Method of making a thin die to be used in a press

Abstract

Disclosed is a thin die adapted to be used in a press and a die press system utilizing the thin die and a die press, such as a platen die press or a roller die press. The die disclosed herein includes a base or backing portion that provides rigidity to the die assembly. The base includes an indentation defining a border around the peripheral edge of the base. A thin die is housed in the indentation of the base. The thin die is positioned in the indentation and adhered using an adhesive, such that the raised portions of the thin die are facing away from the indentation in the base. Ejection foam is adhered to the raised portion side of the thin die by an adhesive so that the ejection foam protects the raised portion of the thin die and ejects a cut shape out of the sheet material.

1 . A method of making a thin die, comprising the steps of: 
 providing a steel material;    chemical etching a near net shape in one side of the steel material so that the steel material has a first flat side and a second side that includes a raised cutting portion;    fixing the steel material into an indentation of a base so that the first flat side of the steel material is adhered to the base; and    adhering an ejection foam to the second side of the steel material so that the ejection foam covers the chemical etched shape.    
   
   
       2 . The method of making a thin die according to  claim 1 , further comprising exposing the steel material to a secondary etching step after etching the near net shape.  
   
   
       3 . The method of making a thin die according to  claim 2 , wherein the chemical etching step is approximately 15 to 30 minutes long, and more preferably 15 to 25 minutes long.  
   
   
       4 . The method of making a thin die according to  claim 2 , wherein the secondary etching step is approximately 10 to 30 seconds long and, more preferably, is approximately 15 to 20 seconds long.  
   
   
       5 . The method of making a thin die according to  claim 1 , wherein chemical etching the near net shape comprises chemical etching the raised cutting portion to be approximately 0.001 inches to approximately 0.008 inches wide.  
   
   
       6 . The method of making a thin die according to  claim 2 , further comprising adhering a laminated film to the steel material to define the raised portion prior to chemical etching.  
   
   
       7 . The method of making a thin die according to  claim 6 , further comprising removing the laminated film prior to exposing the steel material to the secondary etching step.  
   
   
       8 . The method of making a thin die according to  claim 2 , wherein the method includes a rinsing step after the secondary etching step.  
   
   
       9 . A method of making a thin die, comprising the steps of: 
 providing a steel material;    chemical etching a near net shape in one side of the steel material so that the steel material has a first flat side and a second side that includes a raised cutting portion;    exposing at least the second side of the steel material to a secondary etching step;    fixing the steel material into an indentation of a base so that the first flat side of the steel material is adhered to the base;    adhering an ejection foam to the second side of the steel material so that the ejection foam covers the chemical etched shape; and    applying identifying indicia to a side of the base opposite the steel material.    
   
   
       10 . A method of making a thin die, comprising the steps of: 
 chemical etching a near net shape in one side of a die material to produce a die portion having a first flat side and a second side that includes a raised portion; and    fixing the die portion into an indentation of a base so that the first flat side of the die portion is attached to the base within the indentation.    
   
   
       11 . The method of  claim 10 , wherein fixing the die portion into the indentation comprises fixing the die portion within the indentation such that the die portion is substantially surrounded by a peripheral border.  
   
   
       12 . The method of  claim 10 , wherein fixing the die portion into the indentation comprises adhering the first flat side of the die portion to a surface of the indentation of the base.  
   
   
       13 . The method of  claim 10 , wherein the die material comprises steel material.  
   
   
       14 . The method of  claim 10 , wherein chemical etching the near net shape in one side of the die material comprises: 
 laminating a dry film to the die material;    exposing the dry film to light to produce an image on the die material;    developing the dry film;    removing a portion of the exposed dry film from the die material;    chemical etching the die material; and    stripping remaining dry film from the die material.    
   
   
       15 . The method of  claim 10 , wherein chemical etching the near net shape in one side of the die material comprises: 
 laminating a dry film to the die material;    chemical etching the die material;    stripping dry film from the die material; and    performing a secondary etch on the die material.    
   
   
       16 . The method of  claim 10 , further comprising applying an antioxidant to the die portion.  
   
   
       17 . The method of  claim 10 , further comprising applying an identifying label to a back-side indentation of the base, the back-side indentation of the base on a surface of the base opposite the indentation.  
   
   
       18 . The method of  claim 10 , further comprising applying identifying indicia to a surface of the base opposite the indentation.  
   
   
       19 . The method of  claim 10 , further comprising adhering an ejection foam to the second side of the die portion so that the ejection foam covers at least a portion of the chemical etched shape.  
   
   
       20 . The method of  claim 10 , wherein the net shape comprises a raised embossing portion.  
   
   
       21 . The method of  claim 10 , wherein fixing the die portion into the base comprises fixing the die portion into a plastic base.  
   
   
       22 . A method of making a thin die, comprising: 
 chemical etching a near net shape in one side of a die material to produce a die portion having a first flat side and a second side that includes a raised portion;    fixing the die portion into an indentation of a base so that the first flat side of the die portion is attached to the base within the indentation; and    applying identifying indicia to a surface of the base opposite the indentation.    
   
   
       23 . The method of  claim 22 , wherein applying the identifying indicia comprises applying an identifying label to the surface of the base opposite the indentation.