Multi-Layer Printing Process

Abstract

A system and method for forming indicia on a substrate. The system includes a feed system for feeding the substrate and a plurality of stations each operable to apply a processing step to the substrate. A first of the plurality of stations applies an energy curable ink to the substrate using a printing process. In some embodiments, this printing process is a gravure cylinder having indicia grooves formed on the gravure cylinder. The indicia grooves on the cylinder retain the energy curable ink until contact with the substrate whereby the energy curable ink is applied to the substrate. A curing unit is disposed downstream of the first of the plurality of stations. The curing unit receives the substrate and outputs an electron beam directed toward the energy curable ink to cure the energy curable ink and form a resultant energy curable layer upon the substrate.

Claims

1. A method for forming a multi-layer product, the method comprising: applying an energy curable coatings to a substrate at a first station, said energy curable coatings comprising an acrylate material that cures by free radical polymerization; curing the energy curable coatings using an energy curable process including free radical polymerization at a second station downstream of the first station to define a cured energy curable layer bonded to the substrate; routing the substrate to a third station downstream of the second station; applying a metallic ink directly to an intact surface of the cured energy curable layer that consists of the cured energy curable coating to define a metallic ink layer bonded on the cured energy curable layer resulting in a predetermined reflectivity and predetermined durability, wherein the applying the energy curable coating to the substrate at the first station comprises applying the energy curable coating to the substrate at the first station using a gravure cylinder having indicia grooves formed on the gravure cylinder, the indicia grooves being configured to retain the energy curable coating until contact with the substrate whereby the energy curable coating is applied to the substrate to produce a resultant indicia, and automatically and continually inspecting at least one of the group consisting of quality, rate, and condition of at least the resultant indicia.

2. The method according to claim 1, wherein the curing the energy curable coating using the energy curable process comprises curing the energy curable coating using an electron beam at the second station downstream of the first station to define the cured energy curable layer.

3. The method according to claim 1, wherein the curing the energy curable coating using the energy curable process comprises curing the energy curable coating using an ultraviolet beam at the second station downstream of the first station to define the cured energy curable layer.

4. The method according to claim 1 further comprising applying an overcoat layer to the substrate at a fourth station, the overcoat layer being applied over the metallic ink layer.

5. The method according to claim 1, wherein the predetermined reflectivity is a mirror finish.

6. The method according to claim 1, wherein the predetermined durability is configured to be used without an additional protective layer disposed over the cured energy curable layer.

7. A system for forming indicia on a substrate, the system comprising: a feed system for feeding the substrate; a plurality of stations each operable to apply a processing step to the substrate, a first station of the plurality of stations configured to apply an energy curable coatings to the substrate using a printing process, said energy curable coating comprising an acrylate material that cures by free radical polymerization; a curing unit disposed downstream of the first station, the curing unit configured to receive the substrate and output an energy beam directed toward the energy curable coatings to cure the energy curable coatings via a free radical polymerization process and form a resultant energy cured layer bonded to the substrate; a second station of the plurality of stations configured to apply a metallic ink directly to the energy cured layer that consists of the cured energy curable coating, to define a metallic ink layer bonded on the cured energy layer having a resultant predetermined reflectivity and predetermined durability, the curing unit is between the first station and the second station, wherein the first of the plurality of stations is configured to apply the energy curable coating to the substrate with a gravure cylinder having an indicia depression formed on the gravure cylinder, the indicia depression being configured to retain the energy curable coating until contact with the substrate whereby the energy curable coating is applied to the substrate to produce a resultant indicia, and an inspection station configured to inspect at least one of the group consisting of quality, rate, and condition of at least the resultant indicia.

8. The system according to claim 7, wherein the energy beam is an electron beam.

9. The system according to claim 7, wherein the energy beam is an ultraviolet beam.

10. The system according to claim 7, wherein the curing unit is configured to output the energy beam directed toward the energy curable coating to polymerize the energy curable coatings.

11. The system according to claim 7 further comprising a third station of the plurality of stations configured to apply an overcoat to the substrate over the metallic ink and the energy cured layer.

12. The system according to claim 7, wherein the predetermined reflectivity is a mirror finish.

13. The system according to claim 7, wherein the predetermined durability is configured to be used without an additional protective layer disposed over the energy cured layer.

Description

DRAWINGS

[0014] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0015] FIG. 1 is a schematic view illustration of a printing system according to some embodiments of the present teachings;

[0016] FIG. 2A is a schematic cross-sectional view illustrating a product made in accordance with the multi-layer printing process of the present teachings according to some embodiments;

[0017] FIG. 2B is a schematic cross-sectional view illustrating a product made in accordance with the multi-layer printing process of the present teachings according to some embodiments;

[0018] FIG. 3 is a schematic cross-sectional view illustrating a conventional foil stamping product; and

[0019] FIG. 4 is a perspective view illustrating a printing or gravure cylinder having indicia grooves according to some embodiments of the present teachings.

[0020] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0021] Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0022] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms a, an, and the may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms comprises, comprising, including, and having, are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0023] When an element or layer is referred to as being on, engaged to, connected to, or coupled to another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being directly on, directly engaged to, directly connected to, or directly coupled to another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., between versus directly between, adjacent versus directly adjacent, etc.). As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

[0024] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as first, second, and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0025] Spatially relative terms, such as inner, outer, beneath, below, lower, above, upper, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as below or beneath other elements or features would then be oriented above the other elements or features. Thus, the example term below can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0026] With particular reference to FIG. 1, a printing system 10 is provided according to the principles of the present teachings. In some embodiments, printing system 10 is based on a rotogravure (also known as a gravure) printing system. The system is generally an intaglio-type printing system that involves engraving the image onto an image carrier. In gravure printing, the image is engraved onto a cylinder for use in a rotary printing press configuration. However, it should be appreciated that the principles of the present teachings are not limited to only gravure type printing systems and are equally applicable to flexographic printing and the like. In flexographic printing, ink is transferred from a fountain roller to a flexible plate cylinder by a so-called anilox roller that meters the ink.

[0027] Generally speaking, the gravure process system is configured by first creating one or more cylinders with an engraved image to be printed. Engraving of the image on the cylinder can be accomplished according to any one of a number of techniques, including physical engraving (e.g. via a diamond stylus), etching (e.g. chemical etching), and the like. This engraved image is sized to contain the printing ink to be transferred to the substrate. In some embodiments, the substrate can comprise paper or other fibrous material, such as stock, cardboard, corrugated board, polyethylene, polypropylene, polyester, BOPP and the like. It should be noted, however, that alternative substrate materials can be used that are conventional in the art. As noted above, the invention is particularly advantageous for fibrous substrates such as paper or board that present a relatively rough surface. Boards usable in the invention typically have a grammage from about 160 g/m.sup.2 to about 400 g/m.sup.2, often in the range 180 to 280 g/m.sup.2. This corresponds to a thickness in the range of about 180 to 400 depending on the density of the board material. Paper substrates range typically from about 80 g/m.sup.2 to about 160 g/m.sup.2.

[0028] Generally, printing system 10 can comprise a plurality of stations 12, such as a first station 12A, a second station 12B, a third station 12C, a fourth station 12D, a fifth station 12E, a sixth station 12F, a seventh station 12G, an eighth station 12H, a ninth station 12I, and a tenth station 12J. It should be appreciated that printing system 12 can be configured with fewer or greater number of stations; however, the present embodiment represents at least one preferred embodiment. In some embodiments, each of the plurality of stations 12 can be configured for a different purpose, such as application of an energy curable ink or coating (which will be discussed more completely herein), a different color, a different coating, or the like. In this regard, any one of a number of layering and processing patterns can be achieved on the substrate.

[0029] In some embodiments, printing system 10 can comprise a feed system 14 for supplying and feeding a substrate to be printed or web 16, such as paper, stock, cardboard, corrugated board, polyethylene, polypropylene, polyester, BOPP and the like, to each of the plurality of stations 12. Each of the plurality of stations 12 can comprise a printing cylinder 18 disposed therein. The printing or gravure cylinder 18 can have indicia grooves or indicia depressions 19 formed on the gravure cylinder 18. The indicia grooves or indicia depressions 19 retain the energy curable coating until contact with the substrate whereby the energy curable coating is applied to the substrate. However, it should be recognized that each of the illustrated stations 12 do not require the use of a printing cylinder 18 as such station may be used for alternative purposes in some embodiments.

[0030] In some embodiments, printing system 10 can further comprise an optional inspection station 20. Inspection station 20 can be disposed in a downstream position relative to the plurality of stations 12. Inspection station 20 can automatically check and/or continually check the quality, rate, and condition of the now-printed substrate 16 and the resultant indicia contained thereon. The now-printed substrate 16 can then be final processed and palletized, if desired, in finishing station 22. Finishing station 22 can accomplish any one of a number of processing functions, such as creasing, die cutting, palletizing, and the like.

[0031] The printing system 10 further comprises at least one curing station 30. Curing station 30, in some embodiments, can be used for curing an energy curable ink deposited on substrate 16. According to some teachings of the present application, curing station 30 can comprise a beam unit 32 outputting an energy beam 34, such as an electron beam and/or an ultraviolet beam, directed at substrate 16. In some embodiments, a current can be placed across a filament causing electrons to be accelerated off the filament. These electrons can be used with an energy curable ink, such as an energy curable metallic ink, to cause a polymerization in the ink (herein referred to as EB curing). Beam unit 32 can comprise nitrogen to ensure the curing environment is inert, if desired. UV curing can also be under atmospheric condition. EB curing typically does not generate much heat and is therefore beneficial in many applications. However, as mentioned, UV curing can also be used in accordance with the present teachings, although they should not be regarded as obvious variants of each other as various technical and procedural differences exist between the two.

[0032] EB curing generally employs high-energy electrons. These electrons are generally not affected by the thickness of printing inks or the color of the ink. The electron beam 34 provides sufficient energy to cure thick coatings and/or pass through other substrates.

[0033] The energy curable ink of the present teachings can comprise, in some embodiments, an acrylate material that cures by free radical polymerization. Therefore, unlike other curing systems, a photoinitiator is not required. The electron energy is sufficient to cause the acrylate materials to polymerize by opening the acrylate bonds to form free radicals. These radicals then attack the remaining acrylate bonds until the reaction reaches completion. The result is a cured layer upon the substrate that is durable and provides previously-unattained reflectivity and optical characteristics using an ink-type application.

[0034] Process

[0035] While the printing system 10 is in operation, the engraved cylinder 18 is partially immersed in the ink fountain, filling the recessed cells with energy curable ink, conventional ink, and/or the like. As the cylinder rotates, it draws ink out of the fountain with it. Acting as a squeegee, a doctor blade scrapes the cylinder before it makes contact with the substrate, removing excess ink from the non-printing (non-recessed) areas and leaving in the cells the right amount of ink required. Next, the substrate is sandwiched between the impression roller and the gravure cylinder, thereby transferring the ink to the substrate. The purpose of the impression roller is to apply force, pressing the substrate onto the gravure cylinder, ensuring even and maximum coverage of the ink. The capillary action of the substrate and the pressure from impression rollers force the ink out of the cell cavity and transfer it to the substrate. The substrate can then proceed to a dryer to completely dry before application of the subsequent layer.

[0036] The substrate 16 can include application of the energy curable ink or coating at one or more of the plurality of stations 12. For example, the eighth station 12H can include application of an energy curable ink to substrate 16. Substrate 16 can continue its downstream processing, and be directed to curing station 30 (procedurally between eighth station 12H and ninth station 12I), whereby beam unit 32 outputs electron beam 34 directed at the energy curable ink from station 12H. Application of electron beam 34 to energy curable ink on substrate 16 (the EB coating) causes a polymerization or other curing process of energy curable ink. In some embodiments, several layers of coatings can be cured down to a single layer. As a result of this process, the energy curable ink is thus bonded or otherwise cured to substrate 16. It has been found that this process produces a resultant indicia (made from the now-cured energy curable ink) that can be tailored to provide any one of a number of reflectivity characteristics up to at least a mirror finish. In this way, the results of the present process are at least equivalent to foil stamping, but with additional flexibility. Moreover, the durability of the finish composition, in many applications, is sufficient so as to avoid the need for any additional layers or protective coatings, such as lacquer and the like.

[0037] As a result of the aforementioned process, a product 100 is illustrated in FIG. 2A having a substrate 16, an energy cured layer 102, and an optional overcoat layer (e.g. lacquer) 104. In some embodiments as illustrated in FIG. 2B, product 100 can comprise substrate 16, an energy cured layer 102, a metallic ink layer 106 applied above energy cured layer 102, and an optional overcoat layer 104 disposed above metallic ink layer 106. In contrast, a conventional foil stamped product 200 illustrated in FIG. 3 having a substrate 216 and a foil stamping 218.

[0038] In some embodiments, if desired, metallic ink layer 106 (FIG. 2B) can be applied to the now-cured energy cured layer 102 to provide a high finish quality at station 12I or 12J. In some embodiments, the metallic ink used for metallic ink layer 106 can be conventional metallic ink that is available in an assortment of colors. It has been found that application of metallic ink layer 106 to the energy cured layer 102 creates a bond there between that results in increased durability of metallic ink layer 106 relative to conventional application of metallic ink layers. In some embodiments, an overcoat layer 104, which is discussed herein, may not be required to protect metallic ink layer 106. Moreover, the finish quality of the metallic ink layer 106 (being disposed upon energy cured layer 102) is enhanced (e.g. improved reflectivity) compared to metallic ink layers deposited directly on a substrate according to conventional processes.

[0039] In further embodiments, if desired, a lacquer or overcoat layer 104 can be applied to the now-cured energy cured layer 102 and/or metallic ink layer 106 to provide a high finish quality at station 12I or 12J and/or enhance durability. Notwithstanding, however, it has been found that because of the high finish quality provided by the now-cured energy cured layer 102 and/or metallic ink layer 106, application of this overcoat layer (see 104 of FIGS. 2A and 2B) is often not needed to enhance finish quality and, in some cases, application of this overcoat layer may in fact reduce the overall finish quality because of the high native quality of the energy cured layer 102. Moreover, in such applications that do not employ a lacquer or overcoat layer, the durability of the energy cured layer is often sufficient for many, if not all, applications.

[0040] Similar to curing station 30 positioned between stations 12H and 12I, a curing station 30, having a similar construction, can be positioned between any other of the plurality of stations 12, such as between third station 12C and fourth station 12D. In such embodiments, additional or alternative energy cured coating layers can be applied and subsequently cured in curing station 30.

[0041] According to the present discussion, it should be appreciated that the principles of the present teachings provide benefits over conventional foil stamping processes and also over applications intended to achieve a simulated foil/metalized solution or foil/metalized alternative, such as transfer metalized board or vacuum metalized PET, laminated on board, and other techniques.

[0042] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.