Method and embossing structure using high density pressure for creating shadowed or curved highly reflective areas on rotationally embossed foils

A method of embossing individually light reflecting areas on a foil material, the method comprising:

• feeding a foil material into a roller nip between a pair of rollers, the pair of rollers including a motor roller and a counter roller;
• wherein the motor roller and counter roller at least in a determined perimeter includes a plurality of positive and negative projections on a checkered layout, positive and negative projections alternate in axial and radial directions,
• the positive projections of the motor roller together with alternating corresponding negative projections on the counter roller form, during the operation of the rollers and in the roller nip, a first straight line substantially parallel to the axial direction, and
• the negative projections of the motor roller together with alternating corresponding positive projections on the counter roller form, during the operation of the rollers and in the roller nip, a second straight line substantially parallel to the axial direction, and
• each positive projection extends from a base surface of a corresponding roller of the pair of rollers to a top side of the positive projection in a direction away from a rotation axis of the corresponding roller, and each negative projection extends from the base surface of a corresponding roller of the pair of rollers to a bottom side of the negative projection in a direction towards the rotation axis of the corresponding,
• during an embossing operation of the motor roller and the counter roller and in the roller nip, each projection of the motor roller is surrounded on all lateral sides by projections of the counter roller,
• on a roller each positive or negative projection not situated at the determined perimeter, is axially offset relative to the peripherally adjacent positive or negative projections respectively on the same roller, and
• the plurality of positive and negative projections of the counter roller seamlessly and gaplessly join with those corresponding negative and positive projections of the motor roller at the intended embossing of the foil material, enabling a homogeneously jointed embossed polyhedron shape in the foil.
• each positive and negative projections on the motor roller are shaped as an n- cornered polyhedron with a specific surface to produce on the embossed foil surface a corresponding individually light reflecting area, and each positive projection its specific surface corresponding to its top side, and for each negative projection its specific surface corresponding to its bottom side.