CA2207385A1 - Dual substrate, single-pass printing process and substrates printed thereby - Google Patents
Dual substrate, single-pass printing process and substrates printed therebyInfo
- Publication number
- CA2207385A1 CA2207385A1 CA002207385A CA2207385A CA2207385A1 CA 2207385 A1 CA2207385 A1 CA 2207385A1 CA 002207385 A CA002207385 A CA 002207385A CA 2207385 A CA2207385 A CA 2207385A CA 2207385 A1 CA2207385 A1 CA 2207385A1
- Authority
- CA
- Canada
- Prior art keywords
- substrate
- printing
- ink
- process according
- substrates
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000758 substrate Substances 0.000 title claims abstract description 137
- 238000007639 printing Methods 0.000 title claims abstract description 78
- 238000000034 method Methods 0.000 title claims abstract description 33
- 230000009977 dual effect Effects 0.000 title claims abstract description 10
- 238000003847 radiation curing Methods 0.000 claims description 5
- 238000001035 drying Methods 0.000 claims description 3
- 238000007641 inkjet printing Methods 0.000 claims description 2
- 238000001816 cooling Methods 0.000 claims 2
- 239000000976 ink Substances 0.000 description 72
- 239000000835 fiber Substances 0.000 description 27
- 239000004744 fabric Substances 0.000 description 13
- 239000000463 material Substances 0.000 description 8
- 239000000203 mixture Substances 0.000 description 8
- 229920000098 polyolefin Polymers 0.000 description 7
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 4
- 238000013461 design Methods 0.000 description 4
- 235000019441 ethanol Nutrition 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical compound CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 description 3
- DKPFZGUDAPQIHT-UHFFFAOYSA-N butyl acetate Chemical compound CCCCOC(C)=O DKPFZGUDAPQIHT-UHFFFAOYSA-N 0.000 description 3
- 239000003086 colorant Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000004922 lacquer Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- -1 polyethylene Polymers 0.000 description 3
- 206010008531 Chills Diseases 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 239000004745 nonwoven fabric Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- BDERNNFJNOPAEC-UHFFFAOYSA-N propan-1-ol Chemical compound CCCO BDERNNFJNOPAEC-UHFFFAOYSA-N 0.000 description 2
- YKYONYBAUNKHLG-UHFFFAOYSA-N propyl acetate Chemical compound CCCOC(C)=O YKYONYBAUNKHLG-UHFFFAOYSA-N 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- ARXJGSRGQADJSQ-UHFFFAOYSA-N 1-methoxypropan-2-ol Chemical compound COCC(C)O ARXJGSRGQADJSQ-UHFFFAOYSA-N 0.000 description 1
- SBASXUCJHJRPEV-UHFFFAOYSA-N 2-(2-methoxyethoxy)ethanol Chemical compound COCCOCCO SBASXUCJHJRPEV-UHFFFAOYSA-N 0.000 description 1
- DJCYDDALXPHSHR-UHFFFAOYSA-N 2-(2-propoxyethoxy)ethanol Chemical compound CCCOCCOCCO DJCYDDALXPHSHR-UHFFFAOYSA-N 0.000 description 1
- POAOYUHQDCAZBD-UHFFFAOYSA-N 2-butoxyethanol Chemical compound CCCCOCCO POAOYUHQDCAZBD-UHFFFAOYSA-N 0.000 description 1
- YEYKMVJDLWJFOA-UHFFFAOYSA-N 2-propoxyethanol Chemical compound CCCOCCO YEYKMVJDLWJFOA-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- CIWBSHSKHKDKBQ-JLAZNSOCSA-N Ascorbic acid Chemical compound OC[C@H](O)[C@H]1OC(=O)C(O)=C1O CIWBSHSKHKDKBQ-JLAZNSOCSA-N 0.000 description 1
- 206010021639 Incontinence Diseases 0.000 description 1
- 239000006057 Non-nutritive feed additive Substances 0.000 description 1
- 150000001242 acetic acid derivatives Chemical class 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000001723 curing Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000001227 electron beam curing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 238000007647 flexography Methods 0.000 description 1
- FUZZWVXGSFPDMH-UHFFFAOYSA-N hexanoic acid Chemical compound CCCCCC(O)=O FUZZWVXGSFPDMH-UHFFFAOYSA-N 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 238000011416 infrared curing Methods 0.000 description 1
- GJRQTCIYDGXPES-UHFFFAOYSA-N iso-butyl acetate Natural products CC(C)COC(C)=O GJRQTCIYDGXPES-UHFFFAOYSA-N 0.000 description 1
- FGKJLKRYENPLQH-UHFFFAOYSA-M isocaproate Chemical compound CC(C)CCC([O-])=O FGKJLKRYENPLQH-UHFFFAOYSA-M 0.000 description 1
- JMMWKPVZQRWMSS-UHFFFAOYSA-N isopropanol acetate Natural products CC(C)OC(C)=O JMMWKPVZQRWMSS-UHFFFAOYSA-N 0.000 description 1
- 229940011051 isopropyl acetate Drugs 0.000 description 1
- GWYFCOCPABKNJV-UHFFFAOYSA-N isovaleric acid Chemical compound CC(C)CC(O)=O GWYFCOCPABKNJV-UHFFFAOYSA-N 0.000 description 1
- OQAGVSWESNCJJT-UHFFFAOYSA-N isovaleric acid methyl ester Natural products COC(=O)CC(C)C OQAGVSWESNCJJT-UHFFFAOYSA-N 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 230000008447 perception Effects 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 238000012549 training Methods 0.000 description 1
- 238000011282 treatment Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 239000001993 wax Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F5/00—Rotary letterpress machines
- B41F5/04—Rotary letterpress machines for printing on webs
- B41F5/16—Rotary letterpress machines for printing on webs for multicolour printing
- B41F5/18—Rotary letterpress machines for printing on webs for multicolour printing using one impression cylinder co-operating with several forme cylinders
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F17/00—Printing apparatus or machines of special types or for particular purposes, not otherwise provided for
- B41F17/003—Special types of machines for printing textiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41F—PRINTING MACHINES OR PRESSES
- B41F22/00—Means preventing smudging of machine parts or printed articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M1/00—Inking and printing with a printer's forme
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M1/00—Inking and printing with a printer's forme
- B41M1/26—Printing on other surfaces than ordinary paper
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
- Y10T428/1362—Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
- Y10T428/1386—Natural or synthetic rubber or rubber-like compound containing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24851—Intermediate layer is discontinuous or differential
- Y10T428/24868—Translucent outer layer
- Y10T428/24876—Intermediate layer contains particulate material [e.g., pigment, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
- Y10T428/24901—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24934—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including paper layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249994—Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
- Y10T428/249995—Constituent is in liquid form
- Y10T428/249996—Ink in pores
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31855—Of addition polymer from unsaturated monomers
- Y10T428/3188—Next to cellulosic
- Y10T428/31895—Paper or wood
Abstract
A dual substrate, single-pass printing process prints a high weight substrate (14) and a low basis weight substrate (12). Ink striking through the low basis weight substrate (12) is collected and absorbed by the high basis weight substrate (14). The printed substrates are then separated and rewound for subsequent transport and handling.
Description
CA 0220738~ 1997-0~-28 WO96/16809 PCT~S95115167 DUAL SUBSTRATE, SINGLE-PASS PRINTING PROCESS
AND SUBSTRATES PRINTED T~R~RY
The present invention pertains to a process for printing substrates and substrates printed thereby.
The ink printing of fabrics, such as woven and nonwoven fabrics, with various patterns and colors is well known. These printed fabrics are then in~oL~o~ated into various products, such as personal care products. Examples of personal care products include ~iArers~ training pants, incontinence products, and the like. ~he printed fabrics are primarily int~n~e~ to aesthetically ~n~ce the appearance of the products.
one problem with current ink printing procecc~ is that the ink or inks can run through, i.e., strikethrough, the fabric, and particularly a low basis weight fabric. Low basis weight fabrics are generally thin, and inherently include a large number of small voids, or a smaller number of larger voids, through which the ink can strike through. The problem with ink strikethrough is that the ink builds up on, for example, an impression cylinder of the printing apparatus. This ink buildup on the impression cylinder results in= poor print quality on the fabric, the transfer of ink to the back of the fabric, and poor operating efficiency due to machinery down time required to remove the ink buildup.
This problem becomes even more significant in high speed printing environments, where the ink buildup is accelerated and increases the number of times the machinery needs to be shut down for removal of the buildup. As the shut down times increase, so do waste of material and ink associated wit~
machinery start-up.
- - CA 0220738~ 1997-0~-28 . . .
- WO96/16809 PCT~S95/15167 .
-.~ , -~ One attempt to resolve ink buildup is the use of doctor blades on an impression roll or the like. Although doctor blades r remove ink buildup while machinery is operating, their use ~ 5 prematurely wears out the surface of the cylinder or roll supporting the fabric. This, in turn, results in increased - ~ costs due to replacing prematurely worn out equipment.
Another attempt to eliminate ink buildup is to run a layer of ~ 10 material between the fabric and print rollers. The layer is -~ designed to collect or absorb ink strikethrough and carry it -- away. This has proved to be costly, since either the layer ~- must be replaced with a new layer, or the layer must be cleaned of the ink before being rerun through the printing apparatus.
~ Therefore, it is the object of the present invention to provide - a method of printing on a substrate which prevents ;- strikethrough and avoids the prior art attempts disadvantages, and a substrate printed thereby.
--- This ob;ect is solved by the method according to indepen~nt ~ claim 1, and the substrates according to ;n~r~n~ent claims 14 and 16.
-~ 25 Further advantageous features, aspects and details of the - invention are evident from the dependent claims, the ~ description and the drawings. The claims are intended to be -~ - understood as a first non-limiting approach of defining the =~ invention in general terms.
-- 'b Accordingly, the present invention in general pertains to a ~- process for printing substrates and substrates printed -~i thereby, and more particularly to a dual substrate, single-pass - printing process and substrates printed thereby.
.
-= ~ . .
CA 0220738~ 1997-0~-28 WO96/16809 PCT~S95/15167 In one form of the present invention there is provided a process for dual substrate, single-pass printing including providing a continuously moving first substrate, moving the first substrate to an ink printing station, printing a pattern on the first substrate at the ink printing station, illL~od~cing a continuously moving c~co~ substrate between the first substrate and the ink printing station, printing a pattern on the second substrate at the ink printing station, and collecting ink striking through the second substrate onto the first substrate. The ink printing station may comprise at least one ink printing cylinder.
In another form of the present invention there is provided a printed substrate including a substrate having a printing surface and an opposed inner surface, and an ink pattern printed on the printing surface by dual substrate, single-pass printing.
In still another form of the present invention there is provided a printed substrate made by the process including providing a continuously moving first substrate, moving the first substrate to an ink printing station, printing a pattern on the first substrate at the ink printing station, illL~ cing a continuously moving s~con~ substrate between the first substrate and the ink printing station, printing a pattern on the s~co~ substrate at the ink printing station, and collecting ink striking through the second substrate onto the first substrate.
The above-mentioned and other features, aspects and advantages of this invention, and the manner of at~in;ng them, will become more apparent and the invention itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings, wherein:
--~ CA 0220738~ 1997-0~-28 WO96/16809 PCT~S95/15167 ' 4 - Fig. l illustrates schematically one apparatus operated in - ~ accordance with the principles of the present invention;
.
-~ Fig. 2 illustrates a modification to the apparatus of Fig. l;
~ 5 and .,, . . .
:
--~i Fig. 3 illustrates a fragmentary, cross-sectional view through a portion of the central impression cylinder in Fig. l.
~ .
In many prior art proc~C~ec for printing a substrate, portions . . . =
-~ of the ink applied to the substrate can pass through the t substrate and become deposited on the surface of, for example, ~ an impression cyl;n~er. This is termed "strikethrough" and - causes ink buildup on the impression cylinder. It is this ;~ 15 strikethrough and ink buildup that results in poor print - quality on the substrate, the transfer of ink to the back =~ surface of the substrate, and poor operating efficiency due to - - mach; n~ry down time required to remove the ink buildup.
. .
Moreover, ink strikethrough causes various undesirable graphic effects on the substrate, such as the smearing of colors, . . .
blurring of the pattern, misregistration, or the like. These undesirable effects are not pleasing to the consumer, and tend - to cause a perception of poor product quality and performance.
~ -25 Referring to Fig. l, there is illustrated an apparatus lO which - can be operated in accordance with the principles of the present invention to print a continuously moving low basis -~ weight substrate 12 by means of a dual substrate, single-pass -- printing process that substantially eliminates ink buildup on ;- 30 the impression cylinder. The term "substrate" includes, but is - - not limited to, woven or no~ o~en webs, porous films, ink permeable films, paper, or composite structures comprising a - combination thereof. The term "low basis weight" refers to a = substrate that has an inherent propensity for ink to - 35 strikethrough and cause ink buildup on the printing apparatus.
~ .
-.
CA 0220738~ 1997-0~-28 A nonwoven substrate is considered a low basis weight substrate when its basis weight is equal to or less than about 20 grams per square meter. A nonwoven substrate having a basis weight greater than about 20 grams per square meter will be considered a higher basis weight substrate.
The term "pattern" when used with reference to ink printing herein, includes, but is not limited to, any type of design, mark, figure, identification code, graphic, word, image, or the like.
The present invention desirably utilizes a flexographic printing process to provide the proper balance of cost effectiveness, high speed, and high quality. The printing process is suitable for printing low basis weight substrates, such as low basis weight nonwoven webs, while maint~; n; ng the tactile softness of the substrates. Flexography is a printing technology utilizing flexible raised rubber or photopolymer plates to carry the pattern to a given substrate. The flexible plates typically carry a low viscosity ink directly onto the substrate. Examples of suitable low viscosity inks include inks comprising a non-catalytic block urethane resin and a solvent blend comprising up to about 50% by volume of acetate and up to about 75% by volume of glycol ether. The solvent blend also may comprise up to about 10% by volume of alcohol.
Suitable acetates include ethyl acetate, N-propyl acetate, N-butyl acetate, isopropyl acetate, isobutyl acetate, butyl acetate, and blends thereof.
Suitable glycol ethers include ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, diethylene glycol monomethyl ether, diethylene glycol monopropyl ether, propylene glycol monomethyl ether, and blends thereof.
CA 02207385 l997-0~-28 ~;
W O96/16809 PCTrUS9~/15167 : 6 -; .
.
Suitable alcohols include ethyl alcohol, iso~opyl alcohol, N-- propyl alcohol, and blends thereof.
:
L A more detailed description of inks suitable for use with the present invention is contained in U. S. Patent Application Serial Number 08/171,309, filed December 20, 1993, which is - assigned to the assignee of the present invention, the contents of which are incorporated by reference herein.
=~ ~
.~ 10 Various flexographic printing presses can be desirably used ~-~ with the present invention, and two such designs include the central impression cylinder design and the stack-style design.
. . . .
The types of plates that can be used with the flexographic - 15 process include plates identified as DuPont Cyrel~ HL, PQS, ~- HOS, PLS, and LP, which may be commercially obtA;ne~ from E. I.
= DuPont de Nemours and Company, Inc., of Wilmington, Delaware.
Other suitable plates can be commercially obtained from BASF of ~ Clifton, New Jersey, and from W. R. Grace and Company of - 20 Atlanta, Georgia.
:
-- Although flexographic printing is desired, other printing - apparatus or combinations thereof are also contemplated by the present invention. These other printing apparatus include screen printing, rotogravure printing in which an engraved print roll is utilized, and ink jet printing in which nozzles spray ink droplets that are selectively deflected by an electrostatic charge to form the desired pattern on the substrate. It is desirable that the inks used with these - 30 apparatus have a viscosity equal to or less than about 10 centipoise.
~- The dual substrate, single-pass printing process of the present invention is a process that continuously prints low basis - 35 weight substrates. One feature of the present invention is .
CA 0220738~ l997-0~-28 WO 96/1680g PCT/US95/15167 that another substrate, also requiring ink patterns to be printed thereon, serves a~ the "back-up" material to substantially eliminate ink buildup on the printing apparatus.
The other substrate desirably has a higher basis weight than the low basis weight substrate. By eliminating ink h~ r, the present invention improves the ~uality of the printed pattern, and r~ c~C the costs of manufacture.
Referring to Figs. 1, 3, a continuously moving first, or higher basis weight, substrate 14 is supplied from a primary unwind 16. Substrate 14 includes a printing surface 18 (Fig. 3) and an opposed inner surface 20. Substrate 14 passes over a series of idler rollers 22, 24, 26, 30 to a primary steering section 32 that maintains ~l~el lateral alignment of substrate 14 with a printing station 34, and more particularly with a rotatable ~el.L.dl impression cylinder 36. A nip pressure roller 38 holds or maintains substrate 14 in contact with a surface 40 of rotatable central impression cylinder 36.
After nip pressure roller 38, substrate 14 is transported by central impression cyl in~r 36 to front ink printing cylinders 42, 44, 46, which print a first ink pattern 48 (Fig. 3) on printing surface 18. Central impression cylinder 36 can be rotated in any suitable manner well known in the art.
Although Fig. 1 illustrates three front ink printing cylinders 42, 44, 46, a greater or fewer number of printing cylinders can be used to print any desired pattern on printing surface 18.
I
Continuing to refer to Fig. 1, a secondary unwind 50 supplies a continuously moving cecon~, or low basis weight, substrate 12 over an idler roller 52. The purpose of the idler rollers herein is to maintain substrates 12, 14 on a proper path through apparatus 10. Substrate 12 cont; nlles over idler rollers 56, 58, 60 to a secondary steering section 62 that ~ ~ CA 02207385 1997-0~-28 .
'~ - W O96tl6809 PCTrUS95/15167 .... .
.
. ~
-~ maintains proper lateral alignment of substrate 12 with T'n printing station 34.
. .
J7. i ~- From ~co~ry steering section 62, low basis weight substrate-- 5 12 passes over an idler roller 64 and a nip-pressure roller 66 - which maintains low basis weight substrate 12 in contact with '-~ the first substrate 14. As illustrated in Fig. 3, an ink pattern 74 is printed on printing surface 76 of low basis weight substrate 12 by back ink printing cylinders 68, 70, 72 -10 (Fig. 1). Low basis weight substrate 12 also includes an - opposed inner surface 78.
; Another feature of the present invention is the introduction of low basis weight substrate 12 into printing station 34, such - 15 that it lies on top of first substrate 14. Any ink that ~- penetrates or passes through the low basis weight substrate 12 .~ .
~= will be collected by first substrate 14. ~his is illustrated in Fig. 3 in which ink pattern 74, after it has been printed on -Y low basis weight substrate 12, has at least a portion thereof that p~c~ or strikes through low basis weight substrate 12 as .. ~. .
~- - a plurality of ink strikethroughs 80. Because first substrate 14 is between low basis weight substrate 12 and surface 40 of - central impression cylinder 36, substrate 14 collects and -~ absorbs ink strikethroughs 80, thereby eliminating ink buildup r~
=-~ ; 25 on surface 40 of central impression cylinder 36. This is ;~ important to the present invention in improving print ~uality -- and minimizing costs associated with printing, as earlier -- expl~ne~.
.
- 30 Another feature o~ the present invention is the registering of an ink pattern 74 with a substantially identical ink pattern ~ 48. Whether the patterns are of one color or multi-colors, the - ink striking through low basis weight substrate 12 will be collected or absorbed at the same color location in ink pattern 48 of the first substrate 14. This eliminates any "ghost , -..~ .
. . . . .
CA 0220738~ 1997-0~-28 patterns" on printing surface 18 of first substrate 14. This registration is accomplished by the mechAn;cal linkage or electromerhAn;cal control of the relative positions of the printing cylinders. This type of registration is well known in the printing industry. One type of registration system can be commercially obtA;ne~ from Hurletron, Inc. of Danville, Illinois.
After moving past back ink printing cylinder 72, substrates 12 and 14 may be separated from each other with substrate 14 passing through a primary tunnel 82. Within primary tunnel 82, substrate 14 is subjected to a temperature and airflow suitable for drying substrate 14 and the ink printed thereon.
Alternatively or additionally, t~nnel 82 can also be a radiation curing unit to be used in conjunction with radiation curable inks. Examples of radiation curing methods include ultraviolet curing, electron beam curing, infrared curing, and the like.
After exiting primary t~lnn~l 82, substrate 14 cont; nt-~ through primary chill rollers 84 that cool substrate 14 to reduce the substrate temperature to ambient.
Thereafter, substrate 14 pA~se~ over a series of idler rollers 86, 88, 90, 92 to be rewound by a primary rewind 93 for subsequent transport and handling.
Similarly, low basis weight substrate 12 passes through a secondary tunnel 94, through secondary chill rollers 96, and over a series of idler rollers 98, 100, 102, 104 to be rewound by a ceco~Ary rewind 106 for subsequent transport and hAn~ling. Tunnel 94 can effect a suitable temperature and airflow, or radiation curing method, on substrate 12.
-=~. CA 0220738~ 1997-05-28 _ .
W O96/16809 PCTrUS95/15167 , , .
Alternatively, the two substrates 12, 14 can be maint~i~P~ in contact after printing a pattern on them. They will then be -dried and/or cured jointly and wound on a common wind (not shown).
-- .
~ As thus described, the present invention provides for the ink printing of patterns on at least two substrates, in which one of the substrates is so porous, i.e., low basis weight, that ; ink printed thereon can strikethrough. The process of the present invention collects the ink strikethrough on the ~ - underlying substrate. The two substrates 12, 14 are thus - ~ printed in a single-pass through printing station 34.
= ~eferring to Fig. 2, there is illustrated a modification of the apparatus in Fig. 1. In Fig. 2, at the point of separation of ~- substrates 12 and 14, a primary application station 108 applies 'j a suitable liquid, such_ as a lacquer, to substrate 14, and a ~co~ry application station 110 applies a suitable liquid, such as a lacquer, to substrate 12. The lacquers, for example, ~! ' 20 serve to protect or preserve the respective ink patterns.
Other liquids can be applied to serve other desired purposes.
Apparatus 10 can be operated within an optimum speed range -~ which is desirably between about 2.5 to about 10.2 m/s (about ~ 25 500 to about 2000 feet per minute), and can be operated for an ~~ extended period of time since shutdowns caused by ink buildup ~ are eliminated. Although not illustrated, tension on substrates 12, 14 can be controlled by electro-pneumatic dancer = rolls or transducer rollers with feedback to speed control devices, as is well known in the art.
- As described earlier, each substrate can be a woven or nonwoven i - web or fabric, and desirably can be a polyolefin-based web.
-~ Polyolefin-based webs include, but are not limited to, woven - 35 materials, nonwoven materials, knits, and porous films which CA 0220738~ 1997-0~-28 employ polyolefin-based polymers. Examples of such polyolefins are poly~lopylene and polyethylene, including low density, high density, and linear low density polyethylene. It should be appreciated, however, that t ~ present invention is not limited to these types of po-yolefins, but embraces all types of polymers, copolymers, and natural fibers. In woven material applications, these materials can be made into continuous fibers, which are in turn woven into a fabric. In nonwoven applications, the fibers may be long, generally continuous fibers, such as spunbond fibers, or they may be shorter staple length fibers, such as are -~ly used in carded webs. The fibers may also be meltblown to form the desired web. Such polymers or copolymers may be extruded, cast, or blown into films for subsequent use according to the present invention.
Other nonwovens suitable for use with the present invention include airlaid, wet laid, solution spun fiber webs, or the like.
Fibers used in accordance with the present invention can be "straight" fibers in that they have the same general polymer or copolymer composition throughout. The fibers may also be multipolymer or multicomponent fibers, such as bicomponent fibers in which at least one component is a polyolefin, such as a polyolefin sheath and a polypropylene core fiber or a polyethylene sheath and a polyester core fiber. In addition to sheath/core fiber configurations, other examples of suitable fiber cross-sections are side-by-side, sea-in-islands, and eccentric fiber configurations. Furthermore, fibers with non-circular cross-sections such as "Y" and "X" shapes may be used.
The fibers and/or webs may have other components and/or treatments. For example, adhesives, waxes, flow modifiers, processing aids, and other additives may be used during the formation of the fibers or webs. In addition, pigments may be added to the fibers to change their color and other additives ~ CA 0220738~ 1997-0~-28 .
WO96/16809 PCT~S95/15167 r -' 12 t;
- may be incorporated into the compositions to make the fibers or webs elastic. Lastly, blends of fibers, as well as straight -~ and bicomponent fibers, may be combined to form nonwoven or woven webs suitable for use ~th the present invention.
The printed substrate can be used by itself, or in a multilayer configuration such as a laminate of one or more film and/or woven and/or nonwoven layers. Examples of such multilayer configurations include film/nonwoven laminates, or = lO nonwoven/nonwoven laminates such as a spunbond/meltblown/sp~lnhon~ three-layer laminate. By using such multilayer configurations, a variety of properties can be --- imparted to the laminate including breathability and/or liquid impervioll! :r~e~:C .
When forming a nonwoven, such as a nonwoven polyolefin fibrous web, the fiber size and basis weight of the material can be varied according to the particular end use. In personal care t products and medical fabric usage, typical fiber sizes will 20 range from between about O.l to about lO denier.
- While this invention has been described as having a preferred embodiment, it will be understood that it is capable of further modification. This application is thereby int~nd~ to cover =- 25 any variations, equivalents, uses, or adaptations of the invention following the general principles thereof, and ~~ including such departures from the present disclosure as come - or may come within known or customary practice in the art to which this invention pertains and fall within the limits of the - 30 appended claims.
-
AND SUBSTRATES PRINTED T~R~RY
The present invention pertains to a process for printing substrates and substrates printed thereby.
The ink printing of fabrics, such as woven and nonwoven fabrics, with various patterns and colors is well known. These printed fabrics are then in~oL~o~ated into various products, such as personal care products. Examples of personal care products include ~iArers~ training pants, incontinence products, and the like. ~he printed fabrics are primarily int~n~e~ to aesthetically ~n~ce the appearance of the products.
one problem with current ink printing procecc~ is that the ink or inks can run through, i.e., strikethrough, the fabric, and particularly a low basis weight fabric. Low basis weight fabrics are generally thin, and inherently include a large number of small voids, or a smaller number of larger voids, through which the ink can strike through. The problem with ink strikethrough is that the ink builds up on, for example, an impression cylinder of the printing apparatus. This ink buildup on the impression cylinder results in= poor print quality on the fabric, the transfer of ink to the back of the fabric, and poor operating efficiency due to machinery down time required to remove the ink buildup.
This problem becomes even more significant in high speed printing environments, where the ink buildup is accelerated and increases the number of times the machinery needs to be shut down for removal of the buildup. As the shut down times increase, so do waste of material and ink associated wit~
machinery start-up.
- - CA 0220738~ 1997-0~-28 . . .
- WO96/16809 PCT~S95/15167 .
-.~ , -~ One attempt to resolve ink buildup is the use of doctor blades on an impression roll or the like. Although doctor blades r remove ink buildup while machinery is operating, their use ~ 5 prematurely wears out the surface of the cylinder or roll supporting the fabric. This, in turn, results in increased - ~ costs due to replacing prematurely worn out equipment.
Another attempt to eliminate ink buildup is to run a layer of ~ 10 material between the fabric and print rollers. The layer is -~ designed to collect or absorb ink strikethrough and carry it -- away. This has proved to be costly, since either the layer ~- must be replaced with a new layer, or the layer must be cleaned of the ink before being rerun through the printing apparatus.
~ Therefore, it is the object of the present invention to provide - a method of printing on a substrate which prevents ;- strikethrough and avoids the prior art attempts disadvantages, and a substrate printed thereby.
--- This ob;ect is solved by the method according to indepen~nt ~ claim 1, and the substrates according to ;n~r~n~ent claims 14 and 16.
-~ 25 Further advantageous features, aspects and details of the - invention are evident from the dependent claims, the ~ description and the drawings. The claims are intended to be -~ - understood as a first non-limiting approach of defining the =~ invention in general terms.
-- 'b Accordingly, the present invention in general pertains to a ~- process for printing substrates and substrates printed -~i thereby, and more particularly to a dual substrate, single-pass - printing process and substrates printed thereby.
.
-= ~ . .
CA 0220738~ 1997-0~-28 WO96/16809 PCT~S95/15167 In one form of the present invention there is provided a process for dual substrate, single-pass printing including providing a continuously moving first substrate, moving the first substrate to an ink printing station, printing a pattern on the first substrate at the ink printing station, illL~od~cing a continuously moving c~co~ substrate between the first substrate and the ink printing station, printing a pattern on the second substrate at the ink printing station, and collecting ink striking through the second substrate onto the first substrate. The ink printing station may comprise at least one ink printing cylinder.
In another form of the present invention there is provided a printed substrate including a substrate having a printing surface and an opposed inner surface, and an ink pattern printed on the printing surface by dual substrate, single-pass printing.
In still another form of the present invention there is provided a printed substrate made by the process including providing a continuously moving first substrate, moving the first substrate to an ink printing station, printing a pattern on the first substrate at the ink printing station, illL~ cing a continuously moving s~con~ substrate between the first substrate and the ink printing station, printing a pattern on the s~co~ substrate at the ink printing station, and collecting ink striking through the second substrate onto the first substrate.
The above-mentioned and other features, aspects and advantages of this invention, and the manner of at~in;ng them, will become more apparent and the invention itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings, wherein:
--~ CA 0220738~ 1997-0~-28 WO96/16809 PCT~S95/15167 ' 4 - Fig. l illustrates schematically one apparatus operated in - ~ accordance with the principles of the present invention;
.
-~ Fig. 2 illustrates a modification to the apparatus of Fig. l;
~ 5 and .,, . . .
:
--~i Fig. 3 illustrates a fragmentary, cross-sectional view through a portion of the central impression cylinder in Fig. l.
~ .
In many prior art proc~C~ec for printing a substrate, portions . . . =
-~ of the ink applied to the substrate can pass through the t substrate and become deposited on the surface of, for example, ~ an impression cyl;n~er. This is termed "strikethrough" and - causes ink buildup on the impression cylinder. It is this ;~ 15 strikethrough and ink buildup that results in poor print - quality on the substrate, the transfer of ink to the back =~ surface of the substrate, and poor operating efficiency due to - - mach; n~ry down time required to remove the ink buildup.
. .
Moreover, ink strikethrough causes various undesirable graphic effects on the substrate, such as the smearing of colors, . . .
blurring of the pattern, misregistration, or the like. These undesirable effects are not pleasing to the consumer, and tend - to cause a perception of poor product quality and performance.
~ -25 Referring to Fig. l, there is illustrated an apparatus lO which - can be operated in accordance with the principles of the present invention to print a continuously moving low basis -~ weight substrate 12 by means of a dual substrate, single-pass -- printing process that substantially eliminates ink buildup on ;- 30 the impression cylinder. The term "substrate" includes, but is - - not limited to, woven or no~ o~en webs, porous films, ink permeable films, paper, or composite structures comprising a - combination thereof. The term "low basis weight" refers to a = substrate that has an inherent propensity for ink to - 35 strikethrough and cause ink buildup on the printing apparatus.
~ .
-.
CA 0220738~ 1997-0~-28 A nonwoven substrate is considered a low basis weight substrate when its basis weight is equal to or less than about 20 grams per square meter. A nonwoven substrate having a basis weight greater than about 20 grams per square meter will be considered a higher basis weight substrate.
The term "pattern" when used with reference to ink printing herein, includes, but is not limited to, any type of design, mark, figure, identification code, graphic, word, image, or the like.
The present invention desirably utilizes a flexographic printing process to provide the proper balance of cost effectiveness, high speed, and high quality. The printing process is suitable for printing low basis weight substrates, such as low basis weight nonwoven webs, while maint~; n; ng the tactile softness of the substrates. Flexography is a printing technology utilizing flexible raised rubber or photopolymer plates to carry the pattern to a given substrate. The flexible plates typically carry a low viscosity ink directly onto the substrate. Examples of suitable low viscosity inks include inks comprising a non-catalytic block urethane resin and a solvent blend comprising up to about 50% by volume of acetate and up to about 75% by volume of glycol ether. The solvent blend also may comprise up to about 10% by volume of alcohol.
Suitable acetates include ethyl acetate, N-propyl acetate, N-butyl acetate, isopropyl acetate, isobutyl acetate, butyl acetate, and blends thereof.
Suitable glycol ethers include ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, diethylene glycol monomethyl ether, diethylene glycol monopropyl ether, propylene glycol monomethyl ether, and blends thereof.
CA 02207385 l997-0~-28 ~;
W O96/16809 PCTrUS9~/15167 : 6 -; .
.
Suitable alcohols include ethyl alcohol, iso~opyl alcohol, N-- propyl alcohol, and blends thereof.
:
L A more detailed description of inks suitable for use with the present invention is contained in U. S. Patent Application Serial Number 08/171,309, filed December 20, 1993, which is - assigned to the assignee of the present invention, the contents of which are incorporated by reference herein.
=~ ~
.~ 10 Various flexographic printing presses can be desirably used ~-~ with the present invention, and two such designs include the central impression cylinder design and the stack-style design.
. . . .
The types of plates that can be used with the flexographic - 15 process include plates identified as DuPont Cyrel~ HL, PQS, ~- HOS, PLS, and LP, which may be commercially obtA;ne~ from E. I.
= DuPont de Nemours and Company, Inc., of Wilmington, Delaware.
Other suitable plates can be commercially obtained from BASF of ~ Clifton, New Jersey, and from W. R. Grace and Company of - 20 Atlanta, Georgia.
:
-- Although flexographic printing is desired, other printing - apparatus or combinations thereof are also contemplated by the present invention. These other printing apparatus include screen printing, rotogravure printing in which an engraved print roll is utilized, and ink jet printing in which nozzles spray ink droplets that are selectively deflected by an electrostatic charge to form the desired pattern on the substrate. It is desirable that the inks used with these - 30 apparatus have a viscosity equal to or less than about 10 centipoise.
~- The dual substrate, single-pass printing process of the present invention is a process that continuously prints low basis - 35 weight substrates. One feature of the present invention is .
CA 0220738~ l997-0~-28 WO 96/1680g PCT/US95/15167 that another substrate, also requiring ink patterns to be printed thereon, serves a~ the "back-up" material to substantially eliminate ink buildup on the printing apparatus.
The other substrate desirably has a higher basis weight than the low basis weight substrate. By eliminating ink h~ r, the present invention improves the ~uality of the printed pattern, and r~ c~C the costs of manufacture.
Referring to Figs. 1, 3, a continuously moving first, or higher basis weight, substrate 14 is supplied from a primary unwind 16. Substrate 14 includes a printing surface 18 (Fig. 3) and an opposed inner surface 20. Substrate 14 passes over a series of idler rollers 22, 24, 26, 30 to a primary steering section 32 that maintains ~l~el lateral alignment of substrate 14 with a printing station 34, and more particularly with a rotatable ~el.L.dl impression cylinder 36. A nip pressure roller 38 holds or maintains substrate 14 in contact with a surface 40 of rotatable central impression cylinder 36.
After nip pressure roller 38, substrate 14 is transported by central impression cyl in~r 36 to front ink printing cylinders 42, 44, 46, which print a first ink pattern 48 (Fig. 3) on printing surface 18. Central impression cylinder 36 can be rotated in any suitable manner well known in the art.
Although Fig. 1 illustrates three front ink printing cylinders 42, 44, 46, a greater or fewer number of printing cylinders can be used to print any desired pattern on printing surface 18.
I
Continuing to refer to Fig. 1, a secondary unwind 50 supplies a continuously moving cecon~, or low basis weight, substrate 12 over an idler roller 52. The purpose of the idler rollers herein is to maintain substrates 12, 14 on a proper path through apparatus 10. Substrate 12 cont; nlles over idler rollers 56, 58, 60 to a secondary steering section 62 that ~ ~ CA 02207385 1997-0~-28 .
'~ - W O96tl6809 PCTrUS95/15167 .... .
.
. ~
-~ maintains proper lateral alignment of substrate 12 with T'n printing station 34.
. .
J7. i ~- From ~co~ry steering section 62, low basis weight substrate-- 5 12 passes over an idler roller 64 and a nip-pressure roller 66 - which maintains low basis weight substrate 12 in contact with '-~ the first substrate 14. As illustrated in Fig. 3, an ink pattern 74 is printed on printing surface 76 of low basis weight substrate 12 by back ink printing cylinders 68, 70, 72 -10 (Fig. 1). Low basis weight substrate 12 also includes an - opposed inner surface 78.
; Another feature of the present invention is the introduction of low basis weight substrate 12 into printing station 34, such - 15 that it lies on top of first substrate 14. Any ink that ~- penetrates or passes through the low basis weight substrate 12 .~ .
~= will be collected by first substrate 14. ~his is illustrated in Fig. 3 in which ink pattern 74, after it has been printed on -Y low basis weight substrate 12, has at least a portion thereof that p~c~ or strikes through low basis weight substrate 12 as .. ~. .
~- - a plurality of ink strikethroughs 80. Because first substrate 14 is between low basis weight substrate 12 and surface 40 of - central impression cylinder 36, substrate 14 collects and -~ absorbs ink strikethroughs 80, thereby eliminating ink buildup r~
=-~ ; 25 on surface 40 of central impression cylinder 36. This is ;~ important to the present invention in improving print ~uality -- and minimizing costs associated with printing, as earlier -- expl~ne~.
.
- 30 Another feature o~ the present invention is the registering of an ink pattern 74 with a substantially identical ink pattern ~ 48. Whether the patterns are of one color or multi-colors, the - ink striking through low basis weight substrate 12 will be collected or absorbed at the same color location in ink pattern 48 of the first substrate 14. This eliminates any "ghost , -..~ .
. . . . .
CA 0220738~ 1997-0~-28 patterns" on printing surface 18 of first substrate 14. This registration is accomplished by the mechAn;cal linkage or electromerhAn;cal control of the relative positions of the printing cylinders. This type of registration is well known in the printing industry. One type of registration system can be commercially obtA;ne~ from Hurletron, Inc. of Danville, Illinois.
After moving past back ink printing cylinder 72, substrates 12 and 14 may be separated from each other with substrate 14 passing through a primary tunnel 82. Within primary tunnel 82, substrate 14 is subjected to a temperature and airflow suitable for drying substrate 14 and the ink printed thereon.
Alternatively or additionally, t~nnel 82 can also be a radiation curing unit to be used in conjunction with radiation curable inks. Examples of radiation curing methods include ultraviolet curing, electron beam curing, infrared curing, and the like.
After exiting primary t~lnn~l 82, substrate 14 cont; nt-~ through primary chill rollers 84 that cool substrate 14 to reduce the substrate temperature to ambient.
Thereafter, substrate 14 pA~se~ over a series of idler rollers 86, 88, 90, 92 to be rewound by a primary rewind 93 for subsequent transport and handling.
Similarly, low basis weight substrate 12 passes through a secondary tunnel 94, through secondary chill rollers 96, and over a series of idler rollers 98, 100, 102, 104 to be rewound by a ceco~Ary rewind 106 for subsequent transport and hAn~ling. Tunnel 94 can effect a suitable temperature and airflow, or radiation curing method, on substrate 12.
-=~. CA 0220738~ 1997-05-28 _ .
W O96/16809 PCTrUS95/15167 , , .
Alternatively, the two substrates 12, 14 can be maint~i~P~ in contact after printing a pattern on them. They will then be -dried and/or cured jointly and wound on a common wind (not shown).
-- .
~ As thus described, the present invention provides for the ink printing of patterns on at least two substrates, in which one of the substrates is so porous, i.e., low basis weight, that ; ink printed thereon can strikethrough. The process of the present invention collects the ink strikethrough on the ~ - underlying substrate. The two substrates 12, 14 are thus - ~ printed in a single-pass through printing station 34.
= ~eferring to Fig. 2, there is illustrated a modification of the apparatus in Fig. 1. In Fig. 2, at the point of separation of ~- substrates 12 and 14, a primary application station 108 applies 'j a suitable liquid, such_ as a lacquer, to substrate 14, and a ~co~ry application station 110 applies a suitable liquid, such as a lacquer, to substrate 12. The lacquers, for example, ~! ' 20 serve to protect or preserve the respective ink patterns.
Other liquids can be applied to serve other desired purposes.
Apparatus 10 can be operated within an optimum speed range -~ which is desirably between about 2.5 to about 10.2 m/s (about ~ 25 500 to about 2000 feet per minute), and can be operated for an ~~ extended period of time since shutdowns caused by ink buildup ~ are eliminated. Although not illustrated, tension on substrates 12, 14 can be controlled by electro-pneumatic dancer = rolls or transducer rollers with feedback to speed control devices, as is well known in the art.
- As described earlier, each substrate can be a woven or nonwoven i - web or fabric, and desirably can be a polyolefin-based web.
-~ Polyolefin-based webs include, but are not limited to, woven - 35 materials, nonwoven materials, knits, and porous films which CA 0220738~ 1997-0~-28 employ polyolefin-based polymers. Examples of such polyolefins are poly~lopylene and polyethylene, including low density, high density, and linear low density polyethylene. It should be appreciated, however, that t ~ present invention is not limited to these types of po-yolefins, but embraces all types of polymers, copolymers, and natural fibers. In woven material applications, these materials can be made into continuous fibers, which are in turn woven into a fabric. In nonwoven applications, the fibers may be long, generally continuous fibers, such as spunbond fibers, or they may be shorter staple length fibers, such as are -~ly used in carded webs. The fibers may also be meltblown to form the desired web. Such polymers or copolymers may be extruded, cast, or blown into films for subsequent use according to the present invention.
Other nonwovens suitable for use with the present invention include airlaid, wet laid, solution spun fiber webs, or the like.
Fibers used in accordance with the present invention can be "straight" fibers in that they have the same general polymer or copolymer composition throughout. The fibers may also be multipolymer or multicomponent fibers, such as bicomponent fibers in which at least one component is a polyolefin, such as a polyolefin sheath and a polypropylene core fiber or a polyethylene sheath and a polyester core fiber. In addition to sheath/core fiber configurations, other examples of suitable fiber cross-sections are side-by-side, sea-in-islands, and eccentric fiber configurations. Furthermore, fibers with non-circular cross-sections such as "Y" and "X" shapes may be used.
The fibers and/or webs may have other components and/or treatments. For example, adhesives, waxes, flow modifiers, processing aids, and other additives may be used during the formation of the fibers or webs. In addition, pigments may be added to the fibers to change their color and other additives ~ CA 0220738~ 1997-0~-28 .
WO96/16809 PCT~S95/15167 r -' 12 t;
- may be incorporated into the compositions to make the fibers or webs elastic. Lastly, blends of fibers, as well as straight -~ and bicomponent fibers, may be combined to form nonwoven or woven webs suitable for use ~th the present invention.
The printed substrate can be used by itself, or in a multilayer configuration such as a laminate of one or more film and/or woven and/or nonwoven layers. Examples of such multilayer configurations include film/nonwoven laminates, or = lO nonwoven/nonwoven laminates such as a spunbond/meltblown/sp~lnhon~ three-layer laminate. By using such multilayer configurations, a variety of properties can be --- imparted to the laminate including breathability and/or liquid impervioll! :r~e~:C .
When forming a nonwoven, such as a nonwoven polyolefin fibrous web, the fiber size and basis weight of the material can be varied according to the particular end use. In personal care t products and medical fabric usage, typical fiber sizes will 20 range from between about O.l to about lO denier.
- While this invention has been described as having a preferred embodiment, it will be understood that it is capable of further modification. This application is thereby int~nd~ to cover =- 25 any variations, equivalents, uses, or adaptations of the invention following the general principles thereof, and ~~ including such departures from the present disclosure as come - or may come within known or customary practice in the art to which this invention pertains and fall within the limits of the - 30 appended claims.
-
Claims (16)
1. A dual substrate, single-pass printing process, comprising:
providing a continuously moving first substrate (14), moving the first substrate (14) to an ink printing station (34), printing a pattern on the first substrate at the ink printing station (34), introducing a continuously moving second substrate (12) between the first substrate (14) and the ink printing station (34), printing a pattern on the second substrate (12), and collecting ink striking through the second substrate (12) onto the first substrate (14).
providing a continuously moving first substrate (14), moving the first substrate (14) to an ink printing station (34), printing a pattern on the first substrate at the ink printing station (34), introducing a continuously moving second substrate (12) between the first substrate (14) and the ink printing station (34), printing a pattern on the second substrate (12), and collecting ink striking through the second substrate (12) onto the first substrate (14).
2. The process according to claim 1 further comprising registering the pattern of the first substrate (14) and the pattern of the second substrate (12).
3. The process according to claim 1 or 2 further comprising drying the substrates.
4. The process according to any of the preceding claims further comprising cooling the substrates.
5. The process according to any of the preceding claims further comprising radiation curing the substrates.
6. The process according to any of the preceding claims further comprising separating the first substrate (14) and the second substrate (12) after the patterns have been printed.
7. The process according to claim 6 further comprising separately drying the substrates.
8. The process according to claim 6 or 7 further comprising separately cooling the substrates.
9. The process according to claims 6 to 8 further comprising separately radiation curing the substrates.
10. The process according to any of the preceding claims wherein the printing is flexographic printing.
11. The process according to any of the preceding claims wherein the printing is rotogravure printing.
12. The process according to any of the preceding claims wherein the printing is ink-jet printing.
13. The process according to any of the preceding claims wherein the second substrate (12) has a basis weight equal to or less than about 20 grams per square meter.
14. A printed substrate, comprising:
a substrate comprising a printing surface and an opposed inner surface, and an ink pattern printed on said printing surface by dual substrate, single-pass printing.
a substrate comprising a printing surface and an opposed inner surface, and an ink pattern printed on said printing surface by dual substrate, single-pass printing.
15. The substrate according to claim 14 wherein said substrate has a basis weight equal to or less than about 20 grams per square meter.
16. A printed substrate especially according to claim 14 or 15, obtainable by the process according to any of claims 1 to 13.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/347,983 US5501149A (en) | 1994-12-02 | 1994-12-02 | Dual substrate, single-pass printing process |
US08/347,983 | 1994-12-02 |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2207385A1 true CA2207385A1 (en) | 1996-06-06 |
Family
ID=23366161
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002207385A Abandoned CA2207385A1 (en) | 1994-12-02 | 1995-11-20 | Dual substrate, single-pass printing process and substrates printed thereby |
Country Status (12)
Country | Link |
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US (2) | US5501149A (en) |
EP (1) | EP0794868B1 (en) |
JP (1) | JPH11503373A (en) |
KR (1) | KR100375476B1 (en) |
AR (1) | AR000277A1 (en) |
AU (1) | AU701163B2 (en) |
BR (1) | BR9509943A (en) |
CA (1) | CA2207385A1 (en) |
DE (1) | DE69515127T2 (en) |
ES (1) | ES2141975T3 (en) |
WO (1) | WO1996016809A1 (en) |
ZA (1) | ZA9510095B (en) |
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US20030044578A1 (en) * | 2001-08-14 | 2003-03-06 | Nissing Nicholas James | Printed substrate with variable local attributes |
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-
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- 1994-12-02 US US08/347,983 patent/US5501149A/en not_active Expired - Fee Related
-
1995
- 1995-05-12 US US08/440,430 patent/US5597642A/en not_active Expired - Fee Related
- 1995-11-20 ES ES95942458T patent/ES2141975T3/en not_active Expired - Lifetime
- 1995-11-20 DE DE69515127T patent/DE69515127T2/en not_active Expired - Fee Related
- 1995-11-20 WO PCT/US1995/015167 patent/WO1996016809A1/en active IP Right Grant
- 1995-11-20 AU AU43679/96A patent/AU701163B2/en not_active Ceased
- 1995-11-20 BR BR9509943A patent/BR9509943A/en not_active IP Right Cessation
- 1995-11-20 KR KR1019970703661A patent/KR100375476B1/en not_active IP Right Cessation
- 1995-11-20 EP EP95942458A patent/EP0794868B1/en not_active Expired - Lifetime
- 1995-11-20 CA CA002207385A patent/CA2207385A1/en not_active Abandoned
- 1995-11-20 JP JP8518900A patent/JPH11503373A/en active Pending
- 1995-11-28 ZA ZA9510095A patent/ZA9510095B/en unknown
- 1995-12-01 AR AR33448895A patent/AR000277A1/en unknown
Also Published As
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BR9509943A (en) | 1998-01-27 |
US5501149A (en) | 1996-03-26 |
EP0794868B1 (en) | 2000-02-16 |
AU4367996A (en) | 1996-06-19 |
EP0794868A1 (en) | 1997-09-17 |
US5597642A (en) | 1997-01-28 |
MX9703972A (en) | 1997-09-30 |
DE69515127T2 (en) | 2000-09-21 |
KR100375476B1 (en) | 2003-05-16 |
DE69515127D1 (en) | 2000-03-23 |
JPH11503373A (en) | 1999-03-26 |
ES2141975T3 (en) | 2000-04-01 |
WO1996016809A1 (en) | 1996-06-06 |
AR000277A1 (en) | 1997-06-18 |
ZA9510095B (en) | 1996-06-06 |
AU701163B2 (en) | 1999-01-21 |
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Legal Events
Date | Code | Title | Description |
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EEER | Examination request | ||
FZDE | Discontinued |