U.S. patent application number 11/132825 was filed with the patent office on 2005-09-29 for consumer product package and method of manufacture.
This patent application is currently assigned to The C.W. Zumbiel Company. Invention is credited to Yock, Joseph P..
Application Number | 20050215406 11/132825 |
Document ID | / |
Family ID | 32930711 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050215406 |
Kind Code |
A1 |
Yock, Joseph P. |
September 29, 2005 |
Consumer product package and method of manufacture
Abstract
The invention relates to consumer product packages having impact
promotional items printed directly on the package and methods for
manufacturing such product packages. An image constituting the
impact promotional item is printed using blended printing inks and
sublimation dyes onto a paperboard blank, which is folded to form a
product package. The printed image has a visual appearance
substantially unchanged from a conventional printed image. The
sublimation dyes present in the printed image supply a
transferrable image component that, following transfer to a
substrate such as a fabric article, accurately reproduces the
printed image viewed by the consumer on the product package.
Printing ink and sublimation dye blends for printing the image are
also disclosed, as are methods for transferring the transferrable
image component to an article, such as a fabric article or
textile.
Inventors: |
Yock, Joseph P.;
(Cincinnati, OH) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
The C.W. Zumbiel Company
Cincinnati
OH
|
Family ID: |
32930711 |
Appl. No.: |
11/132825 |
Filed: |
May 19, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11132825 |
May 19, 2005 |
|
|
|
10646148 |
Aug 22, 2003 |
|
|
|
6916765 |
|
|
|
|
60452411 |
Mar 6, 2003 |
|
|
|
Current U.S.
Class: |
493/320 ;
156/230 |
Current CPC
Class: |
B41M 5/035 20130101;
D06P 5/006 20130101; B44C 1/1716 20130101; C09D 11/02 20130101;
B41M 1/06 20130101; B41M 1/04 20130101; B41M 1/12 20130101; B41M
1/10 20130101; B41M 5/0356 20130101; D06P 5/004 20130101 |
Class at
Publication: |
493/320 ;
156/230 |
International
Class: |
B44C 001/165 |
Claims
The invention itself should only be defined by the appended claims,
wherein I claim:
1-27. (canceled)
28. A promotional method comprising: distributing a consumer
product package including a transferrable image and a visible image
overlapping with the transferrable image printed on a panel of the
consumer product package; and instructing how to transfer the
transferrable image thermally from the panel of the consumer
product package to a substrate.
29. The method of claim 28 wherein the transferrable image is
formed from sublimation dyes, and instructing how to transfer the
transferrable image further comprises: directing a consumer to
place the panel carrying the transferrable image in contact with a
substrate; and directing a consumer to supply heat energy to the
transferrable image sufficient to sublimate the sublimation dyes to
form vapors that transfer the image to the substrate.
30. The method of claim 29 wherein instructing how to transfer the
transferrable image further comprises: directing a consumer to
apply a pressure sufficient to maintain the contact between the
transferrable image and the substrate while heat energy is supplied
to the transferrable image.
31. The method of claim 29 wherein the panel is coated, and
directing the consumer to supply heat energy further comprises:
directing the consumer to select a temperature at which the coating
on the panel becomes tacky so that the panel adheres releasably to
the substrate.
32. The method of claim 31 wherein the panel is formed from a
material selected from the group consisting of clay coated
newsback, natural kraft, uncoated recycled board, solid bleached
sulfate and coated unbleached kraft.
33. The method of claim 29 wherein the substrate is a fabric
article.
34-38. (canceled)
39. The method of claim 42 wherein the transferrable image and the
visible image are printed simultaneously on the panel.
40. The method of claim 39 further comprising: blending a printing
ink with a sublimation dye to form a composition; and applying the
composition in a pattern consistent with the visible and
transferrable images onto the panel.
41. The method of claim 39 further comprising: blending a plurality
of printing inks with a plurality of sublimation dyes to provide a
plurality of compositions; and applying each of the compositions in
a pattern consistent with the visible and transferrable images onto
the panel
42. A promotional method comprising: printing a transferrable image
capable of being thermally transferred to a substrate on a panel of
a consumer product package; and printing a visible image
overlapping with the transferrable image on the panel of the
consumer product package.
43. The method of claim 42 wherein printing the visible image
further comprises: registering features of the visible image with
corresponding features of the transferrable image.
44. The method of claim 42 wherein printing the transferrable image
further comprises: printing the transferrable image with at least
three sublimation dyes of different color proportionately present
so that said transferrable image is gray balanced.
45. The method of claim 42 wherein printing the visible image
further comprises: printing the visible image with at least three
printing inks of different color proportionately present so that
the visible image is gray balanced.
46. The method of claim 42 wherein printing the transferrable image
and printing the visible image further comprises: printing the
transferrable image and the visible image with a total thickness
ranging from about 10.sup.-6 lbs/in.sup.2 to about 10.sup.-5
lbs/in.sup.2 solid coverage.
47. The method of claim 42 wherein the panel is a portion of a
foldable blank capable of being folded to form the consumer product
package, and further comprising: folding the foldable blank to form
said consumer product package; and positioning the panel inside of
the consumer product package during folding.
48. The method of claim 42 wherein the panel is a portion of a
foldable blank capable of being folded to form the consumer product
package, the panel has a visible side and a non-visible side
opposite the visible side, and the transferrable image is located
on the non-visible side of the panel.
49. A promotional method comprising: printing a visible image on a
panel of a consumer product package printing a transferrable image
capable of being thermally transferred to a substrate on the panel
of the consumer product package such that the transferrable image
overlaps with the visible image.
50. The method of claim 49 wherein printing the transferrable image
further comprises: registering features of the transferrable image
with corresponding features of the visible image.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/452,411, filed Mar. 6, 2003, the disclosure of
which is hereby incorporated by reference herein in its
entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a consumer product package
and, more particularly, to a consumer product package bearing a
printed image having a transferrable image component.
BACKGROUND OF THE INVENTION
[0003] Consumer product manufacturers routinely include or
associate a premium with product packaging for promoting the sale
of the product beyond the marketability of the product alone.
Generally, the premium is a relatively inexpensive item provided to
the consumer as a purchase enticement without increasing the
purchase price. The premium may be an engagement on a package panel
that requires some level of consumer interaction, such as a printed
maze, a connect-the-dots pattern,.or a composite image concealing a
hidden sub-image. Alternatively, the premium may be an impact
promotional item, such as a coupon, toy, or novelty item, inserted
into the product package. One familiar example is a child's toy
inserted in a box of breakfast cereal. Typically, the impact
promotional item is retrieved from the product package after the
package is opened and/or the product is at least partially consumed
or otherwise removed.
[0004] Placing impact promotional items inside the product package,
as is conventional, suffers from several significant disadvantages.
Because the item is concealed from view, the manufacturer cannot
verify that a premium is actually present in any particular product
package. The promotional item is typically dropped by hand into the
product package, which adds labor cost and slows production. If the
promotional item is missing from the product package due to human
error, complaints from dissatisfied consumers may reduce the
product's and/or company's market appeal.
[0005] Printed advertising on the package exterior is required to
indicate the existence of the hidden promotional item. Otherwise,
the presence of the promotional item is undetectable by the
consumer. Moreover, the visibility of only a representative image
of the promotional item in the printed advertising on the exterior
of the product package reduces its promotional value. Another
disadvantage of in-package promotional items is that such items
must be sanitized and wrapped before insertion into the product
package to isolate the promotional item from the package
contents.
[0006] What is needed, therefore, is a product package and method
for its manufacture that overcomes the various deficiencies of
associating an impact promotional item with the product
package.
SUMMARY OF THE INVENTION
[0007] According to this invention, a consumer product package
includes a foldable blank having at least one panel and a
transferrable image printed onto the at least one panel. The blank
forms the product package when folded. The image is transferrable
from the panel of the blank to a substrate, such as textile, fabric
or other article.
[0008] According to the principles of the invention, an impact
promotional item for a consumer product package includes a
transferrable image printed onto a package panel, in which the
image is transferrable from the panel to a substrate such as a
fabric, textile or other article.
[0009] Another aspect of the invention is directed to a method for
applying an image to a consumer product package. The method
includes blending a printing ink with a sublimation dye and
printing the image on the consumer product package using the
blended printing ink and sublimation dye.
[0010] A still further aspect of the invention is directed to a
method for promoting a product, a service, or an organization. The
method includes putting a transferrable image on a panel of a
consumer product package and transferring the image thermally from
the panel to a textile, fabric or other article.
[0011] An impact promotional item in accordance with the principles
of the invention is relatively inexpensive and may be associated
with the product package at little or no additional manufacturing
cost or production time other than those associated with the
elements of this invention. Normal product handling is not
disrupted, unlike when conventional impact promotional items are
inserted into a product package. In contrast, the impact
promotional item is printed on the package blank before the blank
is folded to form the product package and filled with product.
Because the impact promotional item is printed directly on either
the inside or the outside of the product package, the cost of the
impact promotional item does not significantly increase the
production cost nor does the addition of the impact promotional
item slow the throughput of the package filling process for the
product package. Specifically, the impact promotional item is not
dropped by hand into the product package, which eliminates such
labor costs. Preferably, the printed image and other package
indicia are printed in a single pass through a printing line.
[0012] Every product package categorically receives an impact
promotional item as missed package drops arising from inherent
human error are eliminated. The impact promotional item of the
invention does not have to be manufactured, as are conventional
toys and novelty items, and then wrapped to maintain the sterility
of the packaged product. The product package carrying the impact
promotional item of the invention does not require any special
handling in distribution and storage. In addition, the impact
promotional item of the invention is not prone to theft while
displayed at the point of sale and is shelf stable.
[0013] A printing line does not have to be retooled to provide a
product package incorporating the impact promotional item of the
invention. The impact promotional item of the invention may be
added to a product package and delivered to the consumer with a
minimal lead time. The appearance of the transferred image
accurately reproduces the printed image so that the consumer is
able to view an accurate facsimile of the impact promotional item
before purchase. This boosts customer satisfaction, brand
recognition, product differentiation, and product sales, while
maintaining existing shelf imaging of the packaging. If necessary,
printing inks and sublimation dyes may be blended in volumetric
proportions suitable for providing a gray-balanced visible image on
the product and a gray-balanced transferred image on the new image
carrier such as a fabric, textile or other article. The visibility
of the transferred image on the new image carrier advertises the
product and/or product manufacturer to the viewing public, while
delivering value to the consumer.
[0014] In addition to packages for consumer products, the
principles of the invention are also applicable for promoting an
organization by providing a transferrable image on advertising
materials and the like. For example, the transferrable image may be
used to promote sports and civic teams, sports and civic
organizations, and sporting and civic events.
[0015] Various additional advantages and features of the invention
will become more readily apparent to those of ordinary skill in the
art upon review of the following detailed description taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a diagrammatic view of a product package bearing a
printed image in accordance with the principles of the
invention;
[0017] FIG. 2 is diagrammatic view of the product package of FIG. 1
after folding;
[0018] FIG. 3 is a diagrammatic view of a flexographic printing
line suitable for applying a printed image to a product package in
accordance with the principles of the invention;
[0019] FIG. 4 is a diagrammatic enlarged view of the printed image
of FIG. 1;
[0020] FIG. 5 is a diagrammatic view illustrating image transfer
from the product package to a fabric article;
[0021] FIG. 6 is a diagrammatic view of the fabric article of FIG.
5 carrying the image transferred from the product package;
[0022] FIG. 7 is a diagrammatic view of a product package bearing a
printed image in accordance with an alternative embodiment of the
invention; and
[0023] FIG. 8 is a diagrammatic view of a product package bearing a
printed image in accordance with an alternative embodiment of the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] This invention relates to an impact promotional item for
product packaging. In particular, this invention is directed to a
printed image initially provided on a surface of a product package
that incorporates a transferrable image component capable of being
transferred as a transferred image to a substrate, such as a
fabric, textile or other article. The image is typically printed on
a visible panel of the product package using a blend of printing
inks and sublimation dyes. The printing inks provide a visible or
observable image on the product package that is a substantially
accurate reproduction of the transferred image. If required, the
blend of printing inks and sublimation dyes may be adjusted such
that the color and gray balance of the transferred image accurately
reproduces the color and gray balance of the image printed on the
product package. As a result, the preprint design configuration
ultimately achieves visual effect in both the package state and in
the post-manufacturing sublimation application state. The
appearance of the printed image on the product package is
substantially unaffected by the blending of the sublimation dyes
with the printing inks and is comparable to conventional printed
ink images on product packages. The product package has a dual
functionality for conventional usage and for promotional
qualities.
[0025] With reference to FIGS. 1 and 2, a printed pattern or image
10 is provided, as described below, as an impact promotional item
on a board panel 11 of a carton blank 12 (FIG. 1) shaped as a flat
parallelogram. The panels of blank 12 are folded along various fold
lines and glued, after printing and forming, to define a
three-dimensional product package 14 (FIG. 2). The product package
14 surrounds an interior space 13 capable of receiving a packaged
product (not shown). Blank 12 includes an image side 90 that
carries the printed image 10 and a non-image side 94, opposite to
image side 90, that faces inwardly toward the interior space 13. A
significant portion of the image side 90 is visible to an observer
when the blank 12 is folded to form the product package 14.
Additional printed indicia 17 pertinent to the product, such as
product and brand identifiers, nutritional labels, bar codes, and
other artwork, are also printed using one or more conventional
printing inks on the panels of at least the image side 90 of blank
12.
[0026] The invention contemplates that the product package 14 may
have any geometrical configuration characteristic of conventional
product containers or cartons. Examples of such product packages
are disclosed in U.S. Pat. Nos. 5,682,984, D290,584, 6,494,324,
6,082,614 and 3,549,082, each of which is hereby incorporated by
reference herein in its entirety.
[0027] The printed image 10 may be positioned without limitation on
the image side 90 of blank 12 and, subsequently on product package
14. The printed image 10 may be excised from the board panel 11
using a conventional cutting device, such as a pair of scissors.
Alternatively, the printed image 10 may be encircled by score or
tear lines 15 to facilitate removing the printed image 10 from the
product package 14. Generally, the board panel 11 of blank 12
bearing the printed image 10 is perceivable to an observer or
consumer viewing the exterior of the product package 14. If the
product package 14 is commercially displayed, the printed image 10
may be positioned on a board panel 11 that is not observable from
the front of the product package 14, although the invention is not
limited to application to observable panels, which maintains brand
recognition.
[0028] Blank 12 is formed from any of the grades or types of
paperboard used in folding carton manufacture that are printing ink
and sublimation dye receptive materials. In particular, blank 12
may be formed from paperboards such as clay coated newsback (CCN),
uncoated recycled board (URB), solid bleached sulfate (SBS),
natural kraft (NK), or coated unbleached kraft (CUK) available
commercially as solid unbleached sulfate.TM. (SUS.TM.) from
Riverwood International (Atlanta, Ga.) or as coated natural
kraft.TM. (CNK.TM.) from MeadWestvaco Corporation (Stamford,
Conn.). Typically, these grades of paperboard have a thickness that
ranges from about 0.010 inches to about 0.032 inches. Blank 12
commonly has a surface coating that becomes tacky or sticky when
heated so that contacting objects become removably adhered.
[0029] The printed image 10 is a composite of two overlapping and
interlaced components--a transferrable image component and a
visible image component--that are reverse printed onto the panel 11
or other portion of the package 14. As a result, the transferrable
and visible images constituting printed image 10 are a mirror or
reverse image of a transferred image 16 (FIG. 7). Features of the
transferrable image component are typically registered with the
features of the visible image component. The printed image 10 may
be surrounded by a white or non-colored border (not shown) to
clearly demarcate the image boundary. In certain embodiments of the
invention, the visible image component of the printed image 10 may
have features not present in the transferrable image component and,
conversely, the transferrable image component of the printed image
10 may have features absent from the visible image component. The
invention also contemplates that more than one distinct printed
image 10 may be provided on separate surface areas of blank 12.
[0030] The transferrable image component is constituted by
sublimation dyes having thermal transferability when brought into
contact with a new image carrier or substrate, such as a fabric
article 20 (FIG. 7), and heated above a characteristic sublimation
temperature. The sublimation dyes sublimate directly to the vapor
state from the solid state for vapor-phase transport across the gap
between the printed image 10 and fabric article 20 to the fibers
forming fabric article 20. The sublimation vapors color the fibers
constituting the fabric article 20, with the colors of the printed
image 10 being reproduced in the transferred image 16 (FIG. 6). The
visible image component of printed image 10 is constituted by
printing inks that are preferably stable at temperatures at which
the sublimation dyes sublimate.
[0031] The different colors of printing inks used to form the
visible image component are each blended with a corresponding color
of sublimation dye used to form the transferrable image component.
Typically, the printing inks and sublimation dyes are both either
water-based or solvent-based and miscible, and are homogeneously
blended before being applied by a printing process to the board
panel 11 of blank 12.
[0032] Printing inks are fluid or viscous compounds including a
pigment that provides color and opacity finely dispersed in a
vehicle typically including resin and a carrier. After the carrier
is removed by evaporation, the pigment and resin of the printing
ink form a hard film residue having the features of printed image
10 on board panel 11. Generally, sublimation dyes suitable for use
in the invention are disperse dyes, such as those listed in the
Colour Index, which is a publication that contains information on
dye structures, classifications, manufacturers and processes.
Disperse dyes suitable for use in the invention include, but are
not limited to, azo, anthraquinone, quinophthalone, nitro,
azomethine, and styryl-type dyes, which are disclosed, for example,
in U.S. Pat. No. 4,576,610 (Donenfeld), U.S. Pat. No. 4,654,044
(Gilardone), U.S. Pat. No. 4,202,663 (Haigh), U.S. Pat. No.
4,021,591 (DeVires), U.S. Pat. No. 3,508,492 (Seibert), U.S. Pat.
No. 3,502,495 (Akamatsu), and U.S. Pat. No. 2,911,280 (Cicogna),
each of which is incorporated herein by reference in its entirety.
Sublimation dyes and printing inks particularly suitable for
rotogravure, lithography (offset, screen, silkscreen) and
flexography are commercially available from Sun Chemical
Corporation (Fort Lee, N.J.).
[0033] The printing ink and sublimation dye are blended to
correlate the ink film thickness on the paperboard comprising the
blank 12 with the density and thickness of the paperboard. The film
thicknesses of the printing process are at levels of about
10.sup.-6 lbs/in.sup.2 to about 10.sup.-5 lbs/in.sup.2 solid
coverage. Blank 12 is exposed to a heated environment inside a
drying oven between successive printing steps that apply
differently colored sub-images in the composite multi-color printed
image 10. The film thickness must be controlled so that the
sublimation dye is not adversely affected as each blend of printing
ink and sublimation dye is dried before successive steps in the
printing process to prevent smearing. In determining an appropriate
film thickness, solvent or water vapor elimination during drying,
which is related to the ink film thickness, is balanced against the
stabilization of the specific blend without premature activation of
the sublimation properties of the sublimation dye in the drying
oven. Typically, the drying oven operates in the range of about
110.degree. F. to about 280.degree. F. and the sublimation dyes
should be substantially stable in this temperature range. The speed
of the printing line may be slowed if the film thickness is overly
thick as the solvent or water content, which is substantially
removed by heating, increases with increasing film thickness.
[0034] The transferrable image component and the visible image
component may be produced by a suitable color printing process,
such as a four-color process using a CMYK (cyan, magenta, yellow
and black) color scheme or a hexachrome color process, or in
particular, the PANTONE hexachrome color process that uses six
primary colors (cyan, magenta, yellow, orange, green, and black).
The printing inks and sublimation dyes may be blended in volumetric
proportions suitable for providing a gray-balanced visible image on
board panel 11 and a gray-balanced transferred image on fabric
article 20 (FIG. 7). Gray balance in the transferred image 16 is
achieved by providing proper proportions of the sublimation dyes,
such as the colors yellow, magenta and cyan during a four-color
printing process, to create the appearance of neutral gray with no
apparent dominant hue after application to the fabric article 20.
Similarly, gray balance in the visible image component of printed
image 10 is achieved by providing proper proportions of the
printing inks, such as the colors yellow, magenta and cyan in
four-color process printing, to create the appearance of neutral
gray with no apparent dominant hue. It is apparent by a person of
ordinary skill in the art that the transferrable image component
contributes to the perceived appearance of the printed image 10
and, therefore, gray balancing the visible image component must
take the presence of the sublimation dyes into account.
[0035] To that end, the blend of printing inks and sublimation dyes
used to print the printed image 10 may be adjusted proportionately
to one another to provide proper gray balance in both the visible
image component prominent on the product package 14 and the
transferred image 16 transferred to fabric article 20. In an
exemplary four-color CMYK process found to provide acceptable gray
balance in printed image 10 and in transferred image 16, the yellow
sub-image was printed with a 5:1 ratio of yellow printing ink to
yellow sublimation dye, the magenta sub-image was printed with a
3:1 ratio, the cyan sub-image was printed with a 3:1 ratio, and the
black sub-image was printed with a 2:1 ratio. As a result of the
gray balance adjustment, the visible image component of the printed
image 10 on the product package 14 resembles the transferred image
16 on the fabric article 20 and, preferably, the transferred image
16 represents an accurate reproduction of the printed image 10. The
gray balance will vary depending upon the characteristics of the
visible image component and the transferred image 16.
[0036] The invention contemplates that, in certain embodiments, the
transferrable and visible image components of printed image 10 may
be monochrome or printed using any other color combination rather
than a four-color CMYK process, such as a five-color process, a
hexachrome process, or a seven-color process. The printed image 10
may also be line copy consisting of solid lines and/or areas of
specialty or line colors, which represent single colors blended for
shade. Such line colors may be incorporated in any of the printed
processes for providing the printed image 10.
[0037] FIG. 3 illustrates a flexographic printing line, generally
indicated by reference numeral 22, that is capable of applying a
series of substantially identical printed images 10 (FIG. 1) to a
continuous web 24 unrolled from a supply roll 25. After printing,
the web 24 is subsequently transformed into multiple blanks 12 by a
forming process such as rotary die cutting. The flexographic
printing line 22 includes a plurality of, for example, four
stations 26, 28, 30 and 32 that each transfer a sub-image from
among multiple color sub-images of printed image 10 in one of the
characteristic colors of blended printing ink/sublimation dye to
the web 24. The flexographic printing line 22 also includes
additional stations (not shown) capable of repeatedly printing the
indicia 17 (FIG. 1) on the web 24 using conventional printing inks.
The invention contemplates that, if the printed image 10 can be
printed using less than four stations 26, 28, 30 and 32, the unused
ones of stations 26, 28, 30, and 32 may be used to print indicia
17.
[0038] As the stations 26, 28, 30 and 32 are identical, the
following discussion of station 26 is equally applicable to
stations 28, 30 and 32. Station 26 includes a set of rollers 34, 36
and 38, a flexible printing plate 40 attached to the curved outer
surface of roller 38, and a drying oven 42. A replica of one of the
color sub-images is graphically designed and transferred to the
flexible printing plate 40 by any conventional technique, such as
etching, laser engraving, or photolithography. The sub-image
replica includes a relieved non-image area and a raised image area
projecting above the non-image area. Roller 34 transfers amounts of
the blend of printing ink and sublimation dye to the raised image
areas on the flexible printing plate 40 at the nip between rollers
34 and 36. Subsequently, as roller 36 turns, the flexible printing
plate 40 contacts the web 24 at the nip between rollers 36 and 38
and the blend of printing ink and sublimation dye is drawn out by
absorption from the wetted raised areas of the flexible printing
plate 40 to the web 24 so as to transfer the sub-image to the web
24. The web 24 is conveyed, typically in a convoluted path, through
the drying oven 42 in which heat is applied to remove water or
solvent from the transferred sub-image of printing ink and
sublimation dye before the web 24 is transferred to the subsequent
station 28. Similarly, a second color sub-image is transferred to
the web 24 in station 30 by cooperative operation of rollers 44,
46, 48, flexible printing plate 50, and drying oven 52, a third
color sub-image is transferred to the web 24 in station 32 by
cooperative operation of rollers 54, 56, 58, flexible printing
plate 60, and drying oven 62, and a fourth color sub-image is
transferred to the web 24 in station 34 by cooperative operation of
rollers 64, 66, 68, flexible printing plate 70, and drying oven
72.
[0039] The printing line 22 is coordinated or synchronized such
that the different color sub-images printed by the various stations
26, 28, 30 and 32 are registered and constructively add to form
printed image 10. Printing line 22 may be used, for example, to
print printed image 10 with a four-color CMYK color printing
process. The printed image 10 may be color balanced, although the
invention is not so limited. The number of stations required in
printing line 22 to print printed image 10 onto the web 24 depends
upon the characteristics of printed image 10. For example, printed
images 10 that are monochrome may be printed using a single one of
stations 26, 28, 30 and 32 or printed images 10 that are dual color
may be printed using two of the stations 26, 28, 30 and 32.
Additional stations, similar to stations 26, 28, 30 and 32, may be
added to the printing line 22 to print printed images 10 that are,
for example, five-color, hexachrome or seven-color. An additional
station may also be provided for applying a protective layer of
water-base acrylic over the printed image 10.
[0040] The invention contemplates that printed image 10 may be
produced by other mass-production, in-line printing techniques,
such as rotogravure, lithography (offset), and screen (silkscreen)
printing, capable of transferring an image to paperboard. For
example, rotogravure is a rotary printing process in which the
image is etched into a metal printing plate attached to a drum or
cylinder. The cylinder is rotated through a trough containing
printing ink and sublimation dye after which the etched surface is
wiped clean by a doctor blade leaving the non-image area clean. The
web is then passed between two rollers and pressed against the
printing plate.
[0041] An existing printing line may be easily converted to a
printing process that incorporates printed image 10, which provides
cost effectiveness and efficiency due to the ready
interchangeability. To that end, one or more printing plates are
fabricated and installed in the existing printing line and the
blended printing inks and sublimation dyes are substituted for
conventional printing inks in those stations in the existing
printing line that are applying the printed image 10. When the
printing line is operational, the web 24 may be printed with a
succession of images 10, in addition to indicia 17, without a
reduction in production rate or throughput.
[0042] With reference to FIG. 4, the printed image 10 may be
defined by more than one sub-image. The number of sub-images
constituting printed image 10 depends upon the particular color
printing process and the properties of the printed image 10 and the
graphic design. In the four-color printing process illustrated in
FIG. 3, a first color sub-image 73 incorporates a blend of a first
sublimation dye 74 dispersed in a first printing ink 76, a second
color sub-image 77 incorporates a blend of a second sublimation dye
78 dispersed in a second printing ink 80, a third sub-image 81
incorporates a third sublimation dye 82 dispersed in a third
printing ink 84, and a fourth sub-image 85 incorporates a fourth
sublimation dye 86 dispersed in a fourth printing ink 88. With
regard to the exemplary four-color flexographic printing process
depicted in FIG. 3, the first sub-image 73 is applied at station 26
by transfer from raised image areas on printing plate 40, the
second sub-image 77 is applied at station 28 by transfer from
raised image areas on printing plate 50, the third sub-image 81 is
applied at station 30 by transfer from raised image areas on
printing plate 60, and the fourth sub-image 85 is applied at
station 32 by transfer from raised image areas on printing plate
70.
[0043] The sublimation dyes 74, 78, 82, and 86, after drying,
constitute the transferrable image component of printed image 10
and the printing inks 76, 80, 84, and 88 principally constitute to
the visible image component of printed image 10. The sublimation
dyes 74, 78, 82, and 86 contribute the visual appearance of the
printed image 10 but, primarily, participate in the visual
appearance of the transferred image 16 on the fabric article 20 as
the color effect of each of the sublimation dyes 74, 78, 82, and 86
is not fully manifested until after sublimation transfer.
[0044] With reference to FIGS. 5 and 6, the transferable image
component of the printed image 10 may be transferred as a
transferred image 16 from the image side 90 (FIG. 1) of the board
panel 11 to a new image carrier or substrate, such as a textile or
a fabric article 20. The substrate may be, as a more specific
example, a shirt of either cotton, a synthetic textile such as
polyester, or a cotton-synthetic blend. To accomplish the transfer,
the image side 90 of the board panel 11 carrying printed image 10
is positioned in a contacting relationship with a desired location
on the fabric article 20. Alternatively, the portion of the board
panel 11 carrying printed image 10 may be removed from panel 11
with a cutting device or by tearing along a perforation or the
score lines 15.
[0045] A substantially constant pressure is applied by a heating
device 92, such as a conventional iron or steam iron, to the
non-image side 94 of the board panel 11 opposite to image side 90.
The constant pressure applied by the heating device 92 provides a
steady contact and proximity between the board panel 11 and the
fabric article 20, which improves the transfer quality by reducing
their separation. Heat is transferred from the heating device 92
through the thickness of the board panel 11, the sublimation dyes
74, 78, 82, and 86 (FIG. 4) in the printed image 10 are heated to a
temperature sufficient to cause sublimation, and the sublimation
dyes 74, 78, 82 and 86 sublimate as vapor or gas. Preferably, the
pressure and temperature from heating device 92 are uniformly
distributed over the board panel 11 in order to avoid blurring and
distortion of the transferred image 16 and the uniform pressure and
temperature are maintained for a time adequate to accomplish image
transfer. Vapors are transferred from the sublimed sublimation dyes
74, 78, 82, and 86, in accordance with the pattern of the printed
image 10, so that a replica of the printed image 10 is reproduced
on the fabric article 20. Typically, the transfer process takes
approximately 1 minute to 4 minutes at a temperature of about
325.degree. F. to about 400.degree. F. and with pressure in a range
of about 3 pounds per square inch (psi) to about 40 psi applied
during heating.
[0046] The invention contemplates that the transfer process may be
accomplished using other types of heating devices 92, such as a
conventional heat press, a conventional infrared
illumination/heating system with applied pressure from a
conventional pressure-exerting apparatus or a conventional
resistance or microwave-type heating oven with applied pressure
from a conventional pressure-exerting apparatus. The invention
further contemplates that the transferrable image component of the
printed image 10 may be utilized multiple times to transfer an
image to a different fabric article 20, limited only by exhaustion
of the sublimation dyes 74, 78, 82, and 86 in the printed image
10.
[0047] The coating on most board grades softens and becomes tacky
or sticky when heated so that the board panel 11 carrying printed
image 10 (FIG. 1) releasably adheres to the fabric article 20.
Generally, the temperature required to sublimate the sublimation
dyes 74, 78, 82, and 86 in the transferrable image component of the
printed image 10 is sufficient to cause the surface coating of the
board panel 11 to become tacky. This temporary adhesion maintains
the board panel 11 carrying printed image 10 stationary relative to
the fabric article 20 during the transfer process. As a result, the
transferred image 16 is significantly less likely to be blurred or
distorted due to unintentional movement of the board panel 11 and
printed image 10 relative to the fabric article 20 for the duration
of the transfer process.
[0048] With reference to FIG. 7 in which like reference numerals
refer to like features in FIGS. 1-6 and in accordance with an
alternative embodiment of the invention, a printed image 100,
similar or identical to printed image 10 (FIG. 1), may be applied
at a location on the non-image side 94 of the blank 12. This would
likely require one pass through a printing line to apply indicia 17
(FIG. 1) to the image side 90 of blank 12 and a second pass through
a printing line to apply the printed image 10 on the non-image side
94. When the blank 12 is folded to form product package 14 (FIG.
2), printed image 100 faces inwardly toward the interior space 13
and is hidden or concealed from an observer. Therefore, as printed
image 100 is not visible on the product package 14, the printed
image 100 may be printed using blends of printing inks and
sublimation dyes for each color used to construct the printed image
100 or, alternatively, may be printed using only sublimation dyes.
The printed image 100 is applied in the same or similar manner as
printed image 10, as described above, and has the same or
substantially the same characteristics as printed image 10, also as
described above. Despite the need for a second pass, printed image
100 remains cost-effective relative to conventional promotional
items as the costs of item wrapping and package dropping are
avoided and the costs associated with manufacturing a toy or
novelty item are not incurred.
[0049] With reference to FIG. 8 in which like reference numerals
refer to like features in FIGS. 1-7 and in accordance with an
alternative embodiment of the invention, a printed image 102,
similar or identical to printed image 10 (FIG. 1) and printed image
100 (FIG. 7), may be applied on a panel 104 extending from a side
edge of a blank 106 similar to blank 12 (FIG. 1). Printed image 102
may be printed on either the image side 108 or the non-image side
(not shown) of panel 104. As a result, printed image 102 and
indicia 17 may be printed using one or more passes through a
printing line. When the blank 12 is folded to form product package
14 (FIG. 2), the panel 104 bearing printed image 102 is disposed
inside of the interior space 13 and hidden from the view of an
observer or consumer. Therefore, as printed image 102 is not
visible on the product package 14, the printed image 102 may be
printed using blends of printing inks and sublimation dyes for each
color used to construct the printed image 102 or, alternatively,
may be printed using only sublimation dyes. The printed image 102
is applied to the blank 106 in same or similar manner as printed
image 10 is applied to blank 12, as described above, and has the
same or substantially the same characteristics as printed image 10,
also as described above.
[0050] While the present invention has been illustrated by a
description of various preferred embodiments and while these
embodiments have been described in considerable detail in order to
describe the best mode of practicing the invention, it is not the
intention of applicant to restrict or in any way limit the scope of
the appended claims to such detail. Additional advantages and
modifications within the spirit and scope of the invention will
readily appear to those skilled in the art.
* * * * *