Patent Application
20110113976
The present disclosure relates to manufacture of printed packages or secure documents. More specifically, the present disclosure relates to secure printing by embossing patterns or signatures into a printed package or packing seal.
Counterfeiting is a serious problem affecting nearly all aspects of the manufacturing industry. In efforts to prevent counterfeiting, many manufacturers have started to add security features to packaging. One security feature involves branding, or stamping, a product with a licensed image or trademark that indicates the manufactured item is a genuine product of the manufacturer. However, this approach merely slows counterfeiters while they also change their manufacturing processes and techniques to duplicate the changes made by the genuine manufacturers.
Counterfeiting is particularly widespread in the pharmaceutical industry. With the advance of foreign manufacturers and Internet pharmacies, counterfeit medications are becoming a serious threat to the pharmaceutical industry. Counterfeit drugs are sometimes made from different or inferior products that could cause detrimental effects in a patient. In some extreme cases, a patient could even die after receiving a counterfeit medication that is not correctly manufactured or is incorrectly labeled.
To avoid confusion with counterfeited goods, many pharmaceutical companies manufacture custom packaging with printed seals, which indicate authenticity. These printed seals enclose the caps or lids of the medication bottles, and include a stamp or printed item from the manufacturer. However, counterfeiters began copying the printed seals as well, thereby producing accurate packaging containing counterfeit medications.
The invention described in this document is not limited to the particular systems, methodologies or protocols described, as these may vary. The terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present disclosure.
It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to.”
In one general respect, the embodiments disclose a method of embossing toner. The method includes the steps of applying toner to a print substrate, applying an embossing substrate to the toner wherein the embossing substrate imprints a pattern into the toner, melting the toner via a first radiation source such that the toner is liquefied to a molten state, curing the toner via a second radiation source such that an imprint of the pattern is embossed in the toner, and removing the embossing substrate.
In another general respect, the embodiments disclose a system for creating a securely printed document. The system includes a first radiation source configured to expose a first radiation to a printing substrate having an applied amount of toner, thereby liquefying the toner into a molten state, a curing station, a first feeder configured to feed the printing substrate into the curing station, and a second feeder configured to feed the embossing substrate into the curing station, wherein the embossing substrate comprises a pattern to be imprinted into the toner. The curing station includes a combiner configured to press the printing substrate and an embossing substrate together, a second radiation source configured to expose a second radiation to the combined substrates, and a divider configured to separate the printing substrate from the embossing substrate.
In another general respect, the embodiments disclose a method of embossing toner. The method includes the steps of creating a predetermined pattern on an embossing substrate, applying toner to a print substrate, melting, via a first radiation source, the applied toner to liquefy the toner to a molten state, applying the embossing substrate to the toner, wherein the embossing substrate imprints the pattern into toner, and curing, via a second radiation source, the ink such that an imprint of the pattern is embossed in the toner.
Aspects, features, benefits and advantages of the present invention will be apparent with regard to the following description and accompanying drawings, of which:
For purposes of the discussion below, an “assembly” refers to a printer, a copier, a multifunction machine or system, a xerographic machine or system, or any other type of printing apparatus that is capable of applying and curing a toner on a printing substrate.
A “printing substrate” refers to a physical sheet of paper, plastic and/or other suitable substrate for printing text and/or images thereon.
An “embossing substrate” refers to a physical sheet of paper, plastic and/or other suitable substrate for embossing a pattern into an amount of toner applied to a printing substrate.
Another component of the printing and embossing configuration illustrated in
After curing, the embossing substrate 106 is removed to reveal the printing substrate 104 having the cured toner 102. The toner 102, having been cured, becomes crosslinked and therefore allows the security feature to remain in a durable state.
Various types of curable toners may be used. One example of a curable toner is a UV curable toner, such as the toner described in U.S. Pat. No. 7,250,238, the disclosure of which is hereby incorporated by reference. A UV toner has a composition such that, when exposed to UV radiation, such as light having a wavelength of about 100 nm to about 400 nm, the toner cures. UV curing enables toner to be cured, thus resulting in a toner image that is more durable than a non-cured toner image. These cured toner images are more resistant to high temperatures, solvents, and other drawbacks that may degrade the quality of non-cured toner images.
The embossing substrate 106 may be made from a material transparent to any curing radiations used. For example, the embossing substrate 106 may be made from a clear, or semi-transparent material such that the UV light passes there through. The embossing substrate 106 may also be made from a material that is easily removed from the printing substrate 104 and the toner 102, such as clear TEFLON® tape or UV transparent acrylic.
It should be noted that two separate radiations sources may be used. A first radiation source may be used to apply the first radiation to the toner, thereby liquefying the toner to a molten state. A second radiation source may then be used to apply the second radiation to the toner, thereby curing the toner into a solid with the embossing pattern cured into the toner. The printing, embossing and curing mechanisms and methods are discussed in greater detail in the following discussions of
The manufacturing assembly 200 includes two material pathways, one for the printing substrate 104 and one for the embossing substrate 106. The printing substrate 104 enters the assembly 200 via a feeder 202. The feeder 202 may include one or more rotating devices, such as a transport nip, designed to rotate and propel a substrate in a particular direction. In this example, the feeder 202 rotates clockwise and propels the printing substrate 104 through the assembly 200. Similarly, the embossing substrate 106 enters the assembly 200 via a feeder 204. The feeders 202, 204 feed their respective substrates into a curing station 206. In this example, an amount of the toner 102 is already applied to the printing substrate 104; however, an additional component may be present in the manufacturing assembly for applying the toner. Similarly, in this example, the pattern of impressions and/or depressions 108 is already applied to the embossing substrate 106; however, an additional component may be present in the manufacturing assembly for creating the pattern on the embossing substrate.
The manufacturing assembly 200 may further include a thermal radiation source 208 for liquefying the toner into a molten state, typically at a temperature of about 70° C. to 100° C. The curing station 206 may include a combiner 210, a UV curing source 211 for curing the toner and a divider 212. In an embodiment, the thermal radiation source 208 may include a heat producing source such as those discussed above in reference to
As shown in
After the toner is applied 302 to the printing substrate, the printing substrate is fed 304 into the manufacturing assembly. For this example, printing substrate 104 (including applied toner 102) may be fed 304 into the manufacturing assembly 200 by the feeder 202.
As further shown in
By using micro-dot printing, a manufacturing company can quickly change the pattern on the embossing substrate by changing the design of the micro-dot pattern. Similarly, a pattern may be scratched or etched into the embossing substrate. Once the pattern is created 306 on the embossing substrate, the embossing substrate is wound onto a reel for feeding into the manufacturing assembly.
Once the pattern is created and the embossing substrate is wound, the embossing substrate may be unwound from the reel and fed 308 into the manufacturing assembly. To continue the example discussed above, embossing substrate 106 (including impressions/depressions 108) may be fed 308 into the manufacturing assembly 200 by the feeder 204.
When both substrates (i.e., printing and embossing) are fed into the assembly, the two substrates are pressed together 310 to enclose the molten toner on two opposite sides, sandwiching the molten toner between the two substrates. The two substrates proceed through the manufacturing assembly simultaneously at a substantially similar speed. In the present example, the printing substrate 104 may be pressed together 310 with the embossing substrate 106 by combiner 210 of the manufacturing assembly 200, thereby sandwiching the molten toner 102 between the two substrates.
Once the substrates are pressed together 310, the combined substrates are exposed to a radiation source, and the toner applied to the printing substrate may be cured 312. Continuing with the present example, the combined substrates reach the UV curing source 211 of the manufacturing assembly 200. UV light produced by UV curing source 211 passes through the embossing substrate 106 and cures 312 the molten toner 102. During the curing process, any pattern included on the embossing substrate 106 (e.g., impressions/depressions 108) is embossed into the molten toner 102. As it cures 312, the molten toner 102 undergoes a molecular change from a monomer to a polymer. During the curing 312, the toner particles form interconnecting bonds, thereby adding a rigidity to the toner 102, resulting in a cured toner.
The two substrates may then be separated 314. To continue with the above example, the substrates continue through the manufacturing assembly 200 to the divider 212 where the substrates are separated 314.
The process illustrated in
The embossing substrate may be recovered 318 and re-wound onto a roll. Depending on the condition of the embossing substrate, and the desires of the manufacturer, the embossing substrate may be re-used for the embossing of another length of printing substrate.
An alternative method of printing and embossing is discussed in the following discussions of
The manufacturing assembly 400 includes two material pathways, one for the printing substrate 104 and one for the embossing substrate 106. In this example, an amount of toner 102 has already been deposited on the printing substrate 104, been previously heated with a thermal source to a molten state, and has hardened on the printing substrate. The printing substrate 104 enters the manufacturing assembly 400 via a feeder 402. Similarly, the embossing substrate 106 enters the manufacturing assembly 400 via a feeder 404. The feeders 402, 404 feed their respective substrates into a curing station 406. In this example, the pattern of impressions and/or depressions 108 (as shown in
The curing station 406 may include a combiner 408, a heating element 410 for liquefying the dried toner 102 on the printing substrate 104 into a molten state, a UV curing source 411 for curing the toner and a divider 412. The heating source 410 may be similar to the thermal radiation source 208 as shown in
As shown in
After the toner is deposited on and fused 502 to the printing substrate, the printing substrate is fed 504 into the manufacturing assembly. For this example, the printing substrate 104 (including fused toner 102) may be fed 504 into the manufacturing assembly 400 by the feeder 402.
As further shown in
Once the pattern is created and the embossing substrate is wound, the embossing substrate may be unwound from the reel and fed 508 into the manufacturing assembly. To continue the example discussed above, embossing substrate 106 (including impressions/depressions 108) may be fed 508 into the manufacturing assembly 400 by the feeder 404.
When both substrates (i.e., printing and embossing) are fed into the assembly, the two substrates are pressed together 510 to enclose the dried toner on two opposite sides, sandwiching the dried toner between the two substrates. The two substrates proceed through the manufacturing assembly simultaneously at a substantially similar speed. In the present example, the printing substrate 104 may be pressed together 510 with the embossing substrate 106 by combiner 408 of the manufacturing assembly 400, thereby sandwiching the dried toner 102 between the two substrates.
Once the substrates are pressed together 510, the combined substrates pass a heating element where the previously fused toner is reheated 512 once again to a molten state. Once back in the molten state, the predetermined pattern on the embossing substrate may be pressed into the molten toner, thereby transferring the predetermined pattern into the toner. Continuing with the present example, the combined substrates pass the heating element 410 of the manufacturing assembly 400 where the previously fused toner 102 is reheated 512 again to a molten state. Once the toner 102 is reheated, the substrates pass the UV curing source 411 of the manufacturing assembly 400. UV light produced by UV curing source 411 passes through the embossing substrate 106 and cures 514 the molten toner 102. During the curing process, any pattern included on the embossing substrate 106 (e.g., impressions/depressions 108) is embossed into the molten toner 102. As it cures 514, the molten toner 102 undergoes a molecular change from a monomer to a polymer. During the curing 514, the toner particles form interconnecting bonds, thereby adding a rigidity to the toner 102, resulting in a cured toner image.
The two substrates may then be separated 516. To continue with the above example, the substrates continue through the manufacturing assembly 400 to divider 412 where the substrates are separated 516.
The process illustrated in
The embossing substrate may be recovered 520 and re-wound onto a roll. Depending on the condition of the embossing substrate, and the desires of the manufacturer, the embossing substrate may be re-used for the embossing of another length of printing substrate.
It should be noted that the above processes and assemblies provide a manufacturing environment in which security and control features may be quickly and easily altered. By simply changing the pattern of the embossing substrate, a new security feature may be added to the printed substrate. This may enable a manufacturer to quickly change the security features provided with a product should a counterfeiter find a way to reproduce the original pattern embossed in the toner.
For example, a pharmaceutical company may emboss a pattern into the seals they include on their products by using the process described above. For security, every month (or any desired period of time), the manufacturer may change the pattern of the embossing substrate, thereby resulting in an updated seal with a new security feature. By providing pharmacies (or other end users) with an indication of what the updated security feature is, counterfeiting may be reduced because pharmacies will know what security features to look for in genuine products. Similarly, by changing the security feature often, counterfeiters would not have an opportunity to duplicate the security feature because the genuine manufacturer may have changed the security feature by the time the counterfeit products with a copied security feature reach the market.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
