Patent Application
20070196603
The present invention generally relates to a film laminated folding carton formed from a section of carton stock. More specifically, the present invention relates to a film laminated folding carton and a method of forming the folding carton that includes a graphic image printed on a layer of lamination film by using offset printing techniques prior to the formation of the carton stock.
Presently, many different types of folding cartons exist for packaging various types of products. It is desirable for the folding carton to include some type of graphic image to either advertise the product contained within the carton or provide a more visually appealing appearance for the carton to stimulate product interest. Most folding cartons are formed from paper or paperboard, typically called carton or carrier board. Carrier board is specifically manufactured to be used as carton material and typically includes a smooth white surface that is coated onto the carrier board with a white clay-titanium dioxide-latex mixture. The white surface is added to permit printing and colored graphics on the naturally brown, rough surface of the carrier board. The white outer coating creates a surface that will accept graphic images printed using flexo or gravure printing techniques.
Alternatively, the white outer surface can be provided by laminating a thin layer of high-quality label paper, often referred to as Kraft paper, to a thicker backing material. The white outer surface of the Kraft paper again allows for printing utilizing flexo or gravure printing techniques.
Yet another method of providing a graphic image on a paperboard carton is to utilize a plastic sheet that is bonded onto a layer of paper base material, such as shown and taught by U.S. Pat. No. 4,254,173. As taught by the '173 patent, the plastic material is printed utilizing radiation pre-treatment techniques to ensure the proper bonding of the inks to the plastic layer during printing by a printing press through the use of a rotogravure process. Once the laminated film has been printed, it is immediately adhered to the paper material to form the laminated structure.
Although printing on a laminating film prior to the lamination of the film to a paperboard stock is well known, as shown in the '173 patent, conventional methods utilize printing techniques that are unable to create a crisp, clear and detailed graphic image, such as is possible using offset printing techniques. Therefore, a need exists for a film laminated folding carton that includes visually appealing graphic images that can be high speed printed onto a plastic film that can be later applied to a layer of base material to form carton stock.
The present invention is a method for forming a film laminated folding carton that includes a visually appealing graphic image created using an offset printer. The use of an offset printer as compared to other types of printing techniques enhances the appearance of the graphic image contained on the folding carton.
Initially, a continuous supply of a lamination film is drawn from a supply roll. The strip of lamination film is drawn into an offset printer. As the lamination film is drawn into the offset printer, the offset printer prints a graphic image on at least the first surface of the lamination film. While the lamination film is within the offset printer, the offset printer prints directly onto the lamination film without any type of support mechanism adhered to the lamination film.
After the graphic image has been printed onto the lamination film, the lamination film is accumulated onto a transfer roll. The transfer roll thus includes a continuous strip of the printed lamination film. The transfer roll can be moved to a different location for completing the remaining portions of the carton formation method.
After the transfer roll has been moved to the desired location, the continuous strip of the printed lamination film is drawn from the transfer roll. The continuous strip of printed lamination film is drawn over an adhesive supply roll that applies a layer of adhesive to the printed lamination film. Depending upon the orientation of the transfer roll, the adhesive layer is applied to either the first surface that includes the graphic image or the second surface that is opposite the printed graphic image. Alternatively, the adhesive roll used to apply the adhesive can be positioned to selectively apply the adhesive layer to either the first or second surface of the printed lamination film without requiring reorientation of the transfer roll. In either case, the adhesive layer is applied to either the first surface or the second surface of the printed lamination film.
After the adhesive is applied to the desired surface of the printed lamination film, the lamination film is brought into contact with a continuous strip of a base material. Preferably, the printed lamination film and the base material are brought into contact with each other within a laminating nip. However, the printed lamination film and the base material can be combined in other manners. In each case, the layer of adhesive applied to either the first surface or the second surface of the printed lamination film is brought into contact with the top surface of the base material.
When the adhesive layer is applied to the first surface of the printed lamination film, the printed graphic image is sandwiched between the lamination film and the base material such that the printed graphic image is protected. In this embodiment, the lamination film must be transparent such that the graphic image is viewable through the lamination film. Alternatively, if the adhesive layer is applied to the second surface of the printed lamination film, the graphic image contained on the first surface is exposed. Such an embodiment is required where the lamination film is opaque, such as with a metalized or holographic film.
After the carton stock has been formed, the continuous length of carton stock enters into a platen die cutter that cuts the carton stock into the desired shape. After the carton stock has been die cut, the carton blanks are received within a converting station that prepares the cartons for shipment to a third party.
The drawings illustrate the best mode presently contemplated in carrying out the invention.
In the drawings:
After the graphic image has been applied to the first surface of the lamination film 12, the ink used to create the graphic image is dried within the offset printer 14 and the printed, continuous lamination film 16 is accumulated on a transfer roll 18. Since the offset printer 14 is often located at a different location on-site or even at a remote off-site location from the package forming equipment, the accumulation of the printed lamination film 16 onto the transfer roll 18 allows for the printing of the lamination film 12 to occur at either an off-site printer or a different location within a manufacturing facility.
After the printed lamination film 16 has been accumulated on the transfer roll 18, the transfer roll 18 can be moved to an upstream end of a carton forming line 20. Once the transfer roll 18 is in position, the printed lamination film 16 is drawn from the transfer roll over an adhesive applicator 22. Depending upon the desired carton configuration and the graphic image printed onto the printed lamination film 16, the transfer roll 18 can be oriented such that the adhesive applicator 22 can apply the adhesive to either the first or the second surface of the printed lamination film 16.
After the adhesive has been applied to either the first or second surface of the printed lamination film 16, the printed lamination film enters into a lamination nip 24 including a pair of nip rollers 26, 28. Within the laminating nip 24, the adhesive contained on the printed lamination film is brought into contact with a top surface of a base material 30 drawn from a continuous roll 32.
In the embodiment of the invention illustrated, the base material 30 is preferably a 12-point carrier board having a basis weight of approximately 42 lbs., although other weights and thicknesses for the base material 30 are contemplated as being within the scope of the present invention. The base material 30 can be formed from recycled or virgin pulp depending upon the container requirements. Further, the base material 30 can be formed from a number of different recycled paper products, such as carton board, folding carton board or chip board.
Upon being drawn into the laminating nip 24, the base material 30 is adhered to the printed lamination film 16 to create laminated carton stock 34. As discussed above, depending upon the orientation of the transfer roll 18, either the first surface or the second surface of the printed lamination film is in contact with the base material 30.
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As can be understood by the above description, the use of an offset printer to apply the graphic image to the lamination film 12 as the lamination film is otherwise unsupported within the offset printer 14 allows for the creation of high-quality graphic images on the printed lamination film 16. After the lamination film has been printed, the printed lamination film is accumulated on a transfer roll and can be shipped or moved to a separate, carton forming line. Utilization of an offset printing technique prior to laminating the printed lamination film to a sheet of base material allows for more detailed graphic images to be printed without slowing the process of the package formation. The use of offset printing, as opposed to other printing techniques, allows for a more detailed graphic image to be created and the printer lamination film accumulated for later processing.
