System and method for manufacturing decorative laminates

Abstract

This specification discusses methods, systems, and kits for manufacturing decorative laminates. Exemplary embodiments discussed herein relate to printer systems, i.e., roll-to-roll printers, that can deposit and cure both ink and haptic layers onto a film without requiring further steps after the curing of each layer.

Description

[Technical Field]

[0001] (Cross-reference of related applications) This application claims the benefit of U.S. Provisional Application No. 63 / 489,244, filed on 9 March 2023, which is incorporated in its entirety by reference.

[0002] This disclosure generally relates to systems and methods for manufacturing decorative laminates. More specifically, exemplary embodiments discussed herein relate to printer systems, i.e., roll-to-roll printers, that can deposit and cure inks, dyes, or varnishes for decorative, protective, and haptic functions onto a film without requiring further steps. [Background technology]

[0003] Generally, three-dimensional printing, which works by stacking parts in layers, is an additive manufacturing process used to create three-dimensional objects. Certain types can be additive or can treat surfaces to provide relief areas of different heights. Inkjet printing, including drop-on-demand or continuous processes, sprays ink through at least one nozzle of an inkjet head to produce patterns or images on planar or flexible substrates such as paper, polymer films, metallic materials, and combinations thereof. In conventional two-dimensional printing, an inkjet printer moves its print head in one direction relative to the substrate while the inkjet nozzles are in operation, making the ink dot lines parallel on the substrate. This is generally done using planar, roll-to-roll, or hybrid ultraviolet printers to print on digital and flexible media.

[0004] The hybrid method utilizes a 2.5D printing technique, where the defined structure is constructed by stacking multiple layers to achieve surface topographic texture and haptic effects. Existing 2.5D printing today is often achieved by implementing a specific layer configuration that forms the topographic texture beneath the printed image. Digital varnishing methods, which form a clear varnish on top of the printed image to enable a tactile finish, are more commonly used, but often lack the throughput or functionality for large formats. Alternatively, 2.5D texture finishing can be achieved by either additive or subtractive processes, and single-pass processing is also possible, but achieving high throughput requires specialized, sophisticated, and expensive equipment. [Overview of the Initiative]

[0005] An exemplary embodiment relates to a method comprising the steps of: 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; using the control unit to convert the two-dimensional representation to a grayscale image; using the control unit to determine the position of at least one haptic layer to be deposited according to the 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 on the film using at least one ink unit; coating at least one area of ​​the deposited two-dimensional representation, wherein the coating is applied with a thickness relating to the relative color density of the grayscale image; curing the coating and ink layer using the radiation source, wherein the curing of the coating forms at least one haptic layer; and unwinding at least a portion of the provided film onto the second roll. This embodiment or other embodiments may provide that the image is digitized in the form of a data retention record. This or other embodiment may provide that the determining step further includes processing a depth map layer obtained from the conversion and determining step that combines at least one of a color profile, working length, film material, and speed at which the film is moved. This or other embodiment may provide that the ink unit is at least one inkjet printer head. This or other embodiment may provide that the radiation source is a chemical radiation source. This or other embodiment may provide that the chemical radiation source is an ultraviolet laser light-emitting diode. This or other embodiment may provide that the ink layer and the coating layer have the same composition and the coating does not contain any pigments. This or other embodiment may provide that the coating layer is optically transparent or translucent. This or other embodiment may provide that the thickness of the coating layer is about 50 μm to about 150 μm. This or other embodiment may provide that the coating provides a tactile surface to the finished product after curing.This embodiment or other embodiment may provide that the film thickness exceeds approximately 50 μm. This embodiment or other embodiment may provide that no further material processing steps are required after the curing step. This embodiment or other embodiment may provide that the radiation source comprises a plurality of ultraviolet laser light-emitting diodes, each of which is individually controlled by a control unit. This embodiment or other embodiment may provide that the coating unit is at least one inkjet printer head. This embodiment or other embodiment may provide that the film comprises polyvinyl chloride. This embodiment or other embodiment may provide that the film does not contain polyvinyl chloride. This embodiment or other embodiment may provide that the ink unit and coating unit comprises at least 24 staggered variable droplet size print heads. This embodiment or other embodiment may provide that the ink unit comprises a first row of printer heads having a configuration of cyan, magenta, yellow, and black; a second row of printer heads having a configuration of light cyan, light magenta, light yellow, and light black; and a plurality of clear coat heads laterally below the first and second rows of printer heads. In the above embodiment or other embodiments, the vapor deposition and coating are performed at a rate of 30 m per hour. 2 It can offer something that goes beyond that.

[0006] Another embodiment is a system comprising a control unit including at least one sensor; at least one ink unit; a coating unit; a film on a first roll; at least one radiation source; and a second roll of the finished product after exposure to the radiation source, wherein the ink unit operates to deposit an image onto the film, and the coating unit operates to deposit a haptic coating onto the image, and the film has a capacity of 30 m per hour. 2 Regarding systems that travel across boundaries.

[0007] Another embodiment relates to a kit used to produce a tactile surface, comprising a film; a curable pigment ink; a curable non-pigment ink or varnish; and a radiation source. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic diagram of an example printer. [Figure 2] This is a schematic diagram of an exemplary laminated product discussed herein. [Figure 3] This is an exemplary process flowchart of an exemplary method according to the exemplary embodiments discussed herein. [Figure 4A] This is an SEM image of a cross-section of Example 1, which was deposited on a polyvinyl chloride film using the method described. [Figure 4B] This is an SEM image of a plan view of Example 1, which was deposited on a polyvinyl chloride film using the method described. [Figure 5A] This is an SEM image of a cross-section of Example 2, which was deposited on a polyvinyl chloride film using the method described. [Figure 5B] This is an SEM image of a plan view of Example 2, which was deposited on a polyvinyl chloride film using the method described. [Figure 6A] This is an SEM image of a cross-section of Example 3, which was deposited on a polyvinyl chloride film using the method described. [Figure 6B] This is an SEM image of a plan view of Example 3, which was deposited on a polyvinyl chloride film using the method described. [Figure 7A] This is an SEM image of a cross-section of Example 4, which was deposited on a polyvinyl chloride film using the method described. [Figure 7B] This is an SEM image of a plan view of Example 4, which was deposited on a polyvinyl chloride film using the method described. [Figure 8A] This is an SEM image of a cross-section of Example 5, which was deposited on a polyvinyl chloride film using the method described. [Figure 8B] This is an SEM image of a plan view of Example 5, which was deposited on a polyvinyl chloride film using the method described. [Modes for carrying out the invention]

[0009] (definition) As used herein, “optically transparent” or “optically translucent” refers to a material property that means the material’s ability to transmit a portion of the electromagnetic spectrum (e.g., visible light), specifically the visible light spectral range having wavelengths from about 380 nanometers to about 750 nanometers. As used herein, “optically transparent” means any material that does not exhibit 100% absorption of electromagnetic energy (e.g., visible light). Optically transparent materials can transmit all light waves or other electromagnetic energy from <1% to 100%.

[0010] As used herein, "tactile surface" or "haptic layer" refers to a surface that can transmit information and sensations such as texture and feel to the user through touch.

[0011] This specification discusses methods, systems, and kits for manufacturing decorative laminates. Exemplary embodiments discussed herein relate to printer systems, i.e., roll-to-roll printers, that can deposit and cure both ink and haptic layers onto a film without requiring further steps after the curing of each layer.

[0012] Printer system All exemplary embodiments provide a printer system, which includes at least one control unit, at least one motor, at least one ink unit, a coating unit, a first roll of film, a radiation source, and a second roll. The first and second rolls are each mounted on independent rollers. The control unit is electronically coupled to at least one ink unit, the coating unit, the radiation source, and the two rollers. The electronic coupling, movement, and control of such units are discussed in relation to operation.

[0013] In some embodiments, a printer system includes a position sensor, a motor, and a driver assembly, collectively referred to as a control system, which is configured to adjust the printing position of subsequent images on a substrate having a first side and a second side, and may include at least one wireless communication device and an optical sensor. Adjustment of the printing position may be based on using the position sensor to detect the wireless communication device and subsequently using the optical sensor to determine whether the corresponding printed image is properly aligned with the wireless communication device.

[0014] Referring to the drawings, FIG. 1 shows an exemplary embodiment of a printer system 100, and FIG. 2 shows an exemplary stacked product. The printer system 100 may include a motor (not shown) and / or a driver assembly (not shown), a position sensor 102, and an optical sensor 104 (e.g., a camera, an optical recognition device, a video camera). In various embodiments, the position sensor 102 may be configured to detect an object or an image (e.g., an RFID device) using capacitance, RFID transmission, magnetism, or an optical sensor or an image recognition system. In some embodiments, the printer system 100 may be configured to trigger the operation of the optical sensor 104 based on a successful detection of an object or an image. In various embodiments, the operation of the printer system 100 is controlled using one or more combinations of one or more of a processor, a programmable logic device, a programmable logic controller, an ASIC, an integrated circuit, a computer, a server, a mobile device, and a software application.

[0015] In various embodiments, the motor and driver assembly, the position sensor 102, and the optical sensor 104 may be provided in at least one ink unit 106 of the printer system 100. The printer system 100 including at least one ink unit 106, a motor and driver assembly (not shown), a position sensor 102, and an optical sensor 104 may be coupled to a power supply 108. The power supply requirements may vary depending on the power consumed by the various components of the system.

[0016] In many embodiments, the optical sensors 102, 104 are photoelectric sensors or image sensors such as CCD or CMOS devices. In many embodiments, when the sensors 102, 104 detect that the printed position of the printed index is out of tolerance, the printer can be stopped for significant adjustment. On the contrary, when only minor adjustment is required, such fine adjustment can be performed in-line and the printer can continue by automatically adjusting the printing position using a motor and driver system. In some embodiments, the sensors 102, 104 further include dedicated sensor software. In many embodiments, the vision system software can evaluate the initial or late phase shift of the printout to confirm the position of the printout.

[0017] In many embodiments, the printed image can be analyzed and adjusted by the printer. In many embodiments, the printer can be operating while the image is being analyzed and adjusted. By adjusting the image while the printer is operating, the production speed is not slowed down.

[0018] In some embodiments, the printer system 100 can be configured to print on the substrate 112. FIGS. 1 and 2 include the printer system 100, the wireless communication device 110, the substrate 112 having a first side 112A and a second side 112B, the printed image 114, the printing roller 116, and the opposite roller 128.

[0019] In various embodiments, the adjustment of the printing position of the printed image 114 can be performed by pulling the substrate 112 towards the printing roller 116 side or by adjusting the position of the substrate 112 using an additional roller (not shown) that pushes it far away. In some embodiments, the printing position of the printed image 114 is such that after printing using the printing roller 116, the opposite roller 128, or a roller (not shown) that contacts the substrate after printing, and / or before printing using the printing roller 116 (not shown), one or more of the rollers that contact the substrate 112 are braked, stopped, moved, rotated, accelerated, decelerated, speeded up, or slowed down.

[0020] glue The laminates / constructs described herein contain one or more adhesives. The adhesives may be pressure-sensitive adhesives (PSAs), non-pressure-sensitive adhesives, hot-melt adhesives, or a combination thereof. In some embodiments, the adhesive is a PSA. The PSA may be any known PSA. In some embodiments, the PSA is a solvent-based adhesive, an emulsion-based adhesive, or a non-emulsion-based adhesive. In some embodiments, the PSA is an emulsion adhesive. Hot-melt PSAs may also be used. The adhesive may be acrylic, or other useful adhesives having the required hardness and adhesive properties for the laminate and / or the surface substrate to which the adhesive is applied. In certain embodiments, the adhesive must have sufficient hardness to prevent the adhesive from being extruded from the laminate or article during processing.

[0021] Exemplary PSAs can be identified from (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. Patents No. 5,164,444, No. 5,183,459, and No. 5,264,532, all issued by Bernard, and U.S. Patent No. 5,385,965, also issued by Bernard et al.; and (4) combinations thereof. PSAs may be solvent-based or aqueous adhesives. Conventional PSAs, including acrylic PSAs, rubber-based PSAs, and silicone-based PSAs, may be used in the laminates / constructs described herein. In one embodiment, the pressure-sensitive adhesive contains an acrylic emulsion adhesive.

[0022] In some embodiments, pressure-sensitive adhesives are produced by polymerizing alkyl acrylates, vinyl esters, diesters of dicarboxylic acids, and unsaturated acids. Alkyl acrylates typically 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, n-butyl, hexyl, 2-ethylhexyl, and isooctyl acrylates, with 2-ethylhexyl acrylate being preferred. In one embodiment, alkyl acrylates are present in an amount of at least about 35%. In some embodiments, alkyl acrylates are present in an amount of about 35% to about 60% by weight.

[0023] Typically, vinyl esters have about 2 to 12 or 4 to 8 carbon atoms in the alkyl group. Examples of vinyl esters include, but are not limited to, vinyl acetate, vinyl propionate, vinyl butyrate, and vinyl versatate, with vinyl acetate being preferred. In some embodiments, the vinyl ester is present in an amount of about 15% to 35% by weight or about 20% to 25% by weight.

[0024] Diesters of dicarboxylic acids include alkyl esters of maleic acid, or unsaturated dicarboxylic acids such as anhydrides and fumaric acid. Generally, alkyl groups contain about 2 to about 20, about 4 to about 16, or about 6 to about 12 carbon atoms. Examples of diesters of dicarboxylic acids include, but are not limited to, butyl, octyl fumarate; hexyl, decyl malate; di-2-ethylhexyl malate; di-butyl fumarate; and di-2-ethylhexyl fumarate and mixtures thereof. In some embodiments, diesters of dicarboxylic acids are present in an amount of about 20% to about 35% by weight.

[0025] Unsaturated acids generally contain about 2 to 12 carbon atoms, or about 2 to 6 carbon atoms. Examples of unsaturated acids include, but are not limited to, acrylic acid, methacrylic acid, and itaconic acid. In some embodiments, unsaturated acids are present in amounts of up to 5% by weight or about 1% to 3% by weight.

[0026] In exemplary embodiments, the adhesive application weight may be 2 to 100 grams (gsm) per square meter. In other embodiments, the adhesive application weight may be measured as about 20 μm to about 60 μm in thickness.

[0027] Ink unit An exemplary embodiment provides at least one ink unit 106, which may consist of multiple print heads 106A. In the exemplary embodiment, there is at least one row of print heads 106A. In at least one row of print heads 106A, there is a print head row composed of cyan, magenta, yellow, and black pigment inks. In other embodiments, there may be at least one print head in addition to cyan, magenta, yellow, and black, configured to eject at least one white pigment ink. In further embodiments, there is at least a second row of print heads 106B. In this embodiment, the first row of print heads 106A is identical to the second row of print heads 106B and has a composition of light cyan, light magenta, light yellow, and light black pigment inks. The second row of print heads 106B is located laterally below the first row of print heads 106A. In an exemplary embodiment (not shown), there are 24 staggered grayscale variable droplet size print heads having droplet volumes ranging from 7 to 35 pl. The second row may contain 0, 2, or 4 selective print heads. In other embodiments, there may be at least one grayscale print head with one clear coat or textured print head. In other embodiments, there may be up to 60 print heads in total, mixed with colored, uncolored, and clear coat spray types, depending on the desired configuration. The clear coat heads may also be configured to be adjacent to the first and second rows from the left or right side of the color print heads. In other embodiments, the clear coat heads may be laterally positioned above or below the color print heads or other grayscale print heads, depending on the desired configuration. The ink unit 106 operates to deposit curable ink 120 onto the substrate 112. In exemplary embodiments, the curable ink 120 is cured by chemical radiation. The curing process crosslinks the ink 120. In alternative embodiments, the ink unit may deposit dye-based ink or varnish.

[0028] Coating unit An exemplary embodiment provides a coating unit 122. In an exemplary embodiment, the coating unit 122 is at least one clear coat printer head. In an exemplary embodiment, there are multiple clear coat printer heads 122A located laterally below at least one row of printer heads 106A. Alternatively, if there are two rows of printer heads, the coating unit is located laterally below the first row 106A and the second row 106B of the printer heads. In another embodiment, the coating unit is located laterally to the two rows of printer heads. The coating unit 120 operates to deposit a curable material 124 onto the ink layer 114 and / or substrate 112. In an exemplary embodiment, the coating and the ink are made of the same material, and the coating 124 does not contain pigments or dyes to make the coating optically clear. The curing process crosslinks the coating 124. In yet another exemplary embodiment, the coating and the ink have different chemical compositions.

[0029] In one embodiment, the coating thickness of coating 124 is in the range of approximately 5 μm to approximately 300 μm. In another embodiment, the thickness of coating 124 is in the range of approximately 10 μm to approximately 200 μm. In yet another embodiment, the thickness of coating 124 is in the range of approximately 50 μm to approximately 150 μm. This coating provides a tactile surface to the finished product after curing. In addition to providing a tactile surface, this layer also provides a protective layer for wear resistance, which allows it to easily withstand abrasion and rupture due to friction of mechanical parts. Furthermore, the above coating can provide further useful optical properties, such as a glossy or matte appearance.

[0030] In some embodiments, the coating 124 can be partially flood-coated over the entire surface, or partially spot-coated over locally defined areas to achieve surface texture on top of the flood coating. In this case, the coating can be deposited in a first pass to provide a protective layer, and then a further layer of surface topography can be added to provide topographic texture and haptic effect. That is, there may be a thickness of material deposited all along the ink layer 114 and a second thickness forming a haptic layer. In another embodiment, this is called the haptic layer as a whole. The thickness of the flood-coated area may be about 0 μm to about 150 μm, and the haptic layer may be about 0 μm to about 150 μm.

[0031] In an exemplary embodiment, the deposition of the ink and coating 124 is approximately 20 m per hour. 2 ~approximately 100m 2 This is done between [times]. In another embodiment, the coating speed is approximately 20 m / hour. 2 ~about 80m 2 It is within the range. In another embodiment, the coating speed is at least 30 m / hour. 2 That is the case.

[0032] Top coat manufacturing method and application In the exemplary embodiments discussed herein, the topcoat coating is deposited onto a substrate by any suitable method. In an embodiment, the suitable method includes any suitable coating technique. The embodiment includes depositing the coating onto a substrate by 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 print coating, reverse roll coating, knife-over-roll (i.e., gap) coating, metering (Meyer) rod coating, air knife coating, or any combination thereof. Bath coating includes immersion or dipping in an aqueous solution. In one embodiment, the coating is deposited by a bath of aqueous solution. In another embodiment, the coating is deposited by spraying aqueous solution.

[0033] radiation source This exemplary embodiment provides a radiation source 126. In one exemplary embodiment, the radiation source 126 is a chemical radiation source. In this embodiment or other exemplary embodiments, the radiation source 126 is at least one ultraviolet laser light-emitting diode (UV-LED). In this exemplary embodiment, the radiation source 126 is not expected to contain a mercury arc lamp. For the desired implementation, a mercury arc lamp generates excessive heat, which may cause the resulting film to deform or warp when printing layers.

[0034] Multiple UV-LED units, specifically leading and trailing lamps, may be present to fully cure the ink and coating. Each UV-LED unit may be controlled independently. If there are more than one UV-LED unit, they may emit the same or different wavelengths. If different wavelengths are emitted, this may be a dual-curing system where one or more photoinitiators and different activation wavelengths are used. Furthermore, by independently controlling the output of one or more UV-LED units, the appearance of the ink and coating can be made glossy or matte depending on the specific duration and intensity of UV light irradiation of the ink and coating.

[0035] film Suitable film and / or substrate 112 materials include, but are not limited to, synthetic papers such as polyolefin-based and polystyrene-based; and a variety of plastic films or sheets such as polyolefin, polyvinyl chloride, polyethylene terephthalate, polystyrene, polyurethane, polymethacrylate, and polycarbonate. The film material may be or include a multilayer polymer sheet. The multilayers may be co-extruded or the multilayers may be laminated together. In one embodiment, the surface material may include both co-extruded and laminated multilayers. Alternatively, a white pigment may be added to one or more of the above-mentioned synthetic resins to form a white opaque film which can be used as a surface material. In another embodiment, the film material may be a laminate formed by bonding together a plurality of single-layer sheets composed of the materials listed above. Examples of such laminates may include a combination of cellulose fiber paper and synthetic paper, and a laminate consisting of a combination of cellulose fiber paper and a plastic film or sheet. In another preferred embodiment, the film material includes coated and uncoated paper, metallized paper, aluminum foil, laminated paper, and paper having 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 absorption or other liquid absorption properties. The film material may be conductive and / or include conductive coatings or areas. A variety of commercially available film materials can be used, for example, those marketed under the name TESLIN. The surface of the film and / or substrate can have any printable quality. For example, the surface appearance may be glossy, satin, or matte.

[0036] The thickness of the film material is arbitrarily determined by referring to application-specific criteria. Such criteria may include the desired end use. In one embodiment, the film thickness is in the range of approximately 10 μm to approximately 300 μm. In another embodiment, the film thickness is in the range of approximately 20 μm to approximately 200 μm. In yet another embodiment, the film thickness is in the range of approximately 30 μm to approximately 150 μm. In yet another embodiment, the film thickness is in the range of approximately 50 μm to approximately 85 μm. Optionally, priming, corona discharge treatment, or plasma treatment may be applied to the film material.

[0037] Any liner layer In some embodiments, the laminates described herein may include one or more liner layers or release liners. The liner may have a first surface, a second surface opposite the first surface, a first edge, and a second edge opposite the first 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, a paper caliper is sufficient for die-cutting or plotter-cutting the resulting laminate or article. In one embodiment, the liner has planar properties. In some embodiments, the liner has a machine glaze or finish. In some embodiments, the liner has a silicone holdout layer. The holdout layer provides adhesion between the release coating and the release liner. The silicone holdout layer also prevents the silicone release coating from seeping into the liner.

[0038] In some embodiments, the release liner includes a liner having a release coating. The release coating of the release liner provides a releaseable bond with PSA or other adhesives. The release coating may be of any composition that provides the desired releaseable bond strength.

[0039] In one aspect, the release coating is a silicone release coating. The release coating can be produced by curing a silicone polymer in the presence of a controlled release agent. In some aspects, the controlled release agent is a copolymer of monofunctional silicone units of the chemical formula R3SiO 1 / 2 and tetrafunctional silicone units SiO 4 / 2 , where R is an alkyl group or an alkenyl group. In one aspect, the alkyl group or alkenyl group contains from about 1 to about 12, or from about 1 to about 6 carbon atoms. Non-limiting examples of alkyl groups and alkenyl groups include methyl, ethyl, propyl, butyl, hexyl, ethenyl, propenyl, butenyl, and hexenyl groups.

[0040] The controlled release agent generally reacts with the polysiloxane. The polysiloxane can be any polysiloxane useful for forming the release coating. Examples of useful polysiloxanes include, but are not limited to, vinyl-terminated polysiloxanes, hydroxy-terminated polysiloxanes, and epoxy-terminated polysiloxanes. In one aspect, the polysiloxane is a functional polydialkylsiloxane, where the alkyl group contains from about 1 to about 6 carbon atoms. The alkyl groups independently include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, or mixtures thereof. In one aspect, the alkyl group or alkenyl group contains from 1 to about 12, or from 1 to about 6 carbon atoms. The polysiloxane generally has a viscosity average molecular weight of greater than 300,000 centipoise [cps]. In other aspects, the polysiloxane has a viscosity molecular weight of from about 300,000 to about 1,000,000 or more. The polysiloxane can be represented by the following chemical formula (I):

[0041] <Chemical Formula 1> RO((Si(R)2O) x )-Si)-R (I)

[0042] where each R is independently as defined above and x is an integer.

[0043] In some embodiments, the release coating is manufactured using a crosslinking agent. In some embodiments, the crosslinking agent is a reactive polysiloxane such as a polydialkyl or polyhydroalkylsiloxane. The alkyl group is the same as described above.

[0044] The release coating can be applied in the form of a solvent, solvent-free, or emulsion. The release coating can be cured by any known curing process, such as heat or radiation, to form the release coating. Curing can be catalyzed by a silicone-soluble composite compound of a group VIII transition metal, such as platinum.

[0045] Commercially available mold release agents include, but are not limited to, silicone mold release agents dissolved in non-reactive solvents. Commercially available polysiloxanes include, but are not limited to, vinyl-terminated polydimethylsiloxanes. Commercially available crosslinking agents include, but are not limited to, polymethylvinylsiloxanes. Such materials are commercially available from Momentive Performance Materials. Similar silicone products are commercially available from Dow Corning Corporation under the trademark name Syl-off.

[0046] The present invention is not limited to any of the release coatings or formulations mentioned above, but is understood to encompass virtually all release coatings or formulations suitable for the intended end-use application. Furthermore, although the present invention describes release liners, it will be understood that appropriately configured carrier films and other components can be used instead of release liners.

[0047] Laura In this exemplary embodiment, there are at least two rollers, namely a printing roller 116 and a roller 128 opposite to it. The printing roller 116 operates to transfer the roll of film from the wound, unprinted roll to the opposite roller 128, and after printing and curing, operates to roll the finished film within the same apparatus. Further details regarding the operating mechanism will be discussed.

[0048] Kit of components One exemplary embodiment relates to a kit. The exemplary kit may include a printer system comprising a film, a curable pigment ink, a curable non-pigment ink (varnish or coating), and a radiation source. The radiation source may include the curable ink and at least one UV-LED configured to match its specific curing wavelength.

[0049] Exemplary laminate structure As can be seen in Figure 2, an exemplary laminate structure is shown. The exemplary structure includes a substrate 112 longitudinally located below a curable ink 114 longitudinally located below a coating 118. Alternative embodiments may include a substrate laminate comprising a surface material layer having a silicone-treated liner, a pressure-sensitive adhesive layer, and optionally a topcoat layer.

[0050] method After discussing the various components of the device, we will discuss exemplary methods and methodologies for its operation.

[0051] An exemplary method 300 can generally be seen in the flowchart of Figure 3. An exemplary embodiment relates to a method (step 302) that provides a printer system 100 as described herein, 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. A two-dimensional representation is then provided to the control unit (step 304). This can be done by a customer transferring a digital file to the printer or by the printer owner / operator, after which the owner / operator supplies it to the printer.

[0052] The two-dimensional representation can be any digital image file having multiple pixels. In a monochrome image, each pixel has an intrinsic brightness ranging from 0 for black to a maximum value for white (e.g., 255 for an 8-bit pixel). In a color image, each pixel has an intrinsic brightness and color, generally represented by three intensities: red, green, and blue. The control unit can then convert such a two-dimensional representation of relative intensities into a grayscale image (step 306). This image is digitized in the form of a data retention record. From this grayscale image, the control unit determines the position of at least one haptic layer to be deposited depending on the resulting relative color density of the grayscale image (step 308). In this exemplary embodiment, the higher the color density, the higher the final haptic layer. However, depending on the desired implementation, this can be reversed or adjusted to other textures at the request of the end user.

[0053] At this point, at least one roller unwinds at least a portion of the film 112 from the first roll (step 310). Once the roll is aligned with at least one ink unit 106 and the desired position 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 ​​the film 112 or the ink layer 114 is coated to a thickness corresponding to the relative color density of the grayscale image (step 314). Both the coating layer and the ink layer are cured in a layer-by-layer or single-step process using a radiation source 126, where the curing of the coating forms at least one haptic layer (step 316). The cured and printed film is then rewound onto the second roll 128 in its finished state (step 318). In exemplary embodiments, there may be various curing steps depending on the components used in the desired implementation and process. Those skilled in the art will understand that, depending on the layer content and structure of the exemplary printer system 100, curing may need to be performed in multiple individual steps or in one final step after deposition. Furthermore, depending on the purpose of the manufactured structure, a top coat may be added as described above to change or improve the visual appearance (for example, a matte appearance due to a specific coating).

[0054] Further parameters that may be included may be processed by a raster image processor, which may consider determining other parameters, including, but not limited to, a step that processes a depth map layer obtained from a transformation and determination step that combines at least one of the color profile, working length, film material, and film movement speed. Such parameters may be included in a spool file and transmitted to a digital printer or otherwise communicated.

[0055] After curing, all processes are carried out with a single roll-to-roll printer and closed-loop printing operation, eliminating the need for further processing steps. This significantly reduces processing time and the number of processing steps. This method, combined with high operating speed, differentiates it from conventional methods.

[0056] During or before printing, the motor and driver assembly of the printer system 100 may be configured to adjust the position of the image to be printed. In many embodiments, the motor and driver assembly includes a motor connected to a driver by a pulley. The driver may also be connected to a PLC (not shown) and / or a computer (not shown). Furthermore, the computer may be connected to a position sensor 102 and / or a vision sensor 104. Based on feedback from the position sensor 102 and the vision sensor 104, the motor and driver assembly may be configured to automatically adjust the position of the image to be printed.

[0057] For example, in various embodiments, registration may be detected by the intrusion of a printed material into either or both of the first and second fields, and either or both of the two fields may constitute a register. The determination of whether the image is in an acceptable position, too far forward, or too far backward can be determined by evaluating how much the image extends into either the first or second field. The critical values ​​of intrusion may be less than 0.1, 0.3, 0.5, 0.7, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, or 7.5 mm into the first or second field. In some embodiments, the critical values ​​of intrusion may be less than 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, or 65% into the first or second field.

[0058] In some embodiments, if the critical value exceeds the first field and the image moves too far forward, the printer system 100 can automatically rotate the motor to slow down the movement speed of the substrate 112 or pull the substrate 112 backward from the direction in which the substrate is moving. In some embodiments, if the critical value exceeds the second critical value, the printer system 100 can automatically rotate the motor to accelerate the movement of the substrate through the printer system 100 or pull the substrate 112 forward in the direction in which the substrate 112 is moving through the printer system 100.

[0059] For example, in some embodiments, the rotation of the motor may slow down or increase the speed of the drive rollers of the printer system 100 used to cause the movement of the substrate 112. In some embodiments, the rotation of the motor may drive the rotation of further rollers that cause the substrate to extend and / or slide the drive rollers of the printer system 100 back and forth. In some embodiments, the rotation of the motor may drive the rotation of printer rollers to adjust the printing position relative to the substrate 112. In various embodiments, the adjustment of the substrate 112 and / or printer rollers may affect the next image to be printed, rather than causing correction or modification to the evaluated image.

[0060] In numerous embodiments, methods for analyzing and adjusting the position of an image printed on a substrate using a printer system are described herein. In numerous embodiments, the method for analyzing a printed image on a substrate includes the steps of: providing a printer system including a position sensor, a motor and driver assembly, and an optical sensor; supplying a substrate integrated with at least a portion of a wireless communication device to the printer of the printer system; printing an image on a first surface of the substrate opposite to a second surface of the substrate; detecting the previous alignment of the printed image with respect 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 speed of the substrate as it passes through the printer system based on the degree to which the printed image has moved too far forward or too far backward with respect to the position of the corresponding wireless communication device, thereby adjusting the printing position of the subsequent image to be printed with respect to the applicable wireless communication device, the adjustment being performed using the motor and driver assembly.

[0061] Examples Example 1 In Example 1 shown in Figure 4A, which is a method according to this specification, a color layer, a fully flooded clear layer, and a single haptic layer 406 are shown in cross-section via SEM on a PVC surface substrate 404. The same structure is shown in a plan view in Figure 4B. In this example, the thickness of the color layer, the fully flooded clear layer, and the haptic layer 406 is approximately 78 μm, while the thickness of each single haptic layer is approximately 41 μm. The surface substrate is approximately 80 μm thick.

[0062] Example 2 In Example 2 shown in Figure 5A, which is a method according to this specification, a color layer, a fully flooded clear layer, and a double haptic layer 506 are shown in cross-section via SEM on a PVC surface substrate 504. The same structure is shown in a plan view in Figure 5B. The thickness of the color layer, the fully flooded clear layer, and the haptic layer is approximately 100 μm, while the thickness of the double haptic layer is in the range of 59 μm to 70 μm.

[0063] Example 3 In Example 3, shown in Figure 6A, which is a method according to this specification, a bonded color layer, a fully flooded clear layer, and a triple haptic layer 606 are shown in cross-section via SEM on a PVC surface substrate 604. The same structure is shown in a plan view in Figure 6B. In this example, the thickness of the color layer, the fully flooded clear layer, and the haptic layer 606 is approximately 141 μm, while the thickness of the triple haptic layer is in the range of 101 μm to 107 μm.

[0064] Example 4 In Example 4 shown in Figure 7A, which is a method according to this specification, a bonded color layer, a fully flooded clear layer, and a quadruple haptic layer 706 are shown as a cross-section via SEM on a PVC surface substrate 704. The same structure is shown as a plan view in Figure 7B. In this example, the thickness of the color layer, the fully flooded clear layer, and the haptic layer 706 is approximately 166 μm to 182 μm, while the thickness of the quadruple haptic layer is in the range of approximately 123 μm to 132 μm.

[0065] Example 5 In Example 5 shown in Figure 8A, which is a method according to this specification, a bonded color layer, a fully flooded clear layer, and a haptic layer 806 are shown in cross-section via SEM on a PVC surface substrate 804 including an adhesive coating 802. The same structure is shown in a plan view in Figure 8B. In this example, the thickness of the color layer, the fully flooded clear layer, and the haptic layer 806 is approximately 37 μm to 44 μm, while the thickness of the haptic layer is in the range of 18 μm to 25 μm.

[0066] It should be understood that all definitions set forth and used herein take precedence over dictionary definitions, definitions in documents included as references, and / or the general meanings of the terms defined.

[0067] The articles “a” and “an” used herein and in the claims should be understood to mean “at least one” unless otherwise explicitly stated. The phrase “and / or” used herein and in the claims should be understood to mean “either one or both” of the combined elements, i.e., elements that exist together in one case and separately in the other. The various elements listed in “and / or” should be interpreted in the same manner, i.e., “one or more” of the combined elements. In addition to the elements specifically identified by the “and / or” phrase, there may be other elements that are related to or unrelated to the specifically identified elements. Thus, as a non-restrictive example, when used with open language such as “includes,” a reference to “A and / or B” may, in one aspect, refer to A only (optionally including elements other than B); in another aspect, refer to B only (optionally including elements other than A); and in yet another aspect, refer to both A and B (optionally including other elements); and so on. It should be understood that as used herein and in the claims, “or” has the same meaning as “and / or” as defined above. For example, when distinguishing items in a list, “or” or “and / or” should be interpreted as inclusive, that is, including at least one of the number of elements or the list, but possibly one or more, and optionally any additional items not listed. Only explicitly opposite terms, such as “only one” or “exactly one,” or the expression “consisting of” when used in a claim, mean that the number or the list of elements contains exactly one element. In general, the term “or” as used herein should be interpreted as indicating an exclusive alternative (i.e., “one of two, but not both”) only when preceded by an exclusive term such as “one of two,” “one of,” “only one of,” or “exactly one of.” Where the term “essentially” is used in the claims, it shall have the general meaning as used in the field of patent law.

[0068] The phrase "at least one" as used herein and in the claims should be understood to mean at least one element selected from any one or more elements in the element list when referring to a list of one or more elements, but not necessarily including at least one of every element specifically listed in the element list, nor excluding any combination of elements in the element list. Furthermore, this definition allows for the possibility that, in addition to the elements specifically identified in the element list referred to by the phrase "at least one," there may be other elements that are related to or unrelated to the specifically identified elements. Therefore, as a non-restrictive 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, in one aspect, to at least one A (and optionally including elements other than B) that does not contain any B; in another aspect, to at least one B (and optionally including elements other than A) that selectively includes at least one A that does not contain any A; and in yet another aspect, to at least one A that contains at least one, and at least one B (and optionally including other elements) that contains at least one; and so on.

[0069] One aspect is an implementation or example of the present disclosure. In this specification, when "one aspect," "one aspect," "some aspects," "one specific aspect," or "other aspects" is used, it means that certain features, structures, or characteristics described in relation to the above aspects are included in at least some aspects of the present invention, but not necessarily in all aspects. The various expressions such as "one aspect," "one aspect," "some aspects," "one specific aspect," or "other aspects" do not all necessarily refer to the same aspect.

[0070] Where this specification expressly states that a component, feature, structure, or characteristic “may be included,” “may include,” or “may be included,” such component, feature, structure, or characteristic is not necessarily included. Where “one” element is referred to in the specification or claims, it does not mean that only one such element exists. Where “further” elements are referred to in the specification or claims, it does not preclude the existence of one or more such further elements.

[0071] As used herein and in the claims, unless otherwise expressly provided, including in the examples, all numerical values ​​may be interpreted as being preceded by the words "approximately" or "approximately," even if the words "approximately" or "approximately" are not explicitly indicated. The phrase "approximately" or "approximately" may be used when describing size and / or location to indicate that the stated value and / or location is within a reasonable expected range of value and / or location. For example, a numerical value may have values ​​such as ±0% of the stated value (or range of value), ±1% of the stated value (or range of value), ±2% of the stated value (or range of value), ±5% of the stated value (or range of value), ±10% of the stated value (or range of value), etc. All numerical ranges referred to herein are intended to include all subranges contained therein.

[0072] Furthermore, all methods of performing the disclosed procedures may be performed in a different order than those described herein. Therefore, unless expressly stated otherwise, no order of the procedures should be constrained. It can be recognized that similar results can be achieved by performing some steps of the procedures in a different order.

[0073] In the claims and the above specification, all transitional phrases such as “include,” “equip,” “carry,” “have,” “contain,” “accompany,” “possess,” and “compose” are open transitional phrases, meaning “include,” but are not limited to these. Only transitional phrases such as “consist of” and “essentially constitute” are closed or semi-closed transitional phrases, as explicitly stated in the U.S. Patent and Trademark Office's Patent Examination Procedure Manual.

[0074] In the above description, certain terms are used for the sake of brevity, clarity, and understanding. Such terms are used for illustrative purposes and are intended to be interpreted broadly; therefore, any unnecessary restrictions beyond the requirements of the prior art are not permitted.

[0075] Furthermore, the descriptions and examples of various aspects of this publication are examples, and this publication is not limited to the exact details shown or described.

Claims

1. control unit, At least one ink unit, A coating unit configured to apply a coating, The film on the first roll, Radiation sources, and A step of providing a printer system including a second roll; Steps to provide a two-dimensional representation; A step of converting the two-dimensional representation into a grayscale image using the control unit; A step of using the control unit to determine the position of at least one haptic layer to be deposited according to the result of the relative color density of the grayscale image; Steps include unwinding at least a portion of the film from the first roll; A step of depositing an ink layer showing the two-dimensional representation onto the film using at least one of the ink units; A step of coating at least one region of the deposited two-dimensional representation, wherein the coating is applied with a thickness relating to the relative color density of the grayscale image; A step of curing the coating and ink layer using the radiation source, wherein the curing of the coating is a curing step of forming at least one haptic layer; and A method comprising the step of rewinding at least a portion of the provided film onto the second roll.

2. The method according to claim 1, wherein the image is digitized in the form of a data retention record.

3. The aforementioned decision-making step is: The method according to claim 1, further comprising the step of processing a depth map layer obtained from a conversion and determination step that combines at least one of a color profile, a working length, a film material, and a speed at which the film is moved.

4. The method according to claim 1, wherein the ink unit is at least one inkjet printer head.

5. The method according to claim 1, wherein the radiation source is a chemical radiation source.

6. The method according to claim 5, wherein the chemical radiation source is an ultraviolet laser light-emitting diode.

7. The method according to claim 1, wherein the ink layer and the coating layer have the same composition, and the coating does not contain any pigment.

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

9. The method according to claim 1, wherein the thickness of the coating layer is approximately 50 μm to approximately 150 μm.

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

11. The method according to claim 1, wherein the thickness of the film exceeds approximately 50 μm.

12. The method according to claim 1, wherein no further material processing step is required after the curing step.

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

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

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

16. The method according to claim 1, wherein the film does not contain polyvinyl chloride.

17. The method according to claim 1, wherein the ink unit and the coating unit include at least 24 staggered variable droplet size print heads.

18. The aforementioned ink unit is The first row of the printer head having a configuration of cyan, magenta, yellow, and black; The second row of the printer head having a configuration of light cyan, light magenta, light yellow, and light black; and The method according to claim 17, further comprising a plurality of clear coat heads positioned laterally below the first and second rows of the printer head.

19. The aforementioned vapor deposition and coating process is performed at a rate of 30 m per hour. ２ The method according to claim 1, which is performed beyond that.

20. A control unit including at least one sensor; At least one ink unit; Coating unit; Film on the first roll; At least one radiation source; and A system including a second roll of the finished product after exposure to the aforementioned radiation source, The ink unit operates to deposit an image onto the film, and the coating unit operates to deposit a haptic coating onto the image, and the film is deposited at a rate of 30 m per hour. ２ A system that moves beyond [a certain point].

21. A kit used to generate tactile surfaces, film; Curable pigment ink; Curable pigment-free ink or varnish; and A kit containing a radiation source.

Images