s.
HIGH DEFINITION DOOR SHEET AND METHOD FOR MANUFACTURING THE SAME FIELD OF THE INVENTION The invention relates in general to the manufacture of door plates, and more particularly to high definition door plates and to an apparatus and method for manufacturing these plates. doors. BACKGROUND OF THE INVENTION Contemporary metal doors are constructed of thin metal door plates that comprise the exterior of the door. The door plates are formed from cold-stamped, galvanized, hot-dipped steel, which is die-cut to the desired door shape. The door plates form the exterior of the door and can be attached to the perimeter of the plates in flanges, or the door plates can be attached to a frame between the plates. A foam core can be used to fill the internal cavity between the door plates. The appearance of metal doors lagged behind wooden doors for many years until the introduction of enhancements that increase the aesthetic appearance of metal doors by allowing the introduction of geometric impressions on the door panel. By punching metal door plates between male and female dies in a conventional press, the door manufacturers were able to produce metal doors that rival the look of carved wooden doors. However, the wooden doors provide geometric carving that could not be done with conventional embossing techniques for metal doors. Furthermore, the edges of the enhancements on the metal doors were not defined and the number of edges or radii
Consecutive parallels in the enhancements of metal doors could not match the carvings on the wooden doors. Even the glass fiber doors that were introduced to the market shortly after the metal doors, had more definition in the designs of the doors and geometric impressions. The number of radios in a design was limited, which greatly reduced creativity and the number of possible designs that could be enhanced on metal doors. The depth of enhancements in the metal door plates and the profile of the door plates were also limited. Attempts at more intricate and defined enhancements on metal door plates using conventional pressing techniques led to over-fatigue, warping or warping and damage to the steel preform. The steel doors had the advantages of durability, reduced manufacturing cost, insulation efficiency, etc., but the inability to match the definition of the designs of wooden doors and glass fibers was an unsolved problem. In addition, methods and machinery for sheet metal punching for conventional doors, using conventional presses and cushion assemblies, had disadvantages. The conventional cushion assemblies used with the typical sheet metal presses had a high failure rate for the gas filled cylinders in the cushion assemblies, which increased the time and manufacturing costs. In this way, for a long time there has been a need to provide a metallic door panel with an increasing number of radii and complexity in highlights, which rivals the glass doors and fiberglass doors. There is an additional need for an apparatus and method for manufacturing a metal door sheet that reduces the rate of cushion failure, increases the number of spokes in a metal door sheet design, increases the profile range of a
metal door plate and the range of possible depths of enhancement. COMPENDIUM OF THE INVENTION The invention broadly comprises a cushion assembly for forming metal door plates in an industrial press, such as, but not limited to, hydraulic, mechanical or pneumatic presses. Also, the method of manufacturing a door plate using the cushion assembly and the door plate produced by this method. The cushion assembly has a plurality of gas filled cylinders located around the cushion mounting perimeter, a solid interior placed inside the perimeter of the cylinders filled with gas and a transfer cushion placed on the cylinders filled with gas. In some aspects, the solid interior comprises a plurality of solid blocks and the solid blocks extend through openings in the transfer pad. In some aspects, the solid interior comprises at least one solid block and the solid block extends through an opening in the transfer pad. In some aspects, cylinders filled with gas have a chamber that holds gas under pressure and the pressure of each cylinder filled with gas can be regulated. The gas used in cylinders filled with gas may be nitrogen gas, although other alternatives are possible. In some aspects, the plurality of gas filled cylinders are releasably connected with a multiple system and the multiple system is connected to a gas bank, using nitrogen gas or a similar alternative that uniformly regulates the gas pressure in the cylinders filled with gas. The invention also comprehensively comprises a metal door plate formed of a preform having at least one enhancement which is
minus 44.577 mm (1.755 in) wide and the highlight has at least 4 spokes through the enhancement. In some aspects, the enhancement has a depth of less than 7,925 mm (.312 in.). The highlight can have a width range of 44,704 to 83,566 mm (1.76 to 3.29 in) with between 4 and 6 spokes. In some aspects, the enhancement has a depth range of 7,950 to 2.54 mm (.0313 to .10 in). The invention also broadly comprises a method for manufacturing a metal door sheet, with the steps of inserting a steel preform between a male die and a female die; pressing the steel preform between the male die and the female die, in a set of dies on a cushion assembly with an industrial press such as an industrial press which may include a hydraulic, mechanical or pneumatic press; supporting the set of dies with the cushion assembly having a solid member positioned in an interior of the cushion assembly; supporting a force exerted by the press around a perimeter of the cushion assembly with a plurality of absorbent cushions, wherein a perimeter of the steel preform is compressed between the die sets and the absorbent cushions of the cushion assembly; and punching at least one enhancement in the steel preform to produce a door plate. In some aspects, the method includes the step of regulating the pressure in the plurality of cushions, wherein the pressure can be regulated uniformly by a manifold. In some aspects, the enhancement is at least a width of 44.577 mm (1.755 in) has at least 4 spokes through the enhancement and has a depth that is less than 7.925 mm (.312 in). A general object of the present invention is to provide a metal sheet and a method for manufacturing same that increases the definition of the
highlights on the door panel. Another object of the present invention is to provide a metal door plate and a method for manufacturing same that increases the number of radios per design. Another object of the present invention is to provide a metal door plate and a method for manufacturing same, which increase the range of possible profiles for a metal door plate. Another object of the present invention is to provide a metal door plate and a method for manufacturing same, which increase the range of depths of possible enhancements for a metal door plate. These and other objects and advantages of the present invention will be readily apparent from the following description of preferred embodiments of the invention and from the accompanying drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a press with a cushion assembly of the present invention. Figure 2 is an exploded perspective view of a cushion assembly of the present invention; Figure 3 is a plan view of a manifold of a cushion assembly with a transfer cushion located on the top of cushion cylinders; Figure 4 is a cross-sectional view of a manifold of a cushion assembly that is illustrated in Figure 3, which is generally taken on line 4-4 in Figure 3; Figure 5 is a plan view of a manifold of a cushion assembly with a transfer cushion located on the top of cushion cylinders;
Figure 6 is a cross-sectional view of the cushion assembly of Figure 5, which is generally taken on line 6-6 of Figure 5; Figure 7 is a front elevational view of a cushion and press assembly with sets of dies in the punching position; Figure 8 is a top plan view of a door plate; Y
Figure 9 is a cross-sectional view of an elevation of the door panel in Figure 8, which is generally taken on line 9-9 in Figure 8; DETAILED DESCRIPTION OF THE PREFERRED MODALITY At the beginning, it should be appreciated that equal number of drawings in different views of drawings, identify identical, or functionally similar structural elements of the invention. While the present invention is described with respect to what is currently considered to be the preferred aspects, it will be understood that the invention as claimed is not limited to the aspects described. In the following description, the terms "upper", "bottom", "top", "bottom", "front", "back", "back", "left", "right", and their derivatives, shall be interpreted from the perspective of who sees the press shown in Figure 1, or the door plate in Figure 8. Furthermore, it is understood that this invention is not limited to the methodology of particular materials and modifications described and as such can of course vary . It is also understood that the terminology used herein is for purposes of describing only particular aspects, and is not intended to limit the scope of the present invention, which is limited only by the appended claims. Unless defined otherwise, all the technical and scientific terms used here have the same meaning as is commonly understood
by a person with ordinary skill in the art to which this invention pertains. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, preferred methods, devices and materials are now described. Figure 1 is a perspective view of the press 8 with the cushion assembly 12 of the present invention. The press 8 is an industrial press, which may include but is not limited to mechanical, pneumatic and / or hydraulic presses, used to punch sheet steel or sheet steel in various forms. The press 8 has an upper member 9 and base member 11, in which the cushion assembly 12 is placed. As the press 8 is activated the upper member 9 moves downward toward the base member 10 on the pistons 11. In some aspects, the press 8 exerts a force of 1500 tons to stamp embossing on the sheet steel, to form metal door plates, but it will be appreciated that different forces may be used to exert the force necessary to form the embossments and that various presses may be employed known to a person with skill in the art. The cushion assembly 12 is used in conjunction with the press 8 to form the aforementioned door plates. The cushion assembly 12 has the manifold 14 with multiple cushions 16 connected in releasable form. The cushions 16 are cylinders filled with gas having an outer housing with a piston centered in the housing. The cushions 16 have an inert gas, such as nitrogen, injected into a chamber in the cylinder, to press the cushions. Pressure adjustments on the cushions 16 affect the elasticity or strength and support provided by the cushions. Resting on the cushions 16 is the transfer pad 18 with
the solid block 20, formed separately from the transfer pad 18, but placed in the opening 22 in the transfer pad 18. The solid block 20 and the opening 22 are illustrated in this particular figure which are rectangular in shape, but can also be Implement sections of various other shapes and sizes, some of which will be described in more detail below. Conventional cushion assemblies have cushion cylinders distributed across the surface of the manifold, as opposed to cushion assembly 12, an interior is empty except for block 20. This reduction in the number of cushion cylinders reduces the failure rate only by reducing the number of cushions required. The failure rate of the cushions 16 is also reduced by replacing the section of the cushion assembly 12 that absorbs the die impact of the array of dies, i.e. the interior, with the solid block 20. The manifold 14 distributes gas under pressure to the cushions 16 that can be detachably connected to the manifold. The gates 24 on the manifold side 14 can provide access to the interior recesses of the manifold 14 and can allow or activate the gas bank 26 or other gas assortment unit, to pressurize and regulate the pressure in the cushions 16. The gas bank 26 maintains the pressurized gas that is fed through line 28 to the feed gate 26 in the manifold 14, and the pressure valve 29 and pressure gauge 25 are implemented as a means to regulate and monitor the gas pressure. In some aspects, the gas bank 26 provides the gas pressure through the manifold 14 and the individual cushion cylinders 16, since the manifold 14 connects the cylinders 16 in a circuit. In some aspects, the gas contained in a gas bank 26 and distributed through manifold 14, cushions 16, is nitrogen gas. Other gases used in pressure systems, such as cushion cylinders 16 that are
known in the art, they can be replaced by nitrogen gas. Consequently, the gas that presses the manifold 14 and the cushions 16, it is not limited to nitrogen only. In some aspects, the cushions 16 are releasably connected to the manifold 14 and all the cushions 16 are in a pressurized circuit. Therefore, increasing or decreasing the pressure in the manifold 14 increases or decreases the pressure in all the pads connected to the manifold 14. In other aspects, it may be beneficial to regulate and adjust the pressure in pads individually (not shown). To achieve this adjustment, the pressure is regulated by valves that are dedicated to simple cushions, which can be controlled or regulated and adjusted manually by an automated process controlled by an electronic system. Providing adjustability to individual cushions, allows the press operator to control the amount of support transfer cushion 18 that allows different from the multiple in adapting to different intended matrix sets or enhancements. Certain array sets may require additional support only on a portion of the perimeter of the manifold, and regulating pressures on cushions on an individual basis allows the assembly of cushions to adapt to those parameters. The cushions 16 can be commonly used gas-charged shock absorber units of varying pressure ranges and dimensions. Gas cushions or cushions that are capable of varying pressures exerted by the devices are preferred, since they allow the press to adapt to different applications and production requirements. It will be appreciated that the cushions 16 can be detachably connected to the manifold 14 using various detachable connection means and that illustrations showing threaded connections are only an alternative
possible. Any of the various detachable connection means known in the art may be implemented. In addition, in some aspects, the cushions 16 can be connected to the manifold 14 using a connection that is not detachable. Figure 2 is an exploded perspective view of the cushion assembly 12 of the present invention, which exhibits a cushion pattern wherein the interior of the manifold 14 has no cushions 16 connected. The inner portion of the manifold 14 on the other hand has a solid block 20 surrounded by cushions 16 around the perimeter of the manifold 14. The transfer pad 18 rests on the cushions 16 and the solid block 20. The block 20 is located in the opening 22. Vertical lines starting at the corners of the array of dies 32 and ending in sets of rollers 30, indicate the general alignment of the array of dies 32, when completely compressed or subjected to pressure. In some aspects, the cushion assembly 12 removes roller assemblies 30 and has a set of dies 32 that abuts near the position of the roller assemblies 30. Vertical lines starting at the corners of the transfer pad 18 and ending at the inside edge of the roller assemblies 30 indicate the general alignment of the transfer pad 18 on the cushions 16. In some aspects, the solid block 20 is of sufficient height to have the upper part of the block 20 so that it is generally level with the upper part of the transfer pad 18 when the cushion assembly 12 is completely assembled. The adjustment of the block 20 is also complementary to the opening 22 since the parameters of the block 20 are roughly equivalent to the parameters of the opening 22. As the die assembly 32 is pressed down against the cushion assembly 12, the solid block 20 provides support for the female die 34 and the male die 36, to enhance the
laminar steel preforms that are placed between the female die 34 and the male die 36. The pads 16 provide pressure resistance around the cushion mounting perimeter 12, which distributes the force exerted by the press 8 to the perimeter, which allows the assembly of the cushion 12 and the matrix assembly 32 compress and hold the perimeter of the sheet steel preforms that are pressed. In some aspects, the block 20 is located to provide support in regions where the array of dies 32 will enhance a preform. Specifically, enhancements can only be pressed on the preform in regions where solid support has been provided. As the array of dies 62 is pressed against the transfer pad 18 and the solid block 20, the cushions 16 arranged around the perimeter of the manifold 14, forcefully force the transfer pad 18 to bind the perimeter of the inserted sheet steel preforms in the array of dies 32 to prevent slipping of the preform during die cutting. This compression or clamping of the preform at the perimeter is caused by the perimeter cushions 16 exerting resistance against the transfer pad 18, facilitating that the preform does not warp or deform to any undesirable extent, when the array of dies 32 punches the enhancement in the preform. The solid block 20 ensures that the set of matrices 32 having arrays of higher definition, can effectively punch the highlights of higher definition in the preform. Higher definition refers to a higher number of spokes distributed possibly through an enhancement, the depth and profile ranges of the surface layer or door veneer enhancements are wider and / or the highlights are more defined with repetition that gives a more pronounced appearance In some aspects, transfer pins (not shown) which are solid steel structures extend from the base of the perimeter of the assembly
of matrices 32, can used to exert force on the transfer pad 18 as the press 8 punches a steel preform. The transfer pins are located better in the bottom and the perimeter of the array of matrices and can ensure that the edge of the preform is securely held to prevent warping as the die set punches the enhancement in the preform. Figure 3 is a plan view of the manifold 14 of the cushion assembly 12 showing the inner portion of the manifold 14, no cushions 16. The transfer pad 18 is illustrated located on the top of the cushions 16. A portion of the interior of the cushion assembly 12 has been replaced by the solid block 20, while the perimeter of the manifold 14 has been connected multiple cushions 16. The cushions 16 are illustrated in dotted lines to indicate the position of the cylinders 16 under the transfer pad 18 and to indicate that the transfer pad 18 is located on the cushion cylinders 16. Although Figure 3 shows the 16 pads arranged in a particular order, this arrangement is only a variant in the distribution of cushions 16 in the assembly of cushions 12. However, it should be noted that the gap of cushions 16 in the inner portion of the cushion assembly 12, allows that the cushion assembly 12 appropriately distribute the force to ensure that the press 8 can produce door plates of the present invention. Figure 4 is a cross-sectional view of the manifold 14 of the cushion assembly 12 illustrated in Figure 3, which is generally taken on lines 4-4 of Figure 3. The cushions 16 are shown connected to the manifold 14 with threads 17 However, the connection of the cushions 16 to the manifold 14 is not limited to this connection means. Still further, the connection of the cushions 16 can be achieved by a non-detachable connection means. Placed under the cushion cylinders 16 is
the channel 17 that is used to introduce gas under pressure in the cushion. The channels 17 run the length of the manifold 14 and connect the pads 16 in a circuit, which allows the gas pressure in each pad to be regulated as a whole. In alternate modes, each cushion may have a separate channel and the cushions are controlled individually as opp to being linked in a circuit. Solid block 20 is shown connected to manifold 14 with threaded connection means. In some embodiments, solid block 20 may have a threaded base that threads into threaded pins in manifold 14 or may be detachably connected in another manner known in the art. In some aspects, solid block 20 is fixedly connected to manifold 14. Solid block 20 has a height that is approximately the combined height of cylinders 16 and transfer pad 18 and block 20 has a width and length that are approximately equivalent to width and length of the opening 22. Figure 5 is a plan view of an alternative kitchen assembly 112 with cushions 116 connected to the manifold 114, with the transfer pad 118 located at the top of the cushions 116. The mounts Cushion 112 is used with a press similar to the press 8 and acts as the support for the array of dies 32 as the array of dies 32 is pressed against the assembly of cushions 112 during the die cutting process. The cushions 116 are illustrated in dotted lines to indicate the presence of the transfer pad 118 on the upper part of the cushions. Similar to the arrangement of cushions 16 in the cushion assembly 12, the cushions 116 are arranged around the perimeter of the manifold 114. The cushions 116 can be gas-charged shock absorbing units commonly employed, with varying pressure ranges and dimensions. Gas cushions or cushions that are capable of varying pressures exerted by
the devices are preferred, since they allow the press to adapt to different applications and production requirements. The solid block 20 has been replaced by multiple solid blocks 120 inside the manifold 14. Multiple solid blocks 120 function similarly to the solid block 20 since the solid blocks 120 support the male die 36 and the female die 34 to allow die cutting. Enhancement designs previously not achievable. The blocks 120 and the openings 122 are illustrated as rectangular, but other possible alternate shapes may be employed depending on the set of selected matrices or the press employed or other reasons. As the array of dies 32 is pressed against the transfer pad 118 and the solid blocks 120, the cushions 116 arranged around the perimeter of the manifold 114 forcefully force the transfer pad 1 18 to bind the perimeter of the inserted sheet steel preforms. in the array of dies 32 to prevent sliding of the preform during die cutting. This compression or clamping of the preform at the perimeter, which is caused by the perimeter cushions 116 that exert resistance against the transfer pad, facilitates that the preform does not warp or deform to any undesirable extent when the set of dies punches the enhancement in the preform. Solid blocks 120 ensure that the array of dies 32, which has higher definition arrays, can effectively punch the highlights of higher definition in the preform. In some aspects, transfer pins (not shown) which are solid steel structures extending from the base of the perimeter of the array of dies 32, can be used to exert force on the transfer pad 118, as the press 8 punches a preform of steel. The transfer pins are located better in the perimeter of the set of matrices and can ensure that the edge of the
The preform is surely held to avoid sagging as the set of dies punches the enhancement in the preform. A cross sectional view of the cushion assembly 112, taken generally on the line 6-6 in Figure 5, is illustrated in Figure 6. In this view, the height and position of solid blocks 120 are evident in relation to the transfer pad 118 and the cushions 116. The cushion The transfer 118 rests on the upper part of the cushions 116, with the blocks 120 located within the openings 122 of the transfer cushion. The pads 116 are illustrated connected to the manifold 114 with threads 117. However, the connection of the pads 116 to the manifold 114 is not limited to these connection means. In addition, the connection of the cushions 116 can be achieved by non-detachable connection means. Located under the cushion cylinders 116 is the channel 127 that can be used to introduce pressurized gas into the cushion. The channels 127 travel the length of the manifold 114 and join all the pads 116 in a circuit. In alternate modes, each cushion may have a separate channel and the cushions are controlled individually as opposed to being linked in a circuit. Solid blocks 120 are illustrated connected to manifold 114 with threaded connection means. In some embodiments, the solid blocks 120 can have a threaded base that can be connected with threaded connection means to the manifold 114, or can be detachably connected in another manner known in the art. In some aspects, solid blocks 120 are fixedly connected to manifold 114. Solid blocks 120 have a height that is approximately the combined height of cylinders 116 and transfer pad 118, and blocks 120 have a length and width that are approximately equivalent to the length and width of the openings 122. The openings 122 are
they conform and dimension to be complementary to the blocks 120. Any vertical displacement of the transfer pad 118 will have solid blocks 120 running through openings 122. The interior of the manifold 114 has multiple solid blocks 120 arranged to support the array of dies 32, as the press 8 compresses a preform that has been inserted between the female die 34 and the male die 36. The perimeter array of cushions 116 supports the transfer pad 118, with cushions 116 that provide the resistance that allows the transfer pad to compress the perimeter of a laminar steel preform to prevent movement or that suck the edge of the preform during die cutting. The solid blocks 120 provide the support for the array of dies 32 as the press punches a preform. The perimetral bonding of the edge of the preform, due to the cushions 116 around the perimeter, combined with the center of the non-cushioned contrasting manifold 114, due to the solid blocks 120, produces a door plate with highlights that are more refined with superior definition. The perimetral edge of the door plate produced by the press 8 using the cushion assembly 112, can reduce or eliminate warping, due to the perimeter cushioning and the solid center of the manifold 114. As the array of dies 32 is pressed against the cushion of Transfer 118 and the solid blocks 120, the cushions 116 arranged around the perimeter of the manifold 114 are forced to the transfer pad to bind to the perimeter of the lamellar steel preforms inserted in the array of dies 32 to prevent sliding of the preform during die cutting. This compression or clamping of the preform at the perimeter, which is caused by the perimeter cushions 116 that exert resistance against the transfer cushion, facilitates that the preform does not warp or deform in any proportion
undesirable when the set of matrices punches the enhancement in the preform. Solid blocks 120 ensure that the array of matrices 32, which has higher definition arrays, can effectively punch high definition enhancements into the preform. Figure 7 is a front elevation view of the press 8 illustrated in Figure 1, with the array of dies 32 in the die position. Reference to a "die-cutting position" is to mean that the upper press assembly 9 is folded down towards the press base 10 in position to die-cut enhancements in the sheet steel preform 38. The sheet steel preform 38 is fed through of matrices 32. As the preform 38 is fed through the array of dies 32 it is inserted between the female die 34 and the male die 36, which form the array of dies 32. Pressure exerted by the press 8 on the array of dies 32 , imposes force on the array of dies towards the transfer pad 18 and the solid block 20. As the bottom of the array of dies 32 approaches the transfer pad 18 and the solid block 20, the cushion cylinders 16 exert a force against the transfer pad 18 which compresses the perimeter of the preform 38 to prevent the preform 38 from sucking inwardly into the perimeter of the preform during the die-cutting of enhancements in the preform 38 with the array of dies 32. The force of the array of dies 32 can also be transferred to the transfer pad 18 with transfer pins (not shown) as described above. Due to the force exerted by the cushions 16 against the bottom of the transfer pad 18, and the block of solid 20 inside the cushion assembly 12, a set of dies that punch high definition enhancements are possible without warping or tensioning preforms 38. The block of solid 20 in the
Cushion assembly 12 provides the rigid support required to produce higher definition enhancements that have more detail, increased radius and profiles with wider depth and width ranges. The cushions 16, which line the perimeter of the cushion assembly, provide the clamping force required to prevent the preform 38 from slipping, warping or deforming during this intense pressure process. Similar support is provided by the solid block 20 and the solid blocks 120, and the cushions 1 16 function similarly to the cushions 16. The described punching process is applicable and functions similarly with the cushion assemblies 12 and 112. Figure 8 is a top plan view of the door panel 300 having the upper rectangular recess 302 and the lower rectangular recess 304. The overheads shown are not a closed set of possible enhancement designs capable with the described method and apparatus. Numerous other forms of designs are possible using cushion assemblies 12 and 112, sets of high definition arrays and the method that implements these elements. In some aspects, the door plates 300 are manufactured from sheet steel. However, it will be understood that any material known in the art can be used to manufacture the door panels 300. The door panel 300 is manufactured using the press 8 used with the cushion assembly 12 and 12, described above. In particular, the previously described cushion assemblies 12 and 112 provide the contrasting degree of support of the perimeter cushions 16 and 116, which interact with the transfer pads 18 and 118, respectively, to prevent the preform die cut by the array of dies 32, slide during the die cutting process. The solid inserts 20 and 120 provide the elasticity required during the die-cutting process for the array of dies 32 for pressing
more complex door plates. The high definition array 32 dies a pattern into a laminar steel preform that previously was not achieved with conventional door sheet die mounting cushions. Conventional cushion assemblies have cushion cylinders distributed across the surface of the manifold. Therefore, the cushion assemblies described herein provide a nonabsorbent solid support in the center or interior of the cushion assembly coupled with the perimeter lined with absorbent cushions, which traditional cushion assemblies can not provide. An increased number of spokes produced by the array of dies 32 is possible due to the characteristics of the cushion assemblies 12 and 212 and the method described. In some aspects, the spokes 306, 308, 310 and 312 can be die cut into a laminar steel preform using the process and apparatus described above. Alternate enhancement designs, with more than four spokes, can also be stamped on steel preforms with different sets of dies, due to the cushion assemblies 12 and 112. The cushion assemblies 12 and 1 2, and obvious variants of those assemblies of Cushions can accommodate arrays of higher definition dies that previous cushion assemblies were not able to handle. Pressure from more complex array assemblies with more than three spokes using traditional cushion assemblies would cause tearing, warping and / or tension in the steel preforms. Figure 9 is a cross-sectional view of the elevation 302 of the door panel 300 in Figure 8, which is generally taken on the line 9-9. In some aspects, the spokes 306, 308, 310 and 312 are punched into a laminar steel preform using the apparatus and processes described above. In some aspects, the door plate 300 has die-cut spokes 306, 308, 310 and 312
through a width in the range of 44.45 to 83.57 mm (1.75 to 3.29 in) measured from the interior perimeter 314 of the elevation to the exterior perimeter 316 of the elevation. In some aspects, the highlights may have widths greater than 83.57 mm (3.29 in). The door plate 300 also has a depth of enhancement of less than 7,925 mm (0.312 in) as measured from peak 318 to channel 320 of enhancement 302, with a preferred depth in the range of 7,925 to 2.54 mm (0.312 to 0.10 in). The highlights that have more than three radios, which leads to a highlight design that offers greater detail and complexity. It will be understood that changes in the enhancement design are possible and that the enhancements of the present invention are not limited to the exemplary embodiments illustrated in 302 and 304. Other possible shapes and designs that will fall within the radius, width and depth ranges previously described. The ranges in length width and number of radii illustrated in this description are all possible alternatives using the apparatus and process described above, and other embodiments that fall within these ranges are encompassed by the present invention. In this way, it is seen that the objectives of the invention are obtained efficiently, although changes and modifications to the invention will be readily apparent to those having ordinary skill in the art, without departing from the spirit or scope of the invention as claimed. Although the invention is described by reference to a specific preferred embodiment, it is clear that variations can be made without departing from the scope or spirit of the claimed invention.