Unitary type-carrier elements and method of making same

Claim 1

The method of forming from flat metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating both front and back surfaces of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms, respectively; removing photoresist to expose metal stock around the images of the characters on the front side surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any other areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling and the type characters are formed in relief on the arms thereof.

Claim 2

The method of forming from flat metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating both front and back surfaces of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms, respectively; removing photoresist to expose metal stock around the images of the characters on the front side surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any other areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling and the type characters are formed in relief on the arms thereof.

Claim 5

The method of any of the preceding claims 1, 2 or 3 in which image formation is by means of exposure of selected portions of the photoresist material to radiation and the removal of photoresist is by selective solvent removal.

Claim 8

The method of forming from flat metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating the surfaces of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on one surface of the metal stock hereinafter termed the back surface; forming an array of images defining selected type characters in the photoresist on the other surface area of the metal stock, hereinafter termed the front surface, each of said images being arranged to register with one of the arms on the back surface, respectively; removing photoresist to expose metal stock around the images of the characters on the front surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except to facilitate handling and the thickness of the element is decreased overall with the type characters being formed in relief on the arms thereof.

Claim 9

The method of forming from flat metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating the surfaces of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on one surface of the metal stock hereinafter termed the back surface; forming an array of images defining selected type characters in the photoresist on the other surface area of the metal stock, hereinafter termed the front surface, each of said images being arranged to register with one of the arms on the back surface, respectively; removing photoresist to expose metal stock around the images of the characters on the front surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except to facilitate handling and the thickness of the element is decreased overall with the type characters being formed in relief on the arms thereof.

Claim 10

The method of forming from flat metal stock a one-piece type carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating the surfaces of metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms, respectively; removing photoresist to expose metal stock around the images of the characters on the front surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any areas of the surfaces to facilitate handling during fabrication; etching the exposed metal stock to a predetermined depth on the back surface of the metal stock in a preliminary etching step; etching the exposed metal on both surfaces of the metal stock in a primary etching step whereby the thickness of the element being formed is decreased overall and the type characters are formed in relief and any remaining metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling.

Claim 11

The method of forming from flat metal stock a one-piece type carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating the surfaces of metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms, respectively; removing photoresist to expose metal stock around the images of the characters on the front surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any areas of the surfaces to facilitate handling during fabrication; etching the exposed metal stock to a predetermined depth on the back surface of the metal stock in a preliminary etching step; etching the exposed metal on both surfaces of the metal stock in a primary etching step whereby the thickness of the element being formed is decreased overall and the type characters are formed in relief and any remaining metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling.

Claim 12

The method of any of the preceding claims 7 or 8 in which image formation is by means of exposure of selected portions of the photoresist material to radiation and the removal of selected areas of photoresist is by selective solvent removal.

Claim 13

The method of any of the preceding claims 7 or 8 in which the steps thereof are preceded by a coining, grinding, or machining step to form a concave printing surface area in the metal stock.

Claim 14

The method of any of the preceding claims 7 or 8 in which the photoresist is of the negative type.

Claim 16

The method of any of the preceding claims 7 or 8 in which all the etching from one side is performed in a single step, followed by all the etching from the other side in a second step.

Claim 17

The method of forming from metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating both opposing surfaces, hereinafter termed front and back surfaces, of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms on the back surface, respectively; removing photoresist to expose metal stock around the images of the characters on the front side surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any other areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling and the type characters are formed in relief on the arms thereof.

Claim 18

The method of forming from metal stock a one-piece type-carrier element of the kind having a center portion and a plurality of arms extending therefrom, each arm having a printing surface including integrally formed type characters, comprising the steps: coating both opposing surfaces, hereinafter termed front and back surfaces, of the metal stock with photoresist material; forming an image defining the overall shape of the carrier element in the photoresist material on the back surface of the metal stock; forming an array of images defining selected type characters in the photoresist on the front surface area of the metal stock, each of said images being arranged to register with one of the arms on the back surface, respectively; removing photoresist to expose metal stock around the images of the characters on the front side surface of the stock and to expose metal stock around the image shape of the carrier element of the back surface and optionally allowing photoresist to remain on any other areas of the surfaces to facilitate handling during fabrication; and etching the exposed metal stock on both surfaces whereby all of the metal stock surrounding the carrier element is completely removed except for any portions selected to facilitate handling and the type characters are formed in relief on the arms thereof.