US20090317605A1 - Printed foamed film package - Google Patents

Printed foamed film package Download PDF

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Publication number
US20090317605A1
US20090317605A1 US12/487,112 US48711209A US2009317605A1 US 20090317605 A1 US20090317605 A1 US 20090317605A1 US 48711209 A US48711209 A US 48711209A US 2009317605 A1 US2009317605 A1 US 2009317605A1
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United States
Prior art keywords
thin film
printed
foamed thin
indicia
printed surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/487,112
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English (en)
Inventor
Neil John Rogers
Michael Remus
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Priority to US12/487,112 priority Critical patent/US20090317605A1/en
Assigned to PROCTER & GAMBLE COMPANY, THE reassignment PROCTER & GAMBLE COMPANY, THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ROGERS, NEIL JOHN, REMUS, MICHAEL
Publication of US20090317605A1 publication Critical patent/US20090317605A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52—Details
    • B65D75/58—Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5827—Tear-lines provided in a wall portion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/52—Details
    • B65D75/58—Opening or contents-removing devices added or incorporated during package manufacture
    • B65D75/5827—Tear-lines provided in a wall portion
    • B65D75/5833—Tear-lines provided in a wall portion for tearing out a portion of the wall
    • B65D75/5838—Tear-lines provided in a wall portion for tearing out a portion of the wall combined with separate fixed tearing means, e.g. tabs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/24—All layers being polymeric
    • B32B2250/242—All polymers belonging to those covered by group B32B27/32
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/406—Bright, glossy, shiny surface
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    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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    • B32B2439/00—Containers; Receptacles
    • B32B2439/02—Open containers
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1056—Perforating lamina
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/00—Stock material or miscellaneous articles
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    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1376—Foam or porous material containing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/00—Stock material or miscellaneous articles
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/00—Stock material or miscellaneous articles
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    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Definitions

  • This invention relates to the field of packages comprising a foamed film layer.
  • Polyolefin plastic film is used to construct a wide variety of packages such as bags and pouches that hold consumer goods.
  • packages such as bags and pouches that hold consumer goods.
  • bags holding stacks of disposable diapers or hygiene articles, pouches for wet wipes, and bags containing granular laundry detergent are often made from plastic film.
  • the plastic film that forms a package may be a single layer of film (called a monofilm), a combination of layers that are co-extruded, or a laminate of separately produced layers that are adhered to one another. In virtually all packages, some sort of indicia is printed on the plastic film.
  • Flexographic printing employs a flexible printing plate made of a flexible, elastomeric material. A raised relief image of the indicia to be printed on the package is present on the flexible printer plate. The relief image is coated with ink and then pressed onto the plastic film.
  • one or more flexographic printer plates are positioned on a rotating print cylinder that prints on a sheet of film as the film moves beneath the print wheel. Each plate may carry a different type or color ink.
  • Rotogravure printing uses a printer plate that has an engraved relief image. The printer plate is usually made of metal and is often formed into a cylindrical print roll.
  • Ink is drawn into the engraved image and transferred to the plastic film. Because both flexographic and rotogravure printing involve contacting the surface of the plastic film with a relief image to transfer the ink to the film, variations in surface texture of the plastic film will impact print quality. Rotogravure presses may have multiple print rolls whereas each print roll can carry a different type or color ink.
  • foamed polyolefin film of suitable thickness (10-250 microns) and strength for the types of packages described above.
  • foamed polyolefin films that are suitable for packages are described in European Patent No. 1 646 677.
  • the use of foamed thin film allows for replacement of part of the resin (e.g., 5-50% by weight) with gaseous bubbles that are formed or incorporated in the film during a foaming process. Because the voids or cells left by the bubbles occupy volume that was formerly filled with resin, foamed film allows for a reduction in resin without a corresponding reduction in film thickness, commonly referred to as the film's caliper.
  • foamed thin films have a rough surface texture as compared to a non-foamed film of the same caliper.
  • the rough texture caused by the presence of the voids in the film, makes it difficult to print directly on the foamed thin film using flexographic or rotogravure printing.
  • the rough texture tends to cause voids in ink coverage due to the recesses in the surface not contacting the print plate.
  • these voids in ink coverage may degrade an image of a bar code to a such a degree that a bar code reader could not decode the bar code.
  • a method of constructing a package having printed indicia of acceptable quality includes providing at least one layer of foamed thin film wherein the layer of foamed thin film has a caliper of between 10 and 250 microns and comprises between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition.
  • a first surface of the at least one layer of foamed thin film is the printed surface of the package.
  • the indicia is printed on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink.
  • the printer surface includes a plurality of raised dots having top surfaces configured to contact the printed surface to imprint the indicia on the printed surface.
  • the raised dots have a dot percentage no greater than approximately 70%, and in some embodiments the dot percentage is between 50%-60%.
  • the ink may be selected to have approximately a 20 second increased viscosity as compared to ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition.
  • the ink may be selected as having an intensity that is approximately 30%-50% greater than an intensity of an ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition.
  • the printed surface may be contacted with the inked printer surface with a pressure that is greater than a printer pressure that would be used to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition.
  • a package includes at least one layer of foamed thin film wherein the layer of foamed thin film has a caliper of between 10 and 250 microns and comprises between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition.
  • the package also includes printed indicia of acceptable quality is printed on a printed surface of the package.
  • a first surface of the at least one layer of foamed thin film is the printed surface of the package.
  • the package is made of a foamed thin film co-extrusion that has a top layer that includes a foamed thin film that includes the printed surface.
  • the package includes a foamed thin film lamination that has a top layer that includes a foamed thin film that includes the printed surface.
  • FIG. 1 is a top plan view of a foamed thin film with printed indicia in accordance with one or embodiments of the present invention.
  • FIG. 2 is a cross section view of a printer plate acting on the foamed thin film of FIG. 1 in accordance with one or embodiments of the present invention.
  • FIG. 3 is a top plan view of the printer plate of FIG. 2 .
  • FIG. 4 is a cross section view of a prior art printer plate acting on a non-foamed film with printed indicia.
  • the term “thin film” designates a film having a caliper that is suitable for use in packages such as bags and pouches for consumer goods, such as, for example, film calipers of between about 10 and 250 microns.
  • the term “foamed thin film” designates a film containing at least one layer with a caliper of between 10 and 250 microns that contains gaseous bubbles or void volumes or cells wherein that layer exhibits a density reduction of at least 5% yield (as determined by ASTM D4321) versus a film of the same thickness that does not comprise gaseous bubbles or void volumes or cells.
  • the term “printed indicia of acceptable quality” means indicia such as, for example, characters, graphics, and regions of color that meet industry standards for clarity and density of print on consumer packaging.
  • One informal way of determining whether the indicia are of acceptable quality is whether voids in the ink in the region through which the underlying foamed film can be seen with the naked eye.
  • Two industry known tests used to measure whether bar code indicia are of acceptable quality are ISO/IEC 15415 Bar Code Print Quality Test Specification and ISO/IEC 15416 that grades readability of bar codes from “4A” (best) to “0F” (worst).
  • a bar code readability of 2C as measure by ISO/IEC 15416 is generally considered as acceptable quality in the industry.
  • Another exemplary way of determining whether graphics and regions of color are of acceptable quality is to measure the density of the printed area with a densitometer.
  • specific test patterns can be printed and measured using ASTM F 2036.
  • a density of 1.1 to 1.8 Density Units for a solid black region printed on white paper is generally considered to be of acceptable quality in the industry.
  • FIG. 1 is a top plan view of a foamed thin film 10 that has indicia 15 .
  • Foamed thin films 10 can be used to make packages.
  • Foamed thin films 10 typically have a caliper (thickness) of between about 10 to 250 microns and are made of a foamed polyolefin resin.
  • Many different blends of components may be used in the polyolefin and components which are selected for a variety of properties such as strength and opacity.
  • Polyethylene e.g.
  • Low Density Polyethylene LDPE Linear Low Density Polyethylene LLDPE, High Density Polyethylene HDPE, Medium Density Poly ethylene MDPE, Metallocene Polethylene mPE, Ethyl Vinyl Acetate EVA and mixtures thereof) and polypropylene, and blends thereof are exemplary types of materials that are often used in the manufacture of foamed thin films 10 .
  • the thin film 10 shown in FIG. 1 is called a monofilm because it consists of a single layer.
  • the foamed thin monofilm 10 is made up of a resin 12 , such as, for example, polyolefin, in having voids left by gas bubbles 14 .
  • a resin 12 such as, for example, polyolefin
  • One way to produce foamed monofilm 10 is adding one or more chemical blowing agents such as, for example, Sodium Hydro Carbonate Powder and an acidifier to the master batch of resin 12 prior to heating. Upon heating, chemical blowing agents release carbon dioxide. The carbon dioxide expands and forms bubbles 14 in the monofilm 10 during subsequent processing steps.
  • One exemplary chemical equation describing the transition of the blowing agent to carbon dioxide is:
  • An alternative to the use of chemical blowing agents that react in the resin to produce bubbles 14 is to inject a gas such as, for example, carbon dioxide into the plastic extruder during film manufacture.
  • the bubbles 14 shown in FIG. 2 are generally cigar shaped, however, other shapes are contemplated.
  • the bubbles 14 are generally cigar shaped and oriented in the direction of film extrusion. In a foamed thin polyethylene monofilm having a caliper of 40 microns, a typical cigar shaped bubble may be 10 microns in diameter and between 50 and 300 microns in length.
  • the foam structure of a foamed thin monofilm 10 is generally closed towards the surface such that substantially all of the bubbles 14 close to the surface are closed. Because the bubbles 14 create voids that occupy volume that would have been occupied by resin 12 in a non-foamed thin film, the foamed thin monofilm 10 uses less resin 12 than its non-foamed counterpart (see e.g., non-foamed thin film 120 in FIG. 4 ) while maintaining substantially the same caliper. While the bubbles are typically closed, open bubbles that can provide surface irregularities, (e.g. troughs or dimples) may be present.
  • the monofilm 10 may also be a top, or printed, layer of foamed thin film co-extrusion (not shown) or a foamed thin film laminate (not shown).
  • foamed thin film co-extrusion many film packages use thin film co-extrusions or laminates because the composition of each layer may be selected to contribute a desired quality to the resulting package.
  • resins for each layer are co-extruded while molten and cooled together to form a layered thin film co-extrusion.
  • the foamed thin film co-extrusion includes layers of each type of resin directly adjacent one another.
  • Foamed thin film co-extrusions may include layers that are selected to provide, for example, strength, opacity, print quality, and moisture resistance.
  • Foamed thin film laminates are similar to thin film co-extrusions because both include layers of different types that are selected to contribute a desired quality to the resulting package. However, rather than being combined in a molten form, the layers of a thin film laminate are separately formed and cooled. Laminates are often used when one or more of the layers is not well suitable for co-extrusion, such as, for example, metallized layers that require significantly different processing techniques as compared to plastic layers. The separate layers are then fixed to one another, such as, for example, using adhesive. According to the present invention, foamed thin film co-extrusions and laminates have a top layer that is foamed. Package indicia is printed on this top layer.
  • coat-extruded laminates where at least one layer is a foamed layer which can be either the previously formed substrate that is later coat-extruded with a different layer, or the foamed layer can be the coat-extruded layer.
  • the foamed layer can be printed before, during, or after the coat-extrusion process.
  • the foamed layer being the coat extruded layer, it is printed after the coat extrusion process at any time when the layer is sufficiently cooled for printing.
  • a foamed film layer can be printed at any convenient time. It can be printed on one or both sides, and the sides may be printed concurrently or in sequence.
  • the foamed thin film or foamed film layer can receive printing by one or both of flexographic and rotogravure printing processes.
  • Flexographic printing is a method of direct rotary printing that uses a resilient relief image in a plate of rubber or photopolymer to print indicia on plastic film used to make packages.
  • the plate or plates are installed on a rotatable print cylinder that prints on a continuous sheet of plastic film as it passes beneath the print cylinder.
  • FIG. 4 is a cross section view of a prior art non-foamed thin film 120 being imprinted with indicia (such as indicia 15 shown in FIG. 1 ).
  • a printer surface 112 of a printer plate 100 such as, for example, a flexographic plate contacts a printed surface 122 of the non-foamed thin film 120 .
  • the printer surface 112 is substantially planar to provide a full coverage of ink on the printed surface.
  • foamed thin films e.g. foamed thin film 10
  • foamed thin films e.g. foamed thin film 10
  • Voids in the ink are visible to the naked eye, making the print quality unacceptable for many packaging applications.
  • Various adjustments to the flexographic print process used with non-foamed thin films have been made in an attempt to achieve an acceptable level of ink coverage on foamed thin films. For example, the pressure with which the printer surface 112 contacts the printed surface on the foamed thin film has been increased and the viscosity of the ink has been decreased in an effort to better fill the sunken contours of the rough surface of the foamed thin film 10 . Neither of these two approaches was able to produce printed indicia of acceptable quality on the foamed thin film.
  • foamed thin film In light of the difficulties with achieving acceptable print quality on foamed thin films, one way to produce printed packages with foamed thin film would be to cover the foamed thin film with a printable non-foamed layer, such as, for example, a co-extruded or laminated layer.
  • a printable non-foamed layer such as, for example, a co-extruded or laminated layer.
  • inclusion of a specialized print layer on the foamed thin film would cancel out much of the cost savings realized by the use of foamed thin film. Therefore, it is desirable to develop a method for printing directly on a foamed thin film whether the foamed thin film later comprises a monofilm or is used as a layer in a multi-layer structure.
  • FIG. 2 illustrates a dotted, or half tone, flexographic printer plate 30 being used to imprint indicia 15 ( FIG. 1 ) on the foamed thin film 10 .
  • the dotted printer plate 30 includes a printer surface 31 having a plurality of raised dots 32 .
  • the raised dots 32 have top surfaces ( 35 in FIG. 3 ) that contact a printed surface 16 of the foamed thin film 10 to produce printed indicia of acceptable quality (e.g., indicia 15 ) on the foamed thin film.
  • Dotted or half tone printer plates 30 are currently used on many substrates to produce shading in an image. This shading is accomplished by printing dots that have space between them such that the dots, in aggregate, cover less than the full area of the area being printed. The ratio between the print area covered by the top surfaces of the dots and the total surface area being printed is known in the industry as the dot percentage.
  • FIG. 3 is a top plan view of the dotted flexographic printer plate 30 .
  • a relief image 39 of indicia 15 ( FIG. 1 ) is defined by the raised dots 32 .
  • the indicia 15 is imprinted on the printed surface 16 without visible voids in coverage. It has been discovered that using a dotted printer plate 30 plate with a dot percentage of no more than about 70% will produce printed indicia of acceptable quality (e.g. indicia 15 ) on foamed thin film 10 .
  • dotted print plates may work better than solid print plates on foamed thin film 10 may be that the flexible raised dots 32 are able to move and conform with the rough surface, such as into the recessed areas of the rough printed surface 16 of the foamed thin film 10 .
  • increased viscosity ink such as, for example, a 20 second increase in viscosity over the viscosity of ink used on non-foamed thin films also enhances the quality of ink coverage when used in addition to the dotted print plate 30 .
  • Another measure that has been observed to improve print quality on foamed thin films is use of a softer durometer material on the print plate 30 .
  • a dotted printer plate 30 having a dot percentage between about 50%-60% was used to produce printed indicia of acceptable quality on a 40 ⁇ m foamed thin film with approximately 20% resin reduction.
  • the pressure on the print cylinder was increased by 20 ⁇ and the pressure on the anilox roller was increased by 10 ⁇ as compared to the pressures that would be used with non-foamed thin film of the same caliper.
  • An ink having a 20 second increase in ink viscosity as compared to inks used with non-foamed thin films was used. This configuration produced a satisfactory level of ink coverage on foamed thin films.
  • the following chart summarizes printing parameters for direct flexographic printing on foamed films as compared to printing parameters for printing on non-foamed films.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Wrappers (AREA)
  • Laminated Bodies (AREA)
  • Printing Methods (AREA)
  • Bag Frames (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US12/487,112 2008-06-20 2009-06-18 Printed foamed film package Abandoned US20090317605A1 (en)

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CA2728501A1 (en) 2009-12-23
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MX2010013929A (es) 2011-01-21
ATE546284T1 (de) 2012-03-15
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US8173233B2 (en) 2012-05-08

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