U.S. patent application number 15/654119 was filed with the patent office on 2017-11-02 for absorbent articles having variable data thereon and systems and methods for printing such articles.
The applicant listed for this patent is Taylor Corporation. Invention is credited to Ron Hoffmeyer, Martin Koebel, Craig E. Krone.
Application Number | 20170312136 15/654119 |
Document ID | / |
Family ID | 46785821 |
Filed Date | 2017-11-02 |
United States Patent
Application |
20170312136 |
Kind Code |
A1 |
Koebel; Martin ; et
al. |
November 2, 2017 |
ABSORBENT ARTICLES HAVING VARIABLE DATA THEREON AND SYSTEMS AND
METHODS FOR PRINTING SUCH ARTICLES
Abstract
Printed articles having unique data thereon, and flexible
substrate printing systems and methods that allow for customization
of flexible, absorbent substrates. Customization is accomplished by
printing variable data on substrate stock in a single run or
production pass such that at least some of the articles in a set of
articles contains printed matter different from printed matter on
other articles in the same set. The substrate stock can include
napkin material, toilet tissue material, paper towel material, or
any other similar substrate. One or more print engines are
configured to receive substrate stock from the conveyor and print
variable matter on the substrate stock. The methods and systems
allow for economical and efficient production of small or large
customer orders without the need to produce individual printing
dies or plates.
Inventors: |
Koebel; Martin;
(Bloomington, IL) ; Krone; Craig E.; (Mankato,
MN) ; Hoffmeyer; Ron; (Dana Point, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Taylor Corporation |
North Mankato |
MN |
US |
|
|
Family ID: |
46785821 |
Appl. No.: |
15/654119 |
Filed: |
July 19, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13595172 |
Aug 27, 2012 |
9737440 |
|
|
15654119 |
|
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|
|
61527939 |
Aug 26, 2011 |
|
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61534720 |
Sep 14, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06T 11/203 20130101;
Y10T 428/24802 20150115; B41J 3/407 20130101; B41M 5/0047 20130101;
B42D 15/0093 20130101; B41J 11/0085 20130101; A61F 13/15
20130101 |
International
Class: |
A61F 13/15 20060101
A61F013/15; B41J 3/407 20060101 B41J003/407; B41M 5/00 20060101
B41M005/00; B41J 11/00 20060101 B41J011/00; G06T 11/20 20060101
G06T011/20; B42D 15/00 20060101 B42D015/00 |
Claims
1. A system for customizing at least one individual napkin in a set
of napkins, the system comprising: a database or files containing a
set of data to be printed on a set of napkins in a single run,
wherein the set of data comprises variable data to be printed on a
napkin or napkins within the set of napkins in a single run; napkin
stock comprising a plurality of napkins; at least one digital
printing engine adapted to print the napkin stock with the set of
variable data, wherein the at least one digital printing unit is
plateless or dieless; and means for transporting the napkin stock
to and from the at least one digital printing engine, wherein at
least one of the individual napkins in the set of napkins printed
in a single run contains printed data different from the printed
data on other individual napkins in the set of napkins printed in
the single run.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
13/595,172 filed Aug. 27, 2012, which claims the benefit of U.S.
Provisional Application No. 61/527,939 filed Aug. 26, 2011 and U.S.
Provisional Application No. 61/534,720 filed Sep. 14, 2011, both
entitled SYSTEMS AND METHODS FOR PRINTING OF ABSORBENT SUBSTRATES
WITH VARIABLE DATA, and each of which is incorporated herein in its
entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to printed absorbent
substrates, and more particularly, to digital printing on absorbent
substrates, such as paper napkins, with variable data.
BACKGROUND OF THE INVENTION
[0003] Flexible, absorbent substrates are used in many everyday
items, like tissue items such as napkins and paper towels. Many
occasions or events provide for the personalization of such items.
For example, personalized wedding napkins can add an accent to the
theme of a wedding reception. Personalized wedding cocktail napkins
can feature, for instance, the date of the wedding, the bride's and
groom's names or initials, or a meaningful quote or expression, and
are something that is highly impactful on the wedding reception
guests. It can also be highly desirous to have personalized napkins
at other occasions and events, like birthday parties, business
events, or baby showers, for example.
[0004] Generally, in traditional printing systems, the
personalization of flexible substrates is limited to a single
uniform or static print on the substrate in that the same exact
print is repeated on each and every napkin within the print run.
Thus, the level of data is non-variable between substrates of the
same run or production pass, i.e. it is non-variable data. In the
wedding reception example described above, a single production pass
can create the napkins for the wedding reception. However,
implementing differing details between subsets of the production
run of napkins is infeasible without doing a secondary production
run. For example, napkins cannot be generated in the same
production run for a certain subset of guests (e.g. a groom's
friends) that contain unique information, such as a photo or
graphic, message or quote directed to the subset of guests with
different information for another subset of guests (e.g. the
bride's parents). Likewise, a set of napkins, each napkin having
unique information, such as the name of an individual guest printed
on it, similarly cannot be generated in the same production
run.
[0005] Traditionally, printed absorbent substrates, such as
napkins, are produced either on letterpress equipment using dies or
polymer plates, or through the use of flexographic printing, screen
printing, or di-sublimation heat transfer. In the case of processes
utilizing letterpress equipment, the production of a die or plate
is required, which can be expensive to produce for even a single
run of printing where all of the printed matter is uniform.
Further, in the case of the variable data described above, creating
a die or plate for each iteration of variable data is impractical.
In the case of the flexographic, screen, or di-sublimation
techniques, equipment components also vary, depending on the
information to be printed. Additionally, the size of the substrates
and desired size of the printed material can vary, even within the
materials for the same event or occasion. Beverage-size,
luncheon-size, and dinner-size napkins, as well as the printing
prior to or after conversion, further affects the equipment used in
the various traditional processes. For example, the printing of
converted napkins using traditional processes can result in poor
printing quality and/or registration and is limited to static print
with no means to apply variable data at an economical cost.
[0006] Thus, there remains a need for systems and methods of
printing on absorbent substrates which can produce a high-quality
printed substrate having personalized, varied data between pieces
in a single production run.
SUMMARY OF THE INVENTION
[0007] The systems and methods of the present application
substantially meet the aforementioned needs of the industry. The
present invention provides embodiments of an absorbent substrate
printing system and methods capable of printing varied data among a
single production run, eliminating make ready setups for separate
runs, such as change-out or reconfiguration of any of printing
plates or dies, materials including inks and substrates, data to be
printed, and/or combinations thereof.
[0008] The absorbent substrate printing system and methods
according to embodiments of the present invention allows for the
personalization of absorbent substrates. Thus, personalized matter
can be printed on a stock of absorbent substrates that is chosen,
such as facial tissue, tissue paper, napkins, or paper towels.
Further, embodiments of the present invention allow for the
personalization of absorbent substrates by printing variable data
on the substrate stock in a single run or production pass such that
at least some of the individual substrate stock contains printed
matter different from printed matter on other individual substrate
stock. Therefore, in an embodiment of substrate stock comprising
wedding napkins, a subset of unique napkins can be generated in the
same production run for a first subset of guests that contains
unique printed information, such as text, graphics, photos,
symbols, or the like, as napkins with different unique information
for a second subset of guests. Further, a set of napkins can be
generated, in the same production run, which includes unique
information, such as the name of each individual guest, on a
different napkin.
[0009] An advantage of embodiments of the present invention is that
multiple orders during a single production run is more economically
and technically feasible. For example, a gang run, in which
multiple (and different) customer orders are printed during a
single run or continuously in series by combining several orders
right after each other, is easily and efficiently run because the
data for each customer order can easily be converted based on
programming commands, while only requiring a single production run
or minimal changeover (e.g. change of stock) between orders.
Furthermore, all of the data required for the gang run is contained
in a single batch file that is streamed to the print head. These
are advantages over traditional printing systems because to run
multiple orders in a single run, the time and costs required to
calculate ideal gang run impositions can be cost prohibitive, and
often times the ability to gang run jobs is unavailable or
infeasible.
[0010] Another feature and advantage of embodiments of the present
invention is that no plate or die is required. In embodiments, a
digital (e.g. ink jet), and non- or low-impact print engine
comprising a singular or multiple print heads combined in an array
prints onto the substrate. Therefore, production costs are reduced,
as no expensive plate or die needs to be created. Production costs
are further reduced between production runs, as no plate or die
needs to be switched out for each variable data element printed on
the substrate. Additionally, because no switching of plates or dies
is required, the production process is faster and more
efficient.
[0011] Another feature and advantage of embodiments of the present
invention is that the printed napkins no longer have the printing
die impressions left from the pressure of the die hitting the
flexible substrate. Also, because the impression of the die hitting
the flexible substrate is eliminated, there is less "waste" because
fewer napkins, for example, are ripped or receive tears during
production. Furthermore, the impression from the dies would
sometimes result in the layers of the flexible substrate "sticking"
together, resulting in the user of the napkin experiencing
difficulty in opening the napkin (the faces of the napkin would be
stuck together). The elimination of this impression leaves the
napkins without die marks, fluffier, and easier to open and
use.
[0012] Another feature and advantage of embodiments of the present
invention is that the personalized printing can be done before
and/or after conversion of the napkin or tissue product. In an
embodiment, napkins are converted, i.e. folded, embossed to add
ruffles or other non-printed patterns, and cut into the final
napkin form, before they are printed. In another embodiment, raw
stock material, such as in the form of a roll or web, is printed
prior to being folded and cut. In this embodiment, subsequently,
roll material is printed prior to the conversion process into the
final napkin form.
[0013] Another feature and advantage of embodiments of the present
invention is the combining of ink jet printing onto porous flexible
substrate stock, like napkin stock. This allows for high-quality
printing to be achieved on substrates that are traditionally
difficult to print. By offering high-quality printing, indicia that
has not previously been successfully printed on porous or absorbent
substrates due to bleeding of the ink and the limitations of dies
or plates can now be used. Such indicia can include, for example,
small text, high-quality images such as photos or graphics,
graphics or text incorporating intricate designs, patterns, and/or
colors, 2D codes such as QR codes, barcodes, including variable
designs, patterns and colors from substrate to substrate/napkin to
napkin, and the like.
[0014] Another feature and advantage of embodiments of the present
invention is the printing of absorbent substrate stock with digital
technology. As mentioned above, in embodiments, a digital ink jet
non-impact or low-impact printer produces the print on the
substrate. In another embodiment, a laser printer creates the
printed matter on the substrate. Other digital printing
technologies are also considered and the invention is not limited
to those discussed herein.
[0015] Because the printing process is digital whereby there are no
plates or dies, and the data can be varied among a single
production run, the quantity of a single production run can be from
one into the millions all containing similar or variable print
elements. In addition, one or more customer orders can be run in
batch mode (i.e. gang-run) eliminating make ready setups for
separate runs, thereby reducing cost, time, etc. Further, the
digital printing is not limited by the size of the substrate stock,
but only by the size of the print head. Therefore, by utilizing an
array of print heads, the print size is virtually unlimited.
Differing print heads can be utilized in order to change the print
area. The printed matter can be a unique image, pattern, code,
text, 2D code, barcode, other graphical elements, or any
combination thereof.
[0016] The above summary of the invention is not intended to
describe each illustrated embodiment or every implementation of the
present invention. The figures and the detailed description that
follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawings, in which:
[0018] FIG. 1 is a block diagram of a flexible substrate printing
system according to an embodiment of the invention; and
[0019] FIG. 2 is a block diagram of the print engine of FIG. 1;
and
[0020] FIG. 3 depicts a method of printing variable data onto
absorbent substrates, according to an embodiment of the
invention;
[0021] FIG. 4 is a block diagram of three substrates having varied
printed data, according to an embodiment of the invention; and
[0022] FIG. 5 is a block diagram of a web-based flexible substrate
printing system according to an embodiment of the invention.
[0023] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described but rather to
include all modifications, equivalents, and alternatives.
DETAILED DESCRIPTION OF THE DRAWINGS
[0024] In an embodiment, a flexible, absorbent substrate printing
system is shown generally at 100 in FIG. 1. Printing system 100
generally comprises one or more optional feeders 102, a conveyor or
transport device 104, one or more print stations or engines 106,
one or more optional cure stations (not shown), and one or more
deliverers 108.
[0025] Substrate stock 110 generally comprises the material on
which the printing is done. Substrate stock 110 can therefore
comprise napkin material, toilet tissue material, facial tissue
material, tissue paper material, paper towel material, or any other
similar absorbent or porous substrate in either web or
discrete/batch format. In an embodiment, substrate stock 110
comprises converted stock that is printed when substrate stock 110
is in an unfolded form, a partially-folded form, or a final folded
form.
[0026] Feeder 102 comprises a receiver configured to receive
substrate stock 110 and a transporter configured to place substrate
stock 110 on transport device 104. Feeder 102 can comprise any of a
variety of suitable feeders for placing substrate stock 110 on
transport device 104 or other transport device, such as, for
example, continuous feeders, vacuum feeders, stream feeders,
friction feeders, top and bottom feed feeders, carriage feeders, or
combinations thereof. In one embodiment (not shown), more than one
feeder is incorporated into the system to increase throughput. In
this case, each feeder can alternately and/or simultaneously place
a piece onto the conveyor. For example, one feeder can place
product on the conveyor while another is returning to a stock
supply to reload, and/or each feeder can simultaneously place
pieces on the conveyor.
[0027] In an alternative embodiment directed to unconverted raw
stock in web format, feeder 102 is substituted for an unwind
system.
[0028] Transport device 104 can include, for example, a receiver
configured to receive substrate stock 110 from feeder 102 and a
means for transporting or transporter configured to move substrate
stock 110 to print engine 106, or other means for transporting the
substrate stock to the print engine. In an embodiment, transport
device 104 comprises a conveyor. In one particular non-limiting
example, transport device 104 comprises a vacuum conveyor. In such
an embodiment, transport device 104 includes a perforated belt or
drum and an air drawing element. The air drawing element is
positioned underneath the perforated belt such that when substrate
stock 110 is placed on the perforated belt or drum, air is drawn
through the perforations to substrate stock 110, thereby holding
substrate stock 110 substantially flat and in place on the
perforated belt or drum. The air drawing element can be configured
for different pressures, vacuum area, and vacuum sources for
varying types of substrate stock 110. Likewise, varying
perforations can be created in the perforated belt or drum.
[0029] In an alternative embodiment of printing system 100,
transport device 104 is not required. In such an embodiment, feeder
102 is configured to receive substrate stock 110 and subsequently
transport substrate stock 110 to print engine 106 similar to
operation with transport device 104.
[0030] Referring to FIGS. 1-2, print engine 106 is configured to
receive substrate stock 110 from transport device 104 and print
variable matter onto substrate stock 110. Print engine 106 can
utilize any of a variety of digital or non-impact or low-impact
printing techniques, such as, for example, ink-jet (liquid or
solid) such as drop-on-demand or continuous, laser,
thermal-transfer, wet/dry toner systems such as xerographic, and
the like. In an embodiment, print engine 106 comprises a processor
112, database 114, motion encoder 116, and print head 118. Print
head 118 corresponds to the printing technique utilized and can
include piezoelectric or thermal heads, for example, in the case of
drop on demand technologies. Suitable print engines 106 and/or
print heads 118 can include, for example, but not limited to, those
commercially available from Xaar of Marietta, Ga., Dimatix, Inc.
(Fujifilm) of Santa Clara, Calif., Fuji Xerox of Japan, Eastman
Kodak of Rochester, N.Y., Hewlett Packard of Palo Alto, Calif.,
MemJet of San Diego, Calif., Kyrocera of Japan, and Epson of Long
Beach, Calif.
[0031] Processor 112 is configured to transmit and receive data
related to matter to be printed by print head 118. Processor 112 is
further configured to store and retrieve data, in database 114,
related to matter to be printed. Processor 112 can further convert
a source file, such as an order file supplied by a customer, or a
plurality of orders to be run in a single run, to a print-ready
file, such as PDF, PostScript of PRL format file depending on the
print driver being used. Additionally, processor 112 is further
configured to receive data from motion encoder 116 to determine
when substrate stock 110 is under print head 118.
[0032] Database 114 is configured to store data, such as source
files, related to matter to be printed by print head 118. In an
embodiment, database 114 comprises a digital source file. In
another embodiment, database 114 comprises a plurality of files for
a production run. In another embodiment, database 114 comprises a
more traditional database, such as, for example, a relational
database or a blob database. Database 114 can store images, text,
2D codes, barcodes, or any other graphical element that may be
desirous to print. Database 114 can store sequences of data for a
single production run such that during the run, the data
transmitted to print head 118 by processor 112 is variable.
Database 114 can be populated using customer supplied files entered
by a user such as an operator, or can be populated by a customer
directly, such as through a website or portal.
[0033] In an embodiment, motion encoder 116 comprises a digital
optical encoder. The digital optical encoder is configured to sense
the speed of feeder 102 or transport device 104, as appropriate.
Specifically, motion encoder 116 is adapted to convert the motion
of feeder 102 or transport device 104 into a sequence of digital
pulses. Processor 112 is capable of receiving the digital pulses to
determine when print head 106 is appropriately above substrate
stock 110, and more precisely, relative to the location on
substrate stock 110 itself.
[0034] Optionally, print engine 106 can comprise a secondary
optical sensor. The optical sensor is configured to detect when the
substrate stock 110 is under the print head. The optical sensor is
further adapted to transmit data to processor 112 such that, when
combined with motion encoder 116 data, substrate stock 110 can be
precisely related to a location under print head 118.
[0035] Print head 118 is configured to print ink or toner onto
substrate stock 110. Print head 118 is adapted to receive print
data from processor 112. Once substrate stock 110 is under print
head 118, printed matter is imaged onto substrate stock 110 by
print head 118. In a particular embodiment, print head 118
comprises an ink jet unit, such as, but not limited to, one
commercially available from Xaar of Marietta, Ga., Dimatix, Inc.
(Fujifilm) of Santa Clara, Calif., Fuji Xerox of Japan, Eastman
Kodak of Rochester, N.Y., Hewlett Packard of Palo Alto, Calif.,
MemJet of San Diego, Calif., Kyrocera of Japan, and Epson of Long
Beach, Calif. The resolution of print head 118 is suitable for
producing high-quality, recognizable images on absorbent
substrates. A suitable resolution is in a range of about 300-3600
dots per inch (DPI), and more particularly from about 600-1600
DPI.
[0036] Print head 118 can house printing medium appropriate for
printing onto the chosen substrate stock 110. The medium can
comprise a liquid or solid ink, toner, pigment, solvent-based inks,
UV-curable or other radiation curable inks, e-beam curable inks,
thermally curable inks, aqueous inks, metallic inks or pigments, or
any of a variety of dye or pigment based inks or toners available
or combinations thereof for use with digital printing systems.
Suitable inks and toners are available from the print engine and/or
print head manufactures, as well as other suppliers such as SUNCURE
inks commercially available from Sun Chemical of Carlstadt, N.J.,
and UV curable inks commercially available from Flint Inks of St.
Paul, Minn. Preferably, in the case of porous substrates such as
napkins or tissues, the ink or toner does not significantly
permeate the substrate, and rather stands on the surface of the
substrate as a film to prevent or reduce bleeding of the ink or
toner.
[0037] System 100 can optionally include one or more appropriate
curing stations depending on the type of printing medium used.
Suitable cure stations can include, for example, UV curing, LED
lights, heat or IR curing, near infrared (NIR) curing, E-beam
curing, dryers, microwave, and any suitable curing station or
combinations thereof. The printing medium and curing station
combination should be chosen such that the energy to cure the
printing medium does not heat the substrate to such temperatures
that the substrate ignites, distorts, discolors, or otherwise is
destroyed.
[0038] Referring again to FIG. 1, deliverer 108 is configured to
receive a printed substrate stock 110 from print engine 106 and
transport substrate stock 110 to an operator. In an embodiment,
deliverer 108 comprises a take-off conveyor adapted to allow an
operator or automated device to take substrate stock 110 off of the
conveyor and place substrate stock 110 in a shipping container.
Deliverer 108 can optionally have the capability to stack, collate,
sort, or otherwise process an order depending on the order details.
In another embodiment, deliverer 108 comprises a portion of
transport device 104.
[0039] Optionally, printed substrate stock 110 can include a
printed identifier or mark that correlates the printed substrate
stock with a customer order. Deliverer 108 can comprise an optical
sensor for reading the identifier or data, such that deliverer 108
sorts or otherwise collates substrates 110 based on the customer
order. This is particularly useful when multiple customer orders
are being run in a single production run, i.e. gang run, such that
manual sorting is not needed.
[0040] In another embodiment, and referring to FIG. 5, a substrate
stock comprises unconverted stock, such as a web or roll of
material to be printed. In such an embodiment, the printing system
is placed upstream from a converting system that cuts, calendars
and/or folds the web of substrate stock. More particularly, web
printing system 500 generally comprises an unwind 502 for unwinding
a web of substrate stock from a core, a one or more print stations
or engines 504, one or more optional cure stations (not shown), and
optional slitter 506 for slitting a web in a down-web or
longitudinal direction thereby creating multiple webs, one or more
rewinds 508 for taking up the printed web onto a core and to aid in
tensioning the web, one or more converting stations 510 for
converting or cutting the printed web into a plurality of printed
articles, and one or more deliverers 512.
[0041] System 500 can operate at any of a variety of web speeds
including 1 foot per minute (fpm) or less, 1-50 fpm or more, 50-150
fpm, or 150 fpm or more depending on the speed of print engines 504
without comprising quality. Web widths can be any of a selected
variety of widths including 12 inches or less, 12-48 inches, or 48
inches or more. The web speed and/or web width should be selected
so as to provide sufficient print quality including resolution and
color saturation, while providing adequate tension such that the
print quality is substantially consistent both down and cross
web.
[0042] Unwind 502 includes a core receiving, rotatable shaft for
mounting a roll of substrate thereon. System 500 further includes
multiple tensions rolls (not shown) such that the web of substrate
is substantially flat when entering one or more print stations 504.
The one or more print engines 504 and optional cure stations are
similar to print station 106 and cure stations described with
respect to FIG. 1.
[0043] One or more optional slitters 506 are configured to cut or
shear the initial web into multiple webs of narrower width.
Optional slitters 506 can be placed before and/or after print
station(s) 504. Slitter 506 can be of the conventional kind and can
include straight and/or circular cutting blades. The cutting blades
can be set to a desired width.
[0044] The printed and optionally slit stock substrate is then
rewound on paper or plastic cores on one or more rewinds 508
positioned the exit side of system 500. Rewind 508 is similar to
unwind 502, in that it comprises a rotatable shaft.
[0045] Once the printed substrate is rewound onto a core, it is
then converted into one or more articles via one or more converting
stations 510. Converting stations 510 can include, for example,
slitters similar to slitter 506 (if web is to be slit after rewind
operation rather than or in addition to slitting inline with
printing), cutters such as guillotine, rotary die, laser, or any of
a variety of cutting operations for cutting the substrate into
individual articles, calendaring stations, embossing stations,
and/or folding stations, or combinations thereof.
[0046] Deliverer 512 is similar to deliver 108 as described with
respect to FIG. 1, and has the capability to stack, collate, sort,
or otherwise process an order depending on the order details.
[0047] Similar to the embodiment in FIG. 1, the printed substrate
stock can optionally include a printed identifier or mark that
correlates the printed substrate stock with a customer order.
Deliverer 512 can comprise an optical sensor for reading the
identifier or data, such that deliverer 512 sorts or otherwise
collates the articles based on the customer order. This is
particularly useful when multiple customer orders are being run in
a single production run, i.e. gang run, such that manual sorting is
not needed.
[0048] In operation, referring to FIG. 3, a method of printing
variable data onto a flexible substrate is depicted as 200, in an
embodiment of the present invention. Method 200 comprises an
iterative method of producing one or more printed set of substrates
in a single production run. A single production run according to
systems and methods of embodiments of the invention can be
configured to efficiently and economically produce any number
articles, including small set wherein the set of napkins comprises
less than 1,000 napkins for example, less than 500, less than 100,
less than 75, less than 50, less than 24, less than 10, or even a
single article, or larger sets including more than 1,000 napkins,
more than 2,500 napkins, more than 5,000, or more than 10,000
napkins. For non-limiting exemplary purposes only, the method 200
is being correlated to the system of FIG. 1; however the method is
applicable to any of a variety of systems, including the web-based
system of FIG. 5.
[0049] At 202, the variable matter to be printed in the production
run is configured in the system. A user transmits the data to be
printed to processor 112. As mentioned above, the data can vary
between prints. Processor 112 stores this data in database 114.
[0050] At 204, substrate stock 110 is loaded into feeder 102. In an
embodiment, feeder 102 can house all of the stock required for the
production run. The stock can comprise the same or different
substrates as will be described further below. In another
embodiment, feeder 102 is refillable during the production run such
that production can continue while feeder 102 is being refilled. In
yet another embodiment, the feeder is an unwind, and the substrate
stock is a web of flexible material (referring to FIG. 5, for
example).
[0051] At 206, feeder 102 places an individual substrate onto
transport device 104. The individual substrate is fixed in place
due to the vacuum present throughout the perforations in the length
of the belt or drum of transport device 104. Transport device 104
transports the individual substrate from feeder 102 to print head
118 of print engine 106.
[0052] At 208, while the individual substrate is traveling towards
print head 118 along transport device 104, motion encoder 116
senses the speed of transport device 104. Motion encoder 116
transmits this data to processor 112. Optionally, a secondary
optical sensor detects the substrate on the conveyor and transmits
this data to processor 112.
[0053] At 210, processor 112 determines the matter to be printed
for the particular substrate to be printed. Processor 112 reads
database 114 at the appropriate location within database 114. In an
embodiment, processor 112 sequentially reads a digital file and
thereby reads in the matter to be printed. In another embodiment,
processor 112 accesses a relational database with appropriate
database-querying language to thereby read in the matter to be
printed. Processor 112 transmits the matter to be printed to print
head 118. For example, the variable data files uploaded in the
database are ripped or otherwise converted to one or more
print-ready files. This print stream is then sent to print head(s)
118. In one embodiment, multiple front-end rips are feeding print
engine 106.
[0054] At 212, when processor 112 has calculated, based on the data
received from motion encoder 116 and a secondary optical sensor, if
desired, that the substrate is properly in place beneath print head
118, the matter is printed to the substrate with print head
118.
[0055] At 214, deliverer 108 receives the printed substrate from
print engine 106. Deliverer 108 subsequently transports the printed
substrate to a system operator, in an embodiment. The system
operator is able to safely and effectively remove the printed
substrate from deliverer 108. In another embodiment, deliverer 108
transports the printed substrate directly to a shipping
container.
[0056] As shown in FIG. 3, method 200 is an iterative process.
Assuming the steps just described constitute iteration (n) for the
current substrate, at 214, method 200 returns to 206 in order to
process the (n+1) iteration of the process, thereby handling the
next subsequent substrate loaded into feeder 102, or the next
location on a web of substrate. Of course, method 200 is depicted
as it is for simplicity. Portions of the (n+1) iteration of method
200 can occur while the (n) iteration is occurring. Likewise,
portions of the (n+2) iteration of method 200 can occur while the
(n) and (n+1) iterations are occurring, and so on, depending on the
length of transport and the intensity of printing.
[0057] Referring to FIG. 4, a block diagram of three substrates
having varied printed data, according to an embodiment of the
invention, is shown at 300. The varied printed data on the napkins
can be created by the embodiment of operation described above by
method 200 and depicted by FIG. 3 in a single production run. The
set 300 of substrates, as depicted, comprises napkin substrates
having printed data on each napkin in the set. The set 300 of
substrates comprises at least a first napkin 302, a second napkin
304, and a third napkin 306.
[0058] First napkin 302 comprises a first substrate having a
dataset one 308 printed on the first substrate. Second napkin 304
comprises a second substrate having a dataset two 310 printed on
the second substrate. Third napkin 306 comprises a third substrate
having a dataset three 312 printed on the third substrate. As
depicted, datasets one, two, and three 308, 310, and 312 are all
unique from each of the other datasets 308, 310, and 312. Likewise,
first, second, and third substrates 302, 304, 306 are all discrete
from each of the other substrates. The first, second, and third
substrates can be of the same material, size, color, shape,
thickness, fold pattern, or can be different in any of the
above-listed characteristics from each other. Each of the napkins
302, 304, and 306 can be from the same order, or part of a gang run
(i.e. multiple and different orders).
[0059] The products, e.g. napkins, containing variable data
manufactured according to embodiments of the present invention can
utilized in a variety of ways and in a variety of settings. Some
examples are described below, but there remains an infinite number
of uses left to the consumer's imagination.
[0060] In one example, a set of napkins, such as cocktail or dinner
napkins, for any of a variety of events, can be printed as game
pieces, such that each napkin in the set includes a game, puzzle,
riddle, joke, map, clue such as scavenger hunt clues, or the like.
The set of napkins can have different data than the others, or
alternatively, some can have the same static data except for one or
a few unique or winning pieces that have variable data, the set
being run within the same production run.
[0061] Other examples can include: (1) artistic substrates in which
each piece includes instructions to draw a particular item and a
space for drawing the item. The instructions can vary between each
napkin in the set; (2) 2D barcodes, such as matrix-type codes (e.g.
QR codes, DataMatrix, Maxi Code) or stacked bar-type codes (e.g.
PDF417), barcodes, or tags in which each napkin in a set contains a
unique 2D code, barcode, or tag different from the other napkins;
(3) advertisement(s) on some or all of the napkins in the set, the
advertisements containing variable data, such as different
companies, services, and/or goods within the set, one such example
being set forth in U.S. Patent Application Publication No.
2007/0164554, entitled ORDER FULFILLMENT SYSTEM AND METHOD FOR
PRINTING PRODUCTS INCLUDING INDIVIDUALIZED INFORMATION,
incorporated herein by reference in its entirety; (4) coupons with
variable offers within a set of napkins including coupons with
different offers within the set, and/or different companies, each
offering their own goods and/or services within the set. Another
example includes the use of personalized napkins in lieu of or in
addition to place cards in which a guest sits at a table where
their personalized napkin is located.
[0062] In one example, a 2D code, such as, but not limited to, a QR
code, is printed on the napkin. A 2D barcode is a graphical image
that stores information both horizontally and vertically. As a
result of the two-dimensional construction, significantly greater
storage is possible than with the capacity of a one-dimensional
barcode. A device, such as a cell phone, reads the code by taking a
picture of the code, scanning the code, or otherwise reading the
code. The code acts as a key to gain access to any of an unlimited
variety of sources, such as, for example, a database, a wireless
network or WIFI enabled network, games, tools, contests, offers,
coupons, or other otherwise secured information.
[0063] In one particular example, a 2D code is printed on each
napkin of a set of napkins for an establishment, the QR code being
the same or different on each napkin in a set. The 2D code is read
or scanned using a device, such as a QR reader, scanner, or camera
on a handheld device, such as a cell phone. The 2D code grants the
user of the handheld device to a secured wireless network of the
particular establishment. If the 2D code varies within the set of
napkins, the recipient of a particular napkin may have a different
level of access to the network than a recipient of another napkin
having a different code. Additionally or alternatively, the 2D code
can grant the user access to coupons or offers from the
establishment, other products or services, games, contests,
factoids, clues, credits, or any of a variety of otherwise secured
information or combinations thereof. Other codes or tags that are
capable of acting as access keys can also be contemplated.
[0064] Embodiments can also utilize features as discussed and
disclosed in co-pending U.S. patent application Ser. No. 13/396,939
(published as U.S. Patent Application Publication No.
2012/0209688), entitled SYSTEMS AND METHODS FOR MULTI-PLATFORM
TRANSACTION CARD ACCESS AND MANAGEMENT, and filed on Feb. 15, 2012,
which is hereby incorporated by reference in its entirety.
[0065] Various embodiments of systems, devices and methods have
been described herein. These embodiments are given only by way of
example and are not intended to limit the scope of the invention.
It should be appreciated, moreover, that the various features of
the embodiments that have been described may be combined in various
ways to produce numerous additional embodiments. Moreover, while
various materials, dimensions, shapes, locations, configurations
etc. have been described for use with disclosed embodiments, others
besides those disclosed may be utilized without exceeding the scope
of the invention.
[0066] Persons of ordinary skill in the relevant arts will
recognize that the invention may comprise fewer features than
illustrated in any individual embodiment described above. The
embodiments described herein are not meant to be an exhaustive
presentation of the ways in which the various features of the
invention may be combined. Accordingly, the embodiments are not
mutually exclusive combinations of features; rather, the invention
can comprise a combination of different individual features
selected from different individual embodiments, as understood by
persons of ordinary skill in the art.
[0067] Any incorporation by reference of documents above is limited
such that no subject matter is incorporated that is contrary to the
explicit disclosure herein. Any incorporation by reference of
documents above is further limited such that no claims included in
the documents are incorporated by reference herein. Any
incorporation by reference of documents above is yet further
limited such that any definitions provided in the documents are not
incorporated by reference herein unless expressly included
herein.
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