Method of mounting a printing plate on a mounting sheet

A method for mounting a printing plate on a mounting sheet without requiring the intervention of a skilled person working by eye. An original design to be printed is produced on a computer and register marks are added to that design at specific positions. The resultant design data is output to a first printer. A negative of the design and the register marks is produced, and a printing plate is produced from the negative so that the design and the register marks are reproduced on the printing plate. The register mark position data is also output from the computer to a second printer. The dimensions of an article upon which the design is to be printed are input into a second printer and a full size plot of the outline of the article, including the positions of the register marks, is produced from the second printer. The plot is then located in a predetermined overlapping position relative to the mounting sheet on which it is desired to mount the printing plate and the printing plate is secured on the mounting sheet such that the register marks reproduced on the printing plate are aligned with the register marks on the plot.

BACKGROUND OF THE INVENTION 
The present invention relates to a method of mounting a printing plate to a 
mounting sheet, the mounting sheet facilitating subsequent mounting of the 
plate to a printing apparatus such as a printing roller. 
The process of mounting printing plates to a backing sheet is known as 
pre-mounting. In the packaging production industry, for example, in which 
pre-mounted printing sheets are produced to enable a printer to print 
images onto packaging, such as for instance cardboard boxes, the 
established method of producing and pre-mounting printing plates is as 
follows. 
The original artwork is first produced on a computer using a suitable CAD 
software package. Typically the artwork will comprise a number of 
multi-coloured designs for printing on different panels of a cardboard 
box. Once finalised, the computer panel design data is supplied to a 
printer for the production of full sized negative prints of the panel 
designs which are subsequently used to produce the printing plates. Since 
the printing process requires a separate set of plates for each colour to 
be printed, at the artwork production stage each different colour used in 
the panel designs is flagged as such by the software so that separate sets 
of negative prints can be produced for each individual colour. 
The negative prints are then used to produce relief printing plates for 
each panel design from photo-polymer. These plates are then pre-mounted 
before sending to the printer. The plates for each individual colour are 
mounted on separate backing sheets which are generally all of the same 
size. The backing sheets are of a standard size and are provided with 
register holes or other alignment formations for fixing in a predetermined 
position on the printing rollers. The backing sheets and rollers generally 
have centre marks so that the printer can accurately align the separate 
backing sheets carrying the different colour plates. 
It will be appreciated that although the printer can align the separate 
sheets with one another, the plates for each colour must be accurately 
positioned on respective backing sheets at the pre-mounting stage so that 
at the printing stage they are correctly positioned relative to one 
another once the backing sheets are aligned. For instance if each sheet 
carries a single plate each plate must be positioned at the identical 
position on its respective sheet to the position of the other plates on 
their backing sheets. 
Such accurate pre-mounting is achieved as follows. The first sheet is 
placed on a laying up board in a set position for instance by locating one 
corner of the sheet within a right angle. This ensures that successive 
sheets can be positioned on the board in the identical position. 
The dimensions of the cardboard blank, for instance, which the design is to 
be printed on is fed into a plotter which produces a full size plot of the 
blank on a sheet of tracing paper. This sheet of tracing paper is laid 
over the backing sheet and secured against unwanted movement by taping one 
edge of the sheet to the board. 
The printing plate or plates of the first colour are then slipped under the 
tracing paper and fixed to the backing sheet. The correct position of the 
first colour plate or plates is determined by eye with reference to the 
outline of the blank carried by the tracing paper. Register marks are then 
made on the tracing paper to indicate the positioning of the first colour 
plate or plates. 
The first backing sheet is then successively replaced with subsequent 
backing sheets of identical size and which are positioned on the board in 
the same position as the first in the manner discussed above. The tracing 
paper being taped to the board will remain in the same position. 
Subsequent colour plates are then fixed to respective backing sheets, the 
register marks made on the tracing paper after the first colour was 
mounted being used to help correctly align each colours plates with the 
first colours plates and with each other. For instance if an identical 
number and size of plates is used for each colour the mounting of the 
second and subsequent colour plates will be a simple matter of aligning 
those plates exactly with the register marks made after the first colour 
plates are mounted. It will however be appreciated that great care must be 
employed by a skilled worker in positioning the first colour plates as 
this is done by eye with reference only to the outline of the blank. 
In addition, any single colour will often only appear at distinct spaced 
apart portions of any given panel design. In this case, since the cost of 
the photo-resin is high, it is not economical to produce a single printing 
plate for each colour for each panel design but rather a number of smaller 
plates are produced for respective localised areas of any one colour. Thus 
in general there will be a number of separate plates for each colour of 
any one panel design. This complicates the pre-mounting task since each 
plate of the first colour must be positioned accurately, by eye, relative 
to each other as well as to the outline of the blank. 
Moreover, there will often be different numbers of different sized plates 
for each colour and therefore whilst the register marks of the first 
colour plates will aid in positioning subsequent colour plates, the 
positions of the subsequent colour plates may not correspond exactly with 
the register marks. 
Since as many as 100 plates may be used for all the colours for any one 
blank it will be appreciated that the established method of pre-mounting 
is difficult and time consuming requiring painstaking work by a skilled 
worker. Thus even if the design consists of only a single colour the 
process of pre-mounting the plates in the correct relative positions by 
eye alone can be a difficult and time consuming procedure. 
Plate mounting machines have been developed for pre-mounting, such as that 
sold by J. M. Heaford Limited under the trade mark VIPER, which employ 
video cameras to help position the plates. However, such machines are 
generally expensive, typically costing tens of thousands of pounds, and 
the number of plates which can be mounted is limited. For instance, the 
VIPER (trade mark) machine referred to can be used to mount a maximum of 
twelve plates only. 
It is an object of the present invention to obviate or mitigate the above 
disadvantages. 
SUMMARY OF THE INVENTION 
According to the present invention there is provided a method for mounting 
a printing plate on a mounting sheet, the method comprising the steps of: 
a) producing on a computer an original design to be printed, 
b) adding register marks to the design at specific positions, 
c) outputting the design data, including the register mark position data, 
to a first printer, 
d) producing a negative of the design and the register marks, 
e) producing a printing plate using the negative so that the design and the 
register marks are reproduced on the printing plate, 
f) outputting the register mark position data to a second printer, 
g) inputting into said second printer the dimensions of an article upon 
which the design is to be printed, 
h) producing, from the second printer, a full size plot of the outline of 
the article including the positions of the register marks, 
i) locating the plot in a predetermined overlapping position relative to 
the mounting sheet on which it is desired to mount the printing plate, and 
j) securing the printing plate on the mounting sheet such that the register 
marks reproduced on the printing plate are aligned with the register marks 
on the plot. 
Since the plot carries register marks corresponding with register marks on 
the printing plate, accurate positioning of the plate on the mounting 
sheet is a straightforward matter not depending on the skill of the 
pre-mounter to position the plate by eye. 
Preferably data relating to the dimensions of the article on which the 
design is to be printed is input into the computer at the design stage, 
the dimension data being output from the computer to the second printer 
together with the register mark position data. 
The method may be used where there are a plurality of printing plates to be 
mounted to a single mounting sheet, respective register marks being 
allocated at the design stage to each plate. 
The method may also be used where the design comprises a plurality of 
colours such that separate printing plates relating to each colour are 
required, respective register marks being allocated to each printing plate 
at the design stage, and the plot includes all register marks relating to 
all colours. 
At least some of the register marks relating to different plates may be 
identified as such to aid in matching up specific plates with specific 
register marks carried by the plot at the mounting stage.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring to the drawings, the described embodiment of the present 
invention relates to the production and mounting of printing plates for 
printing a design on a cardboard box. Initially the dimensions of the 
cardboard box blank are fed into a computer (not shown) and the outline of 
the blank 1 is displayed on a computer screen 2. The artwork for the 
design of the various panels of the box is then produced on the computer, 
and displayed on the computer screen 2. In the illustrated example the 
design of only one box panel is shown, this is referenced as the panel 
design 3. 
The panel design 3 comprises a red cross 4, a black circle 5 and a red 
square 6. Once the design is completed the designer adds to the design 
register marks 7. Thus there is one pair of register marks 7 which is 
effective for the cross 4, the circle 5 and the square 6. It will be 
appreciated that the design illustrated and described is very simple in 
order to simplify the description of the invention and that in practice 
the design may be much more complex and include a large number of colours. 
Although each colour of the panel design 3 together with the outline 1 of 
the cardboard box and the register mark 7 are displayed on the screen 
simultaneously, the software program is such that the data relating to 
each colour and to the outline 1 exists at different levels of the program 
but that the data relating to the register marks 7 exists on every level 
of the program. A software package which may be adapted to carry out the 
present invention is sold by F.S.L Computer Services Division (of Oakwood 
Avenue, Warrington, Cheshire, England) as "Package Express" software. 
However, once the important features of the present invention are 
understood from the following description, it will be a straightforward 
matter for a computer programmer to develop suitable software for 
performing the invention. Accordingly further details of the computer 
software are not given here. 
Once the design is complete the data relating to the panel design 3 is fed 
to a first printer (not shown). It is to be noted that data describing the 
position of the register marks 7, which data exists at every level of the 
program, is input to the printer together with the panel design data, but 
that the data relating to the dimensions and outline 1 of the blank, which 
exists at a different level of the software, is not. 
The first printer is used to produce full size negatives 8 and 9 (shown in 
FIG. 2) of the panel design 3. Separate negatives are produced for each 
colour layer of the panel design 3. Thus, referring to FIG. 2, the 
negative print 8 relates to the red portions of the design and the 
negative print 9 relates to the black portions of the panel design 3. It 
will be seen, however, that the register marks 7 come out on each negative 
8 and 9 irrespective of the colour to which that negative relates. 
The negatives 8 and 9 are then used in the production of printing plates 
from a photo-polymer sheet in accordance with a known method. Referring to 
FIG. 3, the negatives are laid over a photo-polymer sheet 10 which is then 
exposed to light (indicated by the arrow A). Wherever light passes through 
the negative and strikes the sheet 10 the surface of the sheet raises up 
to produce the appropriate design in relief. The resultant printing plates 
11 are shown in FIG. 4, after they have been cut from the sheet 10. Not 
only are the respective portions of the panel design 3 reproduced on the 
sheet 10, but also each corresponding pair of register marks 7, referenced 
7a. 
The photo-polymer material is very expensive and the sheets tend to be of a 
standard size. Hence before the negatives are laid up on the photo-polymer 
sheet 10 the original negatives 8 and 9 are cut into smaller portions to 
eliminate some of those portions of the original negatives which will not 
contribute to the reproduction of the design on the sheet 10, in order to 
minimise the area of the photo-polymer sheet 10 required to produce the 
plates. It will be appreciated that, again in the interest of efficiency, 
a single photo-polymer sheet 10 will not be exposed until the whole sheet 
has been covered with negatives which may or may not relate to the same 
design. 
Referring to FIG. 5, data relating to the dimensions of the blank together 
with the data representing the positions of the register marks 7 are then 
output from the computer to a plotter (not shown) which is used to produce 
a full sized plot of the outline 1 of the box blank on tracing paper 12. 
The plot 12 includes the register marks 7, referenced as 7b. The plot 12 
is then used in the pre-mounting process as described below. 
Referring to FIG. 6, a plastics mounting sheet 13 of standard size is 
positioned on a laying up board 14 in a predetermined position by locating 
one corner of the mounting sheet 13 within a right angle 15. The tracing 
paper plot 12 is then laid over the carrying sheet 13 in the desired 
position and one edge of the tracing paper plot 12 is taped to the board 
14 to prevent it being moved out of position. Next, each of the printing 
plates 11 is in turn inserted between the tracing paper plot 12 and the 
mounting sheet 13 and located in its correct position by aligning the 
register marks 7a on the printing plate 11 with the corresponding register 
marks 7b on the tracing paper plot 12. Once correctly positioned the 
printing plate 11 is secured on the mounting sheet 13 using adhesive tape. 
This process is repeated for each printing plate 11, each plate being 
readily located on a separate mounting sheet in the correct position be 
aligning the respective register marks 7a and 7b. 
Once the printing plates relating to the first colour, i.e. red, have been 
mounted onto a single mounting sheet 13, that mounting sheet is removed 
from the laying up board 14 without disturbing the position of the tracing 
paper plot 12, which is taped to the board 14, and replaced with a second 
mounting sheet (not shown). The second (and subsequent sheets if more than 
two colour are used for the design) is of identical size to the first and 
is positioned in the same predetermined position on the board 14 again 
using the right angle 15 to locate one corner of the mounting sheet. 
Printing plates relating to the second colour, in this case black, are 
then mounted on the second carrying sheet, again being correctly 
positioned by aligning the respective register marks 7a and 7b. 
Once the printing plates 11 have been pre-mounted they are sent to a 
printer. The printing process may be a conventional process such as that 
discussed in the introduction to this specification. 
It will be appreciated that using the method in accordance with the present 
invention, the pre-mounting process is greatly simplified and is no longer 
required to be carried out by a skilled worker who must align at least the 
first set of printing plates by eye alone. Using the method according to 
the present invention it is a straightforward matter to correctly position 
the first, and any subsequent, set of plates in relation to one another 
and in relation to the outline of the box blank. 
In the illustrated example, two register marks are provided. This is the 
preferred arrangement. However a single register mark might only be 
required for each plate by, for example, forming the register mark as an 
arrow pointing in a predetermined direction, whereby overlaying exactly 
the single register marks carried by the printing plates and the tracing 
paper plot the respective printing plate will be correctly positioned. 
At the design stage register marks relating to different areas of the 
design may be identified as such so that at the pre-mounting stage the 
printing plates can more readily be identified as corresponding to 
specific register marks on the tracing paper plot. This would be 
particularly useful where large numbers of printing plates and/or colours 
are required. 
It will be understood that although the invention has been described in 
relation to a design intended for printing on a cardboard box the 
invention is not so limited and could be applied to the pre-mounting of 
printing plates for printing designs on a wide range of articles.