Paper embossing system with a flexible counter and method of embossing

An embossing system for embossing cards, the system comprising:

• a die having a contoured surface;
• a flexible counter opposing the die and being movable relative thereto, the flexible counter including a resilient mat and a bolster for supporting the mat, the bolster having:
• a table surface;
• a plurality of peripheral walls fixed relative to the table, the peripheral walls extending around a side of the mat;
• and
• a bumper that fits between an upper portion of the wall and the mat.

A method of embossing a paper sheet, the method comprising the steps of:

• pressing a sheet with a contoured die;
• supporting a side of the sheet opposite the die with an upper side of a mat which resiliently deforms to match a contour of the die;
• supporting an underside of the mat against a rigid table;
• supporting peripheral sides of the mat with a resilient bumper, the bumper fitting between the mat and walls fixed to the table.

A flexible counter for supporting a sheet when pressed by an contoured die, the counter comprising:

• a resilient mat;
• a bolster for supporting the resilient mat, the bolster including:
• a table surface;
• a shim on the table and supporting a bottom of the mat;
• and
• a plurality of walls mounted to the table and extending peripherally around edges of the mat.

A flexible counter for supporting a sheet when pressed by a contoured die, the counter comprising:

• a resilient mat;
• a bolster for supporting the resilient mat, the bolster including:
• a table surface supporting a bottom of the mat, the table having at least one groove;
• and
• a plurality of walls mounted to the table and extending peripherally around edges of the mat, at least one of the walls having a projection that fits within the groove of the table.