GB2299537A - Forming three-dimensional graphic image - Google Patents

Description

I- METHOD FOR FORMING A GRAPHIC IMAGE WEB

TECHNICAL FIELD

2299537 1 i The present invention relates generally to methods for creating the illusion of three dimensionality of a graphic image in printed web form, or the three dimensionality of a graphic image that is spot coated with lenticular material.

BACKGROUND OF THE INVENTION

It is known in the art to fabricate generally planar display devices which include an image sheet and a lenticular lens sheet which, in combination, give the image and appearance of three dimensionality. The lenticular lens sheet and the image sheet must be aligned properly to avoid a distorted image. The components have heretofore been in sheet form because the process of combining them is usually manual to ensure necessary registration.

The illusion of three dimensionality requires the image originally be made with a special three dimensional or stereoscopic camera, photographing the desired object from a plurality of angularly displaced positions. Such a camera typically uses a photosensitive film disposed behind a lenticular screen. The lenticular screen is positioned adjacent the photosensitive film so the focal point of each lenticule generally coincides with the front surface of the film. Thus, the image of the object is focused into a narrow image band which is exposed in the film.

As the camera is shifted to the next angular position, the lenticular screen is also shifted slightly. A subsequent picture image of the object from the new angular position is then exposed into a separate image band in the film adjacent the preceding image band. Each time the camera is moved to a new angular position, the object is photographed and the image is exposed in the film as a similar, narrow image band adjacent the previously formed image band, until a series of image bands representing different views of the object is created. To avoid overlap of image bands, the lenticular screen is only moved a distance equal to the width of a single lenticule as the camera is moved through its full angular range. This collection of image bands, which is formed under a single lenticule, may be called an image element. Each image element is approximately the width of a single lenticule and includes all of the condensed views of the object.

Cameras of this type are disclosed in Stockbridge et al., U.S. Patent No. 3,380,360, issued April 30, 1968 and Bonnet, U.S. Patent No. 2,508,487, issued May 23, 1950. Both of those patents disclose three dimensional or stereoscopic cameras used to photograph objects from numerous angular positions where the photograph taken at each position is exposed on a film as a linear image band.

Once the object is photographed from various positions, the film may be developed the same as any other photographic film, but the resulting image is a compilation of the numerous adjacent image bands. Each image band represents the object from a given angle, albeit in a focused or compressed form. This can provide the overall image with a somewhat distorted look to the naked human eye. However, when the developed image is combined with a lenticular screen or sheet having lenticules of approximately the same size and focal length as the lenticular sheet used to expose the film, the image becomes clear to the human eye as viewed through the screen.

The lenticular sheet must be placed over the image elements so the focal point of each lenticular lens coincides with the front surface of the image sheet. The image will appear to be three-dimensional because the observer is viewing the image through the lenticular sheet from a slightly different angle due to the lateral spacing between his eyes. In effect, this allows each eye to focus on a different image band, representing different views of the photographed object from separate angles, thereby giving the viewer the illusion of a three dimensional image.

In the past, the lenticules and image elements were relatively wide and each lenticule had to be perfectly aligned over each image element to obtain clearly defined three dimensional image. It has been difficult to obtain precise alignment and impossible to mass produce three dimensional images efficiently and economically. Typically, the lenticular sheet has been manually positioned over the image sheet and then carefully adjusted to eliminate moire line or interference. This is a time consuming, inefficient and expensive task.

In some situations, it is desirable that the three dimensional image only occurs over a portion of a printed surface. In this case, the lenticular material should only be present over the three dimensional precursor image, and not the entire printed surface, or the lenticules will distort the portion of the image that is not meant to be seen as three dimensional. In the past, it has been necessary to form a lenticular sheet of the appropriate dimensions, and manually apply this sheet to the three dimensional precursor image. This is again a time consuming, inefficient and expensive task.

Further difficulties exist in mass producing three dimensional sheets for use in publications such as magazines due to the size of the lenticules and the consequent thickness of the lenticular lens sheet. However, larger lenticules have longer focal lengths and necessitate a thicker lens overlay so the focal point of the lenticule is approximately adjacent the image elements on the image sheet. This, of course, leads to a relatively thick composite sheet which is not suitable for magazines or other printed media that require a thinner sheet dimension. Making the sheet sufficiently thin to be used in magazines requires the lenticules to be extremely small, thus making it more difficult to form the lenticular lens sheet and properly align it with the image sheet. The required precision has made the use of efficient, high output machinery difficult.

It has long been desirable but unattainable to make both the image sheet and the lenticular lens sheet in continuous form and then combine them at a rapid pace with precise registry to produce a finished product having photographically acceptable quality. Standard printing methods could then be used to reproduce the images in continuous form. Though techniques have been developed for creating a lenticular lens in continuous form. and certain methods and devices have also been used in an attempt to combine an image web with a continuous lenticular lens, none of these devices is able to produce a thin, flexible lenticular image composite for economical use in the production of, for example, magazines, while maintaining the precision necessary to produce quality images having the illusion of three dimensionality without interference lines or distorted appearance.

In three patents to Conley, U.S. Patent No. 4,420,502, issued December 13, 1983, U.S. Patent No. 4,414,316, issued November 8, 1983, and U.S. Patent No. 4,420,527, issued December 13, 1983, an apparatus and method for making a composite sheet material are disclosed. A transparent base web is directed onto the surface of a first roll and advanced along an arcuate path around the first roll and then through a narrow gap disposed between the first roll and a second roll. Before the transparent base web passes between the first and second rolls, a flowable, uncured, actinic, radiation-curable thermosetting resin is directed onto the web behind the narrow gap. The second roll includes grooves so that, as the resin-covered web passes through the narrow gap and around the second roll, lenticular formations are made in the flowable resin. Ultraviolet radiation is directed through the transparent basis web and into the flowable resin layer while it remains in contact with the second roll. Thus, the flowable resin is cured into a composite lenticular lens sheet.

Such a process can produce small, well defined lenticular lenses. However, the difficulty remains in properly joining such a lenticular lens with a corresponding image web in a manner that avoids distortion of the image. Typically, the lenticular lens will still need to be cut in sheets and then carefully aligned by hand with a corresponding image sheet. It would be advantageous, and meet the long-felt need summarized above, if such a lenticular lens could be precisely aligned and combined with the corresponding images while the image sheet and the lenticular lens both remained in continuous form. This would greatly increase the efficiency and volume of the finished web resulting in a very economical product.

Other patents disclose methods and devices for making lenticular lens products but none with the accuracy or precision that would allow the finished product to be used in typical publications such as magazines. For instance, Jerothe et al., U.S. Patent No. 3,264,164, issued August 2, 1966, discloses a device which makes a laminated, flexible, fabric-like 0 0 material having interesting characteristics of color and depth. However, precise accuracy is not necessary since one of the purposes of the patented device is to produce images having a moire effect. Additionally, that approach uses colored lines and various colored shapes placed at different depths between cumulative flexible sheets. In the Jerothe et al. device, a relatively thick sheet is used for the formation of the lenticular lens. The lenticular lens sheet is laminated with various films and the resulting laminate passes between a pressure roll and a gravure roll where surface ribs or lenticular lens type ribs are formed by pressing the relatively thick lens forming sheet against the gravure roll. That device, however, cannot be accurately controlled to make extremely small accurate lenses in alignment with the image bands of an image web to yield photographically acceptable image quality.

Leach, U.S. Patent No. 3,565,733, issued February 23, 1971, discloses an apparatus for making a composite web from a paper web combined with melted plastic. In Leach, a paper web, which can include an image, is passed between a pressure roll and a coating roll and then around a chilled embossing cylinder. A melted plastic is poured onto the coating roll which brings the melted plastic into contact with the paper web. This combined paper web and melted plastic is immediately brought into contact with the surface of the chilled embossing cylinder which solidifies the melted plastic leaving lenticular lens-type formations in plastic. A problem with the Leach apparatus is that it does not provide for the precision alignment of the lenticular lens formations with the image elements on the image web. This prevents the constant replication of high quality images having the appearance of three dimensionality without distortion. Additionally, meltable plastic will not retain its proper shape under the rigors of magazine use and shipping which can tend 0 B 0 to place the lenticular lens formations under harsh conditions of pressure and heat. Once the lenticular lenses degrade, the three dimensional effect is lost. See also U.S. Patent No. 3,607,340 to Stroupe issued September 21, 1971.

In Lemelson, U.S. Patent No. 3,146,492, issued September 1, 1964, an apparatus is disclosed which produces a multiple image sheet display on a continuous basis. In Lemelson, an impressionable sheet is laminated with a plurality of sheets and then passed through a pair of rolls. one of the rolls is an embossing roll which creates lenticular formations in a face of the impressionable sheet. The apparatus is similar to those mentioned above in that it is difficult to form precision lenticules in the solid web without which an image of photographically acceptable quality cannot be reliably and repeatedly reproduced. Additionally, there is no way for the machine to provide precise alignment of the image elements with the lenticules.

The present invention addresses the foregoing drawbacks involved in making a precision lenticular lens image web having three dimensional image characteristics with photographic quality.

SUMMARY OF THE INVENTION

One embodiment of this invention provides an apparatus for forming a graphic image on a surface, wherein a portion of the graphic image has the appearance of three dimensionality, comprising a printer that prints a three dimensional precursor image on a portion of ' the surface and a dispensing system that applies a flowable material to the printed three dimensional precursor image so as to form a lenticular layer over the printed three dimensional precursor image to thereby produce the portion of the graphic image.

00 00 Another embodiment of this invention provides an apparatus for forming a graphic image on a surface, wherein a portion of the graphic image has the appearance of three dimensionality, and wherein an image is printed on the surface, a portion of the image being a three dimensional precursor image, the apparatus comprising a dispensing head including a manifold with a plurality of outlets for dispensing a flowable material onto the portion of the image being a three dimensional precursor image and so as to form a lenticular layer over the portion of the image; a metering device connected to the dispensing head and for metering the amount of flowable material applied by the dispensing head onto the three dimensional precursor image; a motion device, connected to the dispensing head, that is capable of moving the dispensing head laterally, proximally, and distally with respect to the surface; a pressure source selected from the group consisting of pumps, pistons, and impellers, wherein the pressure source acts upon the flowable material to force it to flow through the dispensing head and onto the three dimensional precursor image; and a control device connected to the dispensing head, the metering device, the motion device, and the pressure source, that controls the actions and timing of the dispensing system.

Another embodiment of this invention provides a method of forming a graphic image, wherein a portion of the graphic image has the appearance of three dimensionality, the method comprising the steps of providing a surface; printing an image on the surface, wherein a portion of the image is a three dimensional precursor image; and applying a flowable material with a pressurized dispensing system onto the three dimensional precursor image so as to form a lenticular layer and to thereby produce a graphic image.

Another embodiment of this invention provides a method of forming a package, wherein a portion of the package has the appearance of three dimensionality, the method comprising the steps of providing a package surface; printing an image on the package surface, wherein a portion of the image is a three dimensional precursor image; and applying a flowable material by a pressurized dispensing system to the three dimensional precursor image to produce a graphic image.

Another embodiment of this invention provides an apparatus for forming a graphic image, wherein a portion of the graphic image has the appearance of three dimensionality, and wherein an image is printed on a surface, a portion of the image being a three dimensional precursor image, the apparatus comprising a manifold; an inlet within the manifold; an outlet within the manifold in fluid connection with the inlet; a cylindrical applicator including circumferential lenticule-forming grooves in fluid connection with the inlet; and a driving spool connected to the applicator that can rotate the applicator between an open flow position and a closed flow position.

Other features and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following detailed description, claims, and drawings.

BRIEF DESCRIPTION OF THE DRAWING

The invention will now be described with reference to the accompanying drawing, wherein like numerals denote like elements, and:

Fig. 1 is a schematic view of an object being exposed on photographic film through a lenticular sheet; Fig. 2 is a front elevational view showing the formation of a graphic image web by combining a precursor image web with a lenticular lens web; 1 0 00 Fig. 3 is a schematic perspective view showing the paths of travel of the precursor image web and the lenticular lens web as they are combined; Fig. 4 is a schematic side view of the relief cut roll which forms the lenticules in the lenticular lens web; Fig. 5 is a schematic perspective view of a printing unit used in a web offset press; Fig. 6 is a schematic perspective view of a printing plate; Fig. 7 is a side view of the graphic image web which includes the precursor image web combined with the lenticular lens web; Fig. 8 is a front elevation view showing formation of a graphic image web by combining a precursor image web with a lenticular coating; Figs. 9 and 10 are front elevation views showing formation of a graphic image web by combining a precursor image web with a spot lenticular coating; Fig. 11 is an enlarged view of a graphic image web formed with one form of spot lenticulation; Fig. 12 is a perspective view of an alternative embodiment of the invention; Fig. 13 is a perspective view, partly in phantom, of an embodiment of the manifold of Fig. 12; Fig. 14 is a partial cross-sectional view taken along the line 14-14 of Fig. 13; and Fig. 15 is a side cross-sectional view taken along the line 15-15 of Fig. 14.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention relates generally to methods for producing a printed graphic image having the illusion of three dimensionality and, more specifically, to methods for doing so in which the components are web or continuously fed. The methods of the present invention are characterized by their ability to achieve a finished graphic image having photographically acceptable quality. While photographic quality of a printed image is a complex function of many production variables, ranging from the quality of the optical equipment, grain size and speed of the film, the quality and type of the printing equipment and selected printing process, it can be reduced to a more subjective level. Quality can more conveniently be related to the ability of the observer to differentiate the structure in the finished printed image; for example, the ability to distinguish qualitatively and quantitatively facial features in portraits, tree limbs and foliage in panoramic vistas, and the like. When considered in the context of the present invention and the ensuing description, photographically acceptable quality thus refers to a benchmark measurement of clarity in the finished three dimensional view which is not materially, qualitatively distorted when compared to the precursor image. This is unlike the prior art methods capable of adaptation to web- fed or coating operation; they could not achieve acceptable quality, such quality having been attainable only through labor intensive manual operation using sheet components.

Referring now to the figures of the drawing, a method for forming a graphic image web will now be described. As shown generally in Fig. 1, a three dimensional or stereoscopic camera 10 is used to create an image which, when developed, will give the illusion of three dimensionality when combined with a lenticular lens web having the requisite optical geometry. An image field 12 includes an object 14 which is to be photographed. A single object 14 is used for illustrative purposes, but this should not be deemed as limiting image field 12 to a single object. For instance, numerous objects could be included in the image field even to the extent that image field 12 is filled with various objects as would be the case when photographing certain scenery. Often, however, when creating stereoscopic images, it is desirable to have the object or objects in a relatively narrow plane or lateral field of view to create an enhanced three dimensional effect.

Stereoscopic camera 10 is mounted on a device (not shown) which allows it to be moved through a plurality of spatially disparate positions (shown in phantom) to obtain spatially distinct views of object 14. Each of these spatially distinct views is exposed through a lenticular film assembly 16 which includes a photographically sensitive element 18, such as photographic film, combined with a superimposed lenticular lens 20. As light, reflected from object 14, enters camera 10, it passes through lenticular lens 20 and is focused into narrow condensed bands exposing photosensitive element 18 along narrow image bands 24.

In the preferred embodiment, lenticular lens 20 and photosensitive element 18 are relatively laterally movable. Photosensitive element 18 is preferably mounted in a mechanism (not shown) which moves it in proportion to the movement of camera 10. Thus, as camera 10 moves from one position to the next, photosensitive element 18 will move slightly along the length of lenticular lens 20 (shown in phantom). By moving element 18, the light reflected from object 14 at each adjacent camera position is focused by lenticular lens 20 into narrow bands adjacent the narrow image bands 24 exposed on photosensitive element 18 at the previous camera position. Object 14 is thereby imagewise exposed at different locations along photosensitive element 18 with each exposure location corresponding to one of the spatially distinct views of the object obtained at one of the camera positions.

00 00 More particularly, lenticular lens 20 includes a plurality of lenticules 22 each having a given, preferably similar focal length depending on the size and the curvature of the lenticules 22. When object 14 is photographed, light reflected from object 14 enters camera 10 and strikes lenticular lens 20. Each lenticule 22 focuses the light towards its focal point. Preferably, photosensitive element 18 is disposed approximately in line with the focal points of the plurality of lenticules 22. This insures that light striking each lenticule 22 converges into a narrow band at photosensitive element 18, creating a plurality of narrow condensed image bands 24 where the light focused by each lenticule exposes element 18.

Stereoscopic camera 10 is then moved to an adjacent location which gives a spatially disparate or distinct view of object 14. As camera 10 is moved to the next position, lenticular lens 20 is moved slightly with respect to photosensitive element 18 so that this view of object 14 will be focused on element 18 by lenticules 22 along narrow image bands 24 adjacent the prior image bands 24. Preferably, as camera 10 is moved through its full range of positions, lenticular lens 20 is moved with respect to photosensitive element 18 over a distance approximately equal the width of one lenticule 22. This will ensure that the image bands 24 created at each position of camera 10 will adequately expose the entire surface of photosensitive element 18 while preventing overlap of the image bands 24 formed under one lenticule 22 with those formed under the adjacent lenticule 22.

When photosensitive element 18 is completely exposed, it will include a plurality of image elements 26. Each image element 26 is of approximately the same width as the width of each lenticule 22 and includes a plurality of image bands 24 representing the various spatially disparate views of object 14 taken from and corresponding to the different positions of camera 10.

1 a.0 In the most preferred embodiment, camera 10 is continuously moved through its range of positions with its shutter held open. Simultaneously, lenticular lens 20 is continuously moved laterally with respect to photosensitive element 18 in an amount generally equal to the width of one lenticule 22. This provides for uninterrupted imagewise exposure of object 14 onto photosensitive element 18 so that there are no visually discernable breaks or gaps between image bands 24. Instead, image elements 26 each comprise the focused composite of the spatially disparate views obtained when camera 10 is moved through its range of motion while object 14 is continuously exposed along element 18.

If camera 10 is moved through a substantial range of positions, it is preferably moved along an arcuate path so that the distance between object 14 and camera 10 remains constant. However, if the spatially disparate views of object 14 are created with minimal motion of camera 10, then camera 10 can be moved along a straight line (i.e., a chord) as depicted in Fig. 1. This will not substantially affect the quality of the exposed latent three dimensional image on photosensitive element 18 due to the slight difference between arc and chord length.

Following exposure of image elements 26 on photosensitive element 18, the latent image may be developed by normal methods used in developing photographic film or other light sensitive emulsions. The developed image is then printed on a web, referred to herein as a precursor image web 34, and replicated along the longitudinal length of the web 34 using conventional printing techniques. The web 34 may be made of a variety of materials, including, for example, paper stock typically used for magazines. Image elements 26 are aligned generally longitudinally with the web 34, or in other words, are aligned generally in the machine direction. As discussed below, however, it is preferred that the image elements are disposed at a slight angle to the true machine direction.

The preferred interlacing method of creating the precursor image web 34 can also be used. Instead of taking multiple pictures through a lenticular lens 20 onto a single photographically sensitive element 18, it is possible to take multiple separate pictures on multiple photographically sensitive elements 18 and interlace them into a single 3- D precursor image 162.

Just as for the photographic method detailed above, for the interlacing method it is preferable to take the separate pictures from adjacent positions on an arc or chord of a circle around the image field 12. Then these separate pictures are digitized, such as by scanning them into a computer.

The digitized pictures are then registered to a single pivot point so as to set the correct amount of parallax necessary for the lenticules 22 to be used in the final graphic image web 32. The registered pictures are then combined by the analog method or preferably by the computer method.

In the computer method, the registered pictures are digitally ',sliced" into strips parallel to the line that the lenticules 22 will take in the graphic image web 32. These strips of each picture are then combined in interlacing fashion by the computer and printed as the 3-D precursor image 162. If there are four pictures A-D, the interlaced picture will consist of multiple strips in the order A, B, C, D, A, B, C, D, etc. Because the pictures were registered and the strips sized for the width and focal length of the lenticules 22, the combination of this 3-D precursor image 162 and the lenticular lens web 36 will yield a graphic image web 32 wherein the perceptible three dimensional image possesses photographically acceptable quality.

4 00 In the analog method, the registered pictures are printed as transparencies. These transparencies are used to create a negative picture of the 3-D precursor image 162 through the use of a barrier strip 28 (not shown). The barrier strip 28 is a black cover that fits over each registered picture transparency and blocks out all of the transparency except for multiple, parallel strips. The size and spacing of the strips will vary with the number of transparencies being combined and the width and focal length of the lenticules 22. As each transparency is covered with the barrier strip 28, light shined through the transparency exposes a photographically sensitive element 18. For each transparency, the barrier strip is moved relative to the photographically sensitive element 18, so that when all of the transparencies have been used to expose the photographically sensitive element 18, it is fully exposed but none of the strip exposures overlap.

The exposed photographically sensitive element 18 is used to make a positive image (the 3-D precursor image 162) of the interlaced pictures. When making this positive image, it is important that the size andproportioning of the strips remains constant. Some films may expand or contract upon processing. The preferred film for this process is Duraclear7m, although others also possess acceptable quality characteristics.

To create the illusion of three dimensionality, the precursor image web must be optically combined with a lenticular lens. The lenticules of the lenticular lens are aligned with the image elements 26 so that a person viewing the images on the precursor image web will perceive them as being three dimensional. Forming the lenticular lens and aligning it with image elements 26 of the precursor image web is a precision operation performed by a web apparatus 30, shown generally in Figures 2 and 3.

Web apparatus 30 is used to combine a precursor image web 34, including image elements 26, with a congruent lenticular lens web 36 (which may be left blank, printed with ordinary two dimensional images, or printed with image elements). Precursor image web 34 includes a back side 38 and a three dimensional or 3-D printed side 40 which is placed in registry with lenticular lens web 36.

In the preferred embodiment, shown generally in Figure 2, a printed roll 42 of precursor image 34 is mounted in web apparatus 30. Precursor image web 34 translates through a tensioner assembly 44 and then through a hood 46 where an adhesive 48, such as Morton International Blend 2359 pressure sensitive adhesive, is applied. Precursor image web 34 also moves through an optional lateral registration assembly 50 which slaves precursor image web 34 to lenticular lens web 36 so that they are in proper lateral or transverse registry when combined into graphic image web 32. Registration assembly 50 is optional because it has been found that in some applications lateral registration is not required.

Once precursor image web 34 and lenticular lens web 36 are properly aligned, with or without the assistance of registration assembly 50, the webs are pressed together between a base roll 52 and a biased pressure roll 54. Pressing web 34 and web 36 against base roll 52 allows adhesive 48 to convert the two webs into single graphic image web 32.

In the preferred method for forming lenticular lens web 36, a flexible web 56 is combined with a flowable resin 58. Flowable resin 58 is formed into a plurality of lenticules 60 and cured so that lenticules 60 maintain their shape (see Figure 4). Flexible web 56 preferably comprises a transparent plastic material such as polyester, although other flexible, relatively transparent materials could be used. A plastic roll 62 of flexible web 56 is mounted in web apparatus 30 and supplies the flexible web 56 for combination with resin 58. When web apparatus 30 is operating, web 56 moves through a tensioner assembly 64, around a plurality of guide rolls 68, and into a lenticule forming station 70 (discussed below). After moving through forming station 70, flexible web 56 moves around additional guide rolls 72 and then into contact with precursor image web 34 at base roll 52.

As mentioned above, it is important that precursor image web 34 and lenticular lens web 36 are optically aligned when combined between base roll 52 and biased pressure roll 54. Preferably, lenticules 60 have approximately the same cross-sectional dimensions and focal lengths as lenticules 22 of lenticular film assembly 16. This allows each lenticule 60 to be linearly aligned with a single image element 26 on the precursor image web 34.

If lenticules 60 are large in cross-section, a better three dimensional effect is achieved by laterally aligning a single lenticule 60 directly over each image element 26. However, as lenticules 60 and the corresponding image elements 26 are made narrower, it has been determined in accordance with the present invention that the need for precise lateral alignment is reduced. A desired three dimensional effect is produced by laminating precursor image web 34 to lenticular lens web 36 so that the lenticules 60 are linearly aligned with image elements 26. Proper linear alignment prevents distortion due to the crisscrossing of lenticules 60 with image elements 26.

In the preferred embodiment, the number of the lenticules 60 is at least 100 per inch. At this density of lenticules, a desired illusion of three dimensionality may be achieved without the use of lateral registration assembly 50. In the most preferred embodiment, the density of the lenticules 60 is at least 300 per inch. This eliminates the need for registration assembly 50 and also provides a short lenticule focal length to facilitate an extremely thin graphic image web 32.

In some cases, it may be desirable to alter the orientation of lenticules 60 with respect to image elements 26 to optically align them in a manner which produces moire patterns. However, it is generally desirable to avoid any formation of moire patterns.

When lateral registration is required, registration assembly 50 preferably comprises an ultrasonic guidance system 73. Ultrasonic guidance system 73 uses a pair of ultrasonic sensors 74 and 741, each of which produce an ultrasonic beam which tracks the edge of the web it is monitoring. Sensor 74 monitors an edge of precursor image web 34 while sensor 741 monitors the edge of flexible web 56. The frequency of the ultrasonic beam changes as it passes through different materials. Thus, the frequency of the beam passing through a web is different from the frequency of the beam as it passes through atmosphere. The ultrasonic beam either passes completely through the atmosphere, completely through the web, or partially through each, thereby allowing sensors 74 and 741 to read precisely the lateral position of each web. The preferred guidance system is the Model A9H manufactured by FIFE Corporation.

Since it has been determined that flexible web 56 tends to retain its lateral position, it is preferable to adjust the lateral position of precursor image web 34 to laterally align lenticular lens web 36 and precursor image web 34 prior to laminating them into single graphic image web 32. To obtain this lateral registry, the sensors, 74 and 741, supply an output signal to a controller which, in turn, provides output signals which control a guide roller assembly 76. Guide roller assembly 76 is preferably hydraulically controlled to adjust the position of precursor image web 34 in the lateral direction. Such guide roll assemblies are commonly known and used in the printing industry.

other types of guidance systems 73 may also be used to provide precise lateral registry of the webs. For example, a laser guidance system 73 which uses a laser beam to track the edge of each web may be used. Additionally, a stylus guidance system 73 could be used. In such a stylus guidance system 73, a stylus cooperates with a sensor to track a ridge or a groove disposed along the edge of a web, preferably the lenticular lens web 36. It is important to note that with any of these guidance systems 73, the groove, ridge or edge being tracked must be straight so that the webs can be accurately registered and combined.

In the embodiment illustrated, the precursor image web 34 is slaved to the lenticular lens web 36. However, registration assembly 50 could be connected to slave the lenticular lens web 36 to precursor image web 34. In either case, the lateral registration of webs 34 and 36 occurs during the translation of each web prior to laminating webs 34 and 36 to form graphic image web 32. This process allows efficient production of commercially viable lengths of graphic image web 32 when precise lateral registration is required.

To facilitate efficient production of graphic image web 32, lenticular lens web 36 is created during the translation of flexible web 56 through web apparatus 30. As shown generally in Figure 4, lenticule forming station 70 comprises a coating roll 77 around which flexible web 56 translates in an arcuate path. Flexible web 56 includes an inner surface 78 which is later adhered to the 3-D printed side (i.e. the image side) 40 of precursor image web 34. Flexible web 56 also includes a receiving surface 80 on which the flowable, curable resin 58 is deposited. Flowable resin 58 may be applied directly to receiving surface 80, but in a preferred embodiment, resin 58 is applied to a coating roll 77 which then rotates into cooperation with receiving surface 80 as shown generally in Figure 4. Flowable resin 58 is applied by an applicator 82 which creates a reservoir 84 of flowable resin 58 on the surface of coating roll 77. However, other methods of applying flowable resin 58, such as by spraying it onto coating roll 77, may be used without departing from the scope of the invention.

As flexible web 56 moves into lenticule forming station 70 it is routed around a tension nip roller 86 and then into contact with coating roll 77 in close proximity and on the downstream side of applicator 82. Thus, reservoir 84 is held between nip roller 86 and coating roll 77 so that receiving surface 80 of flexible web 56 is uniformly wetted with flowable resin 58. Once surface 80 is wetted, the desired optical surface pattern is formed in the flowable resin 58 on flexible web 56.

Coating roll 77 is relief-cut in a predefined optical surface pattern. This optical surface pattern is preferably a recessed pattern of lenticules which imparts a convex lenticular pattern to the flowable resin 58. This desired pattern is maintained as flexible web 56 moves through lenticule forming station 70 and is cured prior to any leveling which would materially impair the desired lenticular pattern. The lenticular pattern is maintained by holding flexible web 56 in contact with coating roll 77 until it moves into proximity with a tension roller 88 disposed downstream of coating roll 77. In the preferred embodiment, flowable resin 58 is a UV curable resin and is cured before flexible web 56 moves out of contact with coating roll 77. A plurality of UV radiators 90 are disposed about coating roll 77 in such a manner that the UV rays are directed through the base of transparent flexible web 56 and into resin 58 while it is maintained in the desired lenticular pattern against relief cut coating roll 77.

The relief cut pattern extends in an arcuate path around the circumference of coating roll 77. The pattern can be a screw pattern wherein one continuous relief cut groove, corresponding to the desired physical shape of each lenticule, continually wraps around the coating roll 77 similar to the thread of a screw. Thus, the relief cut groove has a given pitch angle dependent on the size of the groove and the diameter of coating roll 77. Such a continuous groove requires a coating roll 77 of sufficient size so that the pitch of the groove is negligible. This ensures that the lenticular pattern formed in flowable resin 58 is nearly linearly aligned with the machine direction of lenticular lens web 36.

Roll 77 is relief cut to correspond to the desired number and the desired shape of lenticules 60 both of which can vary substantially depending on various image web manufacturing parameters and the desired three dimensional effect. To obtain a thin image web 32, it is desirable to have 100 or more lenticules 60 per inch so that the convex lenticule 60 has a short focal length and the thickness of lenticular lens web 36 is minimized. As mentioned above, a higher density of lenticules 60 reduces or even eliminates the need for precise lateral registration.

The preferred shape of lenticules 60 is of a half cylinder split longitudinally, as shown generally in Figure 7. However, the shape of the lenticule 60 can be adjusted to facilitate shorter focal lengths without having as great a multiplicity of lenticules 60 per inch. Each lenticule 60 can be formed with greater curvature at its apex than throughout the remainder of the lenticule 60 to provide a shorter focal length with a broader overall lenticule cross section. An example of such a lenticule 60 is one having a hyperbolic cross section.

To obtain optical alignment for the greatest three dimensional effect, the images on precursor image web 34 can be tilted slightly with respect to the machine direction of web 34. The tilt of the images corresponds to the pitch of the lenticules 60 so that the image elements 26 are linearly aligned with lenticules 60. In our embodiment, the tilted images can be created on precursor image web 34 with a web offset press, although other types of presses such as gravure or flexographic presses can also be used.

A web offset press uses a printing unit 92 shown schematically in Figure 5. Ink is applied to an image carrier, such as a plate 94, which wraps around a plating cylinder 96. Plate 94 is etched with the desired image and transfers the ink held by the etched image to a blanket cylinder 98 which, in turn, transfers the image to precursor image web 34. Images may be printed on both sides of the precursor image web 34, as shown in Figure 5. Usually, a series of printing units 92 is required since only a single color will be applied at each printing unit 92.

To obtain optical alignment, the images are printed on precursor image web 34 at an angle which matches the pitch angle of the screw threads on coating roll 77. This is preferably accomplished by one of two different methods. According to one method, plate cylinder 96 is cocked or rotated so that it is no longer perpendicular to the machine direction of precursor image web 34. The angle of rotation from perpendicular approximately matches the pitch angle imparted to lenticules 60. Accordingly, the cocked plate cylinder 96 transfers the image to blanket cylinder 98 at the same angle so that the image elements 26 and lenticules 60 will be linearly aligned when graphic image web 34 and lenticular lens web 36 are combined.

According to the second method, the images are etched on plate 94 at the desired pitch angle as shown in Figure 6. Plate 94 includes an axis 100 which is aligned with the machine direction of precursor image web 34. However, when an image 102 is etched in plate 94, it is oriented at an angle with respect to axis 100. This angle corresponds approximately with the pitch angle of the recessed screw threads on coating roll 77. Thus, like before, as precursor image web 34 is laminated to lenticular lens web 36, lenticules 60 will be linearly aligned with image elements 26.

Following the curing of flowable resin 58 and the formation of lenticular lens web 36, lenticular lens web 36 moves around guide rolls 72 and into contact with precursor image web 34 where it is adhered to precursor image web 34 to form graphic image web 32 as described above. As shown generally in Figure 7, graphic image web 32 typically comprises a layer of printing paper 106 on which are printed the image elements 26 creating a printing layer 108. A layer of relatively transparent adhesive 48 is disposed on printing layer 108 and secures inner surface of flexible web 56 to precursor image web 34 (which includes paper 106 and printing layer 108). A pre-defined topography 110 is formed from curable resin 58 and disposed on receiving surface 80 of flexible web 56. In the preferred embodiment, the predefined topography 110 is formed in the pattern of lenticules 60 having the desired configuration and optical qualities so that when image elements 26 are viewed through lenticules 60 and flexible web 56, the illusion of three dimensionality is created. In this respect, it is desirable that each lenticule 60 be of generally the same width as each image element 26 and that each lenticule 60 has a focal length which coincides with its distance from printing layer 108.

Numerous materials may be used to create the various layers which are combined to form graphic image web 32. For example, flexible web 56 and lenticules 60 made be made from polycarbonate and laminated to a polycarbonate precursor image web 34. In another situation, it may be advantageous to use Tyvek, a material manufactured by the DuPont Company, as the precursor image web 34. A wide variety of materials, including synthetics and nonsynthetics, those with woven or nonwoven fibers, and those with oriented or nonoriented fibers may be used to form one or more of the precursor image web 34, flexible image web 56, or lentidules 60.

Referring now to Figure 8, an alternative embodiment of the invention in which the lenticular lens is formed by applying a coating to the precursor image web 34 will now be described. It should be understood that the prior art has concentrated mainly on formation of the lenticular lens without corresponding concern for the optical alignment of the lenticular lens with the base film or precursor image web 34 to which it is joined. In an effort to minimize distortion which occurs when a base film or precursor image web 34 becomes skewed or misoriented in its path of travel, the invention incorporates the combination of a specially processed precursor image web 34 with a curable lenticular lens coating.

In accordance with the invention, precursor image web 34 is formed and processed as described above wherein the image elements are slightly tilted with respect to machine direction of web 34. Web 34 passes through a tensioning device 112 and around a coating roll 114 where a fluid coating 116 is directly applied from a source 118. A fountain blade 120 is utilized to wipe off excess coating 116 from roll 114. Web 34 then passes under a forming member 122, such as a knife or rotating bar, relief cut with the desired lenticular pattern having a pitch corresponding to the tilt angle of the image elements printed on web 34 as before described. After the lenticular coating has been formed, web 34 travels past an ultraviolet lamp, or is otherwise cured, such as by chemical curing, drying, infrared or ultrasonic beam. Composite graphic image web 32 is thus continuously formed such that the lenticules 60 in coating 116 are in registration with the tilted image elements 26 in precursor image web 34.

It should be appreciated that precursor image web 34 may be coated with a lenticular lens 20 in a variety of modes including direct gravure and flexographic methods and in combination with various laminations.

Another particular form of the invention contemplates improved spot or selective lenticulation on the precursor image web. In one such arrangement shown in Figure 9, a rotating coating or anilox roll 126 transfers resin or coating 128 from a reservoir 130 or manifold 132 to the segments 134 of a plate cylinder 136 which is relief cut with the lenticular pattern again matching the angular orientation of the image elements 26 on the precursor image web 34. Rotation of plate cylinder 136 thus transfers segmented or spot lenticulation to precursor image web 34 routed between a displaceable backup cylinder 138 and plate cylinder 136. After the lenticular coating 128 has been deposited on selected areas of the web, a curing source 140, such as an ultraviolet radiator or the like, is used to cure the lenticular coating 128. once again a doctor blade 142 is used to remove excess coating 128 from roll 126.

Figure 10 shows another embodiment wherein coating 144 from a manifold 146 governed by a timing control 146a is directly applied to a relief cut gravure cylinder 136a before spot transfer to web 32.

Segments 134 on plate cylinder 136 are constructed of urethane, rubber, copper or stainless steel and are interchangeable to provide various tapered effects of the lenticular coating. Any number of coating stations, or decks, with various sized segments 134 may be utilized to produce web 32 so as to build up a layered spot lenticulation such as shown in Figure 11 wherein a three-layered coating 148 results in a spot lenticulation of generally frustoconical or trapezoidal cross section having downwardly sloping sides 150 to yield a certain effect.

In another embodiment of the invention shown in Figs. 12-15, the lenticular material is laid down or extruded directly onto a surface 160 including the printed three dimensional (3-D) precursor image 162. In addition to flat surfaces 160, such as a web or sheet of material, the surface 160 may be a non-planar surface 160, such as the exterior of an already-formed package, i.e. a beverage can, a glass bottle, a box, or other container.

After printing, the lenticular material or flowable resin 58 is applied to the 3-D precursor image 162. The flowable resin 58 may be a polyester, vinyl, or polycarbonate material, a UV or EB (electronic beam) curable resin, a thermosetting resin, a thermoreactant resin, a catalyzed resin, or any other formable material with acceptable optical properties.

The flowable resin 58 is dispensed onto the surface 160 by a pressurized dispensing system 164. Preferably, a pressure of between about 20 and 2, 000 lb/in 2 is used. The preferred pressure for any specific embodiment will vary with the temperature and viscosity of the flowable resin 58, with more viscous flowable resins 58 requiring higher pressures to achieve good flow rates.

The dispensing system 164 includes a source 166 of flowable resin 58, a pressure system 168 that applies the necessary pressure to cause the flowable resin 58 to be applied to the surface 160, a dispensing head 170, and a control device 178 (not shown). Optionally, the dispensing system 164 may include a snuffer or draw-back device 172 to prevent drool or leaking of excess flowable resin 58. Also optionally, the dispensing system 164 may include a motion device 180 to move the dispensing head 170 or the entire dispensing system 164.

The pressure system 168 may be based upon air pressure, gravity, or mechanical pressure, where mechanical pressure includes pressure created by impellers, pistons, and peristaltic pumps, among other devices. The pressure system 168 includes a pressure source 174 that in some embodiments is connected to the rest of the dispensing system 164 by a connector or hose 176. The hose 176 may connect to the dispensing system at a variety of locations. It may connect to the source 166 of flowable resin 58, thus placing pressure upon all of the flowable resin 58. It may also connect to a point between the source 166 and the dispensing head 170, or to a position within the dispensing head 170. In some embodiments, the pressure system 168 and the metering device 186 (described below) are the same element, which may be a piston, syringe, or other multi- purpose device.

The dispensing system 164 must have at least one dispensing head 170, and may have large numbers of dispensing heads. Each dispensing head 170 includes at least one manifold 182, and may include more than one. Each manifold 182 contains at least one outlet 184, and preferably contains between about 10 and 300 outlets 184 per inch of width (about 0.4 to 12 outlets per millimeter). The width of the manifold 182 is preferably the same as the width of the 3-D precursor image 162. Each outlet 184 may have any shape, but is preferably round in cross-section. Other preferred shapes include half- round, pyramidal, elliptical, and trapezoidal.

The dispensing head 170 may also include a metering device 186. The metering device 186 controls the amount of flowable resin 58 that is placed upon the surface 160, so that as nearly as possible exactly the desired amount of flowable resin 58 is applied. The metering device 186 may measure out the specific amount of flowable resin 58 volumetrically by allowing a space of known volume to become filled with flowable resin 58 and then discharged by the pressure system 168 onto the surface 160. Preferably, the metering device 186 is a timing device that allows discharge of the flowable resin 58 to occur for a specific amount of time while the pressure system 168 is applying a specific pressure. By controlling both time and pressure in this manner, a controlled amount of flowable resin 58 will be discharged onto the surface 160. Most preferably, the metering device 186 is a metering valve like those made by the DOPAG Corp. of Round Lake, N.Y.

The dispensing head 170 is preferably near the surface 160 when flowable resin 58 is being dispensed. The dispensing head 170 may be either above or below the surface 160, and may be perpendicular to the surface 160, or at any angle to it. If multiple dispensing heads 170 are desired, they may be on the same side of the surface 160, or on opposite sides with the surface 160 between them.

When the flowable resin 58 is applied to the surface 160, there can be a problem with excess flowable resin 58 being applied to portions of the surface 160 other than the 3-D precursor image 162 if too much flowable resin 58 is discharged by the dispensing system 164. Additionally, even if there is no excess discharge of flowable resin 58, there can still be a problem with threads 190 (not shown) of flowable resin 58 forming. This occurs when the flow stops and the dispensing head 170 and the surface 160 move away from one another, and the mass of flowable resin 58 applied to the surface 160 does not immediately break from the mass of flowable resin 58 still within the dispensing head 170. When the forces connecting these two masses of flowable resin 58 are not overcome, excess flowable resin 58 can be drawn out of the dispensing head 170 in a long, thin thread 190 as movement occurs, and this thread 190 will either become applied to the wrong portions of the surface 160 and reduce the quality of the product, or become applied to the components of the dispensing system 164, creating a clean-up problem and potentially causing fouling. The snuffer or draw-back device 172 serves to prevent this problem by placing extra force upon the mass of flowable resin 58 within the dispensing head 170 to pull it back within the dispensing head 170, thus causing it to sever from the mass of flowable resin 58 already applied to the surface 160.

The draw-back device 172 can comprise a vacuum source 192 that is momentarily allowed to act upon the flowable resin 58 within the dispensing head 170 so as to pull the flowable resin 58 back away from the outlet 184, and break the connection between this flowable resin 58 and the mass of flowable resin 58 already applied to the surface 160. The draw-back device 172 can also be a mechanical piston or syringe device that mechanically pulls the flowable resin 58 back into the dispensing head 170.

Distinguished from the above methodology, the draw-back device 172 may operate by directly severing the connection between the flowable resin 58 upon the surface 160 and the flowable resin 58 within the dispensing head 170. The draw-back device 172 may be a rotating valve that is near or part of the outlet 184, and that is in an open position when the flowable resin 58 is being applied to the surface 160, and rotates to a closed position when application is to cease. In this embodiment, there may or may not be a small amount of flowable resin 58 still within the dispensing head 170 that is not cut off from the flowable resin 58 that has been applied to the surface 160, and this small amount of flowable resin 58 may or may not be drawn out of the dispensing head 170 onto the surface 160. However, if it is present and drawn out, it is such a small amount that it does not adversely effect the quality of the final graphic image, nor does it present a danger of fouling the machinery.

The control device 178 directly or indirectly controls the actions of all of the movable components of the dispensing system 164. For example, the control device 178 controls the movement and timing of the metering device 178, the movement and timing of the motion device 180, the pressure of the pressure system 168, and the movement of the surface 160. Most preferably, the control device 178 is a computer that is electrically or mechanically connected to the various components of the dispensing system 164.

The motion device 180 can be used to move the dispensing head 170 or the entire dispensing system 164. This is desired in many applications where it is preferable to move the dispensing head 170 to its aligned position over the 3-D precursor image 162 on the surface 160, rather than move the surface 160 into alignment with the dispensing head 170. The movement ofthe motion device 180 is preferably controlled by the control device 178 so that its movement is accurately tied into the rest of the components controlled by the control device 178. Preferably, the motion device 178 is a mechanical arm, such as a robotic arm, with the dispensing head 170 at its terminus connected to the rest of the system through hoses and electrical connectors. The motion device 178 is most preferably a multidirectional linear device such as the compumotor made by Thomson Industries, Inc.

of Port Washington, N.Y., or that made by the ParkerHannifin Corp.

In another embodiment of the invention shown in Figs. 13-15, the manifold 182 includes an applicator head 202. The applicator head 202 sits in a specially sized recess 214 in the manifold 182. This recess 214 is in fluid communication with an inlet 210 that is connected to the source 166 of flowable resin 58. The recess 214 is also in fluid communication with an outlet 212 that receives excess flowable resin 58 and may either recycle it back into the source 166 or take it to waste as preferred.

The applicator head 202 is preferably cylindrical in shape. Relief-cut grooves 204 run circumferentially around a portion of the applicator head 202. The grooves 204 are sized and shaped so as to produce lenticules 22 having a size and shape as required in the final product. The smooth portion 206 comprises the remainder of the surface of the applicator head 202. It is through the grooves 204 that the flowable resin 58 will flow from the dispensing system 164 onto the surface 160, as explained below.

The applicator head 202 is mounted on a driving spool 208. The driving spool 208 is motor driven and causes the applicator head 202 to rotate within the recess 214 as the control device 178 dictates. When flowable resin 58 is not being applied to the surface 160, the driving spool 208 rotates the applicator head 202 into a closed position wherein the smooth portion 206 is flush with the recess 214 and seals the inlet 210 and outlet 212 from the outside environment. In this position, the inlet 210 and outlet 212 are preferably still in fluid communication with one another, but not with the surface 160.

When it is time to apply the flowable resin 58, the control device 178 causes the driving spool 208 to rotate the applicator head 202 to an open position. Preferably this is done by rotating the applicator head 202 in a direction opposed to the direction of motion of the surface 160. Once the grooves 204 are in contact with the inlet 210, the inlet 210 is no longer sealed closed because the grooves 204 are not flush with the recess 214 as the smooth portion 206 had been. This allows the flowable resin 58 to flow into and down the grooves 204 and into contact with the surface 160. Because the flowable resin 58 will tend to stick to the surface 160, and because the applicator head is preferably made of a non- stick material, the flowable resin 58 will flow smoothly down the grooves 204.

Preferably, relative to the movement of the surface 160, the flowable resin 58 will flow down the upstream side of the applicator head 202. Also it is preferred that the applicator head 202 be in contact with the surface 160. In this manner, as the flowable resin 58 reaches the 3-D precursor image 162 on the surface 160, it must pass between the surface 160 and the grooves 204 of the applicator head 202, and be forced into the shape of the grooves 204, i.e., into the desired shape of the lenticules 60. Curing of the flowable resin 58 will occur next in the process to permanently convert the flowable resin 58 into the lenticules 60.

If the applicator head 202 is rotated further, it will again be in the closed position. The smooth portion 206 will seal the inlet 210 and outlet 212, cutting off the flowable resin 58. Any flowable resin 58 remaining in the grooves 204 will be drawn out of the grooves 204 and onto the surface 160 due to the non-stick nature of the grooves 204 and the stickiness of the flowable resin 58 to itself and the surface 160.

By timing the rotation of the applicator head 202 with the movement of the surface 160, the flowable resin will only reach the surface 160 at the beginning of the 3-D precursor image 162. By again controlling the rotation of the applicator head 202, the flow of flowable resin can be stopped at the end of the 3-D precursor image 162.

It is necessary that the grooves 204 extend far enough to reach between the inlet 210 and the surface 160, or the flowable resin 58 will become applied to the surface 160 from the smooth portion 206, and will not retain the shape imparted to it by the grooves 204. It is also necessary that the smooth portion 206 be long enough to completely seal closed the inlet 210 and outlet 212 when in the closed position. Preferably the grooves 204 extend around about half of the circumference of the applicator head 202.

In another alternative embodiment of the invention, the offset web press of Figure 5 is used to print directly on a web of lenticular film. More particularly the offset web press is used to print onto a lenticular film having lenticules 60 preformed thereon. However, other methods such as flexographic, gravure, and electrodeposition may be used. The lenticular film is manufactured of a transparent material such as polyester, vinyl, or polycarbonate, upon which the precursor image is reverse printed on the flat or non-lenticular side. The transparent material is preferably extruded. The perceptible image is viewed from the lenticular side.

The same absolute registration demands as described earlier in the invention apply to this embodiment; such as tilt of the image, printing plates or cylinder to the angle or pitch of the lenticules, which can be either continuous screw pitch or ',stepand-repeatte.

This form of printed material would greatly reduce the overall thickness of the finished product, thus enabling it to be used in a greater range of applications. The finished product has application in a wide variety of products. For example, the finished product can be used in textbooks, such as medical textbooks, without an undesirably high thickness. The finished product has automotive applications, e.g. to provide an illusion of depth in an instrument cluster, in dashboards, or in other parts of an automobile interior. The finished product has application in packaging materials (e.g. packages that are displayed on store shelves). The finished product has application in magazine covers. Other applications will be apparent to one of ordinary skill in the art.

The printing could be accomplished with (but not necessarily restricted to) any printing method such as web offset, flexographic, gravure, stochastic, or electronic deposition, the latter being a form of printing presently being used for high speed labeling, color productions, etc. Some forms of electronic deposition include laser printing, videojet, and ink jet. Regardless of the method employed, a high precision press should be employed. In the preferred embodiment, a web offset method is employed using a high precision press such as a Harris M-1000. An example of a high precision flexographic press is a Stevens Graphics 2000.

After printing of an image on the lenticular web 36, an opaque coating is used to cover the image printed on the lenticular web 36. The opaque coating has sufficient density to permit printing thereon without the printing on the coating being visible on the side of the lenticular film having the lenticules 60 thereon. A white coating can be used to cover the image that is printed on the lenticular web 36, and a normal 2-D image can be printed on the white coating. This is useful for magazine covers having a 3-D outside cover and a 2-D inside cover. Alternatively, a 3-D image can be formed on the white coating by methods described above.

The locations of the image web relative to machine configuration would be similar to descriptions presented earlier in the patent application.

The lenticular web 36 is pre-manufactured to the correct pitch and thickness to provide the viewer with the illusion of 3-D. The manufacturing process of the lenticular web 36 is through extrusion, coextrusion, casting, embossing, or coating so as to provide a suitable platform for reverse printing thereon for a 3-D image web 32.

This process provides significant cost savings. This process eliminates the printing of the precursor web, the lamination process and the aforementioned casting or coating process.

Manufacture of the cylinder used in the preforming (casting operation) of the lenticular web 36 which is to be printed upon is accomplished through either the continuous screw pitch configuration or through a process of step-and-repeat, whereby a preformed tool is plunged into the media constituting the roll surface, then retracting and moved to the next position as determined by the lenticular screen; i.e., 135 lines per inch or 200 lines per inch. It is imperative that the movement or indexing of the tool conform exactly to the requirements of the printed communication to be viewed through it. The term "tool" used in the last sentence can be used to describe a solid device such as diamond, or carbide or other material removing device such as laser or EDM.

It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention, and that the invention is not limited to the specific form shown. For example, the lenticules 60 may be of different shape or size, different types of curable resin 58 may be used, and the arrangement of various components in web apparatus may be changed. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.

Claims (20)

What is claimed is:

1. An apparatus for forming a graphic image on a surface, wherein a portion of the graphic image has the appearance of three dimensionality, comprising: a printer that prints a three dimensional precursor image on a portion of the surface; and a dispensing system that applies a flowable material to the printed three dimensional precursor image so as to form a lenticular layer over the printed three dimensional precursor image to thereby produce the portion of the graphic image.

2. The apparatus of claim I wherein the flowable material is selected from the group consisting of polyester, vinyl, polycarbonate, ultraviolet or electronic beam curable resins, thermosetting resins, thermoreactant resins, and catalyzed resins.

3. The apparatus of claim 1 wherein the dispensing system includes a dispensing head including a manifold with a plurality of outlets for dispensing the flowable material.

4. The apparatus of claim 3 wherein the dispensing system further includes a metering device connected to the dispensing head and for metering the amount of flowable material applied to the three dimensional precursor image.

5. The apparatus of claim 3 wherein the dispensing system further includes a control device that controls the actions and timing of the dispensing system.

6. The apparatus of claim 5 wherein the control device is a computer.

7. The apparatus of claim 3 wherein the dispensing system further includes a motion device, connected to the dispensing head, that is capable of moving the dispensing head laterally, proximally, and distally with respect to the surface.

8. The apparatus of claim 3 wherein the dispensing system further includes a pressure source selected from the group consisting of pumps, pistons, and impellers, wherein the pressure source acts upon the flowable material to force it to flow through the dispensing head and onto the three dimensional precursor image.

9. The apparatus of claim 3 wherein the dispensing head further comprises a valve that prevents the flow of excess flowable material onto the three dimensional precursor image.

10. The apparatus of claim 3 wherein the dispensing system further includes a negative pressure source selected from the group consisting of pumps, pistons, and impellers, wherein the negative pressure source acts upon the flowable material to prevent the flow of excess flowable material onto the three dimensional precursor image.

An apparatus for forming a graphic image on a surface, wherein a portion of the graphic image has the appearance of three dimensionality, and wherein an image is printed on the surface, a portion of the image being a three dimensional precursor image, the apparatus comprising: a dispensing head including a manifold with a plurality of outlets for dispensing a flowable material onto the portion of the image being a three dimensional precursor image and so as to form a lenticular layer over the portion of the image; a metering device connected to the dispensing head and for metering the amount of flowable material applied by the dispensing head onto the three dimensional precursor image; a motion device, connected to the dispensing head, that is capable of moving the dispensing head laterally, proximally, and distally with respect to the surface; a pressure source selected from the group consisting of pumps, pistons, and impellers, wherein the pressure source acts upon the flowable material to force it to flow through the dispensing head and onto the three dimensional precursor image; and a control device connected to the dispensing head, the metering device, the motion device, and the pressure source, that controls the actions and timing of the dispensing system.

12. A method of forming a graphic image, wherein a portion of the graphic image has the appearance of three dimensionality, the method comprising the steps of: providing a surface; printing an image on the surface, wherein a portion of the image is a three dimensional precursor image; and applying a flowable material with a pressurized dispensing system onto the three dimensional precursor image so as to form a lenticular layer and to thereby produce a graphic image.

13. The method of claim 12 wherein the step of applying the flowable material includes extruding the flowable material onto the three dimensional precursor image using a dispensing head including a manifold with a plurality of outlets.

14. The method of claim 13 and further including the step of aligning the dispensing system with respect to the three dimensional precursor image using a motion device before applying the flowable material.

15. The method of claim 14 further comprising the step of stopping the application of flowable material onto the three dimensional precursor image using an apparatus selected from the group consisting of a valve and a negative pressure source.

16. A method of forming a package, wherein a portion of the package has the appearance of three dimensionality, the method comprising the steps of: providing a package surface; printing an image on the package surface, wherein a portion of the image is a three dimensional precursor image; and applying a flowable material by a pressurized dispensing system to the three dimensional precursor image to produce a graphic image.

17. An apparatus for forming a graphic image, wherein a portion of the graphic image has the appearance of three dimensionality, and wherein an image is printed on a surface, a portion of the image being a three dimensional precursor image, the apparatus comprising: a manifold; an inlet within the manifold; an outlet within the manifold in fluid connection with the inlet; a cylindrical applicator including circumferential lenticule-forming grooves in fluid connection with the inlet; and a driving spool connected to the applicator that can rotate the applicator between an open flow position and a closed flow position.

18. The apparatus of claim 17 wherein the lenticule-forming grooves extend around about half of the circumference of the applicator.

19. The apparatus of claim 17 wherein the driving spool is powered by a motor and controlled by a control device.

20. The apparatus of claim 17 wherein the manifold further comprises a recess in fluid communication with the inlet, the outlet, and the applicator, and into which the applicator fits so as to seal the inlet when rotated by the driving spool into the closed flow position.