Embossing Tool Manufacturing via Spark Erosion
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Solution Overview
Problem
Existing methods for producing embossing tools for hot-cold laminating presses lack precision and environmental friendliness, particularly in creating three-dimensional structures for security documents, and often require toxic chemicals.
Innovation Solution
A method involving spark erosion and electrochemical removal to create recessed embossed structures on metal workpieces, which can be combined with laser deposition welding for raised structures, eliminating the need for toxic chemicals and ensuring high precision and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet-chemical etching methods are used to produce recessed structures, then production capability is achieved, but toxic chemical substances are required which harm the environment
Solution Approach 1:
The patent replaces wet-chemical etching (chemical process) with spark erosion and electrochemical removal (electrical/physical processes). This substitution eliminates the need for toxic chemical substances while maintaining the capability to produce recessed structures on metal workpieces for embossing tools.
Solution Approach 2:
The patent changes the fundamental processing parameter from chemical concentration and reactivity to electrical discharge energy and electrochemical current. This parameter transformation enables the same manufacturing function (creating recessed structures) without using harmful chemicals.
2Manufacturing precision
If conventional structuring methods are used, then embossing structures can be produced, but manufacturing precision is insufficient for high-security documents
Solution Approach 1:
The patent employs spark erosion and electrochemical removal processes that inherently provide higher precision compared to conventional mechanical or chemical etching methods. These electrical-based processes enable more accurate reproduction of the master model's three-dimensional structure, which is critical for security document embossing.
Solution Approach 2:
The patent uses a master model as a precise template and reproduces its three-dimensional structure on the metal workpiece through spark erosion and electrochemical removal. This copying approach ensures high manufacturing precision by directly transferring the exact geometric features of the master model to the embossing tool.
3Adaptability or versatility
If individual embossing tools are produced using traditional methods, then customization is possible, but production cost is high
Solution Approach 1:
The patent replaces traditional high-cost individual tool production methods with spark erosion and electrochemical removal processes. These electrical-based manufacturing methods reduce production costs while maintaining the ability to produce customized embossing tools for different document types and security features.
Solution Approach 2:
The patent changes the manufacturing approach from expensive conventional methods to more cost-effective electrical discharge and electrochemical processes. This parameter change enables economical production of individual embossing tools with customized three-dimensional structures for various security document applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of embossing tools with high precision and environmental sustainability, suitable for various documents, including security documents, by creating secure three-dimensional features without using toxic chemicals, and allows for cost-effective production of individual embossing tools.
Implementation Method 1
An embossed structure of the three-dimensional structure, which is deepened with respect to a glossy surface of the metal workpiece, is produced on the metal workpiece. The deepened embossed structure is produced as part of a structuring of the metal workpiece using at least one processing method from the following group: spark erosion and electrochemical removal.
Implementation Method 2
An embossed structure of the three-dimensional structure, which is deepened with respect to a glossy surface of the metal workpiece, is produced on the metal workpiece. The deepened embossed structure is produced as part of a structuring of the metal workpiece using at least one processing method from the following group: spark erosion and electrochemical removal.
Data Source
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AI summary
The invention relates to a method for manufacturing an embossing tool for a hot-cold laminating press with a three-dimensional structure for forming a security feature when producing a document by laminating and/or surface embossing, comprising providing a metal workpiece and producing a recessed embossing structure of the three-dimensional structure on the metal workpiece with respect to a glossy surface of the metal workpiece, wherein the recessed embossing structure is produced as part of structuring the metal workpiece using at least one machining method from the following group: electrical discharge machining (EDM) and electrochemical machining.