2a) is designed as a magnetic cylinder.

3. Device (1) according to claim 1 or 2, characterized in that the magnetic embossing roller (2a) is tempered, in particular wherein the magnetic embossing roller (2a) has a temperature in the range of 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C.

4. Device (1) according to one of the preceding claims, characterized in that the counter-pressure roller (2b) has a permanent magnet and / or that the counter-pressure roller (2b) is designed as a magnetic cylinder.

5. Device (1) according to one of the preceding claims, characterized in that at least one carrier plate is arranged on the circumference of the counter-pressure roller (2b), wherein on the carrier plate I) a matrix carton is arranged in which at least one corresponding male mold (4b) is molded to the at least one female mold (4a); or II) at least one corresponding male die (4b) is arranged to the at least one female die (4a); or III) a UV-curable plastic is applied over a large area, in which at least one corresponding male mold (4b) is molded to the at least one female mold (4a).

6. Device (1) according to one of the preceding claims, characterized in that the magnetic embossing roller (2a) and the counter-pressure roller (2b) can be driven in opposite directions to one another at corresponding rotational speeds.

7. Device (1) according to one of the preceding claims, characterized in that that the ratio of the diameter of the magnetic embossing roller (2a) to the diameter of the counter-pressure roller (2b) is 1 to 2, preferably 1 to 1.

8. Device (1) according to one of the preceding claims, characterized in that the at least one die (4a) is deformed such that the at least one die (4a) has a rounding which substantially corresponds to the rounding of the magnetic embossing roller (2a).

9. Device (1) according to one of the preceding claims, characterized in that the first metal layer (8) comprises a material or combinations of materials selected from: iron, ferrites, cobalt and / or nickel.

10. Device (1) according to one of the preceding claims, characterized in that the matrix (4a) comprises a second metal layer (10), in particular wherein the second metal layer (10) comprises a material or combinations of materials selected from: brass, bronze, copper, nickel, zinc, tin, lead, iron and / or steel.

11. Device (1) according to one of the preceding claims, characterized in that the matrix (4a) comprises an adhesive layer (9).

12. Device (1) according to one of the preceding claims, characterized in that the film (7) is or comprises a plastic film, in particular wherein the film (7) is formed from a thermoplastic elastomer.

13. Device (1) according to one of the preceding claims, characterized in that the film (7), in particular on the side facing the first metal layer (8), has a film adhesive layer.

14. Device (1) according to one of the preceding claims, characterized in that the at least one matrix (4a) has a layer structure, in particular in the following sequence, starting with the layer facing the magnetic embossing roller (2a): - foil (7); - optional foil adhesive layer; - first metal layer (8); - adhesive layer (9); - second metal layer (10).

15. Device (1) according to one of the preceding claims, characterized in that the at least one die (4a) and the at least one male die (4b) are arranged in such a way that they engage with each other during each revolution in such a way that the substrate (3) located between the at least one die (4a) and the at least one male die (4b), in particular in an overlapping region of the at least one die (4a) and the at least one male die (4b), can be embossed.

16. Device (1) according to one of the preceding claims, characterized in that the at least one die (4a) and / or the at least one male die (4b) has at least one elevation (12a) and / or depression (12b) which corresponds in particular to the relief shape to be embossed in positive and / or negative form.

17. Device (1) according to one of the preceding claims, characterized in that the device (1) comprises a positioning system (6) for arranging the at least one die (4a) on the magnetic embossing roller (2a), wherein the positioning system (6) has a stop (6a).

18. Device (1) according to claim 17, characterized in that the positioning system (6) is arranged in the immediate vicinity of the magnetic embossing roller (2a) and cooperates with the magnetic embossing roller (2a).

19. Device (1) according to claim 17 or 18, characterized in that the position of the at least one die (4a) in the radial direction of the magnetic embossing roller (2a) can be defined via the angle of rotation of the magnetic embossing roller (2a) and the position of the at least one die (4a) in the axial direction of the magnetic embossing roller (2a) can be defined via the position of the stop (6a).

20. Device (1) according to one of the preceding claims, characterized in that the device (1) further comprises one or more further work stations (1 b, 1 c, 1 d) for printing the substrate (3) and / or for cold embossing the substrate (3) and / or for hot embossing the substrate (3) and / or for Braille blind embossing the substrate (3) and / or for separating, in particular cutting, the substrate (3) and / or for creasing and / or folding the substrate (3).

21. Device (1) according to claim 20, characterized in that the one or more further work stations (1b, 1c, 1d) are arranged before and / or after the work station (1a) comprising the magnetic embossing roller (2a) and the counter-pressure roller (2b).

22. Device (1) according to one of the preceding claims, characterized in that an adhesive force per area of ​​the at least one matrix (4a) on the magnetic embossing roller (2a) against approximately tangentially acting forces is at least 5 N / cm 2 amounts.

23. Die (4a), in particular for use in a device (1) according to one of the preceding claims, wherein the die (4a) is multi-layered and has at least a first metal layer (8) made of a ferromagnetic material, characterized in that the die (4a) has a film (7) on its underside.

24. Die (4a) according to claim 23, characterized in that the first metal layer (8) comprises a material or combinations of materials selected from: iron, steel, ferrites, cobalt and / or nickel.

25. Die (4a) according to claim 23 or 24, characterized in that the die (4a) comprises a second metal layer (10), in particular wherein the second metal layer (10) comprises a material or Combinations of materials selected from: brass, bronze, copper, nickel, zinc, tin, lead, iron and / or steel.

26. Die (4a) according to one of claims 23 to 25, characterized in that the die (4a) comprises an adhesive layer (9).

27. Die (4a) according to one of claims 23 to 26, characterized in that the film (7) is or comprises a plastic film, in particular wherein the film (7) is formed from a thermoplastic elastomer.

28. Die (4a) according to one of claims 23 to 27, characterized in that the film (7) has a thickness in a range from 20 pm to 250 pm, in particular from 30 pm to 150 pm.

29. Die (4a) according to one of claims 23 to 28, characterized in that the film (7), in particular on the side facing the first metal layer (8), has a film adhesive layer.

30. Die (4a) according to one of claims 23 to 29, characterized in that the die (4a) has a layer structure, in particular in the following Sequence, starting with the layer facing the embossing roller (2a): - foil (7); - optional foil adhesive layer; - first metal layer (8); - adhesive layer (9); second metal layer (10).

31. Die (4a) according to one of claims 23 to 30, characterized in that the die (4a) has a thickness between 0.1 mm and 5 mm, preferably between 0.5 mm and 3 mm.

32. Die (4a) according to one of claims 23 to 31, characterized in that the die (4a) has at least one elevation (12a) and / or depression (12b), which corresponds in particular to the relief shape to be embossed in positive and / or negative form.

33. Die (4a) according to claim 32, characterized in that the at least one elevation (12a) of the die (4a) has a height of a maximum of 5.0 mm, preferably a maximum of 3.0 mm, more preferably a maximum of 1.0 mm, even more preferably a maximum of 0.5 mm, and / or that the at least one depression (12b) of the die (4a) has a depth of a maximum of 5.0 mm, preferably a maximum of 3.0 mm, more preferably a maximum of 1.0 mm, even more preferably a maximum of 0.5 mm.

34. Die (4a) according to claim 32 or 33, characterized in that the at least one elevation (12a) and / or depression (12b) of the die (4a) has a shape selected from the group: round, flat, round-flat, flat-edged, prismatic, pointed or mixed forms of these shapes.

35. Die (4a) according to one of claims 23 to 34, characterized in that that the die (4a) is rounded, in particular that the die (4a) is deformed such that the die (4a) has a rounding which essentially corresponds to the rounding of a magnetic embossing roller (2a) on which the die (4a) is arranged.

36. Method for the rotary blind embossing of a substrate (3), in particular using a device (1) according to one of claims 1 to 22, wherein the method comprises the following steps, in particular in the following order: a) providing a substrate (3); b) arranging at least one matrix (4a), in particular according to one of claims 23 to 35, on a magnetic embossing roller (2a); c) arranging at least one male die (4b) on a counter-pressure roller (2b); d) blind embossing the substrate (3) by means of the at least one matrix (4a) and the at least one male die (4b).

37. Method according to claim 36, characterized in that in step b) the arrangement of the at least one die (4a) is carried out by means of a positioning system (6) comprising a displaceable stop (6a), in that the positioning system (6) interacts with the embossing roller (2a) in such a way that the embossing roller (2a) is rotated by a predefined angle of rotation in order to fix the position of the at least one die (4a) in the radial direction of the magnetic embossing roller (2a), and in that the stop (6a) fixes the position of the at least one die (4a) in the axial direction of the magnetic embossing roller (2a).

38. Method according to claim 37, characterized in that that in step b) the at least one die (4a) is placed along the stop (6a) and is then magnetically attached to the surface of the magnetic embossing roller (2a).

39. Method according to one of claims 36 to 38, characterized in that before step b) or in step b) the at least one die (4a) is bent, in particular so that the rounding of the at least one die (4a) substantially corresponds to the rounding of the magnetic embossing roller (2a).

40. Method according to one of claims 36 to 39, characterized in that in step b) the at least one matrix (4a) is arranged on the magnetic embossing roller (2a) in such a way that the film (7) faces the surface of the magnetic embossing roller (2a).

41. Method according to one of claims 36 to 40, characterized in that in step c) at least one carrier sheet is first arranged on the circumference of the counter-pressure roller (2b).

42. Method according to claim 41, characterized in that in step c) according to a first variant I) a master cardboard sheet is arranged, in particular glued, on the carrier sheet, and preferably the master cardboard sheet is moistened, and the master cardboard sheet is embossed with the at least one matrix (4a) arranged on the magnetic embossing roller (2a) in order to form the at least one male mold in the master cardboard sheet.

43. Method according to claim 42, characterized in that in step c) during embossing according to the first variant I) the sheet of maternal cardboard is compressed, in particular whereby the moisture is pressed out of the sheet of maternal cardboard.

44. Method according to claim 42 or 43, characterized in that in step c) during embossing according to the first variant I), the magnetic embossing roller (2a) is heated, in particular with a temperature in the range from 25°C to 50°C, preferably from 30°C to 45°C, particularly preferably from 35°C to 40°C, in order to dry the master cardboard sheet so that the at least one male part (4b) solidifies.

45. Method according to one of claims 36 to 41, characterized in that in step c) according to a second variant II) the at least one male part (4b) is provided with a double-sided adhesive tape on its side facing the counter-pressure roller (2b).

46. ​​Method according to claim 45, characterized in that in step c) according to the second variant II) the male part is bonded in a form-fitting manner to the at least one female part (4a) by means of an adhesive or adhesive tape or adhesive pieces and then the at least one male part (4b) is applied to the counter-pressure roller (2b), in particular by bringing the embossing roller (2a) into contact with the counter-pressure roller (2b).

47. Method according to claim 41, characterized in that that in step c) according to a third variant III) a UV-curable plastic is applied to the carrier sheet at least partially or over the entire surface, which is at least partially pre-crosslinked by means of a UV pre-curing light source, and then the pre-crosslinked UV-curable plastic is embossed by means of the at least one matrix (4a) so that at least one male mold (4b) is introduced into the pre-crosslinked UV-curable plastic and finally the pre-crosslinked UV-curable plastic is completely cured by means of a UV final curing light source.

48. Method according to one of claims 36 to 47, characterized in that in step d) the substrate (3) is blind embossed in such a way that the substrate (3) has at least one elevation (5a) and / or depression (5b).

49. Method according to one of claims 36 to 48, characterized in that the at least one elevation (5a) and / or depression (5b) of the substrate (3) in step d) is produced with a height and / or depth of at least 0.01 mm, preferably at least 0.03 mm, more preferably at least 0.1 mm.

50. Method according to one of claims 36 to 49, characterized in that the magnetic embossing roller (2a) and the counter-pressure roller (2b) are driven in opposite directions to one another at corresponding rotational speeds.

51. Method according to one of claims 36 to 50, characterized in that the at least one die (4a) and the at least one male die (4b) engage with each other during each revolution in such a way that the substrate (3) located between the at least one die (4a) and the at least one male die (4b) is embossed, in particular in an overlapping region of the at least one die (4a) and the at least one male die (4b).

52. Method according to one of claims 36 to 51, characterized in that the substrate (3) is embossed in such a way that the deviations between the embossings of each revolution are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

53. Method according to one of the preceding claims 36 to 52, characterized in that the method further comprises the following steps: - Feeding the substrate (3) to the work station (1a) comprising the magnetic embossing roller (2a) and the counter-pressure roller (2b).

54. Method according to one of the preceding claims 36 to 53, characterized in that the method further comprises at least one of the following steps, which are carried out in one or more further workstations (1b, 1c, 1d): - printing the substrate (3); - cold stamping of the substrate (3); - hot stamping the substrate (3); - Braille blind embossing of the substrate (3); - separating, in particular cutting, the substrate (3); - grooving and / or folding the substrate (3).

55. Method according to one of the preceding claims 36 to 54, characterized in that the substrate (3) is processed continuously.

56. Method according to one of the preceding claims 36 to 55, characterized in that in step a) the substrate (3) is provided as sheet material.

57. Method according to one of claims 36 to 56, characterized in that the deviations between the embossings on the sheets of the substrate (3) provided as sheet goods are less than 2% percent, preferably less than 1% percent, even more preferably less than 0.05% percent.

58. Method according to one of claims 36 to 57, characterized in that by means of the method more than 8000 sheets per hour, preferably more than 10000 sheets per hour, more preferably more than 12000 sheets per hour, even more preferably more than 15000 sheets per hour, of the substrate (3) provided as sheet material are processed.

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