Printing press with in-line casting device for the replication and formation of a micro-optical structure

Abstract

There is described a printing press (100***; 100****) adapted to carry out printing on a sheet-like or web-like substrate (S), in particular for the production of security documents such as banknotes, comprising a printing unit (2*; 2**; 2***; 2****) designed to print a first side (I) and/or a second side (II) of the substrate (S). The printing press (100***; 100****) further comprises an in-line casting device (80; 80*; 80**; 80***) adapted to apply a layer of material acting as an optical medium on a portion of a first side (I, II) of the substrate (S) and to replicate and form a micro-optical structure (L) in the layer of material acting as optical medium. The printing unit (2*; 2**; 2***; 2****) is furthermore adapted to print at least one printed pattern on the first or second side (I, II) of the substrate (S) in register with the micro-optical structure (L), wherein the printing unit (2*; 2**; 2***; 2****) comprises at least a first printing group (93) being adapted to print at least one printed pattern on the second side (II) of the substrate (S) in register with the micro-optical structure (L) and wherein the in-line casting device (80; 80*; 80**; 80***) comprises at least one embossing cylinder (85), which embossing cylinder (85) also is acting as counter-pressure cylinder and cooperates with a printing cylinder (8) of the at least first printing group (93) and/or whereas the in-line casting device (80; 80*; 80**; 80***) and the at least a first printing group (93) being arranged at the Substrate transport path such way, that in-line casting of the micro-optical structure, on one side of the sheets S, and printing of the associated pattern, on the other side of the sheets S, are performed in a same step, without this involving any sheet transfer operation.

Claims

1. A printing press adapted to carry out printing on a sheet-like substrate for the production of security documents, the printing press comprising: a printing unit designed to print a first side and/or a second side of the substrate; and an in-line casting device adapted to apply a layer of material acting as an optical medium on a portion of the first side of the substrate and to replicate and form a micro-optical structure in the layer of material acting as the optical medium, the in-line casting device comprising at least one embossing tool and, wherein the printing unit comprises at least a first printing group adapted to print at least one printed pattern on the second side of the substrate in register with the micro-optical structure so that the at least one printed pattern and the micro-optical structure together form a security element in which the at least one printed pattern is visible from the first side of the substrate and the micro-optical structure affects a path of light being reflected off of the at least one printed pattern towards the first side of the substrate, wherein the at least one embossing tool is designed as an embossing cylinder, the embossing cylinder acting as a counter-pressure cylinder and cooperating with a printing cylinder of the first printing group, wherein the embossing cylinder is configured to act as a carrier supporting a replicating medium designed to replicate and form the micro-optical structure in the layer of material acting as the optical medium, and wherein the replicating medium comprises a recessed structure.

2. The printing press according to claim 1, wherein the in-line casting device comprises at least one application unit configured to apply at least a part of the layer of material acting as the optical medium.

3. The printing press according to claim 2, wherein a screen-printing unit or flexographic-printing unit is configured to act as an application unit for applying at least a part of the layer of material acting as optical medium.

4. The printing press according to claim 3, wherein the at least one embossing tool is located in a substrate path immediately after the application unit.

5. The printing press according to claim 1, wherein the embossing cylinder is configured to act as a conveying cylinder carrying and/or supporting the substrate over an angle range.

6. The printing press according to claim 1, wherein the in-line casting device further comprises at least one pressure cylinder or roller configured to cooperate with the at least one embossing tool to press the substrate against the replicating medium.

7. The printing press according to claim 1, wherein the printing cylinder of the first printing group configured to cooperate with the at least one embossing tool is configured to act as blanket cylinder and cooperate with one or more associated plate cylinders to apply the at least one printed pattern on a side of the substrate which is opposite to the side of the substrate where the micro-optical structure is replicated and/or wherein the first printing group is designed as a collect printing group for at least two imprints to be collected before printed onto the substrate.

8. The printing press according to claim 1, wherein the first printing group comprises one or more plate cylinders and associated inking apparatuses designed to enable indirect printing.

9. The printing press according to claim 8, wherein the indirect printing is offset or relief printing.

10. The printing press according to claim 1, wherein the printing unit comprises a second printing group in a substrate path configured to print the substrate on one side.

11. The printing press according to claim 10, wherein the second printing group comprises one or more plate cylinders and associated inking apparatuses designed to enable or carry out indirect printing, and/or is designed as a collect printing group configured to collect at least two imprints before being printed onto the substrate.

12. The printing press according to claim 11, wherein the indirect printing is offset or relief printing.

13. The printing press according to claim 10, wherein the printing unit comprises a third printing group in the substrate path configured to cooperate with the second printing group in order to build a common nip as a double-sided printing group for a simultaneous recto-verso printing of the substrate.

14. The printing press according to claim 13, wherein the third printing group comprises one or more plate cylinders and associated inking apparatuses designed to enable or carry out indirect printing, and/or is designed as a collect printing group configured to collect at least two imprints before being printed onto the substrate.

15. The printing press according to claim 14, wherein the indirect printing is offset or relief printing.

16. The printing press according to claim 1, wherein the micro-optical structure is configured to be replicated by the in-line casting device upstream of a location where the printed pattern is printed by the first printing group of the printing unit.

17. The printing press according to claim 1, wherein the in-line casting device is adapted to apply the layer of material acting as the optical medium on a portion of the first side of the substrate and to replicate and form a micro-optical structure in the layer of material acting as the optical medium by firstly applying the material acting as the optical medium onto the substrate onto the first side and downstream being brought into contact with the at least one embossing tool to form the micro-optical structure.

18. The printing press according to claim 1, wherein the in-line casting device is adapted to apply the layer of material acting as the optical medium on a portion of the first side of the substrate and to replicate and form a micro-optical structure in the layer of material acting as the optical medium by firstly applying the material acting as the optical medium directly onto a circumferential surface of the at least one embossing tool in an angular segment not yet being covered by the substrate to be applied with the material.

19. The printing press according to claim 1, wherein the security documents are banknotes.

20. The printing press according to claim 1, wherein the printing unit comprises a second printing group in a substrate path to print the substrate on the side provided with the micro-optical structure.

21. The printing press according to claim 1, wherein the recessed structure of the replicating medium is positioned so that when the printing cylinder prints the printed pattern on the substrate, the printing cylinder presses the substrate against the embossing cylinder at the location where the replicating medium is recessed.

22. The printing press according to claim 1, further comprising the substrate.

23. The printing press according to claim 1, further comprising a washing device that is configured to be selectively brought into contact with the at least one embossing tool during maintenance operations to clean the surface of the at least one embossing tool, wherein the washing device is configured to clean the replicating medium after the first printing group has printed the at least one printed pattern on the second side of the substrate.

24. The printing press according to claim 1, wherein the replicating medium comprises a recessed structure, and wherein the printing unit and the embossing cylinder are configured so that the at least one printed pattern is printed against the recessed structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other features and advantages of the present invention will appear more clearly from reading the following detailed description of embodiments of the invention which are presented solely by way of non-restrictive examples and illustrated by the attached drawings in which:

(2) FIG. 1 is schematic illustration of recto-verso printing press exhibiting a configuration similar to that disclosed in International PCT Publication No. WO 2007/042919 A2;

(3) FIG. 2 is a schematic partial side view of the printing unit of the printing press of FIG. 1;

(4) FIGS. 3A and 3B are schematic illustrations of a substrate that is provided with a micro-optical structure on top of a window-forming portion created in the substrate;

(5) FIG. 4 is a schematic partial side view of the printing unit of a printing press in accordance with a first embodiment of the invention;

(6) FIG. 5 is a schematic partial side view of the printing unit of a printing press in accordance with a second embodiment of the invention;

(7) FIG. 6 is a schematic partial side view of the printing unit of a printing press in accordance with a variant to the second embodiment of the invention;

(8) FIG. 7 is a schematic partial side view of the printing unit of a printing press in accordance with a third embodiment of the invention;

(9) FIG. 8 is a schematic partial side view of the printing unit of a printing press in accordance with a fourth embodiment of the invention; and

(10) FIG. 9 is a schematic partial side view of the printing unit of a printing press in accordance with a variant to the third and fourth embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(11) Although the present invention in principle is not limited to such an embodiment of the printing press respectively printing unit, it will be described in the particular context of preferred embodiments of a printing press, preferably sheet fed printing press, comprising a printing unit with at least a printing group (91; 92; 93; 94) designed as an collect printing group (91; 92; 93; 94) as mentioned above and/or a, preferably sheet-fed, recto-verso printing press, especially based on indirect printing, exhibiting a (m)-over-(m) configuration (see embodiment of FIG. 4 where m equals 4), a (m+n)-over-(m+n) configuration (see embodiment of FIG. 5 where m, n respectively equal 4 and 2), or a (m)-over-(m+n) configuration (see embodiments of FIGS. 6 and 7 where m, n respectively equal 4 and 3). The expression “(m)-over-(m) configuration” is to be understood a simultaneous recto-verso printing with m colour separations or frames printed on each side and/or a configuration of a recto-verso printing press, printing unit or group comprising a first set of m plate cylinders cooperating with a first printing cylinder and a second set of m plate cylinders cooperating with a second printing cylinder, which first and second printing cylinders cooperate to build a common printing nip. It shall be appreciated however that the invention is not limited to these particular printing press configurations, the number of plate cylinders being purely illustrative. This being said, the printing press configurations as shown in FIGS. 4 to 7 are of particular advantage as they allow very high colour-to-colour register accuracy.

(12) An collect printing group (91; 92; 93; 94) is designed to print at least one side of the substrate by firstly collecting several impressions or patterns from several plate cylinders on a cylinder, e. g. a so called collecting cylinder, before being printed as a collected image as a whole onto the substrate.

(13) In the context of the present invention, the expression “printing cylinder(s)” will be used to designate the relevant cylinders of a printing group (91; 92; 93; 94), e.g. of a main printing group (91, 92) and of any additional printing group (93, 94), that directly cooperate with the first and second sides of the substrates (e.g. sheets) to transfer printing patterns thereon. This expression preferably is interchangeable with the expression “transfer cylinder” or “blanket cylinder”, it being to be understood that the relevant printing cylinders for example each carry an number, e. g. one or several, printing blankets.

(14) The expression “printing group” (91; 92; 93, 94) will be used for the equipment, e.g. the cylinders, rollers and the means of the inking unit(s), belonging to a printing nip for at least printing on one side of the substrate. A double sided printing group (91, 92; 93, 94) therefor is a special printing group (91, 92; 93, 94) with two printing groups (91; 92; 93; 94), one on or for each side of the substrate path, sharing a same printing nip for printing simultaneously both sides of a passing substrate and mutually acting with its printing cylinders as counter-pressure cylinders for the other printing group (92; 91; 94; 93).

(15) It is to be understood, that several printing groups 91; 92; 93; 94 can be arranged in a same printing unit 2; 2*; 2**; 2***; 2****, with these printing groups 91; 92; 93; 94 for example being arranged in single- or multi-part frame walls.

(16) The expression “first side” (designated by reference I) and “second side” (designated by reference II) are used in the following description to designate the two opposite sides of the sheets being printed. More precisely, in the illustrations of FIGS. 4 to 9, the “first side” I designates the side of the sheets that is designated by the white triangles, while the “second side” II designates the side of the sheets that is designated by the black triangles. These expressions are however interchangeable.

(17) FIGS. 3A-B schematically illustrate an example of a substrate S that is provided with an opening (or through-hole) H extending through the substrate S. This opening H is preferably filled by a suitable filling material, which material is preferably substantially transparent, so as to form a transparent or substantially transparent window W visible from both sides I, II of the substrate S. The particular shape and geometry of the opening H and resulting window W may be varied depending on the design requirements. The cross-sectional shape of the opening H could also be different from the depicted example.

(18) In accordance with the invention, one wishes to replicate a micro-optical structure L on one or the other side of the substrate S. More precisely, according to the illustrated example, one wishes to replicate a micro-optical structure L, such as a field of micro-lenses, on top of the window W, on the second side II of the substrate S. To this end, side II of the substrate S is first provided in the relevant portion of the substrate S with a layer of material acting as an optical medium (for instance by means of a suitable screen-printing unit as discussed hereafter) before being brought into contact with and pressed against the surface of a replicating medium RM that is provided with a corresponding replicating structure (formed as a recessed structure in the surface of the replicating medium RM). Any desired shape and geometry could be imparted to the replicating structure in order to form the desired micro-optical structure L.

(19) As schematically illustrated in FIG. 3B, the replicating medium RM is conveniently carried by a suitable carrier CR, especially a cylinder acting as embossing cylinder as described hereinafter.

(20) Subsequent to, or preferably during the replication process, the relevant material acting as optical medium is subjected to a drying or curing process (especially a UV-curing process). This is preferably carried out, as schematically illustrated in FIG. 3B, while the substrate S is still in contact with the replicating medium RM, advantageously by subjecting the substrate S and the relevant material acting as optical medium to UV radiation from the first side I of the substrate, through the window portion W.

(21) It should be appreciated that the invention is equally applicable to other types of substrates than the one illustrated in FIGS. 3A-B, especially polymer or hybrid substrates as for instance described in International Publication No. WO 2014/125454 A1. The illustrations of FIGS. 3A-B are therefore by no way limiting the application scope of the present invention and the substrate material can be any suitable substrate material that can be used as printable material, such as paper, polymer, or combinations thereof.

(22) FIG. 4 schematically shows a partial side view of a printing unit, designated by reference numeral 2*, of a printing press 100* in accordance with a first embodiment of the invention.

(23) The printing press 100* in this embodiment comprises a printing group 91, 92, especially as a main printing group 91, 92, which comprises two printing groups 90; 91, one for each side of the substrate path, forming a so-called double sided printing group 91, 92 for simultaneous printing on both sides. This double sided printing group 91, 92 consists of elements 5, 6, 15, 16, 25, 26, including first and second printing cylinders 5, 6 cooperating with one another to form a first printing nip between the first and second printing cylinders 5, 6, especially transfercylinder, where the first and second sides I, II of the sheets S are simultaneously printed, the first printing cylinder 5 acting as a sheet conveying cylinder of the main respectively double sided printing group. The configuration of the main printing group for example is as such identical to that of the main printing group illustrated in FIGS. 1 and 2. In this embodiment, printing cylinders 5, 6 are likewise three-segment cylinders which are supported between a pair of side frames 20. The printing cylinders 5, 6 serve as ink collecting cylinders 5, 6 and receive and collect different ink patterns in their respective colours from first and second sets of four (m=4) plate cylinders 15, respectively 16, which are distributed around a portion of the circumference of the printing cylinders 5, 6. These plate cylinders 15 and 16, which each carry a corresponding printing plate, are again inked by corresponding sets of four inking apparatuses 25 and 26, respectively. The two sets of inking apparatuses 25, 26 are preferably supported in two retractable inking carriages 21, 22 that can be moved toward or away from the centrally-located plate cylinders 15, 16 and printing cylinders 5, 6.

(24) In contrast to the configuration illustrated in FIGS. 1 and 2, no additional printing group is provided upstream of the main printing group. Instead, an in-line casting device 80 is interposed between the transfer cylinder 9 located at the infeed and the transfer cylinder 10 that transfers the sheets to the main printing group, which in-line casting device 80 will now be described.

(25) In a variant of the first embodiment depicted in FIG. 4, the printing unit 2 can be designed as a on side printing group 91, i.e. can comprise a printing group 91 only on one side of the substrate path.

(26) In this and in the following embodiments, the press 100* or printing unit 2 or main printing group 91; 92 comprises at least one printing group 91; 93 on that side of the substrate path for printing onto the substrate side I; II which opposes the side II, I having already been or still have to be provided with the micro-optical structure upstream. Preferably, this at least one printing group 91; 93 is designed as above mentioned collect printing group 91; 93.

(27) By way of preference—at least for embodiments with application of the material directly onto the substrate—the in-line casting device 80 depicted in FIG. 4 (and in FIG. 5—see also FIG. 7 where the in-line casting device is designated by reference numeral 80*) is of the type comprising a screen-printing unit 82, 82a, 84, namely a printing unit comprising a rotary screen cylinder 82 inside which is provided a squeegee device 82a, which rotary screen cylinder 82 cooperates with an impression cylinder 84, serving as a counter-pressure cylinder, onto which the sheets S are fed in succession from the transfer cylinder 9 at the infeed. More precisely, in according with this first embodiment, the sheets S are transferred in succession to the impression cylinder 84 which supports the first side I of the sheets S and the rotary screen cylinder 82 is brought in contact with the second side II of the sheets S. In this particular context, the screen-printing unit 82, 82a, 84 is adapted to apply a layer of material acting as an optical medium on a portion of the second side II of the sheets S (for instance on a window-forming region W formed in the substrate S as depicted in FIGS. 3A-3B). The relevant material could be any suitable material, especially a transparent polymer material that is preferably curable by UV radiation.

(28) As this will be appreciated from looking at the embodiment depicted in FIG. 7, the screen-printing unit 82, 82a, 84 could alternatively be designed to apply a layer of material acting as the optical medium on a portion of the first side I of the sheets S (for instance on a window-forming region W formed in the substrate S as depicted in FIGS. 3A-3B, however on side I rather than on side II). The substrate then preferably will be printed downstream at least onto its other side, here side II.

(29) The aforementioned screen-printing unit 82, 82a, 84 is designed to act a first application unit for applying the required layer of material where the micro-optical structure is to be replicated. The configuration and operation of the screen-printing unit 82, 82a, 84 is known as such in the art and does not need to be described in detail. Reference can in particular be made to European Patent Publication No. EP 0 723 864 A1 in the name of the present Applicant, which is incorporated herein by reference in its entirety.

(30) In the illustration of FIG. 4 (and FIGS. 5 and 7), only one screen-printing unit is depicted. It should however be appreciated that multiple screen-printing units could be provided, which screen-printing units could cooperate with one and a same impression cylinder. Furthermore, while screen printing is a preferred process for applying the required material, other application processes could be contemplated. For instance, flexographic printing could be contemplated (see for instance the embodiment depicted in FIG. 7).

(31) Downstream of the impression cylinder 84, there is preferably provided at least one embossing cylinder 85, serving as embossing tool 85, which cooperates with the second side II of the sheets S, i.e. the side where the layer of material acting as optical medium was applied by the application unit 82, 82a, 84, especially screen-printing unit 82, 82a, 84. This embossing cylinder 85 preferably carries on its circumference a replicating medium RM (as schematically illustrated in FIG. 3B) designed to replicate a micro-optical structure L, such as but not limited to a field of micro-lenses, into the layer of material applied on the sheets S. In that respect, the screen-printing unit 82, 82a, 84 should be adapted to supply a sufficient amount of material to fill the recessed portion of the replicating medium RM.

(32) A pressure roller or cylinder 86 is furthermore advantageously provided about the circumference of the embossing cylinder 85 in order to cooperate with the first side I of the sheets S and press the sheets S against the circumference of the embossing cylinder 85 (and the surface of the replicating medium RM located thereon), thereby ensuring proper replication of the micro-optical structure L into the layer of material acting as optical medium.

(33) The in-line casting device 80 further comprises a first drying/curing unit 51 located about a portion of the circumference of the embossing cylinder 85, downstream of the possibly pressure roller or cylinder 86, to dry or cure the layer of material acting as optical medium while the sheets S are still being processed and pressed against the circumference of the embossing cylinder 85 and the surface of the replicating medium RM located thereon, thereby ensuring optimal replication and formation of the desired micro-optical structure L. In this context, it shall be understood that the drying/curing operation is carried out from the side opposite to the side being provided with the layer to be cured, here for example the first side I of the substrate, e.g. sheets S, which is especially adequate in the event that the micro-optical structure L is replicated on top of a window-forming portion W as schematically illustrated in FIG. 3B.

(34) Alternatively, or in addition to the aforementioned drying/curing unit 51, the in-line casting device 80 could be provided with a (second) drying/curing unit 52 located about a portion of the circumference of a transfer cylinder 87 that is located immediately after the embossing cylinder 85 as depicted in FIG. 4. In this case, it shall be understood that the drying/curing operation is carried out from the second side II of the sheets S, where the micro-optical structure L has been replicated.

(35) The aforementioned drying/curing units 51, 52 could advantageously be UV-curing units, especially UV-LED curing units, in which case the relevant layer of material acting as optical medium evidently has to be a UV-curable material.

(36) Subsequent to the replication of the micro-optical structure L, the sheets S are transferred to the downstream-located printing unit 2*, namely to the sheet transfer cylinder 10.

(37) In accordance with this first embodiment, the sheets S are accordingly fed in succession from the sheet feeder (not shown in FIG. 4) onto the feeder table 1* where they are conventionally aligned before being fed to the sheet transfer cylinder 9 at the infeed. As illustrated, the sheets are fed in succession by the sheet transfer cylinder 9 to and through the in-line casting device 80 (via cylinders 84, 85 and 87) to the transfer cylinder 10 and then to the first printing cylinder 5 of the main printing group 91, 92.

(38) It will therefore be appreciated in this embodiment that the sheets S are initially provided with micro-optical structures L on side II and then receive at least first impressions on the opposite side I, preferably first and second impressions on both sides I, II, which impressions are performed simultaneously at the printing nip between the first and second printing cylinders 5, 6 of the main printing group 91, 92. It will also be appreciated that transfer of the sheets S from the in-line casting device 80 to the printing unit 2* is carried out exclusively from cylinder to cylinder via cooperating cylinder grippers. Optimal register accuracy between the micro-optical structures L that are replicated by means of the embossing cylinder 85 and the impressions performed by the printing unit 2* is thereby guaranteed.

(39) FIG. 5 schematically shows a partial side view of a printing unit, designated by reference numeral 2**, of a printing press 100** in accordance with a second embodiment of the invention.

(40) This printing press 100** shares a number of common features with the first embodiment of FIG. 4, in particular the same basic components 5, 6, 15, 16, 25, 26 constitutive of the main printing group 91, 92 and the same basic components 82, 82a, 84, 85, 86, 87, 51, 52 constitutive of the in-line casting device 80. The difference between this second embodiment and the first embodiment resides in that an additional printing group 93, 94 is interposed between the in-line casting device 80 and the main printing group. More precisely, the printing press 100** of FIG. 5 comprises third and fourth printing cylinders 7, 8 cooperating with one another to form a second printing nip between the third and fourth printing cylinders 7, 8 where the first and second sides I, II of the sheets S are simultaneously printed, the third printing cylinder 7 acting as a sheet conveying cylinder of the additional printing group 93, 94. Each printing cylinder 7, 8 collects inks from corresponding sets of two (n=2) plate cylinders 17, respectively 18, that are inked by corresponding inking apparatuses 27, 28. These two sets of inking apparatuses 27, 28 are likewise preferably supported in two retractable inking carriages 23, 24 that can be moved toward or away from the centrally-located plate cylinders 17, 18 and printing cylinders 7, 8.

(41) Alternatively, the sets of inking apparatus 25, 27 on the right side of the printing unit 2 and/or the sets of inking apparatus 26, 28 on the left side of the printing unit 2 could be supported in one and a same inking carriage (one on each side).

(42) In the illustrated example, the additional printing group 93, 94 with the basic components 7, 8, 17, 18, 27, 28 is placed upstream of and above the main printing group 91, 92, the first and second printing cylinders 5, 6, on the one hand, and the third and fourth printing cylinders 7, 8, on the other hand, being advantageously aligned along two horizontal planes.

(43) The main printing group 91, 92, comprising the basic components 5, 6, 15, 16, 25, 26, and the additional printing group 93, 94, comprising the basic components 7, 8, 17, 18, 27, 28, are coupled to one another by means of an intermediate sheet conveying system comprising, in the illustrated embodiment, first to third sheet-transfer cylinders 10′,10″,10′″ interposed between the first and third printing cylinders 5, 7. More precisely, the sheets printed in the additional printing group 93, 94 are transferred from the third printing cylinder 7 in succession to the first sheet-transfer cylinders 10′, to the second sheet-transfer cylinders 10″, to the third sheet-transfer cylinder 10′″, and then to the first printing cylinder 5 of the main printing group 91, 92.

(44) On their way to the main printing group 91, 92, the sheets are preferably dried/cured by third and fourth drying/curing units 55, 56. As illustrated, the third drying/curing unit 55 advantageously cooperates with the first sheet-transfer cylinder 10′, i.e. the sheet-transfer cylinder located immediately downstream of the third printing cylinder 7, and the fourth drying/curing unit 56 cooperates with the second sheet-transfer cylinder 10″. The drying/curing units 55, 56 are advantageously UV curing units, preferably UV-LED curing units.

(45) Drying/curing of the second side II of the sheets could alternatively be performed directly onto the third printing cylinder 7, provided suitable measures are taken to ensure that the drying/curing unit does not degrade the performance or usability of the printing blankets on the third printing cylinder 7.

(46) In accordance with this other embodiment, the sheets S are accordingly fed in succession from the sheet feeder (not shown in FIG. 5) onto the feeder table 1* where they are once again conventionally aligned before being fed to the sheet transfer cylinder 9 at the infeed. As illustrated, the sheets are then fed in succession by the sheet transfer cylinder 9 to and through the in-line casting device 80 (via cylinders 84, 85 and 87) to the transfer cylinder 10, to the third printing cylinder 7 of the additional printing group 93, 94 and then to the first printing cylinder 5 of the main printing group 91, 92 via the three intermediate sheet transfer cylinders 10′ to 10′″.

(47) It will therefore be appreciated that the sheets S are initially provided with micro-optical structures L on side II and then receive first and second impressions on both sides I, II, which impressions are performed simultaneously at the printing nip between the third and fourth printing cylinders 7, 8 of the additional printing group and at the printing nip between the first and second printing cylinders 5, 6 of the main printing group. It will likewise also be appreciated that transfer of the sheets S from the in-line casting device 80 to the printing unit 2** is carried out exclusively from cylinder to cylinder via cooperating cylinder grippers. Optimal register accuracy between the micro-optical structures L that are replicated by means of the embossing cylinder 85 and the impressions performed by the printing unit 2** is once again guaranteed.

(48) FIG. 6 shows an alternative embodiment for applying the material acting as optical medium. In this embodiment, the material acting as optical medium is applied directly onto the embossing form, e.g. onto the surface of the embossing cylinder 85 before the substrate, i.e. the sheet S, being arranged on it. In this case the application unit is being placed at the embossing tool 85, preferably at the circumference of the embossing cylinder 85, especially in a peripheral section between take over and delivery of the substrate, respectively sheet S. The application unit can be designed as a screen printing unit or flexographic-printing unit as above, but preferably it is designed like an inking apparatus with at least a fountain roller receiving the material from a reservoir and directly or through other rollers transfer the material onto the surface of the embossing cylinder 85.

(49) The embodiment with direct application onto the embossing cylinder 85 described in the context of the first embodiment is to be transferred to the second embodiment.

(50) FIG. 7 schematically shows a partial side view of a printing unit, designated by reference numeral 2***, of a printing press 100*** in accordance with a third embodiment of the invention.

(51) This printing press 100*** shares a number of common features with the second embodiment of FIG. 5, in particular the same basic components 5, 6, 15, 16, 25, 26 constitutive of the main printing group 91, 92 and the same basic components 8, 18, 28 constitutive of the additional printing group 93, including the three transfer cylinders 10′,10″ and 10′″ ensuring transfer of the sheets S from the additional printing group 93 to the main printing group 91, 92. The main differences between this third embodiment and the second embodiment reside in that (i) the additional printing group is designed in this case to print only the second side II of the sheets S (and comprises three plate cylinders 18 and associated inking apparatuses 28 instead of two) and in that (ii) the in-line casting device, designated by reference numeral 80* in FIG. 7, is adapted to apply a layer of material acting as the optical medium on a portion of the first side I of the sheets S (rather than on the second side II as in the embodiments of FIGS. 4 and 5).

(52) Furthermore, in accordance with this third embodiment, the embossing cylinder 85 is arranged so as to act as counter-pressure cylinder for the (third) printing cylinder 8 of the additional printing group 93. In other words, and in contrast to the first and second embodiments, in-line casting of the micro-optical structure L is performed from and on the first side I of the sheets S and a printed pattern is printed on the second side II of the sheets S, while the sheets S are still being supported on the embossing cylinder 85, i.e. without this involving any sheet transfer between the in-line casting of the micro-optical structure L and the printing of the printed pattern. This is even more favourable in terms of achieving a high register between the micro-optical structure L and the associated printed pattern as in-line casting of the micro-optical structure, on one side of the sheets S, and printing of the associated pattern, on the other side of the sheets S, are performed in a same step, without this involving any sheet transfer operation.

(53) In an non-depicted alternative to the depicted embodiment of FIG. 7, the printing group 93 being designed as collect printing group in the embodiment of FIG. 7 can be replaced by two or more printing groups designed as printing groups comprising only one plate cylinder each. In this embodiment printing cylinders of at least two such printing groups co-operating with the counter-pressure cylinder successively around its circumference. The printing groups accordingly being arranged around the counter-pressure cylinder.

(54) In a variant of the third embodiment depicted in FIG. 7 or its cited alternative, the printing press 100*** do not comprise the double sided printing group 91, 92, but only the printing group 93 co-operating with the casting unit 80*; 80**; 80***. In just another variant the press comprises an further printing group downstream the printing group 93 co-operating with the casting unit, but of any other type.

(55) Thus, also in this and in the following embodiments, the press 100* or printing unit 2 or main printing group comprises a printing group 91; 93 at least on that side of the substrate path for printing onto the substrate side I; II which opposes the side II; I having been provided with the micro-optical structure upstream and/or downstream the casting device 80; 80*; 80**; 80***. Instead or in addition, the embossing cylinder 85 acts as counter-pressure cylinder and cooperates with a cylinder 8 of the at least one printing group 93. Preferably, this at least one printing group 93 preferably is designed as above mentioned collect printing group 93, i.e. the cylinder 8 acting as collecting or transfer cylinder, especially as collecting blanket cylinder, and cooperating with several associated plate cylinders 18 to apply the at least one, preferably several collected, printed pattern on a side II; I of the substrate S which is opposite to the side I; II of the substrate S where the micro-optical structure L is replicated.

(56) Operation of the in-line casting device 80* (and of the components thereof 82, 82a, 84, 85, 86) is basically identical to that of the in-line casting device 80 depicted in FIGS. 4 and 5, except that the micro-optical structure L is ultimately formed on the first side I of the sheets S. It will be appreciated that an additional transfer cylinder 9′ is provided downstream of the transfer cylinder 9 at the infeed and that transfer cylinder 87 has been omitted as the sheets S can be transferred directly from the embossing cylinder 85 to the transfer cylinder 10′. Transfer cylinder 10″ is furthermore a double-sized cylinder in this third embodiment to increase space between the additional printing group and the main printing group, thereby allowing the integration of a third plate cylinder 18 and associated inking apparatus 28 in the additional printing group.

(57) As transfer cylinder 87 has been omitted, so has the associated drying/curing unit 52, as well as the downstream-located sheet transfer cylinder 10. This being said, an additional drying/curing unit could be provided about the circumference of the embossing cylinder 85, downstream of the printing cylinder 8 and upstream of the sheet transfer cylinder 10′.

(58) In accordance with this third embodiment, the sheets S are accordingly fed in succession from the sheet feeder (not shown in FIG. 7) onto the feeder table 1* where they are once again conventionally aligned before being fed to the sheet transfer cylinder 9 at the infeed. As illustrated, the sheets are then fed in succession by the sheet transfer cylinder 9 to the additional sheet transfer cylinder 9′, through the in-line casting device 80* (via cylinders 84 and 85), and then to the first printing cylinder 5 of the main printing group via the three intermediate sheet transfer cylinders 10′ to 10′″.

(59) It will therefore be appreciated that the sheets S are initially provided with micro-optical structures L on side I and immediately receive a first impression on side II thanks to the additional printing unit. Further impressions are then formed on both sides I, II of the sheets S by means of the main printing group, which impressions are performed simultaneously at the printing nip between the first and second printing cylinders 5, 6 of the main printing group. As already mentioned, and in contrast to the first and second embodiments, it will be appreciated that the in-line casting device 80* is designed in this case to be an integral part of the printing unit 2*** (the same applies in respect of the in-line casting device 80** depicted in FIG. 8 which likewise forms an integral part of the printing unit 2****). Highly optimal register accuracy between the micro-optical structures L that are replicated by means of the embossing cylinder 85 and the impressions performed by the printing unit 2*** is therefore guaranteed.

(60) FIG. 8 schematically shows a partial side view of a printing unit, designated by reference numeral 2****, of a printing press 100**** in accordance with a fourth embodiment of the invention.

(61) This printing press 100**** shares a number of common features with the third embodiment of FIG. 7. The sole difference between this fourth embodiment and the third embodiment resides in that the in-line casting device, designated by reference numeral 80**, is making use of a flexographic-printing unit 83, 83a, 84* to applying at least a part of the layer of material acting as the optical medium, instead of the screen-printing unit 82, 82a, 84 depicted in FIG. 7. This flexographic-printing unit 83, 83a, 84* includes a plate-cylinder 83, which cooperates with an impression cylinder 84*. The plate cylinder 83 carries a suitable flexographic printing plate (with relief portions corresponding in shape and position to the area on the sheets S where the layer of material is to be applied) which cooperates with an anilox roller 83a equipped with an associated supply chamber where the material to be applied is supplied. Flexographic-printing units are known as such in the art, especially for varnishing applications (see e.g. International PCT Publication No. WO 2011/145028 A1).

(62) Processing of the sheets S on printing press 100**** of FIG. 8 is carried out in the same way as on printing press 100*** of FIG. 7, with the only difference that the layer of material designed to act as optical medium is applied by flexographic-printing rather than by screen-printing. It shall be understood that a similar flexographic-printing unit 83, 83a, 84* could also be used as application unit in the context of the first and second embodiments in lieu of (or even as a complement to) the screen-printing unit 82, 82a, 84.

(63) FIG. 9 shows an alternative embodiment for applying the material acting as optical medium. In this embodiment, the material acting as optical medium is applied directly onto the embossing form, e. g. onto the surface of the embossing cylinder 85 before the substrate, i.e the sheet S, being arranged on it. In this case the application unit 80*** is being placed at the embossing tool 85, preferably at the circumference of the embossing cylinder 85, especially in a peripheral section between take over and delivery of the substrate, respectively sheet S. The application unit 80*** can be designed as a screen printing unit or flexographic-printing unit as above, but preferably, it is designed similar to an inking apparatus with at least a fountain roller receiving the material acting as the optical medium from a reservoir and directly or through on or more further rollers transfer the material onto the surface of the embossing cylinder 85.

(64) Variants of the aforementioned embodiments could be contemplated without departing from the scope of the invention as defined by the annexed claims. For instance, the main printing group 5, 6, 15, 16, 25, 26 in the embodiments of FIGS. 5 and 7 to 9 could be omitted altogether and the additional printing group 7, 8, 17, 18, 27, 28, respectively 8, 18, 28 used exclusively for the purpose of printing the desired pattern in register with the micro-optical structure L. The integrated solution depicted in FIGS. 7 to 9 could in particular be conceived as a combined printing and in-line casting platform or module that could serve as a stand-alone printing press or as modular printing unit that could be combined with additional printing units if necessary.

(65) It should be appreciated that the actual numbers m and n of plate cylinders 15, 16, 17, 18 illustrated in FIGS. 4 to 7 are not limitative and that other combinations are possible. This being said, the illustrated examples are particularly advantageous in that machine footprint is limited and machine operability and accessibility are not compromised.

(66) As a possible refinement of the invention, as illustrated in FIGS. 4 to 7, it may be convenient to additionally provide the printing press with a recto-verso inspection system 11, 12, 61, 62 adapted to inspect the first and second sides I, II of the sheets printed by the additional printing group and the main printing group, including the micro-optical structures formed by means on the in-line casting device 80, 80* or 80**.

(67) Furthermore, the printing presses 100* of FIGS. 4 and 6 and 100** of FIG. 5 can also conveniently equipped, as illustrated, with automatic blanket washing devices 71, 72, 73, 74 adapted to clean the surface of the first, second, third and fourth printing cylinders 5, 6, 7, 8, respectively, during maintenance operations. The printing presses 100*** of FIGS. 7 and 100**** of FIGS. 8 and 100***** of FIG. 9 can likewise be equipped, as illustrated, with automatic blanket washing devices 71, 72, 74 adapted to clean the surface of the first, second and third printing cylinders 5, 6, 8, respectively, during maintenance operations. By the same token, as illustrated for instance in FIGS. 7 and 8, a suitable automatic washing device 88 could be provided to clean the surface of the embossing cylinder 85 during maintenance operations (which automatic washing device 88 could also be contemplated in the context of the embodiments of FIGS. 4, 5 and 6).

(68) Various modifications and/or improvements may be made to the above-described embodiments without departing from the scope of the invention as defined by the annexed claims. In particular, while the embodiments of the invention where described with reference to sheet-fed printing press configurations, the invention could equally be applied to print on web-like substrates, i.e. successive portions of a continuous web of printable material.

(69) Furthermore, the in-line casting device could be adapted to apply a layer of material acting as an optical medium on a portion of either the first or second side of the substrate and to replicate and form the micro-optical structure accordingly. In that respect, the configurations of the in-line casting devices 80, 80*, 80** shown in FIGS. 4 to 7 are only illustrative of possible machine configurations.

LIST OF REFERENCE NUMERALS USED THEREIN

(70) 100 printing press (prior art of FIGS. 1 and 2)

(71) 100* printing press (first embodiment of FIGS. 4 and 6)

(72) 100** printing press (second embodiment of FIG. 5)

(73) 100*** printing press (third embodiment of FIG. 7)

(74) 100**** printing press (fourth embodiment of FIG. 8)

(75) 100***** printing press (fourth embodiment of FIG. 9)

(76) 1 sheet feeder

(77) 1* feeder table

(78) S substrate material (e.g. individual sheets)

(79) I first side (“side I” or “recto side”) of the substrate material S

(80) II second side (“side II” or “verso side”) of the substrate material S

(81) H through opening in substrate S

(82) W window-forming portion of substrate S

(83) L micro-optical structure (e.g. lens structure) replicated/formed into a layer of material acting as optical medium applied on e.g. side II of the substrate material S

(84) RM replicating medium used to replicate and form the micro-optical structure L

(85) CR carrier supporting the replicating medium RM (e.g. embossing cylinder 85—embodiments of FIGS. 4 to 7)

(86) 2 printing unit (prior art of FIGS. 1 and 2)

(87) 2* printing unit (first embodiment of FIGS. 4 and 6)

(88) 2** printing unit (second embodiment of FIG. 5)

(89) 2*** printing unit (third embodiment of FIG. 7)

(90) 2**** printing unit (fourth embodiment of FIG. 8)

(91) 2***** printing unit (fourth embodiment of FIG. 9)

(92) 3 sheet conveying system (chain gripper system with spaced-apart gripper bars)

(93) 4 substrate delivery unit, sheet delivery unit

(94) 5 sheet conveying cylinder/(first) printing cylinder (main printing group)/three-segment blanket cylinder

(95) 6 (second) printing cylinder (main printing group)/three-segment blanket cylinder

(96) 7 sheet conveying cylinder/(third) printing cylinder (additional printing group)/two-segment blanket cylinder (embodiment of FIG. 5 only)

(97) 8 (third, resp. fourth) printing cylinder (additional printing group)/two-segment blanket cylinder (prior art of FIGS. 1, 2/second to fourth embodiments of FIGS. 5 to 7)

(98) 8′ sheet conveying cylinder/two-segment cylinder (prior art of FIGS. 1 and 2 only)

(99) 9 sheet transfer cylinder (infeed)

(100) 9′ sheet transfer cylinder (third and fourth embodiments of FIGS. 6 and 7) sheet transfer cylinder (prior art of FIGS. 1, 2/first and second embodiments of FIGS. 4 and 5)

(101) 10′,10″,10′″ sheet transfer cylinders (intermediate sheet conveying system interposed between additional printing group and main printing group—embodiments of FIGS. 5 to 7 only)

(102) 11 inspection cylinder or drum (part of inspection system)

(103) 12 inspection cylinder or drum (part of inspection system)

(104) 15 (m=4) plate cylinders cooperating with printing cylinder 5

(105) 16 (m=4) plate cylinders cooperating with printing cylinder 6

(106) 17 (n=2) plate cylinders cooperating with printing cylinder 7 (embodiment of FIG. 5)

(107) 18 (n=2, resp. 3) plate cylinders cooperating with printing cylinder 8 (prior art of FIGS. 1, 2/second to fourth embodiments of FIGS. 5 to 7)

(108) 20 printing press main frame

(109) 21 retractable inking carriage supporting inking apparatuses 25

(110) 22 retractable inking carriage supporting inking apparatuses 26

(111) 23 retractable inking carriage supporting inking apparatuses 27 (embodiment of FIG. 5)

(112) 24 retractable inking carriage supporting inking apparatuses 28 (prior art of FIGS. 1, 2/second to fourth embodiments of FIGS. 5 to 7)

(113) 25 (m=4) inking apparatuses each cooperating with a corresponding one of the plate cylinders 15

(114) 26 (m=4) inking apparatuses each cooperating with a corresponding one of the plate cylinders 16

(115) 27 (n=2) inking apparatuses each cooperating with a corresponding one of the plate cylinders 17 (embodiment of FIG. 5)

(116) 28 (n=2, resp. 3) inking apparatuses each cooperating with a corresponding one of the plate cylinders 18 (prior art of FIGS. 1, 2/second to fourth embodiments of FIGS. 5 to 7)

(117) 31 pair of chain wheels of sheet conveying system 3 (upstream end)

(118) 50 drying/curing unit (prior art of FIGS. 1, 2)

(119) 51 (first) drying/curing unit acting on side I of the sheets S, e.g. UV-LED curing unit (located about a portion of the circumference of embossing cylinder 85)

(120) 52 (second) drying/curing unit acting on side II of the sheets S, e.g. UV-LED curing unit (located about a portion of the circumference of transfer cylinder 87/first and second embodiments of FIGS. 4 and 5)

(121) 55 (third, resp. second) drying/curing unit acting on side I of the sheets S, e.g. UV-LED curing unit (located about a portion of the circumference of transfer cylinder 10′/embodiments of FIGS. 5 to 7)

(122) 56 (fourth, resp. third) drying/curing unit acting on side II of the sheets S, e.g.

(123) UV-LED curing unit (located about a portion of the circumference of transfer cylinder 10″/embodiments of FIGS. 5 to 7)

(124) 61 inspection camera (side I of the sheets S) cooperating with inspection cylinder or drum 11, e.g. line-scan camera

(125) 62 inspection camera (side II of the sheets S) cooperating with inspection cylinder or drum 12, e.g. line-scan camera

(126) 71 automatic blanket washing device cooperating with printing cylinder 5

(127) 72 automatic blanket washing device cooperating with printing cylinder 6

(128) 73 automatic blanket washing device cooperating with printing cylinder 7 (embodiment of FIG. 5)

(129) 74 automatic blanket washing device cooperating with printing cylinder 8 (embodiments of FIGS. 5 to 7)

(130) 80 in-line casting device for the application of a layer of material acting as optical medium and for the replication and formation of the micro-optical structure L in the said layer of material acting as optical medium (first and second embodiments of FIGS. 4 and 5)

(131) 80* in-line casting device for the application of a layer of material acting as optical medium and for the replication and formation of the micro-optical structure L in the said layer of material acting as optical medium (third embodiment of FIG. 6)

(132) 80** in-line casting device for the application of a layer of material acting as optical medium and for the replication and formation of the micro-optical structure L in the said layer of material acting as optical medium (fourth embodiment of FIG. 7)

(133) 82 screen-printing cylinder (part of the screen-printing unit acting as application unit for the layer of material acting as optical medium/first to third embodiments of FIGS. 4 to 6)

(134) 82a squeegee device of screen-printing cylinder 82

(135) 83 plate-cylinder (part of the flexographic-printing unit acting as application unit for the layer of material acting as optical medium/fourth embodiment of FIG. 7)

(136) 83a anilox roller and associated supply chamber for plate-cylinder 83

(137) 84 impression cylinder (remaining part of the screen-printing unit acting as application unit for the layer of material acting as optical medium)

(138) 84* impression cylinder (remaining part of the flexographic-printing unit acting as application unit for the layer of material acting as optical medium)

(139) 85 embossing cylinder carrying replicating medium RM for the replication and formation of the micro-optical structure L

(140) 86 pressure cylinder or roller cooperating with embossing cylinder 85

(141) 87 transfer cylinder cooperating with embossing cylinder 85 for transfer of the sheets S to the downstream-located printing unit 2*, 2** (first and second embodiments of FIGS. 4 and 5)

(142) 88 automatic washing device cooperating with embossing cylinder 85 (embodiments of FIGS. 6 and 7)

(143) 91 printing group, preferably collect printing group

(144) 92 printing group, preferably collect printing group

(145) 93 printing group, preferably collect printing group

(146) 94 printing group, preferably collect printing group