Engraved plate making method

FIELD: manufacture of plates used for intaglio printing.

SUBSTANCE: method for making engraved plate with use of tool such as laser beam comprises steps of using engraving tool operating with use of data of depth card formed on base of three-dimensional raster image of printed document; similarly making intermediate engraved plates.

EFFECT: shortened time period for engraving high-quality plates, prevention of warping of plates at printing process.

21 cl, 15 dwg

 

The invention relates generally to the field of gravure printing for the production of securities, in particular banknote.

More precisely specified the invention relates to a method of manufacturing an engraved plate for gravure printing of sheets of securities, which are not engraved plate undergoes programmed engraving process using a computer, which controls the engraving tool.

Traditionally, the manufacture of the plates by the method of gravure printing is a lengthy and complex process that begins with hand engraving a steel or copper plate, make a copy of the specified first plate, add other elements using chemical etching, producing several plastic reprints of this end plate of the original, welding them together and pass through a significant amount of the electroplating bath to obtain the final product, and the printing plate (plate) for gravure printing must be installed on the machine. The whole process of manufacturing plates may require several months and, therefore, is very time consuming and expensive.

In the application EP 0322301 described a little shorthand method for manufacturing steel plates by intaglio with stage electroerosive processing. First get copper contracep of otoplenie manually copper plates of the original using an electric formation. After this, contracep used as the electrode in the process electroerosive processing, in which the electrode and the steel plate, which must be engrave, are moved relative to each other. Thus, this method does not avoid prolonged and complicated production of handmade plates of the original. Actually this method of manufacturing a wafer is not used in the printing industry securities, as the plates do not have the necessary precision.

In the application WO 97/48555 described the process defined above type for the manufacture of steel plates with deep drawing, which eliminates the step of hand engraving. In a linear pattern chosen by the surface elements, and the boundary surface element specifies the nominal paths. Each nominal path for which distributed the nominal depth, then calculate the route tool. Then engraving tool, laser, or cutter, is controlled so that the removed part of the surface of the plate corresponding to different surface elements. Part of the surface element, the remote on a predefined depth, can be further enhanced by the additional step of etching, so that the depth of this surface element is not necessarily constant. However, clarity otherwise the data image below, than the clarity of the picture of the original, as it is related to depth change.

In the application WO 96/26466 described a method of manufacturing a polymer intermediate plate for gravure printing using photoablation, which also eliminates the manual process of engraving. First image corresponding to the template is converted into a mask, which has opaque and transparent parts. The light from the excimer laser generates a polymeric working the workpiece image mask area, and the transparent portions correspond to regions that are removed in the harvesting. The mask and the workpiece are moved in such a way as to provide a scanning image. Because the mask is an image composed only of transparent and opaque parts, this method does not use information relating to a variable depth, and does not provide precise control of the depth of the engraving.

In the patent DE 10044403 described method of gravure printing, creating a grayscale image, presents a mixed linear structures. In the first stage, the image in the form of pixel data is provided and displayed using the computer. The designer analyzes the image in the form of variables and different linear structures. Then the data corresponding linear structures, remember the computer in vector data format. On the trail is the next stage of engraving formatted vector data control engraving tool thus engraving plate for gravure printing, the following data, the corresponding linear structures.

One object of the present invention is to reduce processing time and cost of wafer production method of gravure printing by eliminating the tedious steps of engraving vignettes and portraits manually.

An additional objective is to simultaneously maintain a high level of quality of the plates by the method of gravure printing, as traditionally manufactured, that is, to get very clear cut engraving.

Modern practice in the printing industry securities provided by the Union of several printing processes on the same securities, that is, to subject the sheet securities to many different printing processes for a more difficult play fakes. As examples of other printing processes used in the printing industry securities, especially banknotes, can result in offset printing, screen printing, mounting film and digitizing.

Known fact in the printing industry securities is that the method of gravure printing causes warping of the sheet because of the high pressure seal is required to compress the sheet of paper to the cliché plate. Other above-mentioned printing processes used to create the project of the same sheet, do not cause such distortion. As a result of this warping is not all prints from different processes will be combined on one sheet. The term "sheet" refers in this description as a separate, generally rectangular sheets of paper, and continuous strips of paper.

An additional object of the present invention is the elimination of this distortion so that all the prints obtained using different printing processes will be adjusted.

These tasks are accomplished by using the method as described in the introduction of the present description, in which are mentioned the programmed process of engraving engrave not engraved plate according to the three-dimensional control of the pixel data (X, Y, Z) maps the reference depth mentioned plate, with the specified map reference depth is formed at least with one card reference depth stored in the computer, and referred to the map reference depth is a three-dimensional bitmap image of at least part of one of the mentioned securities in which the elementary stage of engraving associated with three-dimensional data of each pixel.

Thus, the present invention is based on the use of a depth map, which is a computer file that contains a three-dimensional raster image is of engraving, on the plate, as the engraving of the working of the workpiece and the tool operating in accordance with the depth map information.

Preferably engraving tool is a laser engraving device, and the elementary stage laser engraving is associated with each pixel of the bitmap. The depth of etching is set to each pixel data of the bitmap. Successive stages of engraving can follow the column of the pixel plate, then the adjacent column, etc. Because nearby, located on a diagonal pixels can show the same depth, corresponding, for example, a line drawing, the finished plate provides an image corresponding gravure printing, while the manufacturing process of the plate corresponds to the bitmap image. Plate, which engrave, may be a gravure printing plate. Plate, which engrave, may also be intermediate plate for gravure printing plate, which is then further treated with metallization, as known from the prior art.

Three-dimensional bitmap image associated with this valuable paper, contains information relative to the coordinates (X,Y) location of each pixel together with the information (Z) oglobin, associated with the same pixel.

It is obtained by processing one or more three-dimensional elements. These elements can be:

(a) three-dimensional linear Marov;

b) three-dimensional raster image, especially bitmaps protection;

C) three-dimensional elements, consisting of a number of flat areas, built-in or not, of different depths and shapes;

d) three-dimensional scan of relief.

Such three-dimensional linear Marov can consist of a sequence of segments, where each segment has its own specified length, width, and depth.

Three-dimensional raster image can be directly formed using the computer or received from a scanned drawings or designed using computer drawings, which are processed by the algorithm, which determines the depth of each pixel of the bitmap. The algorithm links the depth of each pixel so that the bitmap like the line proles observed in hand engravings.

Map reference depth provides many repetitions card depth of the original engraved plate and contains information about their locations in the plane of the plate. Thus, the map reference depth can provide a number of repeat the depth map of the original in accordance with a pattern of rows and columns.

In accordance with a preferred embodiment of the invention map reference depth contains information about the warping of the sheet in the process of gravure printing and parameters to compensate for the above-mentioned warpage.

Map reference depth can be continuously contain the pixel data for the engraving of the whole plate, in particular the pixel data generated in accordance with information, to compensate for warping of the sheet.

The computer may also store map (maps) the depth of the original corresponding to one security, and the parameters of the distortion correction so that the data depth map template was generated quickly during the engraving process to save time and disk space.

Other features and advantages of this invention will be clear to experts in the art from the following description of a preferred variant of the invention, referring to the drawings, in which:

figure 1 schematically illustrates the method of manufacturing a plate for gravure printing of the prior art;

figure 2 schematically illustrates the content of the method of this invention, intended for the manufacture of plates for intaglio printing;

figa illustrates a three-dimensional line, and fig.3b illustrates a three-dimensional image is their linear moire;

figure 4 illustrates a three-dimensional bitmap;

figure 5 illustrates other three-dimensional image;

6 illustrates a three-dimensional depth map of the original;

Fig 7a, fig.7b and figs illustrate the depth map of the original;

Fig map illustrates the reference depth;

figa, fig.9b, figs and fig.9d illustrate embodiments of the present invention.

Figure 1 schematically illustrates the method known from the prior art, traditionally used in the factories printing of securities for the manufacture of plates for intaglio printing.

The first step is hand engraving on steel or copper matrix image with depth, like the portrait. This step requires months of skilled engraver.

The second step consists in making copies of the engraved manually matrix and adding using chemical etching other lines on the matrix. These lines can be generated using computer image protection, printed during the process of gravure printing.

The third step consists in the manufacture of plastic sheets of this matrix. Will be made so many impressions, how many documents will be security printed on each sheet.

The fourth step consists in cutting the prints to shape.

The fifth step consists in placing upon the other cut sheets in rows and columns, and then joining them together to create a plastic set of multiple images.

The sixth step consists in coating the silver plastic kit set of images.

The seventh step consists of applying a plastic kit of a layer of copper in the bath galvanic deposition of copper to create copper plates.

The eighth step consists in applying a layer of Nickel on the copper plate in the bath for applying a Nickel coating.

The product resulting from all of these stages in the technology of the prior art is the so-called nickel-alto, i.e. with a high Nickel content, which will be used as an intermediate model for the production of Nickel plate for gravure printing, which is installed in printing machines for gravure printing.

Figure 2 illustrates the main steps of the present invention, which will eliminate at least the first seven stages described in the prior art.

The first step is to create a depth map of the original, which is formed as follows:

1. Carry out the formation of three-dimensional elements with information about the depth. These elements can be, not limited to, the following types:

A. Three-dimensional linear Mary. For example, these Mary can consist of a sequence of segments, where each segment has its own the th specified length, the width and depth. Figa depicts a magnified portion of the lines with variable width and depth, where the depth of each segment is displayed on the computer screen its color and shades of gray in this black-and-white print screen image. Fig.3b depicts a simple computer generated three-dimensional linear moire with variable width and depth.

b. Three-dimensional raster image protection, for example, a computer generated or created from scanned hand drawings or computer-generated images, processed using an algorithm that determines the depth of each pixel of the raster image in accordance with the line profiles similar to the profiles observed in hand prints, as illustrated in figure 4. For example, profiles can be selected for each line or for any group of lines. The profile types include, but are not limited to, V-shaped and U-shaped profiles of different initial angles and profiles of rectangular shape. Must be set to the maximum depth of the line, and the ratio of the depth lines with line width.

C. Other types of three-dimensional elements, such as three-dimensional elements, consisting of a number of flat areas, nested or not, of different depths and shapes (figure 5) or three-dimensional scan of the bas-reliefs.

2. Assemble the three-dimensional elements in the file the original with information about the depth, as illustrated in Fig.6.

3. Form a depth map of the original. Processing file creates one of the original three-dimensional raster image. Figa, fig.7b and figs depict the same depth map with increasing magnification. The depth of each pixel is represented using its brightness level. On figs you can see the individual pixels. Their size corresponds to a resolution of 8000 dpi.

The second step consists in generating the reference depth, which includes information about the repetition and locations on the plate depth map of the original, as well as information about the warping used to compensate for warping of the sheet, which occurs during printing (Fig), for all printing processes applied to the same sheet, were mangled.

Map reference depth used engraving tool, which etches the plate consistently pixels. Laser engraving machines that are capable of transferring the information stored for each pixel, well-known specialists from the technical level.

The map data of the reference depth can be formed quickly during etching to save time and disk space. This is particularly useful when the map reference depth corresponds to the repetition of the depth map of the original.

The special is iality in the art will understand, there are many variants of the process of formation depth map.

Three-dimensional elements can be collected in several files of the original, for example, multiple separate files for non-overlapping elements. Depth map of the original formed from them, may be repeated in the map reference depth in accordance with different rules than simply repeating in rows and columns.

The layout of the matching elements in the original file and the depth map information (X, Y, Z) for each pixel may be subject to different rules depending on the desired final visual effect, such as whether one element locally overlapped by another (other) or not.

Figa, fig.9b, figs and fig.9d illustrate embodiments of the present invention.

On figa engraving tool is a laser based on YAG (yttrium aluminium garnet), and the engraved plate is a polymer plate, which serves as an intermediate plate for gravure printing. Engraved plate mounted on a rotating cylinder. The laser is moved in a direction parallel to the axis of the cylinder. Control movement of the laser and its intensity, as well as the cylinder rotation is performed with the aid of a computer, which quickly generates data depth map of the original, a modification of the into account the compensation of the deformation of a sheet, which is in the process of gravure printing.

A variant embodiment of the invention depicted in fig.9b, such a variant embodiment of the invention, described in figa, except that the plate is installed on a flat surface. Movement of the laser beam and plate parallel to the plate.

Engraved polymer plates covered with silver, and they serve as intermediate plates for Nickel-alto plates (plates with a high content of Nickel in electroplating baths for the deposition of Nickel.

In accordance with the embodiment of the engraving plate consists of a layered structure containing

the metal plate basics

the adhesive layer

polymer layer.

Polymer layer engrave in accordance with the method of the present invention. Particularly suitable polymers for the process of engraving are polyimides containing a black substance dispersed graphite for increased absorption of the laser beam. This type of material allows for engraving particularly high resolution. An example of a suitable material is a polyimide introduced with graphite, sold under the trade name "Kapton etc" company "Du Pont de Nemours.

On figs shows a variant embodiment of the invention, which is similar to the variant of implementation, described in figa, for which the conclusion of the addition, the plate is metal and the laser is an excimer laser.

On fig.9d presents an implementation option, which is similar to the variant of implementation, described in fig.9b, except that the plate is metal and the laser is an excimer laser.

These embodiments of the invention are given only as examples, and other embodiments of falling under the scope of the claims, may be developed by experts in the field of technology. For example, there may be many engraving tools, managed card reference depth, and these tools are synchronous manner, in particular can be used in such an amount engraving tools, how many columns of securities on the printed sheets with the mentioned securities.

1. A method of manufacturing an engraved plate for gravure printing of sheets of securities, in which nigroviolacea plate undergoes programmed engraving process using a computer-controlled engraving tool, characterized in that the said programmed process of etching includes etching mentioned nigroviolacea plate in accordance with the three-dimensional control of the pixel data (X, Y, Z) maps the reference depth od the CSOs mentioned sheet, in which mentioned map reference depth is formed at least with the one stored in the computer depth map of the original, consisting of a three-dimensional bitmap image of at least part of one of the mentioned securities, and in which the elementary stage of engraving associated with three-dimensional data of each pixel.

2. The method according to claim 1, characterized in that the said engraving tool is a laser engraving device.

3. The method according to claim 1, characterized in that the said engraving tool is an excimer laser or YAG laser.

4. The method according to claim 1, characterized in that the said three-dimensional raster image is formed by processing at least one three-dimensional element, selected from a list containing (a) a three-dimensional linear Mary, b) three-dimensional raster image, (c) three-dimensional elements, consisting of flat areas, d) three-dimensional scan of the bas-relief or a combination of both.

5. The method according to claim 4, characterized in that the said three-dimensional linear Mary consist of a sequence of segments, where each segment has its own specified length, width, and depth.

6. The method according to claim 4, characterized in that the said three-dimensional bitmap form using your computer or create from scanned ru is different drawings or designed using computer graphics, processed in accordance with the algorithm that determines the depth of each pixel of the raster image in accordance with the profiles of the lines of hand prints.

7. The method according to claim 2, characterized in that the said three-dimensional raster image is formed by processing at least one three-dimensional element, selected from a list containing (a) a three-dimensional linear Mary, b) three-dimensional raster image, (c) three-dimensional elements, consisting of flat areas, d) three-dimensional scan of the bas-relief or a combination of both.

8. The method according to claim 7, characterized in that the said three-dimensional linear Mary consist of a sequence of segments, where each segment has its own specified length, width, and depth.

9. The method according to claim 7, characterized in that the said three-dimensional bitmap form using your computer or create from scanned hand drawings or designed using computer images, processed in accordance with the algorithm that determines the depth of each pixel of the raster image in accordance with the profiles of the lines of hand prints.

10. The method according to any one of claims 1 to 9, characterized in that the said map reference depth provides plenty of repetitions of the plate, each depth map of the original and contains information about the places which the provisions of repetitions in the plane of the plate.

11. The method according to claim 10, characterized in that the said map reference depth contains pixel data formed in accordance with the information used to compensate for warping of the sheet during the process of gravure printing, and in accordance with the specified manages engraving tool.

12. The method according to claim 10, characterized in that there are many engraving tools, managed mentioned card reference depth, and these tools are synchronous manner.

13. The method according to item 12, characterized in that is provided by the number of copper tools in accordance with the presence of a number of columns of securities on the printed sheets with the mentioned securities.

14. Engraved plate, obtained by the method according to any one of claims 1 to 13.

15. Engraved plate for gravure printing, wherein it was produced using the process according to any one of claims 1 to 13.

16. Engraved intermediate plate plate for gravure printing, wherein it was produced using the process according to any one of claims 1 to 13.

17. Plate according to item 16, characterized in that the said engraved plate is a metal plate.

18. Plate according to item 16, wherein said plate includes a polymer layer and said polymer layer is g is overovanim.

19. Plate on p, characterized in that the said engraved plate is an intermediate plate containing the following layers: a metal base, an adhesive layer, the polymer layer.

20. Plate according to claim 19, characterized in that the said polymer layer is a polyimide containing a black substance dispersed graphite.

21. Engraved intermediate plate plate for gravure printing, characterized in that the said plate is composed of a polyimide material containing a black substance dispersed graphite, and the above-mentioned etching is carried out by means of the process according to any one of claims 1 to 13.



 

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