Patent Application
20080053328
The accompanying drawings, which are incorporated into and form part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
a,b) is a schematic representation of preparation of an item for printing according to the present invention.
a,b) is a schematic representation of preparation of an item for printing according to the present invention.
a,b) is a schematic representation of preparation of an item for printing according to the present invention.
a,b) is a schematic representation of preparation of an item for printing according to the present invention.
The present invention provides a method of configuring a printable item for use with a printer, where the printer has a maximum allowable item thickness and a maximum allowable item thickness variation, and where the thickness of the printable item varies by more than the maximum allowable item thickness variation. The method involves providing a conformable substrate material; placing the printable item in contact with the substrate material, forming a composite item; and treating the composite item such that the final thickness of the composite item is not more than the maximum allowable item thickness and such that the variation in thickness of the composite item is not more than the maximum allowable item thickness variation.
The printable item can be, as examples, textile items and fabrics such as hemmed silk scarves, cotton handkerchiefs, or twill or canvas items. For best performance with some inks, the items can be treated. Suitable treatments are known in the art, for example as applied to inkjet printing on canvas, fabric, or paper.
The conformable substrate material can comprise, as examples, a compressible material, or an expansible material, or a coating that conforms to irregularities in the item and yields a consistent thickness once combined with the item. Examples of suitable compressible materials include waxed paper, soft paper, soft plastic such as sintra, soft cardboard, foam core, rice paper, and water-soluble paper. In many applications, the compressible material can be the same size or larger than the item, and have a stiffness that is compatible with the requirements of the printer, and have a thickness when combined with the item that is compatible with the requirements of the printer, e.g., one eighth of an inch or less with some contemporary printers. The printable item and a compressible substrate can be pressed together. As examples, applying pressure to the composite item can comprise passing the composite item through a roller press, wherein the space between the surfaces of the roller press is less than the maximum allowable item thickness; or placing the composite item between parallel plates as in a block press, and urging the parallel plates toward each other until their separation is not more than the maximum allowable item thickness, or placing the composite item in a vacuum press under conditions such that the final thickness variation is within allowable limits. Examples of suitable expansible materials and coatings include foams, expansible plastic, settable liquids and resins, and starch or paste. Processing of these can depend on the specifics of the material, and can involve spray application and subsequent self- or mechanical-leveling, vacuum expansion, and thermal or UV curing. Adhesion between the item and certain substrates can be enhanced with adherents, generally specific to the item and substrate materials.
Items prepared according to the present invention can be presented to a digital printer. As examples, sheet feeder mechanisms known in contemporary ink jet printers can be used. As examples, direct sheet feeders and feeder trays or bins can be used, such as those found in Epson's large format ink jet printers (e.g., Epson's model numbers 4000, 7600, and 9600). Digital representations of designs to be printed can be provided, for example in a print on demand method like that in U.S. patent application Ser. No. 09/974,621, “On-Demand Reproductions of Visual Images,” filed Oct. 10, 2001, incorporated herein by reference.
a,b) is a schematic representation of the preparation of an item for printing according to the present invention. An item 21 to be printed is substantially planar, but has thickness variations such as hemmed or serged edges 23. In
In some applications of the present invention, the item can be a textile item with hemmed or serged edges. Examples of such include silk scarves, cotton handkerchiefs, and twill or flannel panels (e.g., for crafts or wall hangings). The compressible substrate can comprise materials such as foam core, thick and soft paper, mat board, and greyboard. Pressures of 10 psi to 100 psi can be suitable, depending on the item and the substrate material. About 30 psi can be suitable for commonly-available substrates.
a,b) is a schematic representation of the preparation of an item for printing according to the present invention. An item 31 to be printed is substantially planar, but has thickness variations such as hemmed edges 33. In
Items to be printed can include silk scarves, ties, clothing, pillowcases, purses, fabric components for complex items, linen, canvas, poplin, silk. Substrates can include foam core, rice paper, paper, and plastics. Substrates such as “Dissolvo”, a water-soluble paper material, can be used and then readily removed by water. Pressure required to conform the substrate can depend on the substrate, e.g., for foam core substrates about 30 psi can be suitable. For other substrates, pressures of from 10 psi to 100 psi can be suitable (depending on the substrate hardness or resistance to deformation). The composite item can be configured to a thickness of about 2 mm, after compression, for use with printing presses such as models currently available from Epson; other presses can accommodate greater thicknesses. The final thickness achieved can be designed to match the requirements of the printer to be used; available printers can be accommodate materials of thicknesses of ⅛ inch to ¼ inch. The combination of the item and the substrate can provide adequate stiffness for the requirements of the printer, although some flexibility can aid in handling. For use with roll-fed printers, more flexibility can be desired. For use with flat or single sheet fed printers, greater stiffness can be accommodated and can be desirable. The item and substrate can be conveniently handled by encouraging adherence between them, for example by disposing a polyurethane wax or 505 adhesive spray between the item and the substrate. The item, the substrate, or both can be exposed to heat, humidity, or both (e.g., by dampening the item, or use of a steam press) before or during compression to promote adhesion, encourage flatness, and facilitate conformance of the item and the substrate.
a,b) is a schematic representation of the preparation of an item for printing according to the present invention. An item 41 to be printed is substantially planar, but has thickness variations such as hemmed edges 43. In
a,b) is a schematic representation of the preparation of an item for printing according to the present invention. An item 51 to be printed is substantially planar, but has thickness variations such as hemmed edges 53. In
The characteristics of the conformable coating can be selected for the specific application, cost, and performance desired. As an example, the coated substrate can comprise waxed paper. The printable item can be pressed into the wax. The resistance to deformation of the wax can be altered by heating the wax before or while pressing. Removing the heat can then allow the wax to harden, filling in the gaps and adhering the printable item to the wax paper, yielding a uniform thickness composite item ready for printing. As another example, the coated substrate can comprise a thin plastic sheet coated with a UV-curable resin. The printable item can be urged toward the plastic sheet, displacing the resin and filling any gaps. The resin can then be cured by exposure to UV energy, yielding a uniform thickness composite item ready for printing.
As an example, the present invention can be practiced with a pre-serged silk scarf blank. A polyurethane wax can be used as an adherent between the silk scarf blank and a substrate such as foam core or rice paper. The composite item (silk scarf blank, polyurethane wax, and substrate) can be subjected to heat and pressure such as that provided by a TEANECK heated graphic arts vacuum system. The heat can help activate the adherent, while the pressure can help in conforming the substrate to the scarf so that the final thickness and uniformity is attained. A graphic image, such as an image of a work of art or a person, can be printed on the resulting composite item using a printer such as an Epson 9800 Pro printer, with Epsom ultrachrome K3 inks. The printed item can be rinsed in cold water to help set the inks (depending on the specific inks chosen), and the substrate separated from the scarf; for example, if a water soluble substrate is used, then the cold water rinse can also remove the substrate.
The particular sizes and equipment discussed above are cited merely to illustrate particular embodiments of the invention. It is contemplated that the use of the invention may involve components having different sizes and characteristics. It is intended that the scope of the invention be defined by the claims appended hereto.
