CA2089060A1

CA2089060A1 - Intelligent foil transfer

Info

Publication number: CA2089060A1
Application number: CA002089060A
Authority: CA
Inventors: Robert H. Johnstone
Original assignee: Moore Business Forms Inc
Current assignee: Moore Business Forms Inc
Priority date: 1993-02-08
Filing date: 1993-02-08
Publication date: 1994-08-09
Also published as: AU3289593A; AU661889B2; NZ245863A

Abstract

ABSTRACT OF THE DISCLOSURE
Colored or metallic foil is applied to toner printed onto a substrate, such as paper, in a high speed, versatile manner, using a rotating impression cylinder, and a rotating transfer cylinder having circumferentially spaced heated raised portions. The toner, which preferably includes a thermoplastic component, is applied to the paper with any suitable printer, such as a computer controlled MIDAX (ion deposition) print engine. The toner may be heated by an infra red heater just before the paper is fed to the nip between the impression and transfer cylinders. A foil strip having an adhesive layer facing outwardly, a foil layer, and a release coating on a backing, is also fed to the nip, and the backing taken up downstream of the nip. Heat and pressure applied at the nip transfer the adhesive and foil from the foil strip to the tacky toner, producing the desired foil printed paper, which then may be further processed.

Description

.F~ 8-'~3 MON 12:35 ID:MOORE RES CTR G I NY TEL NO:716-773-2016 ~194 P~3/29~

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C~S. ~OIL ~RAN8F~

~here ~re many circum~anc~ ln whlch lt 1 de~lr~d to UEIe eolorod or m~a~alllc ~oll~, lncluding -:
~old, ~llver, r~d, and holo~raphic fo~ 1 mhter~
on ~iub8tr~tes~ lhclu~ln~ ln the manuf~ctu~o o pl~.~tic componen~, uncl in ~dverti~lng whnre prlntin~ 1~ de~ired to ~e partlculArly decorAtlve.
Tl~ pr~ont approachea to producirlg BUbl~trAtOI!I wlth ~olored or metallic fo~l p~intin~ ther~on i~ both : :
oxtr~mely ~l~w and extr~mely l~mlt~d ln ~pplicatlon. Ev~n with th~ mo~t ~fectlve ~ : :
Utillz~tlon o~ conve~tlon~l o~ulpment, productlon --:
~p~ on the order of only abou~ 20 Sont p~ minu~e ~r~ po~ le. Evon more slgnlflc~ntly, howev~r, tho lmage~ sre typlcAlly ~lxod ~n nature ~ueh a~ r~l~ed plato), or thero i~ only A very llmlted p~ttcrn v~rl~tlon, ~uch as prod~ce~le rom a num~erin~
m~clllno o~ tho llke. :~
A~cordlng to the prosont lnvention, it 1 po~lbl~ for the ir~t tlm~ to proc~uce adv~rtl~lng -:
printlng or the like wlt~ ~olored or metall~ c foll~
~t hl$~h ~peec~ ~ e . g . ~bout 100 eet per mlnt~te or ~ ~, S7r~ter), and with ~lmo~t lhflnlte v~riety. Thl~ la a~mpllshed, accordln~ to the lnvonti~, by utllizln~ ~ computer ~ontrolled prlnt ongln~ whlch prlnt~ tonex partlcle~ on-llno, ln ~ny d~lDired, var~ able, p~tt~rn (worda, imAge0~ and/o~ oth~r indicia), ~he toner typic~lly havlng ~ thermopl~tl c component, ~rhe l~ventlon al~o 1~ Accompl~h~d by ut~ lizln~ a. cOmpl~thly rotary approach to e~oct the ~:

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tr~n-~-t of ~h- colored or met~lllc foll ~rom ~ ~oll ntrlp to th~ ~ub~trst~, rather th~n tho oonv~ntlonAl primarily reclproc~l (and th~ lnherently ~peod llmit~d) ~proache~, ~u~h a~ protrlded ln 'c~o :Eoll-~lt~mplng aqulpment p~oduc~d by Kluge of Co~m~ny.
The foll utl~lzed ln the product~on of printed ~ubo~rnt~ uccoldin~ to the lnv~ntlon 1 conventlo~nl ~oil h~vin~ c~lng or a car~l~r ~llm, wlth ~ relea~ coating thereon, wlth th~ ~oll ov~r th~ rele~e c~atlng, A~d ~ ~ran~fer adho~v~ on th~ oxterlor aurf~C~ o~ the foil. The adh~slve 18 brou~ht lnto contact wlth the toner on thc ~ub4tr~te, and by th~ appllcation of he~t and pro~4ure to the foll strlp the ~dh~ e ~nd ~oll ar~
tr~n~f~rred to the tGno~, hA~lng a great~r af~lnlty ~or tho toner th~n the releA~e eo~ting on th-backlns. The receptabillty o the toner to th~
Adhe~lvo and foil ~y ~e enhanc~d by he~tl~ the t-on~r, 81~ with ~n 1nfrared hellter, ~u~t prior to the application of he~t ~nd pre~ re to ~h~ foll ~trip ~nd ~ubJtrAte~ If desired th1 ~ ~ff~Ct can be enhancad ~ur~c~er ~y h~atln~ an lmpreo~ion cyllnder over W~ich the ~ubatrate continuougly trAvelo durih proce~slng.
Tr~n~fer ~8 eS~ect~d utlllzlng ~ tran~er oyl~nder and An impre~eicn cylinder . On~ of the oyllnders 1~ of ~ r~ metal materlal; whlle ~ho other iB ~rd rubber or the l~Xe (e.g. hea~ed oillcone, xnown per ~e for thi~ purpo~e). The tran~er cyllnder has ~ plur~lity ~
clrcumfe~entlally spAced heat~d r~l~ed portlonn, ~nd the tr~n~fer cylinder 1~ eontlnuou~ly rotated wlth the ~p~ced ral~ed heated portlons periodicAlly ~~ FEB-~9-'93 ~ON 12:37 ID:MOORF RES CTR G I NY TEL NO:716-773-2~16 ~194 P05/2g --2~8~

comln~ in~co contact w~ th the ~oi 1 ~'crlp ~nd Applyln ;r prol~ure ~t ~o nip between th~ t~An~r cyllnde~
and tho lmpr~s~n c~llnder. Utilizing thl~ rot~ry p~l~clple, 3peed~ of op~ra~lon in exco~ o~ about lOO ~aet por mlnute (e.g. at lea~t about 120 fo~t por mlnute, and ~ven ~o hlgh a~ about 300 ~oet per m~n~to) ~r~ po~ible.
~ ho print ~n~lne, ~uch A~ a MIDAX print ongln~, for apply~ n~ the ton~r pattern acoordlng to th~
lnventlon 1~ comput~r ~ontrolled an~ c~n provide a vlrtually inflnlt~ varl~ty o~ varlAbl~ patt~rn~
lncludi~g word~ age~, snd/or ~irt~ally ~ny typ~
o~ indicla, on t~e ~u~3t~at~. Th~ ~ubatra~e 1 typicAlly pape~, and ia typlCAlly ln wab form, although it ~l~o ~y be ln ~h~t ~orm.
Aocording to Ono ~p~o~ of the pre~ent :
lnvantion, a m~thod o~ produclng a prlnt~d ~ub~tr~te havih~ colored or metalll~ foil over at laa~t a pArt of the prlnting lr pro-tlded, oomprl~lnçl the ~:
following ~top~ ) P~lntlng a defflred p~ttern on A OUbJtrato uolng ~onor h~vin~ ~I thorm~7p~ c compon~nt. (b) Contin~ou~l~ eedlnq tho aub~trate ~o and pa~t a tr~n~~r locatlon. ~c) Feedln~ A oll st~p havlnsl an outer ~dho~lve l~ye~, a colored or metallic foll l~ycr, and ~ ~ele~e ~oat~d earrier, to 'cho trsn~fer locatlon, w~th ~he ~dheoive fsclng the ~ub~tr~te. ~4) ~eat~ng the toner pattern on tho ~ub~r~te ~u~t prio~ to th~ tr~n~f~r locatlon to ma~c the thermoplA~tlc compon~nt o th~ tone~ :
~c~ptlve to the oll and ~dhe~lvo 1AYO~O o th~
foll rtrlp. And, ~e) applylng hoa~ to the ~oll 0t~p, ~nd prq~ure to th~ roll ~trlp ~nd oub~tratc, ~he tr~ f~r loc~tlon oo A~ to 'cr~n~r tho ~ ~:

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adh~ d and color~d o~ met~ oll onto th~
~o~t~d ~oner patt~rn.
8top ( A) 14 ~r~ferably practl~ed by v~ri~bly ~rint~ng th~ p~t~ern utlll~ln~ a comp~ter controll~d prlnt en~ln~ (such a~ a MIPAX print~t), and ~ep ~b) -- w~ether th~ ~ub~trat~ 1~ in w~b or ~eet ~orm --1~ prActlc~d at ~ ~peed o~ at lea~ about 100 foet pcr m~n~ta.
Accordlng to anothor ~pe~t o~ the ps~ent ~inY~ntlon, A simllar mothod i~ pro~ided comprl~l~g the followlng Bt~p~ ) V~rlably prl~tlng ~ ~ :
deslred pat~ern on a ~ubst~t~ u31ng tonar. (b) ¢ontinuo~ly foodin~ tho oub~trate to and pa~t ~
tr~n~fer loeatlon. ~c) Feed1ng a foll ~trlp hsvlng an outor adhealve lay~r, ~ ~olored or metA111~ foll l~y-r, and ~ rele~ o~ted cArrl~r~ to tho ~ran~er locatlon, wlth the ~h~lve ~acln~ th~ sub~rato.
And, ~d) applylng heat to ~he foil ~rlp, ~nd pros~ure to t~e oll ~tr~p ~nd ~ub~trat~, at the t~a~sf~r lo~atlon o ~6 to tr~n~fer the adhesive and colored or met~lllc ~ol1 onto t~e toner p~tt~rn, by pa~ain~ ~h~ ~ub~tr~te ~nd foil ~trip betwoen an :~
~pre~sion cyllnder snd ~ trA~~ cyllnde~, the BU~tr~to en~a~ing th~ lmpre-3l0n cyll~de~. The t~sn~fer cylinder pref~r~bly h~ a plurallty o~
Ci~CUmfer~ntlAlly ~p~c~d ho~tod r~ln~d ~ur~ce porkion~ w~ich engage the ~oll 8trlp, an~ ~ep ~d) i~ furth~r prsctlced by contln~ou~ly rot~tln~ the ~ :
tr~4f~r cyllnder ~o thst ~he rsl~ed hented ~urfAco po~lon~ p~riodic~lly como lnto contac~ With th~
foll strlp ~nd exert ~ pr~ure on ~h~ Jtrlp ~nd ~b~rate wh~n t~ey do come into coPtact, FFB-~8-'93 MON 12:38 ID:MOORE RES CT~ G I NY TEL NO:7i6-773-c016 ~19~ P07/29- ~

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t~an~er~ the eolor~d or metqll~c ~oll to th-p~lnt~ p~tt~n.
T~o lnYention also comprl~es ~n appar~tu~ ~or produclnsr the printed 0ub~trAte ~o~ordlng to t:~
lnvention. The AppAr~tu~ eompr~ Mean~ for vArl~bly prlntlng ~ prede~ermlned pattern, wlth tonor, on tho ~ub~trRt~. An lmpr~lon cyllnder mount~d for ~atlon about a flr3t axl~. A ~An~r cyll~dor moun~ed o~ rot~lon Abou~ a ~ocond ~xl~
p~r~ l to the ~ir~t axlD, and to duflna A hip ~ctw~en the lmpre~ion cyllnd~r and the impro~lon cylinder. MeAn~ for contlnuo~ly fe~dln~ t~e .:
~ub~trate to and pAot the nl p b~tween tho ~r~n~fer cyllnder ~nd impre~lon cyllnder, wlth the to~r pattern on the ~u~rRte f~ln~ ~he tr~n~er cyllndor. Mean~ ~o~ ~eedlng a foil 3trip havln~ an ~dhesi~e, A fo~l, and ~ eklnsl, to the n~p wlth tho ~dh~lve And feil facln~ th~ lmpre~ion cyllnd~r. :
M~-n~ ~or tak~ n~ up t~e ~oll strlp b~c~ln~ a~ter ~ -pA~ 0~; ~he ~oil IJtr~,p t~to~ gh th~ nip. And, me~na or he~tlng the tr~n~~r cyltnder to ~clllt4te tran~fer of th~ adhs~v~ hnd oll from ~ :
th~ ~oll rtrlp to ~he toner pAttOrn on ~he sub~tra~e.
Typlcall~ the ton~r ha~ a thermopla~tlc :
componant, ~nd the ~pp~r~tus further comprl~e~ me~na or prehe~tino the toner on the ~ubstrate ~ust pr~o~
to lt anterlng th~ nlp to r~nder the thermopla~tic component tAcky. ~he me~n~ for fcedlhg the foll ~trlp t~ ~n~ p~t the nlp and t~lng up ~ho ~oil strlp b~cklng prefer~bly comprl~e~ a at~pper motor ::~
and motion control driver. :
One of tho ~rAn~fer cyllnd~rA and impr~ion cyl~nders i~ h~rd, whlle the other 1~ ~omewhAt , FEB-~18-'93 MON 12:39 ID:MDORE RES CTR G I NY TEL NO:716-777-2016 t~10'1 PE18/29--.' .
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ormabl~, For oxun~le, the ralsed port~ on~ o t~le tr~n~ cyl~nd~r Are ~loxi~ . of ~lllcor~e, whllo the I mpro~Yion cyllnd~r ha~ a rl5;~d m~
~ur~ac~ which ~gag3~ the ~ ra~e 2nd wh~ ch may b- .
}~o~d. The pr~nt~ ~g means pre~erA~ly compriaes n varlablo prln~r 8UC~1 as a oomputar ~:ontrollsd M~
p~l n"c ~hg~ln~ ~
It i8 tho primary ob~o~t o th~ preoant lnv~ntlon to prov$d~ for the quicX ~r~d v~r~t~
productlon o~ prlnted eub~tr~te~3 hAvinç oolor~d or metsllic ~oll over ~t le0L8t n p~rt of the prlntlng ~reon. ~i5 and othe~ ob~cts o the lnvent~ on wlll becom~ ~le~r from an ~n~pection of tho ~at~llod do~c~lption of the lnventlon, and from the apponcl~d lmo.

FICIJRE 1 1~ a ~lde l~chem~t~ c crc; o~-oec~ional view of A ~b~t~te prlntod wlth toner A~ A
p~llm~nary to pro~uclng the prlntod ~ub~tr~te ac~o~dln~ to ~e lnv~n~l on;

FIGURE 2 ~ ld- eroas-~ectlonal ~ w o~ a typical conv~nt~onal foll ~trlp utlllzed in the pr~ot- c~ o~ the pre~en~ lnventlon~

~ IC;U~E 3 1~ a ~ch~maSlc vlew of oxompla~y ~pp~atu~ 4ccording to the lnvention, ~or p~odu~ing B prlnted ~ tr~te hhvlng eolorod o~ nletall~ c foll over ~It lea~t ~ p~rt of the printlng, E~coor~ to th- lnvontlon?

FEEl-E18='~3 MON 12:4E~ ID:MOnRE RES CTR G I NY TEL NO:716-773-2016 ~tl'3~ P09/29 r 2 ~
7 ~ -E~CURE ~ i~ A ~ld- croa~-soctlorl~l v~ow o~
p~lntod ~lubot2~te accor~ing to thc ~ nv~n~lon;

~ XC;URE 5 ~ nd vl~w of Bn exempl~ry t~ano~or roll~r tA~'c m~y be utlllzed ~ccot~!ilnq to p~o~nt lnv~ntlonS

FIGUR~; 6 1~ ,rlow o ~ho tr~n~e~ rollo~
o~ 0TJRE 5 :, -~ ou~ 7 is 8n ~nd ~r~ow of ~ ~leeve ~or thot~An8~er roll~r o~ FIGURE8 5 and 6 provldlnsJ r~l~ed po~lon8 tl~ereof; ~nd ~auRE 8 ~ h~matl :: vlew o a ~oeond ~xomplt~ry err;bc~dim-~nt o~ ~pparatu~ accordln~ to the p~q~ t lnvan~ion. ~ ~ :

According to t~e pr~a~lnt lnvo~tion a mot~od and a ppA~l,tUO Aro provl~e~ ~or quleXly producin~
va~ le lmA~o ~ubetrAto~ havlng colo~e~ or motalllc foll over port~on~ th~r~o~. The rlr~t ba~c ot~p accord~ng to the method o the present lnv~ntlon 1~ ~ :
to prlnt ~ ~ub~trate, ~uch a~ ~ web or ~ho~t o pQp~ 10 (~ IGURES 1 ~nd 3) wl~h toner imag~
ln ~ ~edetermlned p~ttern, t~ produce ~ prlntod ub~trAte 1~. Ihe varia~le lmsglng o~ the tonor 11 onto the ~ubotrAte 10 p~So~bly lo ~ccompllDh~d wltn A cv~nput~r corltroll~d prlnter, ~uch ~c ~ MIDJ
prlnter ~8n lon depo~ltlon pr~nter), the bA~lc ~e~ture~ o~ whlch are de~cr~bod ln ~n ~rtlcle ~ 8-'93 ~ION 12:4~ ID:~OORE RES CTR G I NY TEL NO:716-773-2~16 ~i94 Pi0/Z9~
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B
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~nt:ltled "Ion Prlntln~, P~l~t, Pr~ent, ar~d Future"
by It$c~rd A. Fotl~nd, I~:C Conf-~ence o~ D~po~it~ on Pr~n~:ln~, Mo~ter~y, ~ll ornla, M~rc:h 29-31, ~9~7.
~-~ 'con~r 11 ~pplied by th~ ~2DAX pr~nt ~ng~no ~ :
own ~ch~matlcally ~t ~4 in FIGURE 3 -- aç~
knowr~ par qe, may h~ve n khermopl~tic componen'c. A
convontional toner or t~i ~ p~rpo~e 1~ Oc~
Indu~t~1~6 o ~::hic:~go, ~ nol~, type "F2". Th~
toner ll ~ rec~ptive to convontlor~al ~oil~ with tr~nsfer 8dh~ V~ ut mAy b~ mado even moro receptlve ~y heatln~ ~t ~u~t prlor to tran~ferrlng ~:
0~ oll onto the ton~r 11, and ~av~n l~y h~Atlnçl the trat~ 12 aR pr~ure ~n~ hea~ ara belng ~Ippll~d to a foll sCrlp dutlng trAn~sfer. H~tlrg of tl~ner 11 to render lt ~e~ptlve to the adhe~ and ~oil from ~ $oll 4trlp ~typlcally by rend~lng tho ton~r 11 t~c)cy) may be accompllJh~d ~l~illz~ng an lnf~a~od pr~-heater 15 or th~ l~ke (~e~ F~auRE 3), nd by upplyls~g~ h~at -- a~ lllu~tratl~d ~ehema~cally i~t 16 -- to a ri~l~ me~al sur ace lmp2~ 0n cyllnder 17 ove~ w~ich the Jub~tr~te 1 pa~o~, wlth tho toner ll scln~ AwAy ~rom th~
~yllndor 17 ~r~aco.
A typlcal foll strlp that m~y be u~od 1~
produclng produ~t~ sccordlng to ~he lnventlon lb lllu~trated ~c~ematlc~lly by ro~erencc numerAl 20 ln FIGU~ES 2 And 3. Th~ ~oll ~tr~p may be ~ de~crlbed in U.S. pstent 4,~91,260, or one o ~ wld~ v~rloty ~f ~ommorcially s~A~lable ~oils ~uch as tho~e ~ol~
by R.W. G~auort, Inc. o~ C~nton~ Connccticut u~der the n~me "Spar~ o~l". The oll s~rip 20 ~nclud~
~ carricr fllm or ~ACXih~ 21, typlcAlly of 8 plastlc h~vlng ~iubst~ntlal lntegrlty, ~iah a~ Mylar ~ - *B-~18-'93 I~ON 12:41 ID:MOORE RES CTR G I NY TEL NO:716-77~ 016 111~4 Pll/29-- ---' - 20~0~U
g ~poly~t~r). T}l~ bac~lny 21 ~8 e~ er lnh-r-~ltly o~
r01~ o m~lter~ ~1, o~ he~ a r~loa~o c:o~tlng 22 ( ~e FIOURE 2), such a~ o~ ~lllcone, polytotra1uorc)ethylene, or another ~ighly lubrlclou~ mate~lal. Next to tlle rel~a~e coatln~ 2Z
18 th~ ~oil mat~r~ ~1 23, whlch may b~ o~ ~ny conventlonal ~orm, includlng c:olor~d or m~t~lllc fo~l~ or ~e llXe (o. ~. #~ lvor, gold, ~od, hol~r~ph4 e, e~ n t}~e oppo~l~e ~ ~o o~
fo~l mater~ al 23 lo a ~nofe~ e41ve 24. T~
oll material 23 h~ a much hlgher ~f~inity to the . :~
transfer ~d~e~lve 24 thAr~ ~ eloe~ ~o the sel~-a~e ::
coatln~ 22, therefore wh~n he~t And pre~6ure are appl~ ~d to th~ ba~klng 21 ~nd ~h~ adh~slve matsrlal 24 e~ e~ a receptlYe materlal t ~uch as the ton~r 11 lmago~, the adho~lYe 2d~ and foll materlal Z3 wlll ~ran~r to tho ~eeeptlve materl~l w}~exe (but ~nly wh~) lt 1~ locatod.
The fo~l atrip 2Q -- ~or th~ ~mbodlm~nt lllu~tratod In FIGURE 3 ~ fed util~zln~ an unl~ned ~oll 26 or the llke, and a take-up roll 27 or t~e 1~ k- . Th~ taX~-up roll 27 ta~e~ up tho backln~ 21 (wlth rele~e coatin~ 22~ well as any ~dh~ or foll 24, 23, r~poct~v~ly not t~no~red to the toner 11 imAgc~. The me~n~ or let-o~f and take up of the oll ~trlp 20 include, ln a~dltion to the rolls 26, 27, me~na or ~ontrolllng~
tho ten~lon And feed-to-len~th p~r~met~r~ of tho ~o~l ~trlp Z~, e~ch ~a the atepper motor ~nd motion cont~ol d~i~er lllu~trsted ~chematic~lly by re~oren~e numer~l Z~ in FIGU~ 3.
T~ah~f~r o th~ ~oil 23 to the toner 11 la provided at a tran~er statlon, shown ~chematlcally ~ FE~-08-'93 MON 12:42 ID:~IOORE ~E8 CTR G I NY TEL ~o:7l6-773-20l6 ~194 P12/2g~
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by ~o~r~nc:e nuun~r~l 29 ~ IGURE 3. $he lmpreac10n cylln~e~ 17 l ~ loeAtod at trllhO~e:r otation 29 ~nd ~otata~lo about T~n ~xle 30 ~typica1ly horlzontal), 4~ la n tr~ns~ar cyllnder 31, ghown ~chen~htlcally ~n EICUR~ 3 . Ths tran~f~r cyllnder 31 1 R rotatable about An ax~ 5 32, typl~ ly a horizont~l axl~
parall~1 to the ax1s 30, and ~ nlp, ~ho~tm gonorAlly by ro~rence num~r~l ~3, 1~ ~e~lned be~weon ~he cyllnde2~ 17, 31.
I~ tran~rer ~ylinder 31 m2~y hA~e a b~
~urface ~ rom which ral~e~ ~lex1ble ~dofo~n~ble) he~ted circ~lm~rentlally ~p~çe~ ~rcuste ~u~f~ce portlon~ 3S extend. Th~ rPAce po~tlor~ 35 A~e hoA~od ~rom heat so~ ce 36, which may be an extc~n~1 ln~a~ed heat soure~, or ~n ~n~ernal lleat ~ourc~
The porSlon~ 35 m~y comprlse a fl~xlble m~erlal ~uch a~ ~lllcone. The utilization of ~ilicone on roll~r 1~ Xnown per ~o, ~uch ~s in Sho Acrcm~rk 700 hot stampl~ a~ ~m~nu~A~tured by Acromark Cvmpany, Inc. of ~erkel~y Helght~, Now Jor~y). ~h~
roller 31 i~ typlc~lly nub4~nt~lly contlnuou~ly rotet~d, but pr~eure (~nd ~e~t) ~u~flc~ent to ~ e~ t~anefer o the ~dh~aive 24 And ~oll Z3 to the to~er 11 o the ~ub~trat~ 12 18 effecte~ only :~
wh~n tho ~paced srcllate 8ll~f~ce portlon~ 35 form A
part of the nlp 33, spplyln~ ~ub~tantlal pre~Bu~c~
~ he lmpres~lon cyllnder and tr~n~for cyl~der m~y h~o the m~te~l~lo thereo f re~erood. ~h~t 1~, if th~ tr~ns~er cyllnder 31 18 flexlble, tho lmp~e~4lon cylinder 17 ie ri~id, a~d ~lce vor~a.
T~o oub~trate 12 1B cont~nuou~ly ed t~ the nlp 33 o~ t~e trsnsfer ~tatl~n 29, And p~Yt lt, ~ by utlllzlh~ ths e~d rollo 38 ~ee F~UR~ 3), and llke FE~-~8-'93 MON 1~:43 ID:MOQRE RES CTR G I NY TEL NO:716-773-2016 ~194 Pi3/~
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o~r ~ollo (nc~t ~hown in FIGIJRE ~ llo tb~
~5tr4to 12 1~ ~hows~ ln w~b form ln FIOURE 3, ~t to ~ nd~rl3tood t:hAt lr~dividual E~h~ts could ~e o~Q~ A~ly contlnuouoly ~sd to the ~t~tion 2g utlll~lng converltion~l ~hoet ~eeding e~ulpment.
After proc~s~lng at the tranl~f*r ~t~ticn ~9, ~ :
the ~lnal ~ul~str~.te -- lllu~trAted gQn~lrally by re~or~nco numeral 4~ ln F~auR~s 3 and 4 -- m-ay pa~s to ~u~he~ prv~:o~ g l~tAgG8 (lllul~tr~t~
~c~omatlcally At 41 ln FIat7RE 3) . r;~urin~ ~urthor oporQtlonE~ tho ~ub~trate 40 eould be adcliSlonally . ~ ~
prln'ced, ~llt, folded, collated, paekas~d, and ~ :
ot~-rwl~e proce~ed.
~ e flnAl produGt 40 produc~d accordlng to th~
lnv~nt~,on, h~ soen ln ~URE 4, lnelude~
oubstrato 10 and ton~r ~m~go~ ll, with tho tran~for adh~lve 24 ~etwe~n the tonor lma~e~ 11 And the colore~ or metallic (e.~. ~old, s~lve~, ~ed, h~l~g~phia, etc.) oll 23 vl~lble ~y ono looki~g at tho product 40.
Becauso t~e components o~ tho app~rAtu~ of ~IqU~E ~ are rotary ln nAture, and do not rely upon ~n lnnorently ~low reclprocat~on ~c~lon, th~ pro~u~t 40 ~an be producod at ~pecd~ l~ exceJ~ o~ lO0 ~ot per minute, ~.g. ~bout 120 ~et per m~nut~, Rnd oven as hlgh a~ 300 foo~ pe~ mlnu~e. Beeause vArlabl~
tonor im~e~ ll qre ~PPl i~d to the ~ub~trate lO, the product 4~ a~cordlng to the lnventlon al ~o has eno~mously ~reAter ve~atillty than prior art procoa~e~ And pro~ucts, whlch re~ulro A
~ub~ta~tlally flxed imAge, or llmlted pattern varlAtlon ~uch a~ produced by a nu~be~ m~chlne.
..,, .! .' . :

~ EB-~8-'93 MO~ 12:43 ID:~OORE RES CTR G I NY TE~ NO:716-773-2016 ~194 P14/29 - _ -. . .. .

In ~n~1 ~o~m ~ho ~pparatuo A ::cordin~ ~o th~
~ nvontlon, hC:~aOmAt~ c:~lly lllu~t~t~d in FIGURI; 3, mlly lncl~clo ~any ~cceE~sory component~ not e~nti~l to t~h~ b~aic featu~ o~ the ln~es~t~Lon. For ~xampl~ .
noz~le 45, or li)co mean~, c~7nn~s;ted up to ~ cool I~lr oou~ce 45, m~y b~ pro~ld~d for direc~cinçl A bla~t a coolin~ slr toward the tranafer c:yll nder 31 durlng lntorrupt~-c,n o~ the msthod ~op~ for produclnst ~a product 43. Al~o, the cyllnder 31 coul~ be ~on'ct~olled by Servo motlon contro~ chnolo~y, ths rAlsed portlon~ 35 may be ln the form o~ p~ds whlch msy be removed rom and repo~ltloned on the ourf~ce 34 ~ ~oslred ~or ~ p~rtlcular product 40 boln p~sduced, ~losed loop temper~ture control m~y provl~d ~or ~3t~ the pre-hoa~ Appsratu~ 15 ~nd th~
cyllnder~ 3~,, 17, ~r~d varlou~ othe~r ~tru~ture~ may b~ utlll~ed for ~upporting the non-~r~n~fer portlons 34 of the roller 31 durlnq ~ormal opeFstion ~yclea, md or ~upplyln~ cool1ng water for the heAting ~qulpmont. 1~ d~tails Or ~uc~ componen'co are not lmpor~nt to the ba~lc uF~ctlon~1ity o tho apparJ~cus o~ FIGUR~ 3, or for the ~ C mc~hod~
acoor~ing to the ~nventl~n.
A~cordln~ to an ex~inpl~ry me~hod of produclng a prlnted ~ubntrato 4t:~, havlng colored or metalll~
fo~l over ~t least ~ part of t~e prlntlng, sccordlnç~
to ~;he lnvent~on, the following ~tep8 ar~ follo~edt --~rl~tln~ A desired patt~rP on ~ ~ub~trt~t~ lO
utilizln5~ the tc~ner 11, ~uch ~1~ v~rlAbly prln'clng $~ tonor imago~ 11 utilizing MIDAX ~ lon -dopo~ltion) pr~nt en~lne 14, with the toner havlng a t~ormop~tlc component.

.

_FE8-08-'93 MON 12:44 ID:MOORE RES CTR G I NY TEL NO:716-773-2016 ~194 P15/28 . .~

3 ~ ~
~ 13 -~Continuou~ly ~edlng th~ tr~t~ ~ to ~nd p-l~'C th8 tran0fer loe~tlon 29, ~# wit~ tho rol l~r~
38. ~ may be practleed ~at ~peed~ ln oxee~ of 10~ po~ m$nUto.
--F~edin~ t~e foll 8~ip 20 havlnç~ arl QUto~
adhe~l~re le.yer 24, a color~d or met~lllc ~oil layer 23, ~nd ~ rsl~a~ 22) co~t~d c~ier (~cklr~ 21) to the 'cran~or location 29 with thc adhenlvo 24 ~acln~ t~e ~ub3tr~t~ ~2. T~ compllsh~d u~ ln~ the app~rAtuo ~$-2~
re ~he toner 11 lmages h~vs B
thormoplel~tl ;: compone~t, 2pplyitlg hea~c t~ tho to~e~
patte~rl 11 on ~he ~ tr~te 12 ju~t prior t~
trJlnsfer lo~atlon 29 ~ . wlth I.R. h~t~r 15) to ma~q the thermoplARtlc component o~ the toner rcc~ptlve to the foll ~nd adhe~ive l~yers 23, 24 o~
th~ foil strip 20 ~enderin~ ~he tonor ~m~ge0 11 t~cky).
--Applylng hea~ to the foi~ ~trlp 20, and prol~uro t~ the fol 1 3trlp 20 and ~ubs~crat~ 12, at tho trarlo~er loc~tlon 2g, ~o ~ to tr~n~f~r the adheolv- 24 And colo~d o~ metalllc ~oil 23 onto Sho h~at~d tonor patt~rn 11.
--Tran~er at tr~n~fer ~ tion 29 41 ACCompliehed ln a ~ot~lry manne~, by cont~nuou~ly totatlng th~ lmpre~ n cyllndcr 17 and tran~r oyllndet 31, with tran~fer taklng place only wh~n t~ r~iaed hoated ~urace pQrtlOn4 ~5 clrcumfercntially apa~ed along the ~urfac~ 34 ~ng4ge the ~tr~ p 20 at th- nlp 33, llpplyln~ ~r~no~r pr~ ure.

FE~-08-'93 MON 12:45 ID:MO~IRE RES CTR G I NY TEL NO:716-~73-~016 U1~14 P16/29 - ~
!, ~ . .

~4 :

in~l p~:oduct 40 p~oduced m~y b~ p-e0¢cl to rth~r proc~ ng elthOO~I, a~ lllu-~tr~tod a~chom~'clc~lly ht 41 ln FI~t~E 3.
~ 1hlle tho t~anEI~or roll~r 31 ac:~o~tlns~ to th~
p~e~ont ~nv~ntion may ~ake a wlde vArlety o~
on~ orm t:hAt m~y be de~irable, and ~llows fo~ eaay repl~omen~ of di~erent Go~flgurationo of r~l~od ~urf~e4, is illu~trated ln FIouREs S throu~h 7. ~n FICURES 5 ~rough 7 ~tructure~ compA~bla to tho~
ln l;hQ FICURE ~ ambodlm~n~ are ~hown by tho re~erQnco nume~sl only p~eced~d by ~ "l".
The tre.n6fe~ roller 131 ~A~ ~n t nkerlor portion 132 thoro~ ~hat ~o k~yed to n ~h~t drlv-s- by a convont~on~l driv~ unl~. The rc>ller 131 may ~ of a polymsrlc ~ erial ~hieh will with4t~nd th~
~pprox~mately 500~ temperature that the ~y~tQnl i~
normally expo~ed to), wlth gener~lly radl~lly extendlng opent n~s 51, 52 bein~ provlded theroln ~or recelpt o~ fastener4 for connectlng the ~leev~
~hown ln ~IGURE 7 ~nd to bo further d~crlb~d herea~ter) ~ th~ r 131 maln body 50. Th~ : :
roller 131 aloo ~nclude~ a concentrtc exton~lon 53, ~:
w~ich ha~ ~ r~lal ps~ge S4 therein or rece~pt o~

4 ~toner that facillt~te~ attachmqnt oE th~ rol~er lJl to ~ ~h~
A sleev~ ~or placln~ around th~ roller 131 body 50, and h~vl~g ~ubat~ntl~lly the ~am~ axl~ ngt~
a~ ~ho body 50, l~ 8~0wn by the two ~e~menta 57 ::
il~u~tratot in FIOVRE 7. The ~le~ve ~ trated ln FIGURE 7 may be o on~-p~ece conatructlon, but tho two-pi~c~ construction S7 l~lustrated in FI~UR$ 7 18 preerred. Each ~eqment 57 has gen~rally radl~lly ~ ~ :
extendlng hole~ 5~, $9 the~eln or eooperAtlo~

F~-Q8-'93 MON 12:45 ID:MOORE ~ES CTR G I NY TEL ~0:716-773-2016 ~194 P17/29 2 ~ $ ~

r4-po~t~vely~ w~th tho holoG 51, 52 ln th~ ro~l~r 131 maln body 50, 80 that each ~ nt 57 1~
esnn~¢tod ~t four pol~ y ~a~tonera ~o ~he roller 131. ~he ~gm~nts 57 may b~ o~ alumlnum, or the 1~kQ. The se~m~nt~ 57 provido ~he ro~q~a~d c~roum~erentl~l portion 134, and tho rAl~od, ~r~n~or, portl~n~ 135. A plurslity o~ dl~feront Det~ v~ ~e~m_~t~ 57 can bo provlded h~ng dlfer~nt ~u~ka len~th~, the ralssd por~lons 135, or havlng ~ ~lffar~nt numbor and ~p~cin~ of t~e ~Glso~
port~ono 13~.
FICURE ~ 1~ A ~chems~io lllu~tration of a cy~tem slmllar to thst illu~trated ln FIOURE 3, but wlth ~ ~ew dlfference~, primarily with re~pect ~o th~ ~oll le~ of and take up arrangemRnt- In tho FIGUR~ 8 embodlmont ~trust~reo ~ompn~able to tho~e ln the FIGUR~ 3 ombodimen~ are ~hown by the ~e two ~ ::
dl~t ~eerence nume~a~ o~ly preceded by ~ "2".
In the FIGUR~ a embodlment, maxlmum floxlbillty 1~ providyd ln ~e production of th~ de~lred end product by efQctlvely providlng "one ~l~e flts all"
~almo~t) ~rom the prlnt len~t21 pglnt of v1ew. 5~c veloclty of the trAn~f~r roll~r 231 lo pro~iled during ~he proc~ cycle and all~o trlgger4 an output to ot~rt the foll ~eed 224 8t A DelectCd polnt in the profllc. For th~ oll feed two a~t~ of ~tructuro~, 62-64 d~po~e~ ~etwe~n the ~oll unwlnd 2~6 and the ~ran~fer cyl~nder Z31, a~d ~tru~tur~
66-6~, dispo~ed betwoen the foll tAke up 227 and thu tr4n~f~r eylinder 231, are provlded. The a~embly ~2-64 preci~ely control~ thc o~1 foed to th~ n~p 233 util~ln~ a ~Bln ~ollor 62 And ~ xider roller 63, t~e maln rollor 62 ~elng ~rlven by a ~t-pp~r FEB-08-'93 MON 12:.46 ID:I~lClORE RES CTR G I NY TEL NO:716-773-2016 ~184 PlEv29- --;~. . .
' , ~Qg~O~J

motor 64 And pr :>gr~ d Gont~ol 8y~t6m . The ey~tem 66-6~ no~er lntermlttent feed Hyetem, lik~ th-~y~t~m 62-64, but rather utlli2;e~ ~ drlve w~lch pro~lda~ A COnMtl-nt pUll th~t c:an be ot~ d. ~rhat ~ ~, tho d~ivo s~ollor 66 ~nd r~dsr roller 67 coopo~to to taXo up the web 221 w~,~h t~e r~llox 66 drlv~n by Ah electrle~l or pneumJ~tlc "torque" or ~t~ll" motor 68 wlth A~ocla~c~d control oy~tl~m.
~h~a motor 6~ rq-le" or "~tall" functl~n 14 provlded, or example, ~y Rn a~r mo~or who~a relo~:lty, and torc~ue, 1~ controlled by the alr pr~ure ~uppll~d to lt, wh~ch celn b~ proportlonal to the Proce~ ~psed to allow ln~:rozl~ of tho pull ~tatlon ~p~ed a~ the press speed lnc:rea40 Note th~t ln the FIS~URE 8 em~odlment the he~t :
~or th~ tran~f~r c:yllnd~r ~ys~m ~3~ l~ provldod by an ln~rAred hea~ ~our~e 236, and 1~ the transfer :~ :
cylln~ler 231 ~a~ the ~en~tructiOn illu~trated ln F~ ES 5 through 7, ~he 1rnpre~on cyllnder 21~
o~ deo~mable ma'c~rlal ~.q., ~illcone). In both ~ -:
th~ ~IGURE 8 ~nd FIGUR~ 3 embodim~n~, the ten~l~n :~
An~ f-ed-to-len~th p~r~metors o~ the ~oll ~trip ~r~ :
controlled.
It will thu~ bo ~oen thAt accordlng to the p~ront lnvont~on a f~t yet vereAtlle proce~, and appa~atu~ for practle~ng thc p~o~o~, have been prov~dod fo~ p~oduolng printed ~ub~trate~ havln~
~olo~d or metallle oll ov~r ~t l~a~t A pa~t of tho prl~ting thetoof. Whlle the inventlon has been ~ :
ho~ein Bhown nnd descrlbed ln what 1~ pr-sently con~elved to be th~ mo~t practic~l and preferred ombodlment it wlll b~ apparent to tho~e o or~n~ry ~111 In thc Ar~ that m~ny modl~ca~lon~ ~y b~ e.
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~ _ FE~-38-'93 MON 12:47 ID:MOORE RES CTR G I NY TEL NO:716-773-20i6 ~194 Pl9/29 .. _ .i ~ , 2~890~ ~ :

tbclroo~ wlthln th~ ~op~ o~ ~e ln~-ntlon, whlch aaop~ to be acco~ded t~o broad-~t lnt~rpret~tlon o tht~ App~nd-~d cla~.m~ ~lo a~ to l~nGompa~ All q~lval~nt m~tbod~ d pp~ tU~.

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Claims

1. A method of producing a printed substrate having colored or metallic foil over at least a part of the printing, comprising the steps of:
(a) printing a desired pattern on a substrate using toner having a thermoplastic component capable of being rendered receptive;
(b) continuously feeding the substrate to and past a transfer location;
(c) feeding a foil strip having an outer adhesive layer, a colored or metallic foil layer, and a release coated carrier, to the transfer location, with the adhesive facing the substrate;
(d) acting on the toner pattern on the substrate just prior to the transfer location to make the component thereof capable of being receptive, receptive to the foil and adhesive layers of the foil strip; and (e) applying heat to the foil strip, and pressure to the foil strip and substrate, at the transfer location so as to transfer the adhesive and colored or metallic foil onto the heated toner pattern.

2. A method as recited in claim 1 wherein the toner has a thermoplastic component, and wherein step (d) is practiced by continuously applying heat to the toner.

3. A method as recited in claim 1 wherein the transfer location includes an impression cylinder and a transfer cylinder; and wherein step (e) is practiced by passing the substrate and foil strip between the impression cylinder and transfer cylinder, the substrate engaging the impression cylinder.

4. A method as recited in claim 3 wherein step (e) is further practiced by continuously applying heat to the substrate at the transfer location by heating the impression cylinder.

5. A method as recited in claim 3 wherein the transfer cylinder has a plurality of circumferentially spaced arcuate heated raised surface portions which engage the foil strip; and wherein step (e) is further practiced by continuously rotating the transfer cylinder so that the raised heated surface portions thereof periodically come into contact with the foil strip and exert a pressure on the foil strip and substrate when they do come into contact with the foil strip, transfer of colored or metallic foil to the printed pattern occurring only when the raised heated surface portions come into contact with the foil strip.

6. A method as recited in claim 5 utilizing a foil strip let off and foil strip take-up; and wherein step (c) is practiced by controlling the tension and feed-to-length parameters of the foil strip.

7. A method as recited in claim 1 wherein step (a) is practiced by variably printing the patterns utilizing a computer controlled ion deposition print engine.

8. A method as recited in claim 1 wherein step (b) is practiced at a speed of at least about 100 feet/minute.

9. A method as recited in claim 1 wherein step (a) is practiced by moving the substrate as a web continuously to and past the transfer station.

10. A method as recited in claim 3 comprising the further step of directing a blast of cooling air toward the transfer cylinder during interruption of the method steps.

11. A method of producing a printed substrate having colored or metallic foil over at least a part of the printing, and utilizing a transfer location including an impression cylinder and a transfer cylinder; comprising the steps of:
(a) variably printing a desired pattern on a substrate using toner;
(b) continuously feeding the substrate to and past a transfer location;
(c) feeding a foil strip having an outer adhesive layer, a colored or metallic foil layer, and a release coated carrier, to the transfer location, with the adhesive facing the substrate; and (d) applying heat to the foil strip, and pressure to the foil strip and substrate, at the transfer location so as to transfer the adhesive and colored or metallic foil onto the toner pattern, by passing the substrate and foil strip between the impression cylinder and transfer cylinder, the substrate engaging the impression cylinder.

12. A method as recited in claim 11 wherein the transfer cylinder has a plurality of circumferentially spaced arcuate heated raised surface portions which engage the foil strip; and wherein step (d) is further practiced by continuously rotating the transfer cylinder so that the raised heated surface portions thereof periodically come into contact with the foil strip and exert a pressure on the foil strip and substrate when they do come into contact with the foil strip, transfer of colored or metallic foil to the printed pattern occurring only when the raised heated surface portions come into contact with the foil strip.

13. A method as recited in claim 12 wherein step (a) is practiced utilizing a computer controlled ion deposition print engine.

14. A method as recited in claim 11 wherein step (b) is practiced at a speed of at least about 100 feet/minute.

15. A method as recited in claim 11 wherein step (a) is practiced by feeding the substrate as a web to and past the transfer station.

16. Apparatus for producing a printed substrate having colored or metallic foil over at least a portion of the printing on the substrate, comprising:

means for variably printing a predetermined pattern, with toner, on the substrate;
an impression cylinder mounted for rotation about a first axis;
a transfer cylinder mounted for rotation about a second axis parallel to said first axis, and to define a nip between said impression cylinder and said impression cylinder;
means for continuously feeding the substrate to and past the nip between the transfer cylinder and impression cylinder, with the toner pattern on the substrate facing the transfer cylinder;
means for feeding a foil strip having an adhesive, a foil, and a backing, to the nip with the adhesive and foil facing the impression cylinder;
means for taking up the foil strip backing after passage of the foil strip through the nip; and means for heating said transfer cylinder to facilitate transfer of the adhesive and foil from the foil strip to the toner pattern on the substrate.

17. Apparatus as recited in claim 16 wherein the toner has a thermoplastic component, and further comprising means for preheating the toner on the substrate just prior to the substrate entering the nip to render the thermoplastic component in the toner tacky.

18. Apparatus as recited in claim 16 wherein said means for feeding the foil strip to and past the nip, and taking up the foil strip backing, comprises a stepper motor and motion control driver.

19. Apparatus as recited in claim 16 wherein said means for feeding the foil strip to and past the nip, and taking up the foil strip backing, comprises an electrical or pneumatic torque or stall motor.

20. Apparatus as recited in claim 16 wherein said transfer cylinder comprises a plurality of circumferentially spaced arcuate heated raised surface portions, and means for essentially continuously rotating said transfer cylinder about its axis, pressure being applied to the nip by said raised surface portions and said impression cylinder when they are in alignment.

21. Apparatus as recited in claim 20 wherein said impression cylinder has a rigid metal surface which engages the substrate.

22. Apparatus as recited in claim 20 wherein said transfer cylinder is rigid and said impression cylinder is of flexible material.

23. Apparatus as recited in claim 21 further comprising means for heating said impression cylinder.

24. Apparatus as recited in claim 16 wherein said printing means comprises a computer controlled ion deposition print engine.