System and method for producing decorative laminates

Abstract

Methods, systems, and kits related to the production of decorative laminates are discussed herein. Exemplary embodiments discussed herein relate to a printer system, i.e., a roll-to-roll printer, capable of depositing and curing ink and haptic layers on a thin film without further processing after curing each of the ink and haptic layers.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Patent Application No. 63 / 489,244, filed on March 9, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0002] The present disclosure generally relates to systems and methods for producing decorative laminates. More specifically, exemplary embodiments discussed herein relate to printer systems, namely roll-to-roll printers, that are capable of depositing and curing inks, dyes, or varnishes for decorative, protective, and tactile functions on thin films without the need for further processing. Background Art

[0003] 3D printing, which typically works by building parts layer by layer, is an additive manufacturing process used to construct three-dimensional objects. Some types can be additive, or the surface can be treated to provide relief areas of varying heights. Inkjet printing (including drop-on-demand or continuous processes) involves the ejection of ink through at least one nozzle of an inkjet head to create a pattern or image on a flat or flexible substrate, such as paper, polymer films, metallic materials, and combinations thereof. In traditional 2D printing, an inkjet printer produces parallel lines of ink dots on a substrate by moving its print head in one direction relative to the substrate while actuating the inkjet nozzles. This is typically accomplished by printing on digital and flexible media using flatbed, roll-to-roll, or hybrid UV printers.

[0004] A hybrid approach is to use 2.5D printing methods, where defined structures are built up in a layer-by-layer approach, resulting in surface topography, textures, and tactile effects. Today, conventional 2.5D printing is typically achieved by implementing a specific layer configuration by building the topography underneath the printed image. Digital varnishing methods (which also allow tactile finishes with transparent varnish to be built on top of the printed image) are more commonly used, but generally lack the throughput or capabilities for large formats. In other cases, 2.5D textured finishes can be achieved through additive or subtractive processes, which also allow single-pass processing, however, specialized, complex, and expensive equipment is required to achieve high throughput. Summary of the Invention

[0005] An exemplary embodiment relates to a method comprising: providing a printer system comprising: a control unit, at least one ink unit, a coating unit configured to apply a coating, a film on a first roll, a radiation source, and a second roll; providing a two-dimensional representation; converting the two-dimensional representation into a grayscale image using the control unit; determining, using the control unit, a position of at least one tactile layer to be deposited as a result of relative color density of the grayscale image; unwinding at least a portion of the film from the first roll; depositing an ink layer representing the two-dimensional representation onto the film via the at least one ink unit; coating at least one area of ​​the deposited two-dimensional representation, wherein the coating is applied to a thickness related to the relative color density of the grayscale image; curing the coating and ink layer using a radiation source, wherein curing of the coating forms the at least one tactile layer; and rewinding at least a portion of the provided film onto the second roll. This or another embodiment may provide for digitizing the image in the form of a data-bearing record. This or another embodiment may provide for the determining further comprising processing a depth map resulting from the converting and determining steps, the depth map combining at least one of color profile, job length, film material, and speed of moving the film. This or another embodiment may provide that the ink unit is at least one inkjet printer head. This or another embodiment may provide that the radiation source is an actinic radiation source. This or another embodiment may provide that the actinic radiation source is a UV laser emitting diode. This or another embodiment may provide that the ink layer and the paint layer are of the same composition, wherein the paint does not contain any pigment. This or another embodiment may provide that the paint layer is optically transparent or translucent. This or another embodiment may provide that the coating layer has a thickness between about 50 µm and about 150 µm. This or another embodiment may provide that the coating layer provides a tactile surface to the finished product after curing. This or another embodiment may provide that the film thickness is greater than about 50 µm. This or another embodiment may provide that no further material processing steps are required after the curing step. This or another embodiment may provide that the radiation source includes a plurality of UV laser emitting diodes, and each of the plurality of UV laser emitting diodes is individually controlled by a control unit. This or another embodiment may provide that the paint unit is at least one inkjet printer head. This or another embodiment may provide that the film comprises polyvinyl chloride. This or another embodiment may provide that the film does not contain polyvinyl chloride. This or another embodiment may provide that the ink unit and coating unit include at least 24 staggered variable drop size printheads.This or another embodiment may provide that the ink unit includes: a first row of printer heads configured with cyan, magenta, yellow, and black; a second row of printer heads configured with light cyan, light magenta, light yellow, and light black; and a plurality of clear coating heads positioned laterally below the first and second rows of printer heads. This or another embodiment may provide that the deposition and coating process is performed at a rate greater than 30 m / h. 2 occur.

[0006] Another embodiment is directed to a system comprising: a control unit comprising at least one sensor; at least one ink unit; a coating unit; a film on a first roll; wherein the ink unit is operable to deposit an image onto the film, and wherein the coating unit is operable to deposit a tactile coating onto the image, wherein the film is moved at a rate greater than 30 m / h. 2 motion; at least one radiation source; and a second roll of the finished product after exposure to the radiation source.

[0007] Yet another embodiment is directed to a kit for creating a tactile surface comprising: a film; a curable pigmented ink; a curable unpigmented ink or varnish; and a radiation source. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a schematic diagram of an exemplary printer.

[0009] Figure 2 is a schematic diagram of an exemplary layered product as discussed herein.

[0010] Figure 3 is an exemplary flow chart of an exemplary method according to the exemplary embodiments discussed herein.

[0011] Figure 4A is a SEM image of a cross section of Example 1 deposited on a polyvinyl chloride film according to the method.

[0012] Figure 4B is a SEM image of a top view of Example 1 deposited on a polyvinyl chloride film according to the method.

[0013] Figure 5A is a SEM image of a cross section of Example 2 deposited on a polyvinyl chloride film according to the method.

[0014] Figure 5B is a SEM image of a top view of Example 2 deposited on a polyvinyl chloride film according to the method.

[0015] Figure 6A is a SEM image of a cross section of Example 3 deposited on a polyvinyl chloride film according to the method.

[0016] Figure 6B is a top view SEM image of Example 3 deposited on a polyvinyl chloride film according to the method.

[0017] Figure 7A is a SEM image of a cross section of Example 4 deposited on a polyvinyl chloride film according to the method.

[0018] Figure 7B is a SEM image of a top view of Example 4 deposited on a polyvinyl chloride film according to the method.

[0019] Figure 8A is a SEM image of a cross section of Example 5 deposited on a polyvinyl chloride film according to the method.

[0020] Figure 8B is a SEM image of a top view of Example 5 deposited on a polyvinyl chloride film according to the method.

[0021] definition As used herein, "optically transparent" or "optically translucent" may refer to a property of a material that refers to the ability of a material to allow a portion of the electromagnetic spectrum (such as visible light) to pass through it (particularly within the visible spectrum with a wavelength of about 380 nanometers to about 750 nanometers). As used herein, "optically transparent" refers to any material that does not exhibit 100% absorption of electromagnetic energy (such as visible light). An optically transparent material may allow from <1% to 100% of all light waves or other electromagnetic energy to be transmitted through it.

[0022] As used herein, a "tactile surface" or "tactile layer" refers to a surface capable of conveying information or sensation (such as a texture or feel) to a user via the sense of touch. DETAILED DESCRIPTION

[0023] This document discusses methods, systems, and kits related to producing decorative laminates. Exemplary embodiments discussed herein relate to a printer system, namely a roll-to-roll printer, capable of depositing and curing ink and tactile layers on a film without requiring further processing after curing each of the ink and tactile layers.

[0024] Printer system Exemplary embodiments provide a printer system. The printer system includes at least one control unit, at least one motor, at least one ink unit, a coating unit, a film on a first roll, a radiation source, and a second roll. Each of the first roll and the second roll is attached to a separate roller. The control unit is electronically coupled to the at least one ink unit, the coating unit, the radiation source, and the two rollers. The electronic coupling, movement, and control of these units will be discussed below with respect to operation.

[0025] In some embodiments, a printer system may include a position sensor, a motor, and a driver assembly (collectively, a control system) configured to adjust a print position of a subsequent image on a substrate having a first side and a second side, as well as at least one wireless communication device and an optical sensor. The print position may be adjusted based on detecting the wireless communication device using the position sensor and subsequently determining whether a corresponding printed image is properly aligned with the wireless communication device using the optical sensor.

[0026] With reference to the accompanying drawings, Figure 1 An exemplary embodiment of a printer system 100 is shown, and Figure 2 represents an exemplary layered product. Printer system 100 may include a motor (not shown) and / or a drive assembly (not shown), a position sensor 102, and an optical sensor 104 (e.g., a camera, optical recognition device, or video camera). In various embodiments, position sensor 102 may be configured to detect an object or image, for example, via capacitance, RFID transmission, magnetism, or by using an optical sensor or image recognition system (e.g., an RFID device). In some embodiments, printer system 100 may be configured to trigger operation of optical sensor 104 based on successful detection of an object or image. In various embodiments, operation of printing system 100 is controlled using one or a combination of one or more processors, programmable logic devices, programmable logic controllers, ASICs, integrated circuits, computers, servers, mobile devices, and software applications.

[0027] In various embodiments, the motor and drive assembly, the position sensor 102, and the optical sensor 104 can be mounted on at least one ink unit 106 of the printer system 100. The printer system 100, including the at least one ink unit 106, the motor and drive assembly (not shown), the position sensor 102, and the optical sensor 104, can be connected to a power source 108. Power requirements may vary depending on the power drawn by the various components of the system.

[0028] In many embodiments, the optical sensors 102, 104 are photoelectric sensors or image sensors, such as CCD or CMOS devices. In many embodiments, the sensors 102, 104 detect that the print position of the print index is out of tolerance, and the printer can then be stopped to make major adjustments. Otherwise, in cases where only minor adjustments are required, the printer can continue while making these minor adjustments online by automatically adjusting the print position using the motor and drive system. In some embodiments, the sensors 102, 104 also include specialized sensor software. In many embodiments, the vision system software can verify the position of the printout by evaluating early or late phase shifts in the printout.

[0029] In many embodiments, the printed image can be analyzed and adjusted on the printer. In many embodiments, the printer can operate while the image is being analyzed and adjusted. By adjusting the image while the printer is operating, production is not slowed down.

[0030] In some embodiments, printing system 100 may be configured to print on substrate 112 . Figure 1 and Figure 2 Included are a printing system 100 , a wireless communication device 110 , a substrate 112 having a first side 112A and a second side 112B, a printed image 114 , a print roller 116 , and a counter roller 128 .

[0031] In various embodiments, adjustments to the print position of print image 114 may be performed by adjusting the position of substrate 112 with additional rollers (not shown) that pull substrate 112 toward or away from print roller 116. In some embodiments, adjustments to the print position of print image 114 may be performed by one or more of braking, stopping, moving, rotating, accelerating, decelerating, speeding up, or slowing down: print roller 116, counter roller 128, or a roller that contacts the substrate after printing has occurred using the print roller (not shown), and / or a roller that contacts substrate 112 before printing has occurred using print roller 116 (also not shown).

[0032] Adhesives The laminates / constructions described herein comprise one or more adhesives. The adhesive can be a pressure-sensitive adhesive (PSA), a non-pressure-sensitive adhesive, a hot melt adhesive, or a combination thereof. In some embodiments, the adhesive is a PSA. The PSA can be any known PSA. In some embodiments, the PSA is a solvent-based adhesive, an emulsion adhesive, or a non-emulsion adhesive. In some embodiments, the PSA is an emulsion adhesive. Hot melt PSAs can also be used. The adhesive can be an acrylic or any other useful adhesive having the hardness and bonding properties required for the laminate and / or the facestock to which the adhesive is applied. In certain embodiments, the adhesive should have sufficient hardness to prevent the adhesive from being squeezed out of the laminate or article during handling.

[0033] Exemplary PSAs can be found in: (1) Encyclopedia of Polymer Science and Engineering, Vol. 13, Wiley-Interscience Publishers (New York, 1988); (2) Polymer Science and Technology, Vol. 1, Interscience Publishers (New York, 1964); (3) those described in U.S. Pat. Nos. 5,164,444, 5,183,459, and 5,264,532 (all issued to Bernard), and U.S. Pat. No. 5,385,965 (issued to Bernard et al.); and (4) combinations thereof. The PSAs can be solvent-based adhesives or can be water-based adhesives. Conventional PSAs, including acrylic-based PSAs, rubber-based PSAs, and silicone-based PSAs, can be used in the laminates / constructions described herein. In one embodiment, the pressure-sensitive adhesive comprises an acrylic emulsion adhesive.

[0034] In some embodiments, the pressure-sensitive adhesive is prepared by polymerizing an alkyl acrylate, a vinyl ester, a diester of a dicarboxylic acid, and an unsaturated acid. The alkyl acrylate typically contains from about 2 to about 12 or from about 4 to about 8 carbon atoms in the alkyl group. Examples of alkyl acrylates include, but are not limited to, diester acrylate, n-butyl acrylate, n-hexyl acrylate, 2-ethylhexyl acrylate, and isooctyl acrylate, with 2-ethylhexyl acrylate being preferred. In one embodiment, the alkyl acrylate is present in an amount of at least about 35%. In some embodiments, the alkyl acrylate is present in an amount of from about 35% to about 60% (by weight).

[0035] Vinyl esters typically have from about 2 to about 12, or from about 4 to about 8, carbon atoms in the alkyl group. Examples of vinyl esters include, but are not limited to, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl versatate, and the like, with vinyl acetate being preferred. In some embodiments, the vinyl ester is present in an amount of from about 15% to about 35%, or from about 20% to about 25% by weight.

[0036] Diesters of dicarboxylic acids include alkyl esters of unsaturated diacids, such as maleic acid or anhydride and fumaric acid. The alkyl group typically contains from about 2 to about 20, from about 4 to about 16, or from about 6 to about 12 carbon atoms. Examples of diesters of diacids include, but are not limited to, butyl fumarate, octyl fumarate; hexyl maleate, decyl maleate; di-2-ethylhexyl maleate; dibutyl fumarate; and di-2-ethylhexyl fumarate, and mixtures thereof. In some embodiments, the diester of the diacid is present in an amount of from about 20% to about 35% by weight.

[0037] The unsaturated acid typically contains from about 2 to about 12 or from about 2 to about 6 carbon atoms. Examples of unsaturated acids include, but are not limited to, acrylic acid, methacrylic acid, itaconic acid, and the like. In some embodiments, the unsaturated acid is present in an amount up to 5% or from about 1% to about 3% by weight.

[0038] In certain exemplary embodiments, the adhesive may have a coating weight between 2 grams per square meter (gsm) and 100 grams per square meter (gsm). In further embodiments, the adhesive may have a coating weight between about 20 μm and about 60 μm, as measured in thickness.

[0039] Ink unit The exemplary embodiment provides at least one ink unit 106. The at least one ink unit 106 can be a plurality of printer heads 106A. In the exemplary embodiment, there is at least one row of printer heads 106A. Within the at least one row of printer heads 106A, there is a row of printer heads configured to dispense cyan, magenta, yellow, and black colored inks. In another exemplary embodiment, the exemplary embodiment may include at least one printer head in addition to cyan, magenta, yellow, and black, configured to dispense at least one white colored ink. In an additional embodiment, there is at least a second row of printer heads 106B. In this embodiment, the first row of printer heads 106A and the second row of printer heads 106B are identical and configured to dispense light cyan, light magenta, light yellow, and light black colored inks. The second row of printer heads 106B is positioned laterally below the first row of printer heads 106A. In an exemplary embodiment (not shown), there are 24 staggered grayscale variable drop size printheads, with drop volumes ranging from 7 pl to 35 pl. The second row can include 0, 2 or 4 optional printer heads. In other embodiments, there can be as few as one grayscale printhead with one clearcoat or texture printhead. In other embodiments, there can be up to 60 printheads in total, mixed between colored, uncolored and clearcoat distribution, depending on the desired implementation. In addition, the clearcoat head can also be configured to be adjacent to the first and second rows on the left or right side of the color printhead. In other embodiments, the clearcoat head can be located above or below the color printhead or other grayscale printhead in the horizontal direction, depending on the desired implementation. The ink unit 106 is operable to deposit a curable ink 120 onto the substrate 112. In an exemplary embodiment, the curable ink 120 is cured by actinic radiation. The curing process will crosslink the ink 120. In an alternative embodiment, the ink unit can deposit a dye-based ink or varnish.

[0040] Coating unit The exemplary embodiment provides a coating unit 122. In the exemplary embodiment, coating unit 122 is at least one clear coating printer head. In the exemplary embodiment, there are multiple clear coating printer heads 122A, which are located laterally below at least one row of printer heads 106A. In an alternative embodiment where there are two rows of printer heads, the coating unit is located laterally below the first row of printer heads 106A and the second row of printer heads 106B. In another embodiment, the coating unit is located adjacent to both rows of printer heads. Coating unit 120 is operable to deposit a curable material 124 onto ink layer 114 and / or substrate 112. In the exemplary embodiment, the coating and ink are made of the same material, wherein coating 124 lacks pigments or dyes to make the coating optically clear. The curing process crosslinks coating 124. In another exemplary embodiment, the coating and ink have different chemical compositions.

[0041] In one embodiment, coating 124 is applied to a thickness ranging from about 5 μm to about 300 μm. In another embodiment, coating 124 has a thickness ranging from about 10 μm to about 200 μm. In yet another embodiment, coating 124 has a thickness ranging from about 50 μm to about 150 μm. This coating provides a tactile surface to the finished product after curing. In addition to providing a tactile surface, this layer also serves as a wear-resistant protective layer that can easily withstand wear caused by friction on mechanical parts. Additionally, the coating can provide additional useful optical properties, such as a glossy or matte appearance.

[0042] In some embodiments, coating 124 can be partially flood coated across the entire surface and partially spot coated in locally defined areas to achieve surface texture on top of the flood coating. In this regard, the coating can be deposited in a first pass to provide a protective layer, followed by adding surface topography in additional layers to provide topographic texture and tactile effects. That is, there can be one thickness of material deposited anywhere along ink layer 114 and a second thickness that will create a tactile layer. Other embodiments may refer to this entirely as a tactile layer. The thickness of the flood coated area can be between approximately 0 μm and approximately 150 μm, while the tactile layer can be between approximately 0 μm and approximately 150 μm.

[0043] In the exemplary embodiment, deposition of ink and coating 124 occurs at approximately 20 m 2 About 100m per hour 2 In another embodiment, the coating speed is between about 20m / s. 2 About 80 m per hour 2 In another embodiment, the coating speed is at least 30 m 2 per hour.

[0044] Top coat formation and application In the exemplary embodiments discussed herein, the top coating is deposited on the substrate by any suitable method. In certain embodiments, suitable methods include any suitable coating technology. Embodiments include coating deposited on the substrate by any suitable liquid deposition method. Without limitation, the example of suitable methods includes bath coating, spray coating, slot coating, spin coating, curtain coating, gravure coating, reverse gravure printing coating, reverse roll coating, knife-to-roll (i.e., gap) coating, metering (Meyer) rod coating, air knife coating or any combination thereof. Bath coating includes immersion or immersion in an aqueous solution. In one embodiment, coating is deposited by bathing in an aqueous solution. In other embodiments, coating is deposited by spraying an aqueous solution.

[0045] Radiation source Exemplary embodiments provide a radiation source 126. In exemplary embodiments, radiation source 126 is an actinic radiation source. In this or another exemplary embodiment, radiation source 126 is at least one ultraviolet laser emitting diode (UV-LED). In exemplary embodiments, radiation source 126 is not contemplated to include a mercury arc lamp. Mercury arc lamps generate too much heat for the desired implementation, and the resulting film may deform or warp as the layers are printed.

[0046] Multiple UV-LED units can be present, particularly headlamps and backlamps operable to cure inks and coatings. Each UV-LED unit can be independently controlled. When one or more UV-LED units are present, they can emit the same wavelength or different wavelengths. In the case of different wavelengths, this may be the case in a dual-cure system, where one or more photoinitiators with different activation wavelengths are used. Furthermore, by independently controlling the output of one or more UV-LED units, the inks and coatings can be configured to have either a glossy or matte appearance, depending on the specific timing or intensity of the UV light irradiating the inks and coatings.

[0047] film Suitable film and / or substrate 112 materials include, but are not limited to: synthetic papers, such as polyolefin and polystyrene types; and various plastic films or sheets, such as polyolefins, polyvinyl chloride, polyethylene terephthalate, polystyrene, polyurethane, polymethacrylate, and polycarbonate. The film material may be or include a multilayer polymer sheet. The multilayers may be coextruded or laminated together. In one embodiment, the facestock includes both coextruded and laminated multilayers. Furthermore, a white opaque film may be formed by adding a white pigment to one or more of the aforementioned synthetic resins and used as the facestock. In another embodiment, the film material may be a laminate formed by combining multiple single-layer sheets composed of the materials listed above. Examples of such laminates include combinations of cellulose fiber paper and synthetic paper, and laminates of cellulose fiber paper combined with plastic film or sheet. In another suitable embodiment, the film material includes coated and uncoated paper, metallized paper, aluminum foil, laminated paper, and paper with a polymer material extruded onto the paper surface. The film material may exhibit certain visibility characteristics, such as opacity, color, and / or brightness. The film material may include water or other liquid absorbing properties. The film material may be electrically conductive and / or include a conductive coating or region. A variety of commercially available film materials may be used, such as, for example, those available under the name TESLIN. The surface of the film and / or substrate may have any printable quality. For example, the surface appearance may be glossy, satin, or matte.

[0048] The thickness of the film material may optionally be determined by reference to application-specific standards. These standards may include the desired end use. In one embodiment, the film thickness ranges from about 10 μm to about 300 μm. In another embodiment, the film thickness ranges from about 20 μm to about 200 μm. In yet another embodiment, the surface thickness ranges from about 30 μm to about 150 μm. In yet another embodiment, the film thickness ranges from about 50 μm to about 85 μm. Optionally, the film material may be primed, corona-discharge-treated, or plasma-treated.

[0049] Optional padding layer In some embodiments, the laminates described herein may include one or more liner layers or release liners. The liner may have a first side, a second side opposite the first side, a first edge, and a second edge opposite the second edge. The liner may be any useful liner that provides the necessary support and release properties. The liner may be made of a variety of materials, including but not limited to paper or polymer film liners. In one embodiment, the paper has a caliper sufficient to die-cut or plotter-cut the resulting laminate or article. In one embodiment, the liner has lay-flat properties. In some embodiments, the liner has a machine glaze or finish. In some embodiments, the liner has a silicone support layer. The support layer provides adhesion between the release coating and the release liner. The silicone support layer also prevents the silicone release coating from soaking into the liner.

[0050] In some embodiments, the release liner comprises a liner having a release coating. The release coating of the release liner provides a releasable bond to the PSA or other adhesive. The release coating can be any composition that provides the desired releasable bond strength.

[0051] In one embodiment, the release coating is a silicone release coating. The release coating can be prepared by curing a silicone polymer in the presence of a controlled release agent. In some embodiments, the controlled release agent is a silicone polymer having the formula R3SiO 1 / 2 The monofunctional silicone unit and the tetrafunctional silicone unit SiO 4 / 2 The copolymer of wherein R is an alkyl or alkenyl group. In one embodiment, the alkyl or alkenyl group contains from about 1 to about 12 or from about 1 to about 6 carbon atoms. Non-limiting examples of alkyl and alkenyl groups include methyl, ethyl, propyl, butyl, hexyl, vinyl, propenyl, butenyl, and hexenyl.

[0052] The controlled-release agent is typically reacted with a polysiloxane. The polysiloxane can be any polysiloxane used to form a release coating. Examples of useful polysiloxanes include, but are not limited to, vinyl-terminated, hydroxy-terminated, and epoxy-terminated polysiloxanes. In one embodiment, the polysiloxane is a functional polydialkylsiloxane in which the alkyl group contains from about 1 to about 6 carbon atoms. The alkyl group independently includes, but is not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, or mixtures thereof. In one embodiment, the alkyl or alkenyl group contains from 1 to about 12 or from 1 to about 6 carbon atoms. The viscosity average molecular weight of the polysiloxane is typically greater than 300,000 centipoise (cps). In another embodiment, the viscosity average molecular weight of the polysiloxane is from about 300,000 to about 1,000,000 or more. The polysiloxane can be represented by formula (I): RO((Si(R)2O) x )—Si)—R (I) wherein each R is independently as defined above, and x is an integer.

[0053] In some embodiments, a crosslinking agent is used to prepare the release coating. In some embodiments, the crosslinking agent is a reactive polysiloxane, such as a polydialkyl or polyhydroxyalkylsiloxane. The alkyl group is the same as those described above.

[0054] The release coating can be applied in solvent, solventless, or emulsion form. The release coating can be cured by any known curing process (e.g., heat, radiation, etc.) to form a release coating. Curing can be catalyzed by silicon-soluble complexes of Group VIII transition metals (such as platinum).

[0055] Commercially available release agents include, but are not limited to, silicone release agents in non-reactive solvents. Commercially available polysiloxanes include, but are not limited to, vinyl-terminated polydimethylsiloxanes. Commercially available coupling agents include, but are not limited to, polymethylvinylsiloxanes. These materials are available from Momentive Performance Materials. Similar silicone products are available from Dow Corning Corporation under the trade name Syl-off.

[0056] It should be understood that the subject matter is not limited to any of the described release coatings or release agents, but rather encompasses virtually any release coating or release agent suitable for the intended end-use application. Furthermore, while the subject matter has been described in conjunction with a release liner, it should be understood that appropriately configured carrier films and other components may be used in place of the release liner.

[0057] roller In the exemplary embodiment, there are at least two rollers: a print roller 116 and a counter roller 128. The print roller 116 operates to transfer the film roll from a wound, unprinted roll to the counter roller 128, which is operable to wind up the finished film after printing and curing within the same apparatus. Additional details regarding the operation are discussed below.

[0058] Kit of parts Example embodiments relate to a kit. The example kit may include a film, a curable pigmented ink, a curable unpigmented ink (varnish or paint), and a printing system including a radiation source. The radiation source may include at least one UV-LED configured to be suitable for the curable ink and its specific curing wavelength.

[0059] Exemplary Laminate Constructions like Figure 2As seen in FIG, an exemplary laminate construction is shown. This exemplary construction includes a substrate 112 longitudinally beneath a curable ink 114, which longitudinally beneath a coating 118. Alternative embodiments may include a substrate laminate comprising a siliconized liner, a pressure sensitive adhesive layer, and a facestock layer with an optional top coat.

[0060] method After discussing the various components of the apparatus, exemplary methods and methods of operation will be discussed.

[0061] The exemplary method (300) may generally be Figure 3 , as seen in the flowchart of FIG. An exemplary embodiment relates to a method that includes providing a printer system 100 as described herein, the printer system 100 including a control unit, at least one ink unit 106, a coating unit 122 configured to apply a coating 124, a film 112 on a first roll, a radiation source 126, and a second roll (step 302). A two-dimensional representation is then provided to the control unit (step 304). This can be accomplished by a customer sending a digital file to the printer or the owner / operator of the printer, who then provides the file to the printer.

[0062] The two-dimensional representation can be any digital image file with a plurality of pixels. Each pixel in a monochrome image has its own brightness, ranging from 0 for black to a maximum value of 255 for white (e.g., 255 for an eight-bit pixel). In a color image, each pixel has its own brightness and color, typically represented as a triplet of red, green, and blue intensities. The control unit can then convert the two-dimensional representation of these relative intensities into a grayscale image (step 306). This image is digitized in the form of a data-bearing record. Based on this grayscale image, the control unit determines the position of at least one tactile layer to be deposited based on the relative color density of the grayscale image (step 308). In an exemplary embodiment, the greater the color density, the taller the resulting tactile layer. However, depending on the desired implementation, this can be adjusted to either an inverse texture or other texture as desired by the end user.

[0063] At this point, at least one roller unwinds at least a portion of film 112 from the first roll (step 310). When the roll is aligned with at least one ink cell 106 and the desired location of the image, an ink layer 114 representing the two-dimensional representation is deposited onto the film (step 312). Then, at least one area of ​​film 112 or ink layer 114 is coated with a thickness corresponding to the relative color density of the grayscale image (step 314). Both the coating and ink layers are cured using radiation source 126 in a layer-by-layer process or a single process, with the curing of the coating forming at least one tactile layer (step 316). The cured and printed film is then rewound onto second roll 128 upon completion (step 318). Furthermore, in the exemplary embodiment, multiple curing steps may be present, depending on the desired implementation and components used in the process. Those skilled in the art will appreciate that, depending on the layers and structure of the exemplary printer system 100, curing may need to be performed as multiple separate steps or as a final step after deposition. Furthermore, depending on the intended purpose of the structure being produced, a top coating, as described above, may be added to alter or enhance the visual appearance (e.g., the matte appearance of certain coatings).

[0064] Additional parameters that may be included may be determined by a raster image processor, which may take into account other parameters including, but not limited to, processing a depth layer resulting from the conversion and determination steps, the depth layer incorporating at least one of color profile, job length, film material, and speed of moving film. These parameters may be packaged into a spool file and sent or otherwise communicated to a digital printer.

[0065] After curing, no further processing steps are required, as all steps are completed in a single roll-to-roll printer and closed printing action. This significantly reduces processing time and processing steps. This, combined with the high operating speed, distinguishes this method from those of the prior art.

[0066] During or before printing, the motor and drive assembly of printer system 100 can be configured to adjust the position of the image to be printed. In many embodiments, the motor and drive assembly includes a motor connected to a drive via a pulley. The drive, in turn, can be connected to a PLC (not shown) and / or a computer (not shown). The computer can, in turn, be connected to position sensor 102 and / or vision sensor 104. Based on feedback from position sensor 102 and vision sensor 104, the motor and drive assembly can be configured to automatically adjust the position of the image to be printed.

[0067] For example, in various embodiments, registration can be detected by intruding printed matter into one or both of the first and second fields of view, which can comprise a register. Whether an image is acceptably placed, placed too far forward, or placed too far back can be determined by evaluating how far the image extends into one of the first or second fields of view. The threshold for intrusion into the first or second fields of view can be less than 0.1 mm, 0.3 mm, 0.5 mm, 0.7 mm, 0.9 mm, 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, or 7.5 mm. In some embodiments, the threshold for intrusion into the first or second fields of view can be less than 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, or 65%.

[0068] In some embodiments, if the threshold has crossed the first field of view and the image is too forward, the printer system 100 can automatically cause the motor to rotate to slow the movement of the substrate 112 or to pull the substrate 112 back from the direction the substrate is moving. In some embodiments, if the threshold has crossed the second threshold, the printer system 100 can automatically cause the motor to rotate to speed up the movement of the substrate through the printer system 100 or to pull the substrate 112 forward in the direction the substrate 112 is moving through the printer system 100.

[0069] For example, in some embodiments, the rotation of the motor can slow down or speed up a drive roller of the printer system 100 that is used to cause the substrate 112 to move. In some embodiments, the rotation of the motor can drive the rotation of an additional roller that causes the substrate to stretch and / or slide forward or backward relative to the drive roller of the printer system 100. In some embodiments, the rotation of the motor can drive the rotation of a printer roller to cause an adjustment in the printing position relative to the substrate 112. In various embodiments, the adjustment of the substrate 112 and / or the print roller can affect a subsequently printed image rather than causing a correction or change relative to the evaluated image.

[0070] In many embodiments, methods are described herein for analyzing and adjusting the position of an image to be printed on a substrate using a printer system. In many embodiments, a method for analyzing a printed image on a substrate includes providing a printer system including a position sensor, a motor and drive assembly, and an optical sensor; feeding a substrate integrated with at least a portion of a wireless communication device into a printer of the printer system; printing an image on a first side of the substrate, the first side opposing a second side of the substrate; detecting a previous alignment of the printed image relative to the wireless communication device on the substrate using the optical sensor or the position sensor; and adjusting the alignment of a subsequent image to be printed on the substrate by adjusting the position and / or movement speed of the substrate as it passes through the printer system based on the extent to which the printed image has moved too far forward or too far backward relative to the position of the corresponding wireless communication device, thereby adjusting the print position of the subsequent image to be printed relative to its corresponding wireless communication device, the adjustment being made using the motor and drive assembly.

[0071] Example Example 1 According to the method described in this article, Example 1 Figure 4A , showing a color layer, a fully flooded clear layer, and a single tactile layer 406 on a PVC facestock 404 in cross-section via SEM. Figure 4B is shown as a top view in FIG. In this example, the color layer, the full-flood clear layer, and the tactile layer 406 have a thickness of approximately 78 μm, while the individual tactile layers have an individual thickness of approximately 41 μm. The facestock (substrate) is approximately 80 μm.

[0072] Example 2 According to the method described in this article, Example 2 Figure 5A , showing the color layer, full flooded clear layer and dual touch layer 506 on the PVC facestock 504 in cross section via SEM. Figure 5B The top view is shown in Figure 2. The thickness of the color layer, full flood clear layer, and tactile layer is approximately 100µm, while the thickness of the dual-tactile layer ranges from 59µm to 70µm.

[0073] Example 3 According to the method described in this article, Example 3 Figure 6A , showing a combined color layer, full flood clear layer, and triple tactile layer 606 on a PVC facestock 604 in cross section via SEM. Figure 6B In this example, the color layer, full flood clear layer, and tactile layer 606 have a thickness of approximately 141 μm, while the triple tactile layer has a thickness in the range of 101 μm to 107 μm.

[0074] Example 4 According to the method described in this article, Example 4 Figure 7A , showing a combined color layer, full flooded clear layer, and quadruple tactile layer 706 on a PVC facestock 704 in cross section via SEM. Figure 7B In this example, the color layer, the full flood clear layer, and the tactile layer 706 have a thickness of about 166 μm to about 182 μm, while the quad tactile layer has a thickness in the range of about 123 μm to about 132 μm.

[0075] Example 5 According to the method described in this article, Example 5 Figure 8A , a combined color layer, full flood clear layer, and tactile layer 806 on a PVC facestock 804 containing an adhesive coating 802 is shown in cross section via SEM. Figure 8B In this example, the color layer, the full-flood clear layer, and the tactile layer 806 have a thickness of about 37 μm to about 44 μm, while the tactile layer has a thickness in the range of 18 μm to 25 μm.

[0076] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0077] Unless expressly indicated to the contrary, the articles "a" and "an," as used herein in the specification and claims, should be understood to mean "at least one." The phrase "and / or," as used herein in the specification and claims (if any), should be understood to mean "either or both" of the elements so combined, i.e., elements present in some cases combined and in other cases separated. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so combined. In addition to the elements specifically identified by the "and / or" clause, other elements may optionally be present, whether related or unrelated to those specifically identified. Thus, as a non-limiting example, when used in conjunction with open-ended language such as "comprising," a reference to "A and / or B" may, in one embodiment, refer to only A (optionally including elements other than B); in another embodiment, to only B (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); and so on. As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" as defined above. For example, when separating items in a list, "or" or "and / or" should be interpreted as being inclusive, i.e., including at least one, but also including more than one of several elements or lists of elements and optionally additional unlisted items. Only terms that clearly indicate the contrary (such as "only one of..." or "exactly one of...", or when used in a claim, "consisting of...") will refer to including exactly one element of several elements or lists of elements. In general, the term "or" as used herein should only be interpreted to indicate exclusive alternatives (i.e., "one or the other, but not both") when preceded by an exclusive term (such as "any," "one of...", "only one of...", or "exactly one of..."). When used in a claim, "consisting essentially of..." shall have its ordinary meaning as used in the art of patent law.

[0078] As used herein in the specification and claims, the phrase "at least one" referring to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of every element specifically listed in the list of elements, nor does it exclude any combination of elements in the list of elements. This definition also allows for the optional presence of other elements, whether related or unrelated to those specifically identified, in addition to the elements specifically identified in the list of elements to which the phrase "at least one" refers. Thus, as a non-limiting example, "at least one of A and B" (or equivalently, "at least one of A or B," or equivalently, "at least one of A and / or B") can, in one embodiment, mean at least one (optionally including more than one) A, without B (and optionally including elements in addition to B); in another embodiment, mean at least one (optionally including more than one) B, without A (and optionally including elements in addition to A); in yet another embodiment, mean at least one (optionally including more than one) A and at least one (optionally including more than one) B (and optionally including other elements); and so on.

[0079] An embodiment is an implementation or example of the present disclosure. References in the specification to "an embodiment," "one embodiment," "some embodiments," "a specific embodiment," or "other embodiments" mean that a particular feature, structure, or characteristic described in conjunction with the embodiment is included in at least some embodiments of the present disclosure, but not necessarily in all embodiments of the present disclosure. The various expressions "an embodiment," "one embodiment," "some embodiments," "a specific embodiment," or "other embodiments" do not necessarily refer to the same embodiment.

[0080] If the specification states that a component, feature, structure, or characteristic "may," "might," or "might" be included, that does not necessarily mean that particular component, feature, structure, or characteristic is included. If the specification or claims refer to "a" or "an" element, that does not mean there is only one of the element. If the specification or claims refer to "an additional" element, that does not preclude the presence of more than one of the additional element.

[0081] As used herein in the specification and claims (including as used in the examples), and unless expressly indicated otherwise, all numbers are to be read as if preceded by the word "about" or "approximately," even if the term does not expressly appear. The phrase "about" or "approximately" may be used when describing a magnitude and / or position to indicate that the value and / or position being described is within a reasonably expected range of values ​​and / or positions. For example, a numerical value may have a value that is + / -0.%, + / -1% of the stated value (or range of values), + / -2% of the stated value (or range of values), + / -5% of the stated value (or range of values), + / -10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all subranges subsumed therein.

[0082] In addition, any method of performing the present disclosure may occur in an order different from those described herein. Therefore, unless explicitly stated, the order of the method should not be interpreted as a limitation. It will be appreciated that performing some steps of the method in a different order can achieve similar results.

[0083] In the claims and the foregoing description, all transitional phrases (such as "comprises," "comprising," "with," "having," "containing," "involving," "having," "consisting of," etc.) are to be construed as open-ended, meaning including, but not limited to, including. Only the transitional phrases "consisting of" and "consisting essentially of" are to be considered closed or semi-closed transitional phrases, respectively, as set forth in the U.S. Patent Office Manual of Patent Examining Procedure.

[0084] In the foregoing description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations should be implied thereby, as these terms are used for descriptive purposes and are intended to be broadly interpreted, except as required by the prior art.

[0085] Moreover, the descriptions and illustrations of the various embodiments of the disclosure are examples, and the disclosure is not limited to the exact details shown or described.

Claims

1. A method comprising: A printer system is provided, comprising: control unit, at least one ink unit, a coating unit configured to apply coating, The film on the first roll, radiation sources, and Second roll; Provides two-dimensional representation; converting the two-dimensional representation into a grayscale image using the control unit; determining, with the control unit, a position of at least one tactile layer to be deposited as a result of the relative color densities of the grayscale image; unwinding at least a portion of the film from the first roll; depositing a layer of ink representing the two-dimensional representation onto the film via the at least one ink unit; coating at least one area of ​​the deposited two-dimensional representation, wherein the coating is applied to have a thickness related to the relative color density of the grayscale image; curing the coating and ink layers using the radiation source, wherein the curing of the coating forms the at least one tactile layer; and The at least a portion of the provided film is rewound onto the second roll.

2. The method of claim 1, wherein the image is digitized in the form of a data-bearing record.

3. The method of claim 1 , wherein the determining further comprises: A depth map resulting from the converting and determining steps is processed, the depth map combining at least one of color profile, job length, film material, and speed of moving the film. The method of claim 1 , wherein the ink unit is at least one inkjet printer head.

5. The method of claim 1, wherein the radiation source is an actinic radiation source.

6. The method of claim 5, wherein the source of actinic radiation is an ultraviolet laser emitting diode.

7. The method of claim 1, wherein the ink layer and the paint layer are of the same composition, wherein the paint does not contain any pigment.

8. The method of claim 7, wherein the coating layer is optically transparent or translucent.

9. The method of claim 1 , wherein the coating layer has a thickness between about 50 μm and about 150 μm.

10. The method of claim 9, wherein the coating provides a tactile surface to the finished product after curing.

11. The method of claim 1 , wherein the film thickness is greater than about 50 μm.

12. The method of claim 1, wherein no further material processing steps are required after the curing step.

13. The method of claim 1, wherein the radiation source comprises a plurality of ultraviolet laser emitting diodes, and each of the plurality of ultraviolet laser emitting diodes is individually controlled by the control unit.

14. The method of claim 1, wherein the coating unit is at least one inkjet printer head.

15. The method of claim 1, wherein the film comprises polyvinyl chloride.

16. The method of claim 1, wherein the film is free of polyvinyl chloride.

17. The method of claim 1, wherein the ink unit and the coating unit comprise at least 24 staggered variable drop size printheads.

18. The method of claim 17, wherein the ink unit comprises: a first row of printer heads having a cyan, magenta, yellow, and black configuration; a second row of printer heads having a light cyan, light magenta, light yellow, and light black configuration; as well as A plurality of clear coating heads are located laterally below the first row of printer heads and the second row of printer heads.

19. The method of claim 1, wherein the depositing and coating is carried out at a rate greater than 30 m / h. 2 occur.

20. A system comprising: a control unit comprising at least one sensor; at least one ink unit; coating unit; a film on a first roll; wherein the ink unit is operable to deposit an image onto the film, and wherein the coating unit is operable to deposit a tactile coating onto the image, wherein the film is heated at a rate greater than 30 m / h. 2 move; at least one radiation source; as well as A second roll of finished product after exposure to said radiation source.

21. A kit for creating a tactile surface, comprising: film; Curable pigmented inks; Curable unpigmented inks or varnishes; as well as Radiation source.

Images