Systems and methods for depositing and identifying dendritic patterns

Abstract

The present disclosure relates generally to adhesive films and laminates, and methods of producing and using the same are described herein. In particular, discussed herein are adhesive films and laminates including unique dendritic identifiers and methods of producing the same.

Description

[0001] Cross-references to related applications This application claims priority and benefit to U.S. Provisional Patent Application No. 63 / 509,559, filed June 22, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to adhesive films and laminates, and describes methods for their production and use. Specifically, it includes adhesive films and laminates with unique dendritic identifiers and methods for their production. Background Technology

[0003] Laminated materials are known in the art. These products are available in various forms, including, for example, tapes, sheets, and labels. While satisfactory in many respects, there is a need for new kinds of laminated materials that offer one or more functionalities and can be produced in a cost-effective manner.

[0004] Various techniques are known for applying coatings or adhesives to face materials. Methods are also known in which the coating or adhesive is applied to a secondary material and then combined with the face material. The coating or adhesive layer can be continuous or discontinuous. Discontinuous coating or adhesive layers generally include regular or uniform patterns or structures. While such patterning can reduce adhesive usage, regular or uniform patterns or structures can have limitations, such as uncoated / uncoated edges on the label leading to poor dispensing, flapping, poor print quality, and / or poor die-cutting. Despite being satisfactory in many respects, additional strategies are still needed for depositing coatings or adhesives on face materials, where the specific properties and / or characteristics of the resulting structure can be maintained or improved.

[0005] Furthermore, there is a need for materials that convey additional information within a smaller area. This can promote sustainability by reducing the area required to adequately communicate the information. Summary of the Invention

[0006] Exemplary embodiments relate to a system comprising: a control unit; at least one motor; at least one ink unit adapted to dispense ink capable of forming a dendritic trunk pattern; at least one ink unit adapted to dispense ink capable of forming a dendritic branch pattern; a first roll driven by the at least one motor and operable to unwind a substrate; a laminator unit having at least one roll assembly; and a second roll driven by the at least one motor and adapted to wind a laminated structure. This embodiment or other exemplary embodiments provide a spraying unit operable to spray a protective varnish. This embodiment or other exemplary embodiments provide at least one radiation source operable to cure the ink into a dendritic ink pattern. This embodiment or other exemplary embodiments provide that the at least one radiation source is selected from photochemical radiation sources and infrared radiation sources. This embodiment or other exemplary embodiments provide that the at least one ink unit is at least one piezoelectric control device operating between about 1000 Hz and about 10000 Hz, positioned longitudinally between about 0.1 mm and about 3 mm above the substrate. This embodiment or other exemplary embodiments provide that the at least one ink unit is at least one coil-actuated pneumatic nozzle (solenoid actuated pneumatic nozzle) operating between about 100 Hz and about 1000 Hz. This embodiment or other exemplary embodiments provide that the at least one ink unit is at least one autoinjector with a needle inner diameter between about 0.1 mm and about 0.5 mm and disposed longitudinally above the substrate between about 0.1 mm and about 1 mm. This embodiment or other exemplary embodiments provide a substrate adapted to receive the ink, wherein the substrate is a polymer substrate and has a surface energy greater than about 30 dynes / cm. This embodiment or other exemplary embodiments provide a second layer, wherein the second layer is applied by the laminating unit, and wherein the second layer has a surface energy less than or equal to that of the substrate. This embodiment or other exemplary embodiments provide that the second layer is the same material as the substrate. This embodiment or other exemplary embodiments provide that the second layer is a different material from the substrate. This embodiment or other exemplary embodiments provide that the (dendritic) ink precursor has a viscosity between about 1000 cps and about 5000 cps. This embodiment or other exemplary embodiments provide that the ink includes at least one of pigment, conductive metal sheet, sintered metal, and molten metal.

[0007] In another embodiment, a method is provided comprising: providing a printing press system including: a control unit; at least one ink unit; a substrate on a first roller; a laminator having a pressure roller; at least one radiation source; and a second roller; unwinding at least a portion of the substrate from the first roller; generating a dendritic trunk pattern on the substrate via the at least one ink unit; generating a dendritic branch pattern on the substrate via the at least one ink unit; laminating at least one layer onto the ink using the laminator and the pressure roller; exposing the ink; curing the ink with the at least one radiation source to produce a fixed dendritic ink pattern; and winding the resulting laminate containing the patterned ink onto the second roller. This embodiment or other exemplary embodiments provide: providing a varnish to the laminate. This embodiment or other exemplary embodiments provide: laminating an optically transparent layer onto the dendritic ink pattern. This embodiment or other exemplary embodiments provide: recording the shape of the exposed section of the laminate containing the dendritic ink using a detector; and creating a data-bearing record associated with the shape. This embodiment or other exemplary embodiments provide that the ink pattern is generated by at least one piezoelectric control device, which operates between about 1000 Hz and about 10000 Hz, and is positioned longitudinally above the substrate at a distance between about 0.1 and about 3 mm. This embodiment or other exemplary embodiments provide that the piezoelectric control device is heated to about 100°C. This embodiment or other exemplary embodiments provide that the ink pattern is generated by at least one autoinjector, which has a needle inner diameter between about 0.1 and about 0.5 mm and is positioned longitudinally above the substrate at a distance between about 0.1 and about 1 mm. Attached Figure Description

[0008] Figure 1 This is a schematic example of a cross-section of a dendritic pattern on a substrate, based on this subject matter.

[0009] Figure 2 It is the area along the dendritic pattern on the substrate according to this theme. Figure 1 Example: A schematic diagram of the cross-section of line 2-2.

[0010] Figure 3 This is a planar example of an exemplary implementation of a label with a tree-like pattern, as discussed herein.

[0011] Figure 4 It is an exemplary implementation of the label. Figure 3 Schematic example of the cross section of line 4-4.

[0012] Figure 5 It is the path of alternative implementation schemes Figure 3Schematic example of the cross section of line 4-4.

[0013] Figure 6 This is a planar example of another exemplary implementation of a label with a tree-like pattern, as discussed herein.

[0014] Figure 7 It is an exemplary implementation of the label. Figure 6 Schematic example of the cross section of line 7-7.

[0015] Figure 8 This is a planar example of another exemplary embodiment of a label with a tree-like pattern as discussed herein.

[0016] Figure 9 It is an exemplary implementation of the label. Figure 8 A schematic example of the cross-section of line 9-9, and the working depositor nozzle.

[0017] Figure 10 This is a schematic diagram of an exemplary roller configuration as discussed herein.

[0018] Figure 11A This is an exemplary implementation of the roller assembly.

[0019] Figure 11B This is another exemplary implementation of the roller assembly.

[0020] Figure 11C This is yet another exemplary embodiment of the roller assembly.

[0021] Figure 11D This is yet another exemplary embodiment of the roller assembly.

[0022] Figure 12 This is a system block diagram of the exemplary system discussed in this article.

[0023] definition As used herein, the term “dendritic” refers to highly ordered, branching micropattern shapes, specifically referring to the IUPAC Recommendations “Nomenclature and terminology for dendrimers with regulardendrons and for hyperbranched polymers (IUPAC Recommendations 2017)”, which is incorporated herein by reference.

[0024] As used herein, “optically transparent” refers to a material property that allows a portion of the electromagnetic spectrum (e.g., light waves) to pass through it (specifically within the visible spectrum at wavelengths from about 380 nanometers to about 750 nanometers). As used herein, “optically transparent” refers to any material that does not have 100% impedance to electromagnetic energy (e.g., light waves). Optically transparent materials can allow 1% to 100% of all light waves or other electromagnetic energy to pass through.

[0025] As used herein, “exposed” or “exposed” means a state in which a material is not covered or otherwise obscured by a layer of material, or, if a physical covering of material is present, that material is optically transparent. In short, “exposed” means the fact that a sensor or other similar optical unit detects that the material described in this disclosure does not have an obstacle, obstruction, or barrier.

[0026] As used herein, the term "laminated material" means, in terms of construction, at least one adhesive-coated material having one or more additional layers in general. Non-limiting examples of such layers constituting a multilayer include protective layers, spacer layers, adhesive layers, layers containing optical components, metallic layers, barrier layers, release liner, tie coat layers, transparent layers, color layers, white layers, reflective layers, fluid transfer layers, strength-enhancing layers, topcoats, print receptive layers, print containing layers, marking layers, functional layers, and combinations thereof. The multilayer laminated material constructions described herein can be used in a variety of applications, including but not limited to graphic applications such as automotive and architectural wraps; reflective applications such as road and traffic signs, trains and other commercial vehicles; and labeling and packaging applications. Detailed Implementation

[0027] adhesives The laminated materials / constructions described herein comprise one or more adhesives. The adhesives (one or more) may be PSAs, non-pressure-sensitive adhesives, hot-melt adhesives, or combinations 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 may also be used. The adhesive may be an acrylic adhesive or any other useful adhesive—having the required hardness and adhesive properties for the laminated material and / or adhesive coating surface. In some embodiments, the adhesive should have sufficient hardness to prevent the adhesive from being extruded from the laminated material or article during processing.

[0028] 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. Patent Nos. 5,164,444; 5,183,459; and 5,264,532 (all belonging to Bernard) and U.S. Patent No. 5,385,965 (belonging to Bernard et al.); and (4) combinations thereof. The PSA may be a solvent-based adhesive or a water-based adhesive. Conventional PSAs—including acrylic PSAs, rubber PSAs, and silicone PSAs—can be used in the laminates / constructs described herein. In one embodiment, the pressure-sensitive adhesive comprises an acrylic emulsion adhesive.

[0029] In some embodiments, the pressure-sensitive adhesive is prepared by polymerizing alkyl acrylates, vinyl acrylates, diesters of dicarboxylic acids, and unsaturated acids. Alkyl acrylates generally contain about 2 to about 12, or about 4 to about 8, carbon atoms in the alkyl group. Examples of alkyl acrylates include, but are not limited to, ethyl acrylate, n-butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, and isooctyl acrylate, preferably 2-ethylhexyl acrylate. 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 about 35% to about 60% by weight.

[0030] Vinyl esters generally have about 2 to about 12, or 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 tert-carbonate, etc., with vinyl acetate being preferred. In some embodiments, the vinyl ester is present in an amount of about 15% to about 35% by weight, or about 20% to about 25% by weight.

[0031] Diesters of dicarboxylic acids include alkyl esters of unsaturated diacids, such as maleic acid or anhydrides and fumaric acid. The alkyl group generally comprises about 2 to about 20, or about 4 to about 16, or about 6 to about 12 carbon atoms. Examples of diesters of diacids include, but are not limited to, butyl octyl fumarate; hexyl decylmaleate; 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 from about 20% by weight to about 35% by weight.

[0032] The unsaturated acid generally comprises about 2 to about 12, or about 2 to about 6 carbon atoms. Examples of unsaturated acids include, but are not limited to, acrylic acid, methacrylic acid, itaconic acid, etc. In some embodiments, the unsaturated acid is present in an amount of up to 5% by weight, or about 1% by weight to about 3% by weight.

[0033] In an exemplary embodiment, the coating weight of the adhesive can be between 2 gsm and 100 gsm.

[0034] Peeling liner In some embodiments, the laminated material described herein may include one or more release liner pads. 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 providing the necessary support and release properties. The liner may be constructed or made of a variety of materials, including but not limited to paper or polymer film liner pads. In one embodiment, the paper thickness (caliper) is sufficient to die-cut the resulting laminated material or article. For example, for PET liner pads, the liner thickness may range from about 18 mm to 23 mm. In one embodiment, the liner has a flattening property. In some embodiments, the liner has a glaze or finish. In some embodiments, the liner has a silicone hold-out layer. The hold-out layer provides adhesion between the release coating and the release liner. The silicone hold-out layer also prevents the silicone release coating from penetrating into the liner.

[0035] In some embodiments, the release liner includes a liner having a release coating. The release coating of the release liner provides a releasable bond with PSA or other adhesives. The release coating can be any composition that provides the desired releasable bond strength.

[0036] In one embodiment, the release coating is a silicone release coating. This release coating can be prepared by curing a silicone polymer in the presence of a control release agent. In some embodiments, the control release agent is of the formula R3SiO. 1 / 2 Monofunctional silicone units and tetrafunctional silicone units SiO 4 / 2 The copolymer, wherein R is an alkyl or alkenyl group. In one embodiment, the alkyl or alkenyl group comprises about 1 to about 12 carbon atoms, or 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.

[0037] The release agent is generally reacted with a polysiloxane. The polysiloxane can be any polysiloxane that can be used to form a release coating. Examples of useful polysiloxanes include, but are not limited to, vinyl-terminated, hydroxyl-terminated, and epoxy-terminated polysiloxanes. In one embodiment, the polysiloxane is a functional polydialkylsiloxane, wherein the alkyl group comprises 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 comprises 1 to about 12 carbon atoms, or 1 to about 6 carbon atoms. Polysiloxanes generally have a viscosity-average molecular weight greater than 300,000 centipoise (cps). In another embodiment, the polysiloxane has a viscosity-average molecular weight of about 300,000 to about 1,000,000 or higher. A polysiloxane can be represented by formula (I): RO((Si(R)2O) x )—Si) —R (I) Each R is defined independently as above, and x is an integer.

[0038] In some embodiments, the release coating is prepared using a crosslinking agent. In some embodiments, the crosslinking agent is a reactive polysiloxane, such as a polydialkyl or polyhydroalkyl siloxane. The alkyl group is the same as those described above.

[0039] Release coatings can be applied in solvent-based, solvent-free, or emulsion form. Release coatings can be cured by any known curing process (e.g., heat, radiation, etc.). Curing can be catalyzed by silicone-soluble complexes of Group VIII transition metals (such as platinum).

[0040] Commercially available stripping agents include, but are not limited to, GE SS-4335, a silicone stripping agent in a non-reactive solvent. Commercially available polysiloxanes include, but are not limited to, GE SS-4331, a vinyl-terminated polydimethylsiloxane. Commercially available linkers include, but are not limited to, GE SS-4300C, a polymethylvinylsiloxane. Exemplary catalysts include, but are not limited to, SS-8010 catalyst in toluene. These materials are commercially available from the Silicone Products Division of General Electric Company. Similar silicone products are available from Dow Corning Corporation under the trade name Syl-off.

[0041] It will be understood that this subject matter is not limited to any of the release coatings or release agents mentioned, but includes virtually any release coating or release agent suitable for the intended end-use application. Furthermore, although this subject matter has been described in conjunction with release liner, it will be understood that appropriately configured carrier films and other components may be used in place of release liner.

[0042] Facial materials Suitable face materials include, but are not limited to, synthetic papers such as polyolefin and polystyrene types; various plastic films or sheets such as polyolefins, polyvinyl chloride, polyethylene terephthalate, polystyrene, polyurethane, polymethacrylate, and polycarbonate. Other examples of suitable face materials include paper and paperboard. The face material can be or may include multilayer polymer sheets. The multilayers can be co-extruded, or the multilayers can be laminated together. In one embodiment, the face material includes both co-extruded and laminated multilayers. Furthermore, a white opaque film can be formed and used as a face material by adding a white pigment to one or more of the aforementioned synthetic resins. In one embodiment, a foam film is used as a face material. The foam film can be formed by conventional foaming operations. In another embodiment, the face material can be a laminate formed by combining multiple single-layer sheets composed of the materials listed above. Examples of such laminates may include combinations of cellulose fiber paper and synthetic paper, and laminates combining cellulose fiber paper and plastic films or sheets. In another suitable embodiment, the face material includes coated and uncoated paper, metallized paper, aluminum foil, laminated paper, and paper with a polymer material extruded onto its surface. In some forms, the face material may be coated with a liquid-absorbing material. The chosen face material may be porous or semi-porous. The face material may exhibit certain visual characteristics, such as opacity, color, and / or brightness. The face material may include water or other liquid-absorbing properties. The face material may be conductive and / or include conductive coatings or areas. A variety of commercially available face materials may be used, such as those available, for example, under the name TESLIN.

[0043] The thickness of the facial material is optionally determined with reference to application-specific standards. Such standards may include the desired end use. In one embodiment, the sheet thickness ranges from about 10 μm to about 300 μm. In another embodiment, the sheet thickness ranges from about 20 μm to about 200 μm. In yet another embodiment, the sheet thickness ranges from about 30 μm to about 150 μm. Optionally, a primer treatment, corona discharge treatment, or plasma treatment may be applied to the facial material to increase the bonding strength between the facial material and the dried topcoat composition to be formed on the surface of the facial material.

[0044] In some embodiments described herein, the facial material exhibits one or more functions or functional properties. For example, the facial material may be selected to enable or facilitate indications such as visual indications such as: liquid, gas release (e.g., guiding or allowing the flow of air or gas across the thickness of the facial material), water or liquid retention within the facial material, electrical discharge or conductivity of the facial material, delivery of chemical agents across the thickness of the facial material, sound propagation across the thickness of the facial material, and / or combinations of these functions or properties.

[0045] Optional layer The adhesive-coated face material and / or laminate material described herein may include one or more additional layers or components. Non-limiting examples of such layers include protective layers, adhesive coatings, clear layers, color layers, white layers, reflective layers, fluid transfer layers, strength promoting layers, top coatings, print accepting layers, print inclusion layers, marking layers, functional layers, etc.

[0046] Properties of laminated materials The laminates described herein may possess specific and useful properties or functionalities. In some embodiments, the techniques described herein enable the formation of laminates in which the transfer, propagation, and / or migration of liquids, gases, sound waves, electric currents, and / or other agents or elements across or through the laminate in the Z-direction can occur and be controlled. The term "Z-direction" as used herein refers to the direction across the thickness dimension of the laminate or a portion thereof; therefore, the terms "X-direction" and / or "Y-direction" refer to directions perpendicular to the Z-direction and correspond to the width and length dimensions of the laminate.

[0047] Non-limiting representative examples of laminates with certain functionalities provided by this topic include liquid indicator laminates, gas-releasing laminates, water-absorbing laminates, sound-channeling laminates, conductive laminates, and laminates having combinations of these functionalities and / or laminates having one or more of these functionalities in combination with other functionalities.

[0048] For example, liquid-indicating laminates can be produced such that the rate of color change is correlated with the choice of face material and the properties of the porous adhesive. Discontinuous structures (such as those created by pores in adhesive layers or regions(one or more)) can allow, for example, liquid to be conducted from one side of the adhesive to the other through the discontinuous adhesive, and produce permanent color change when dyes or other agents in the functional coatings of the laminate are dissolved.

[0049] In one embodiment, a liquid-indicating laminate is provided. The rate or extent of the color change is correlated with surface material properties such as, for example, the absorption of the liquid and the porosity of the patterned adhesive, in the Z direction. The indication is generally irreversible and can be measured by color change or by simple visual comparison.

[0050] Discoloration of a facet or area of ​​a laminate can be measured and quantified by optical changes, such as through CIE Lab or by simple visual comparison. Discoloration can be permanent or non-permanent. It can also be temporary, returning to its initial state after a period of time. In some implementations, this time period is predetermined.

[0051] This phenomenon of transport in the adhesive through discontinuities in the Z-direction can be implemented in other labeling applications, particularly pressure-sensitive adhesive labels, such as those intended for purposes such as: degassing the substrate—e.g., by guiding gas in the Z-direction; marking a wet substrate—e.g., by guiding liquid in the Z-direction; discharging electricity in the Z-direction; transporting chemicals from one layer to another in the Z-direction; and / or conducting sound in the Z-direction. This phenomenon enables the passage, transfer, and / or migration of a medium or agent from one side of the adhesive region of the laminate to the other. Although it is mentioned that the medium penetration or transport is in the Z-direction, it will be understood that the subject matter is not limited to this and may also include penetration / transport in the X-direction and / or Y-direction.

[0052] In some embodiments, the laminated material described herein includes a secondary adhesive layer or region. The secondary adhesive is generally used to bond the laminated material to a target substrate. The secondary adhesive may comprise one or more adhesives, which may be the same as or different from the adhesives of the patterned or porous adhesive. This document provides a description of representative examples of secondary adhesives. In such an adhesive configuration, a primary adhesive may be applied to a facestock, a secondary adhesive may be applied to a release liner, and the applied adhesives and the release liner may be laminated together such that the primary and secondary adhesives are in direct contact with each other. Optionally, or additionally, both the primary and secondary adhesives may be applied to either the facestock or the release liner and then laminated together. Consideration may be given to a layering of the primary and secondary adhesives relative to the facestock and release liner as facestock, primary adhesive, secondary adhesive, and release liner; or facestock, secondary adhesive, primary adhesive, and release liner. Regardless of the order of the primary and secondary adhesives, at least one of the primary and secondary adhesives is considered to be patterned, while the other adhesive may be continuous.

[0053] In some embodiments, a variety of different arrangements of layers and components can be employed. In some embodiments using patterned adhesives (e.g., layers of discontinuous adhesives), the layer is disposed between the functional face material and the padding or functional layer. In liquid-indicating laminates, the patterned adhesive may be disposed between the functional face material and a functional agent layer or region sensitive to liquid penetration of the laminate. Furthermore, in liquid-indicating laminates, the functional agent layer or region may be disposed between the patterned adhesive and the carrier layer.

[0054] The use of the techniques and features described herein enables the production of adhesive-coated laminates and / or adhesive-coated face materials with fluid / air control properties, controlled removability, and / or unique thermal and / or electrical conductivity. Furthermore, the use of these techniques and features enables material (e.g., adhesive) reduction, thereby achieving cost savings. However, it will be understood that this subject matter includes the adhesive-coated face materials and laminates described herein formed by methods other than those described herein.

[0055] Topcoat preparation and application In the exemplary embodiments discussed herein, the top coating is deposited on the substrate by any suitable method. Suitable methods in these embodiments include any suitable coating techniques. Embodiments include depositing coating on the substrate using any suitable liquid deposition method. Without limitation, examples of suitable methods include bath coating, spray coating, slot coating, spin coating, curtain coating, gravure coating, reverse gravure printcoating, reverse roll coating, squeegee (i.e., gap) coating, metering bar coating, air knife coating, or any combination thereof. Bath coating includes immersion or soaking in an aqueous solution. In one embodiment, the coating is deposited by immersion in an aqueous solution. In other embodiments, the coating is deposited by spraying an aqueous solution.

[0056] ink In an exemplary embodiment, an ink layer or a printed layer is present. This ink layer can be an ink layer or a graphic layer, and the printed layer can be a monochrome or multicolor printed layer—depending on the information to be printed and / or the intended graphic design. These include variable printed data such as serial numbers, barcodes, trademarks, etc. The thickness of the printed layer is generally in the range of about 0.5 to about 10 micrometers, and in one embodiment is about 1 to about 5 micrometers, and in another embodiment is about 3 micrometers. The inks used in the printed layer include commercially available water-based inks, solvent-based inks, silicone-based inks, or radiation-curable inks. Examples of these inks include Sun Sheen (a product of Sun Chemical, labeled as an alcohol-dilutable polyamide ink), Suntex MP (a product of Sun Chemical, labeled as a solvent-based ink for surface printing on acrylic coated substrates, PVDC coated substrates, and polyolefin films), X-Cel (a product of Water Ink Technologies, labeled as a water-based film ink for printing film substrates), Uvilith AR-109 Rubine Red (a product of Daw Ink, labeled as a UV ink), and CLA91598F (a product of Sun Chemical, labeled as a multibond black solvent-based ink), Lexmark laser printer inks or powder inks, and Xerox laser printer inks or powder inks.

[0057] In one embodiment, the printing layer comprises polyester / vinyl ink, polyamide ink, acrylic ink, and / or polyester ink. The printing layer can be formed in a conventional manner, such as by gravure printing, flexographic printing, UV flexographic printing, or similar printing on one or more desired areas of a film using an ink composition comprising a resin, a suitable pigment or dye, and one or more suitable volatile solvents. After the ink composition is applied, the volatile solvent components (one or more) of the ink composition evaporate, leaving only the non-volatile ink components to form the printing layer.

[0058] If desired, techniques known to those skilled in the art can be used to improve the adhesion of ink to the polymer film surface. For example, as described above, an ink primer or other ink adhesion promoter can be applied to the polymer film layer or other underlying layer before ink is applied. Alternatively, the surface of the polymer film can be corona-treated or flame-treated to improve the adhesion of ink to the polymer film layer.

[0059] Useful ink base coatings can be transparent or opaque, and can be solvent-based or water-based. In one embodiment, the base coating is radiation-curable (e.g., UV). The ink base coating may include a lacquer and a thinner. The lacquer may consist of one or more polyolefins, polyamides, polyesters, polyester copolymers, polyurethanes, polysulfones, polyvinylidene chloride, styrene-maleic anhydride copolymers, styrene-acrylonitrile copolymers, ionomers based on sodium or zinc salts of ethylene methacrylate, polymethyl methacrylate, acrylic polymers and copolymers, polycarbonates, polyacrylonitrile, ethylene-vinyl acetate copolymers, and mixtures of two or more thereof. Examples of usable thinners include: alcohols, such as ethanol, isopropanol, and butanol; esters, such as ethyl acetate, propyl acetate, and butyl acetate; aromatic hydrocarbons, such as toluene and xylene; ketones, such as acetone and methyl ethyl ketone; aliphatic hydrocarbons, such as heptane; and mixtures thereof. The ratio of lacquer to thinner depends on the viscosity required for applying the ink base coating, and this viscosity selection is within the scope of the art. The ink base coating may have a thickness of about 1 to about 4 micrometers or about 1.5 to about 3 micrometers.

[0060] In an exemplary embodiment, in addition to variable printed data such as serial numbers, barcodes, and trademarks, a unique identifier structure is also present. This unique identifier structure may include fillers such as pigments, dyes, near-infrared (NIR) dyes, metallic flakes, conductive metallic precursors, and reflective materials. In an exemplary embodiment, the ink may be conductive. One or more tracers may also be included in the exemplary embodiment. A tracer is a unique chemical compound with a specific detection agent. Tracers have various uses; security ink is one of them, where the tracer can act as a form of anti-counterfeiting. These anti-counterfeiting inks can be used on security labels, or even on the product packaging itself, as they are very suitable for use on a variety of substrates. Tracer characteristics that make a tracer suitable for anti-counterfeiting measures include: being uniquely encoded like a fingerprint; being visible or invisible to the naked eye; being detectable with special equipment; being able to be field-tested with low-cost detectors; and being permanent and irremovable once integrated into the article. The printed unique identifier may have a viscosity between approximately 1000 cps and approximately 100000 cps. In an exemplary embodiment, the surface tension of the unique identifier structure is less than 50 dynes / cm. In other embodiments, the surface tension of the unique identifier structure is less than 40 dynes / cm. In still other embodiments, the surface tension of the unique identifier structure is less than 30 dynes / cm.

[0061] The unique identifier structure is deposited in a specific dendritic shape. Specifically, the unique identifier structure can be deposited in two distinct pieces—a trunk pattern and branch patterns. The trunk pattern is relatively large, with various parts of the branch patterns emerging from the trunk. In some embodiments, the trunk pattern may include an embedded radio frequency identification (RFID) chip. The branch patterns allow various branches to emerge from the trunk in semi-random or pseudo-random patterns, which will be discussed in more detail below regarding the laminated structure.

[0062] Additionally, in an exemplary embodiment, the ink can be a fluid capable of responding to changes in polarity. This allows for the selective adjustment of the pattern using magnetic or other external forces to optimally manipulate a given desired shape. Optionally or additionally, additives present in the ink can be used to control the wetting properties of the ink.

[0063] Various nozzles can be used to apply ink and print unique identifiers. In one embodiment, at least one piezoelectric nozzle or electro-pneumatic nozzle is used to apply the printed unique identifier. An exemplary piezoelectric nozzle can operate between about 1000 Hz and about 10000 Hz, while an exemplary electro-pneumatic nozzle can operate between about 100 Hz and about 1000 Hz. Each of the exemplary piezoelectric nozzles or electro-pneumatic nozzles can be positioned about 10 μm to about 3 mm above the substrate and heated to about 100°C.

[0064] In another embodiment, at least one syringe injector is used to apply the printed unique identifier. The syringe injector may be positioned approximately 0.1 mm to approximately 1 mm above the substrate. The needle of the syringe injector may have an inner diameter between approximately 0.1 mm and approximately 0.5 mm. The syringe may also be heated to approximately 100°C. All embodiments discussed can produce a pattern diameter between approximately 0.002 mm and approximately 0.5 mm.

[0065] In yet another embodiment, at least one stencil screen print or rotary screen is used to apply the unique identifier for printing. In yet another embodiment, electrostatic printing is used to apply the unique identifier for printing. These embodiments will be discussed later in terms of operation. Any or all of these ink deposition techniques can produce a three-dimensional shape, and this three-dimensional shape may have specific properties, which will be discussed and identified in the methods below.

[0066] radiation source Exemplary embodiments provide a radiation source. In an exemplary embodiment, the radiation source is a photochemical radiation source. In this or other exemplary embodiments, the radiation source is at least one ultraviolet laser light-emitting diode (UV-LED). In exemplary embodiments, the radiation source does not include a mercury lamp. For desired implementations, mercury lamps generate excessive heat, and the resulting film is prone to melting or deformation during the printing of (various) layers.

[0067] There can be multiple UV-LED units, specifically leading and trailing lamps, which are operable to cure inks and coatings. Each UV-LED unit can be controlled independently. When one or more UV-LED units are present, they can emit the same wavelength or different wavelengths. In the case of emitting different wavelengths, this can be in a dual-curing system, where one or more photoinitiators with different activation wavelengths are used.

[0068] In other embodiments, the radiation source provides heat and can be a heat source operable to dry and optionally sinter and / or melt ink particles together.

[0069] Exemplary laminate (material) structure One such lamination structure conceived according to this disclosure is a label-on-label method. This structure is shown in... Figure 1 and Figure 2 Above. See details for reference. Figure 1 The image shows a top plan view of this exemplary configuration. Label 100 is shown, with various components on its top surface 102, including various identification markers 104A, 104B, and 104C. In this embodiment, the locations of text identification information 104A, QR code 104B, and dendritic pattern 104C are present. The dendritic pattern 104C is optically isolated by an outer boundary 104D.

[0070] For details, please refer to the following: Figure 2 It shows Figure 1 A cross-sectional view of the laminated structure along line 2-2. In this view, there is a substrate layer 202, followed by a label material 204, and then a secondary label 406—where a dendritic pattern 104C is deposited. With the dendritic pattern deposited in this manner, three-dimensional touch and sensation are possible. Additional security features may be incorporated, and may include, but are not limited to, at least one tracer, metal sheet, or other detectable marker.

[0071] In another exemplary laminated structure, a pattern may be applied beneath a portion of the laminated structure. This structure is shown in... Figure 3 , Figure 4 and Figure 5 Above. See details for reference. Figure 3The image shows a top plan view of this exemplary configuration. Label 300 is shown, with various components visible from its top surface 302, including various identification markers 304A, 304B, and 304C. In this embodiment, the locations of text identification information 304A, QR code 304B, and dendritic pattern 304C are present. The dendritic pattern 304C is optically isolated by an outer boundary 304D.

[0072] For details, please refer to the following: Figure 4 It shows Figure 3 A cross-sectional view of the laminated structure along line 4-4 is shown. In this view, a substrate layer 402, an adhesive substrate layer 402, a coating or adhesive layer 406, a dendritic pattern 404C, an optically clear layer 408, and a mask layer 410A with an optically clear window 410B, each mask layer 410A and optically clear window 410B including a top surface 402. Additional security features may be incorporated and may include, but are not limited to, at least one tracer, metal sheet, or other detectable marker. The final size and area covered by the optically clear window 1010B depends on the desired implementation.

[0073] Now for specific reference Figure 5 It shows Figure 3 A cross-sectional view taken along line 4-4 of an alternative form of the structure. In this embodiment, the structure is similar to... Figure 3 and Figure 4 The structure shows a substrate layer 502, an adhesive substrate layer 504, a dendritic pattern 506—in which the dendritic pattern is laminated and planarized within the structure—an optically transparent layer 508, and a mask layer 510A with an optically transparent window 510B, each mask layer 510A and optically transparent window 510B including a top surface 502. Due to the planarization of the dendritic pattern layer, air trapping within the layer can be kept to a minimum. Additional security features can be incorporated and may include, but are not limited to, at least one tracer, metal sheet, or other detectable marker. The final size and area covered by the optically transparent window 610B depends on the desired implementation.

[0074] In another exemplary laminated structure, a pattern can be digitally applied to the top of the laminated structure using near-infrared (NIR) ink. Such an exemplary structure is shown below. Figure 6 , Figure 7 , Figure 8 and Figure 9 For details, please refer to [the relevant source]. Figure 6 The diagram shows a top view of this exemplary construction. Figure 6The viewpoint is taken from what is seen in the visible spectrum. Label 600 is displayed, with various components visible from its top surface 602, including various identification markers 604A, 604B, and 604C. In this embodiment, the locations of text identification information 604A, QR code 604B, and NIR embedded dendritic pattern 604C are present.

[0075] For details, please refer to the following: Figure 7 It shows Figure 6 This exemplary configuration is shown as a top-down plan view, taken from the perspective of what is seen under NIR light. Label 600 is displayed, with various components visible from its top surface 602, including various identification markers 604A, 604B, and 604C. In this embodiment, the locations of text identification information 604A, QR code 604B, and NIR-embedded dendritic pattern 604C are present, which currently allows viewing the property of the paint or adhesive component 604C optically isolated by its outer boundary 604D, currently identifiable by NIR light.

[0076] For details, please refer to the following: Figure 8 It shows Figure 6 A cross-sectional view taken along line 8-8 of an alternative structural configuration. In this embodiment, a substrate layer 802, an NIR reflective substrate layer 804, a dendritic ink layer 806, and a label film substrate 808 are shown. Additional security features may be incorporated and may include, but are not limited to, at least one tracer, metal sheet, or other detectable marker. The coating or adhesive component 806 may include pigments that are opaque to both visible light and NIR. This contrasts with the label film substrate 808, which may have NIR dyes that are opaque in the visible light spectrum but transparent in the NIR spectrum. Therefore, in this configuration, the substrate becomes transparent, while all identification features remain transparent. This concept is... Figure 9 The example is further illustrated because Figure 9 It is along Figure 7 The cross-section is taken from line 9-9. It can be seen that... Figure 9 The display is taken from the perspective of what is seen under NIR light. In this case, regarding the substrate layer 902, the NIR reflective substrate layer 904, the paint or adhesive layer 906, and the label film substrate 908, only the pigment-colored paint or adhesive 906 absorbs NIR light. In an exemplary embodiment, the pigment is based on carbon black.

[0077] In all the embodiments discussed above, a contrasting color is required between the adhesive layer and the main label color. For example, if the coating or adhesive layer is beneath the optically clear film, the adhesive layer can be black and the main label can be white. In other embodiments, when using NIR, the NIR reflective background can be white or metallic when contrasting with the colored adhesive.

[0078] Alternatively, an implementation may be a hybrid of the above disclosures. That is, at least two patterns may be on top of each other. The first pattern may be visible, while the second pattern may be readable by an infrared reader. Alternatively, the patterns may be readable by an antenna of a radio frequency identification (RFID) device.

[0079] For details, please refer to the following: Figure 10 This illustrates an exemplary roll-to-roll manufacturing unit 1000. Specifically, an unwinding roller 1002 is present, operable to unwind a substrate 1004. The substrate 1004 is positioned above an ink dispensing unit 1006, where ink 1008 is deposited in a dendritic pattern and the substrate 1004 continues to travel along a path in the direction of arrow "A". Although a single ink unit is shown in the exemplary embodiment, it will be understood that multiple ink units may be included in desired embodiments. In the exemplary embodiment, the substrate 1004 is made of a polymer film. Specific polymer films may include, but are not limited to, polyethylene terephthalate (PET), biaxially oriented polypropylene (BOPP), polyethylene (PE), and polyurethane (PU). In the exemplary embodiment, the surface energy is greater than about 30 dynes / cm. In another embodiment, the surface energy is greater than about 40 dynes / cm. The ink 1008 is deposited in a dendritic pattern as consistent small droplets and may be deposited in a single pass or in multiple passes. Specifically, a trunk portion may be applied, followed by branch portions. In an exemplary embodiment, according to the desired implementation, the substrate 1004 will have sufficient temperature resistance and sufficient ink adhesion.

[0080] As the substrate 1004 continues along the path, it is positioned between the pressing roll 1010 and the web roll 1012. The web roll 1012 moves in the direction of arrow "B" and is driven by its own unwinding roll 1012A and second roll 1012B, pressing the substrate 1004 and ink 1008 together with the web roll 1012. Specifically, wet ink droplets can be flattened between these two different film surfaces, and dendritic patterns can also be formed or elongated at this time. In an exemplary embodiment, the web roll 1012 can be the same material as the substrate 1004. In an alternative embodiment, the web roll 1012 is a different material from the substrate 1004. In an alternative embodiment, the web roll 1012 can be a lower-energy film, such as a silicone pad. For example, if a polar ink is to be used, cleaning the silicone and reusing the silicone roll is easier. In yet another alternative embodiment, the roll 1004 may be made of hard silicone having peroxide-cured nitrile or other similar materials.

[0081] After contact between the laminator roller 1010 and the roll material 1012, the resulting leveling material 1014 is formed and continues to travel in the direction of arrow "A" and is moved to a first radiation source 1016. The first radiation source 1016 may be a UV curing lamp or an IR oven and is operable to cure or dry ink 1008. Thereafter, the leveling material 1014 may be placed below an spraying unit 1018, which may apply a coating or varnish 1020 over the leveling material 1014 using a depositor unit. The leveling material 1014 then continues to travel in the direction of arrow "A" and is moved to a second radiation source 1022. The second radiation source 1022 may be a UV curing lamp or an IR oven and is operable to cure or dry ink varnish 1020. Although in the exemplary embodiment the leveling material 1014 moves along a path, in other embodiments, either or both of the first radiation source 1016 or the second radiation source 1022 may be movable. The resulting material 1024 can then be wound onto the winding station roller 1026.

[0082] As in Figures 11A-11D As seen, various alternative implementations of ink patterns in different simplified exemplary roll-to-roll manufacturing units are shown. See also: Figure 11A It shows the relationship with Figure 10 A similar roll-to-roll manufacturing unit. In this embodiment, the unwinding roller 1100A moves the substrate 1102A in the direction of arrow "C"—while the pressing web 1104A moves in the direction of arrow "D," where it is then wound by the winding roller 1106A. Due to the contact of the pressing web 1104A, a 90-degree lamination occurs, resulting in a slight elongation of the dendrites 1108A, as shown below.

[0083] Now for reference Figure 11B This illustrates an alternative embodiment of the ink pattern implementation in a different simplified exemplary roll-to-roll manufacturing unit. In this embodiment, the unwinding roller 1100B moves the substrate 1102B in the direction of arrow "E"—while the pressure belt 1104B moves in the same direction of arrow "E," where it is then wound by the winding roller 1106B. Due to the contact of the pressure belt 1104B, there is a lamination angle greater than 90 degrees, which results in slightly elongated dendrites 1108B, as shown below.

[0084] Now for reference Figure 11CThis illustrates another alternative embodiment of the ink pattern implementation in a different simplified exemplary roll-to-roll manufacturing unit. In this embodiment, the unwinding roller 1100C moves the substrate 1102C in the direction of arrow "F"—while the silicone film jacketed PDMS rubber roller 1104C applies pressure to the ink, which is then wound by the winding roller 1106C. Due to the contact of the pressure belt 1104C, there is a 90-degree lamination, which results in slightly elongated dendrites 1108C, as shown below.

[0085] Now for reference Figure 11D This illustrates yet another alternative embodiment of the ink pattern implementation in a different simplified exemplary roll-to-roll manufacturing unit. In this embodiment, the unwinding roller 1100D moves the substrate 1102D in the direction of arrow "G"—while applying pressure to the ink using the padding tape 1104D, which is then wound by the winding roller 1106D in the direction of arrow "H," while the pressing padding tape moves in the directions of arrows "J" and "K." Due to the contact of the pressure tape 1104D, a 180-degree lamination occurs, resulting in dendrites 1108D of similar size to those before lamination, as shown on the left. In yet another embodiment (not shown), two substrates may be deposited with dendritic structures and then pressed together to form a dendritic pattern.

[0086] In some exemplary embodiments, the shape of the dendrites can be primed. In these embodiments, a standard shape can be placed at a specific location on the substrate. Within this standard shape, there may be locations for RFID or other optical sensing functional units. This standard shape can form the trunk of the dendritic shape. This shape can be achieved by applying force to the substrate simultaneously with or after ink deposition. This force can be, but is not limited to, electrostatic effects, magnetism, and recesses and / or stamps within the roller body. In the case of electrostatic effects, polytetrafluoroethylene or other similar coatings can be used, which allow the ink to migrate almost freely and then, when passing through nip or other similar rollers, allow the ink to flow to the path of least resistance according to rheological properties. For it to be magnetically influenced, the ink will need to be filled with particles in some way. Furthermore, the ink can simply be rheologically controlled and will allow the first pattern deposition, which can remain consistent or relatively consistent throughout the process of forming the final shape.

[0087] Additionally, after the trunk shape is formed, further ink is deposited to form branches, completing the dendritic pattern. The additional ink can also be shape-controlled during deposition, including by applying force to the substrate simultaneously with or after ink deposition. Optionally, the ink can be deposited by a depositor into a specific pattern to produce the branching pattern. Furthermore, the branching and trunk patterns can be altered through lamination, as described above regarding... Figure 11A , Figure 11B , Figure 11C andFigure 11D The discussion.

[0088] Another method of applying ink is to use a rotating screen 1200. In this embodiment, there is a squeegee 1202 and a flat screen 1204 with a template having narrow perforations 1204A. In this embodiment, the substrate 1206 moves in the direction of arrow "L" while the squeegee 1202 moves in the same direction. This allows a pattern to be placed on the substrate based on a stencil type.

[0089] In other embodiments, the pattern can be computationally generated. In this embodiment, all or part of the pattern can be defined via an array of electrodes electronically controlled beneath the surface. Each electrode within the array can be actuated between an operating and non-operating state, and is operated by a controller operatively connected thereto. The electrodes then manipulate an electroresponsive fluid to form the pattern via forces generated by an electric or magnetic field.

[0090] Alternatively, the pattern can be printed directly onto a curved substrate, which acts as the roller. In this embodiment, ink can be deposited and the second roller will have a tape (web) similar to those in other disclosed embodiments. The tape will contact the droplet and then be lifted, leaving the pattern on the bottle.

[0091] Alternatively, patterned structures can be created, with additional blank structures temporarily laminated onto them, and the patterned structures placed adjacent to the blank structures. This allows two different patterns to exist and be mirror images of each other.

[0092] method After discussing the various components of the equipment, exemplary systems, methods, and methodologies for operation will be discussed.

[0093] An exemplary embodiment provides a method comprising: providing a printing press system including: a control unit; at least one ink unit; a substrate on a first roll; a laminator having a pressure roll; at least one radiation source; and a second roll. At least a portion of the substrate on the first roll is unwound and a dendritic trunk pattern is formed on the substrate via ink. Then, a dendritic branch pattern of ink is formed on the substrate. Next, at least one layer is laminated onto the ink using at least one pressure roll, and then the ink is exposed and cured using at least one radiation source to produce a fixed dendritic ink pattern. The resulting laminate is then wound onto the second roll. In some embodiments, a varnish or topcoat is applied to the laminate after the dendritic ink pattern is deposited. Additionally, an optically transparent layer may be laminated onto the dendritic ink pattern. In an exemplary embodiment, the ink pattern is formed by deposition using at least one piezoelectric control device operating between about 1000 Hz and about 10000 Hz, positioned longitudinally between about 0.1 and about 3 mm above the substrate. In some embodiments, the piezoelectric control device may be heated to about 100°C, and deposition is performed by at least one autoinjector having an inner needle diameter between about 0.1 and about 0.5 mm and being positioned longitudinally above the substrate between about 0.1 and about 1 mm.

[0094] Feature deposition, detection and extraction Another implementation relates to a system that images and stores the features of a patterned coating on a laminated material. Specifically, an exemplary system is schematically shown in… Figure 13The exemplary system 1300 may include: at least one detector 1302; at least one processor 1304; and at least one memory unit 1306; wherein the at least one detector 1302 is operable to image dendritic ink on a laminate, the at least one processor 1304 is operable to identify features of the dendritic ink, and the at least one memory unit 1306 is operable to store the image and its identified features. The system 1300 may further include: at least one coating unit 1308 operable to deposit dendritic ink; at least one lamination unit 1310 operable to combine one or more layers of a laminate; and at least one ink unit 1312, wherein the ink unit is also operable to deposit near-infrared (NIR) ink onto the top of the laminate. Additionally, other embodiments may include a depositor unit 1314 operable to deposit dendritic ink. Although different components are connected in the exemplary figures, this is to be considered exemplary and merely an example of how things are physically connected. In other embodiments (not shown), the connection may be electrically coupled or linked wirelessly to communicate information and / or data with other components, and such examples are not to be considered limiting. Deposition can be performed by a variety of methods, including but not limited to droplet distribution, gravure coating, screen printing, or rotary screen application.

[0095] The exemplary system 1300 operates by passing a patterned coating laminate material through at least one detector 1302, which performs measurements, and this can be in the form of scale-invariant feature transform (SIFT) descriptors. These SIFT descriptors are then processed by a memory unit and stored in a feature database. SIFT descriptors can be, for example, vectors of 128 floating-point values, allowing feature tracking and subsequent feature matching via descriptors that are robust to varying observation conditions and independent of feature illumination or scale. In short, image content is simplified to a set of points used to detect similar patterns in other images. Therefore, feature vector points are used to extract serialization information and create digital recognition of the laminate material with dendritic patterns deposited on it.

[0096] Exemplary embodiments also relate to a method comprising: processing a provided image of a dendritic pattern on a laminate; analyzing the provided image against a database of recorded dendritic patterns; matching the provided image with entries in the database; and providing a response corresponding to the entry. This embodiment, or other exemplary embodiments, may involve the dendritic pattern being longitudinally located below at least one layer of the laminate when the laminate is multilayered. Optionally, the dendritic pattern is positioned on top of the laminate. In exemplary embodiments, the dendritic pattern is discontinuous and semi-random, and the pattern of the coating covers an area of ​​at least one layer of the laminate with a coverage greater than about 2% and less than about 75%.

[0097] All definitions used herein should be understood to take precedence over dictionary definitions, definitions referenced and incorporated into a document, and / or the general meaning of the terms in the definition.

[0098] Unless explicitly stated otherwise, the articles “a” and “an” used in the specification and claims shall be understood to mean “at least one / amount”. The phrase “and / or” (if any) used herein in the specification and claims shall be understood to mean “any or all” of the elements so connected, i.e., elements that exist jointly in some cases and independently in others. Multiple elements listed with “and / or” shall be interpreted in the same manner, i.e., “one or more” of the elements so connected. Elements other than those specifically identified by the “and / or” clause may optionally be present, whether related to or unrelated to those specifically identified elements. Thus, as a non-limiting example, the reference to “A and / or B” when used in conjunction with open-ended expressions such as “comprising” may refer to: in one embodiment, only A (optionally including elements other than B); in another embodiment, only B (optionally including elements other than A); in yet another embodiment, both A and B (optionally including other elements); and so on. As used in the specification and claims, “or” shall be understood to have the same meaning as “and / or” as defined above. For example, when items are separated in a list, “or” or “and / or” should be interpreted as inclusive, that is, including at least one of multiple elements or listed elements, and more than one, as well as optional additional unlisted items. Only terms that explicitly indicate the opposite, such as “only one of…” or “just one of…”, or “consisting of…” when used in a claim, will refer to one of multiple elements or listed elements. In general, the term “or” as used herein should be interpreted only as indicating an exclusive option (i.e., “one or the other but not all”) only when accompanied by exclusive terms such as “any one,” “one of,” “only one of,” or “just one of.” When used in a claim, “consisting primarily of…” should have its common meaning as adopted in the field of patent law.

[0099] As used in the specification and claims, when referring to an enumeration of one or more elements, the phrase "at least one" should be understood to mean at least one element selected from any one or more elements in the enumeration, but does not necessarily include every element specifically listed in the enumeration and does not exclude any combination of elements in the enumeration. This definition also allows for the optional presence of elements other than those specifically identified in the enumeration referred to by the phrase "at least one," whether related to or unrelated to those specifically identified elements. 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") may refer to at least one (optionally including more than one) A in one embodiment, and B is absent (and optionally includes elements other than B); in another embodiment, it refers to at least one (optionally including more than one) B, and A is absent (and optionally includes elements other than A); in yet another embodiment, it refers to at least one (optionally including more than one) A and at least one (optionally including more than one) B (and optionally includes other elements); and so on.

[0100] The embodiments are implementations or examples of this disclosure. References to "implementation," "one embodiment," "some embodiments," "a specific embodiment," or "other embodiments," etc., in the specification mean that a specific feature, structure, or characteristic described in connection with that embodiment is included in at least some, but not necessarily all, embodiments of the invention. Various expressions, such as "implementation," "one embodiment," "some embodiments," "a specific embodiment," or "other embodiments," or similar expressions, do not necessarily refer to the same embodiment.

[0101] If this specification states that a component / part, feature, structure, or characteristic "may," "may," or "can" be included, that specific component / part, feature, structure, or characteristic is not required to be included. If the specification or claims refer to an element as "a" or "an," this does not mean that there is only one such element. If the specification or claims refer to an element as "an additional / other," this does not exclude more than one such additional / other element.

[0102] As used herein in the specification and claims, including in the examples, and unless otherwise expressly stated, all numerical values ​​are to be interpreted as predicated with the words “about” or “approximately”, even if the term is not explicitly stated. The phrase “about” or “approximately” may be used when describing magnitude and / or location to indicate that the described numerical value and / or location is within a reasonably expected range of values ​​and / or locations. For example, a numerical value may have values ​​of + / -0.0%, + / -1%, + / -2%, + / -5%, + / -10%, etc. Any numerical range described herein is intended to include all subranges included therein.

[0103] Furthermore, any method of this disclosure may be performed in a different order than that described herein. Therefore, unless explicitly stated otherwise, the order of methods should not be construed as a limitation. It will be appreciated that performing some of the steps of the methods in a different order can achieve similar results.

[0104] In the claims and the foregoing description, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “involving,” “holding,” “constituting,” etc., should be understood as open-ended, meaning including but not limited to. Only the transitional phrases “constituting of,” and “mainly composed of,” should be closed or semi-closed transitional phrases, respectively, as described in the United States Patent Office Manual of Patent Examining Procedures.

[0105] In the preceding description, certain terms were used for the sake of brevity, clarity, and understanding. No unnecessary limitations beyond the requirements of the prior art are implied, as these terms are used for descriptive purposes and are intended to be interpreted broadly.

[0106] Furthermore, the descriptions and examples of various embodiments of this disclosure are examples, and this disclosure is not limited to the exact details shown or described.

Claims

1. A system comprising: a control unit; at least one motor; at least one ink unit configured to dispense an ink capable of forming a dendritic trunk pattern; at least one ink unit configured to dispense an ink capable of forming a dendritic branch pattern; a first roller driven by the at least one motor operable to unwind a substrate; a laminator unit having at least one roller assembly; and a second roller driven by the at least one motor and configured to wind a laminated structure.

2. The system of claim 1, further comprising: a jetting unit operable to jet a protective varnish.

3. The system of claim 1, further comprising: at least one radiation source operable to cure the ink into a dendritic ink pattern.

4. The system of claim 3, the at least one radiation source is selected from the group consisting of: actinic radiation source and infrared radiation source.

5. The system of claim 1, wherein the at least one ink unit is at least one piezoelectric control device operating between about 1000 Hz and about 10000 Hz disposed between about 0.1 mm to about 3 mm longitudinally above the substrate.

6. The system of claim 1, wherein the at least one ink unit is at least one coil actuated pneumatic nozzle operating between about 100 Hz and about 1000 Hz.

7. The system of claim 1, wherein the at least one ink unit is at least one auto-injector having an inner needle diameter between about 0.1 mm and about 0.5 mm and disposed between about 0.1 mm to about 1 mm longitudinally above the substrate.

8. The system of claim 1, further comprising: a substrate configured to receive the ink, wherein the substrate is a polymeric substrate and has a surface energy greater than about 30 dynes / cm.

9. The system of claim 8, further comprising: a second layer, wherein the second layer is applied by the laminator unit, and wherein the second layer has a surface energy less than or equal to the surface energy of the substrate.

10. The system of claim 9, wherein the second layer is the same material as the substrate.

11. The system of claim 9, wherein the second layer is a different material than the substrate.

12. The system of claim 1, wherein the ink has a viscosity between about 1000 cps and about 5000 cps.

13. The system of claim 1, wherein the ink comprises: at least one of a pigment, a conductive metal flake, a sintered metal, and a fused metal.

14. A method comprising: providing a printer system comprising: a control unit, at least one ink unit, a substrate on a first roller, a laminator having a press roller, at least one radiation source, and a second roller; unwinding at least a portion of the substrate from a first roller; creating a dendritic trunk pattern on the substrate via ink by the at least one ink unit; ​ creating a dendritic branch pattern on the substrate via ink through the at least one ink unit; laminating at least one layer onto the ink with the laminator and the press roller; exposing the ink; curing the ink with the at least one radiation source creating a fixed dendritic ink pattern; and winding the resulting laminated material containing the patterned ink onto the second roller.

15. The method of claim 14, further comprising: providing a varnish to the laminated material.

16. The method of claim 14, wherein exposing further comprises: laminating an optically transparent layer over the dendritic ink pattern.

17. The method of claim 14, further comprising: recording a shape of an exposed segment of the laminated material containing dendritic ink with a detector; and creating a data bearing record relating to the shape.

18. The method of claim 14, wherein the creating of the ink pattern is through at least one piezoelectric control device operating between about 1000 Hz and about 10000 Hz disposed between about 0.1 to about 3 mm longitudinally above the substrate.

19. The method of claim 18, further comprising: heating the piezoelectric control device to about 100°C.

20. The method of claim 14, wherein the creating of the ink pattern is through at least one auto-injector having an inner needle diameter between about 0.1 and about 0.5 mm and disposed between about 0.1 to about 1 mm longitudinally above the substrate. ​

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