WO2015161093A1

WO2015161093A1 - Textured printed image

Info

Publication number: WO2015161093A1
Application number: PCT/US2015/026200
Authority: WO
Inventors: Justin FAWSON; Jared Johnson
Original assignee: Fawson Justin; Jared Johnson
Priority date: 2014-04-16
Filing date: 2015-04-16
Publication date: 2015-10-22

Abstract

A textured, printed image and a method for printing the textured image that is durable and cost effective is disclosed. The textured image has a base layer of colored ink, a first fill layer of fill ink, a first colored layer of colored ink, a second fill layer of fill ink, and a top layer of colored ink.

Description

TEXTURED PRINTED IMAGE

REFERENCE TO EARLIER FILED APPLICATION

This application claims the benefit under 35 U.S.C. § 1 19(e) of U.S. Provisional Patent Application No. 61 /980,264, filed April 16, 2014, and titled "TEXTURED PRINTED IMAGE," which is incorporated, in its entirety, by this reference.

TECHN ICAL FIELD

This application is generally directed to the field of printing and more specification to printing textured images. BACKGROUND

Images may be printed using common print technologies such as ink jet and laser technologies. Such technologies are useful for printing on common media such as paper or other prepared surfaces. Other printer designs have been developed for printing on other surfaces, or when more durability is necessary than that afforded by traditional printers. Another type of printing that has been developed is ultraviolet (UV) printing, in which UV curable ink is applied to a surface and cured using an UV light. The curing process may take place immediately after the UV ink is applied to the surface. The UV ink may be applied using a process similar to an ink jet printer. This process is particularly suitable for large format printing and prints that require enhanced durability.

Print systems are generally designed to print on a substrate in a two dimensional pattern at a uniform height. However, an added benefit of UV printing is that UV ink may be applied at a thicker layer than dye-based inks enhancing the ink layer's durability. If additional thickness is required, UV ink can be applied over an existing layer of UV ink to obtain a desired depth. In prints in which a large thickness is required, a fill ink may be used since it may be applied at a thickness greater than that of a dithered colored ink. A fill ink may have a greater volume of gas within it so that it not as dense as normal ink and can be applied at a lower cost. A standard ink may be used to build up layers, but typically requires more ink which in turn takes longer and adds to the expense of printing.

Recent attempts have been made to replicate original artwork and accurately reproduce the artwork including textures through the use of layers of UV ink. In the process, layers of fill ink are used to build up the textures and colored ink is applied over the fill ink once a desired texture has been achieved. This process has been successfully used with common substrates to which the fill ink readily adheres, but unsatisfying when printed on non-standard substrates. Additionally, the durability of the prints may be compromised through the use of the fill ink which is less durable than standard ink.

It would be beneficial to have printing systems and methods that enable production of thickened, textured prints that maintain the durability of a colored ink print without the added cost and time of non-fill ink printing. It would also be beneficial if such a print could be applied to non-standard substrates to which fill ink does not readily adhere.

BRIEF SUMMARY

In one aspect, a method for printing a textured image is disclosed. The method includes printing a base layer of colored ink on a substrate, printing a first fill layer of fill ink in contact with at least a portion of the base layer, printing a first colored layer having colored ink in contact with the first fill layer, printing a second fill layer of fill ink in contact with at least a portion of the first colored layer, and printing a top colored layer including a colored ink representation of the image. In some embodiments the base layer and/or the first colored layer may have a uniform thickness. In some embodiments, the colored ink may include at least one of cyan, magenta, yellow, and black inks. In some embodiments the fill ink may be white ink. In some embodiments, the base layer may be an untextured representation of the image.

In some embodiments, the method may further include printing alternating additional colored and fill layers between the second fill layer and the top colored layer. In some embodiments the first fill layer is printed with a beveled edge, and wherein the first colored layer extends laterally beyond the beveled edge. In some embodiments, the first fill layer is printed with an edge having colored ink. The method of any one of claims 1 through 9, wherein the substrate has first and second sides, and the textured image is printed on the first side and a second textured image is printed on the second side.

In some embodiments, a tag may be placed between the substrate and the top colored layer, wherein at least one layer of colored or fill ink is printed over the tag. The tag may be a radio frequency identification tag in some embodiments. In some embodiments the method may further include printing a glossy finish on a first portion of the top colored layer, and printing a matte finish on a second portion of the top colored layer.

In another aspect, a printed, textured image is disclosed. The image includes a substrate, a base layer of colored ink in contact with the substrate, a first fill layer of fill ink in contact with the base layer, a first colored layer of colored ink in contact with the first fill layer, a second fill layer of fill ink in contact with the first fill layer, and a top colored layer comprising a colored ink representation of the image. In some

embodiments, the base layer is a two dimensional representation of the textured image. In some embodiments, the fill ink consists substantially of white ink. In some embodiments, the first colored layer of colored ink is a representation of the image.

In some embodiments, the image includes alternating layers of colored ink and fill ink between the first colored layer and the top colored layer.

In some embodiments, the image may further include a tag embedded between the substrate and the top colored layer.

In some embodiments, the substrate has first and second sides, and the base, first fill, first colored, second fill, and top colored layers are printed on the substrate's first side and the substrate's second side has a second side base layer, a second side fill layer, and a second side colored layer.

In some embodiments, the first fill layer has a beveled edge, and the first colored layer extends beyond the beveled edge of the first fill layer. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic of a printer suitable for use with embodiments of the invention.

FIG. 2 illustrates a schematic of another printer suitable for use with embodiments of the invention.

FIG. 3 illustrates a simplified schematic of a print head printing on a substrate.

FIG. 4 illustrates a print having a base layer of ink being printed on a substrate.

FIG. 5 illustrates a first fill layer printed on the print of FIG. 4.

FIG. 6 illustrates a first colored layer printed on the print of FIG. 5.

FIG. 7 illustrates a second fill layer printed on the print of FIG. 6.

FIG. 8 illustrates a top layer printed on the print of FIG. 7.

FIG. 9 illustrates a finish coat applied to the print of FIG. 8.

FIG. 10 illustrates beveled edges of a fill layer.

FIG. 1 1 illustrates a print having embedded tags.

DETAILED DESCRIPTION

The presently disclosed embodiments will be best understood by reference to the drawings, wherein like reference numbers indicate identical or functionally similar elements. It will be readily understood that the components of the present disclosure, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description, as represented in the figures, is not intended to limit the scope of the invention as claimed, but is representative of some embodiments disclosed herein.

The following terms used in the specification and claims have a meaning defined as follows.

The term "substrate" refers to a material that is being printed on. Examples of substrates include materials such as plastic, metal, glass, fabric, paper, wood, rubber, cement, and combinations of these materials. A substrate may have more than one side suitable for printing. For example, a sheet substrate may have a front side and a back side, while a cube substrate may have six surfaces suitable for printing. A substrate does not need to have a flat surface. For example, a cylindrical substrate which has a curved surface may serve as the substrate.

The term "colored ink" refers to a substance having color

characteristics suitable for application to a substrate. In general printing, the three main colors of colored ink are cyan, magenta, and yellow. Other colors are possible such as light cyan and light magenta.

The term "fill ink" refers to an ink that is used to create fill within a print. It is generally not intended to be viewed with the exception that a white ink layer may be used as a base for colored ink. The white ink may be useful for printing colors over a dark surface.

The term "pixel" refers to a point element in a print. A pixel's appearance is dependent upon the amount and variety of ink printed within it. For example, a cyan pixel may include entirely cyan ink printed on it. A pixel having a shade of color other than the three main colors may be achieved by varying the relative density of color dots within the pixel in a process known as dithering. For example, printing cyan and magenta dots will result in the appearance of a blue pixel. For a shade closer to magenta in color, such as purple, more magenta may be printed relative to the cyan to obtain purple.

The term "pixel thickness" refers to the thickness of the ink within a pixel. When the ink is applied to a surface, it will pile above the surface at a thickness dependent on the amount of ink applied.

The term "pixel height" refers to the total height of ink on a pixel. The pixel height is a function of the pixel thickness and the number of ink applications. The pixel height may be increased by applying ink multiple times on the same pixel.

FIG. 1 illustrates an overview of an embodiment of a printer 100 and a substrate 102. This particular embodiment of a printer 100 is generally referred to as a moving media printer. The printer 100 includes a feed table 104, a take-up table 106, a gantry 1 10, and a print carriage 108. The print carriage 108 includes a print head (shown in FIG. 3) for printing ink. The feed table 104 and the take-up table 106 support the substrate 102 as it moves through the gantry 1 10. The substrate 102 moves through the gantry 1 10 in the direction of arrows 1 12. In some embodiments, rotation of a roller within the gantry 1 10 may cause the substrate 102 to move. In other embodiments, a roller may be a part of the feed table 104 and movement of the roller beneath the substrate 102 may drive the substrate 102. In still other embodiments, the feed table 104 and the take up table 106 form a single unit that travels through the gantry 1 10 moving the substrate 102 along with it.

The substrate 102 moves through the gantry 1 10 in fixed increments corresponding to a printing width of the print head. The print carriage 108 passes over the substrate 102 moving in the direction indicated by arrows 1 14 which are perpendicular to arrows 1 12. The print head deposits ink in a controlled fashion to print a first band of an image. The substrate 102 then advances the width of the band, and the print carriage 108 passes over the substrate 102 with the print head depositing ink in a second band adjacent the first band. The process of printing bands is repeated until the substrate 102 has passed through the gantry 1 10, or until the edge of the printing has been reached. Each complete pass of the substrate 102 through the gantry 1 10 is referred to a pass. If additional layers of ink are necessary, additional passes may be performed with the substrate 102 passing back through the gantry 1 10. In some embodiments, the substrate 102 may pass through the gantry 1 10 in a direction opposite the direction it was initially advanced such that the feed table 104 becomes a pickup table and the take-up table 106 becomes a feed table.

FIG. 2 illustrates another embodiment of a printer 200 commonly referred to as a flatbed printer. The printer 200 includes a table 202, a gantry 204, and a print carriage 206 having a print head. In this

embodiment, the substrate 208 remains stationary while the gantry 204 passes over the substrate 208 in fixed increments corresponding to the print width of the print head. The table 202 may have a plurality of channels (not shown) having a vacuum to secure the substrate 208 in place. In use, the gantry 204 remains stationary as the print carriage 206 travels across the substrate 208 in the directions indicated by arrows 210 depositing ink in a first band of an image. When the print carriage 206 has completed a pass across the substrate 208, the gantry 204 may advance the width of the first band in direction 212, and the print carriage 206 passes back over the substrate 208 printing a second band adjacent the first band. The gantry 204 is then advanced again, and the process repeats until the edge of the substrate is reached. Each complete pass of the gantry 204 over the substrate 208 is referred to as a pass. If another pass is necessary, the gantry 204 may pass back over the substrate 208 depositing another layer of ink.

FIG. 3 illustrates a schematic side view of a print head 300 printing on a substrate 302. The print head 300 may have an array of nozzles from which ink is ejected onto the substrate 302 to form dots. Although FIG. 3 illustrates a single drop being deposited on a pixel, in practice a pixel may be formed of a group of many dots. In the simplified schematic of FIG. 3, the ink is shown as a single droplet 303 coming from the print head 300. Each group of dots forms a pixel 308 of a printed image. The print head may include ink colors such as cyan (C), magenta (M), yellow (Y), and non- colored inks such as black (K) and white (W), collectively CMYKW. The combination of different colors of droplets within a pixel results in different shades of color. The ink adheres to the substrate and solidifies. In embodiments using UV ink, the UV ink is cured by a UV light 304. In another embodiment, the print head 300 may contain hot-melt inks that solidify upon contacting the substrate 302 and cooling.

The print head 300 is movable relative to the substrate 302 in at least 3 dimensions, X and Y along the surface of the substrate 302, and Z which is perpendicular to the substrate 302. The print head 300 may have an optimal set off 306 from the substrate 302, but may print at other set offs as well. Each pixel has a thickness that may be dependent upon the number and size of the droplets applied to the substrate within the pixel. Some printers may have variable sized droplets. Larger droplet sizes may take longer to set limiting the thickness that may be achieved.

The location of the print head 300 is controlled by a print controller that converts print instructions into movement of the print head and application of ink. The print instructions may specify the amount of ink to apply at specific locations for each pass of the print head 300 over the substrate. The textured image may be divided into horizontal layers printed in each pass of the print head.

FIGS. 4 through 8 demonstrate the process by which a textured image may be printed on a substrate by a printer such as the printers shown in FIGS. 1 and 2. The substrate 400 is shown in simplified form as a cross section being printed. In actuality the substrate may be a plurality of pixels wide and a plurality of pixels deep, e.g. dozens, hundreds, thousands, millions, and more. Six pixels 402, 404, 406, 408, 410, and 412, collectively 414, are shown on the substrate 400. Initially a base layer of ink 416 is printed on the collective pixels 414 of the substrate 400. The base layer of ink 416 has a colored ink, such as a cyan, magenta, yellow, or a combination of colors. The base layer 416 may be applied uniformly, such that each pixel 414 has the same thickness and color. In other embodiments, the base layer 416 may printed with a two dimensional representation of the image being printed, similar to a traditional print, or may be printed with a varying thickness.

FIG. 5 illustrates a first fill ink layer 450 being printed on a portion of the base layer 416. The first fill ink layer 450 may include an ink that is less dense than colored ink such that less ink by weight may be used to build the thickness of the first fill ink layer. As opposed to a layer of colored ink which uses dithering to achieve color shades, fill ink may be applied uniformly within the pixel to achieve a maximum thickness. The first fill ink layer 450 covers at least a portion of the base layer 416. In some embodiments, the first fill ink layer 450 covers the entire base layer 416. In other

embodiments, the first fill ink layer 450 covers the base layer 416 in only a portion of the print having a raised texture. In still other embodiments, the first fill ink layer 450 may be printed with an outer edge having colored ink. The outer edge of colored ink may be a partial representation of the image being printed. For example, the first fill layer at pixel 404 may be printed with a colored ink in place of the fill ink. More than one pixel may be printed at the outer edge of the first fill layer 450 and a single pixel is only given as an example.

The first fill ink layer 450 may be applied one pixel at a time, stacking ink applications on top of one another while the print head is in position over the pixel. For example, the print head may print fill ink over pixel 404, and then move to the next pixel 406 and print a first application of fill ink. The print head may then print a second application of fill ink on pixel 406 to stack two applications of fill ink. The print head would then move to pixel 408 and continue stacking the applications of fill ink.

In another embodiment, the first fill ink layer 450 may be applied to each pixel one pass at a time. For example, the print head may print fill ink on pixel 404, 406, 408, 410, and 412 in a first pass. In a second pass, the print head may then print a second fill ink application on pixels 406, 408, 410, and 412. The print head then continues making passes until each pixel has the desired pixel height.

In some embodiments, the print head may move in the Z axis as it prints different pixel heights. For example, the print head may move upward a pixel depth each time fill ink is applied to a pixel.

FIG. 6 illustrates a first colored layer 460 printing on the first fill ink layer 450. In some embodiments the first colored layer 460 may extend beyond the outer edge of the first fill ink layer 450, such that a pixel, such as pixel 402, may be printed with the base layer 416 and then covered with a colored ink application from the first colored layer 460. In other

embodiments, the first colored layer 460 may be printed over only the first fill ink layer 450. The first colored layer 460 includes a colored ink, such as a cyan, magenta, yellow, or a combination of colors. The first colored layer 460 may be applied uniformly, such that each pixel 414 has the same thickness and color. In some embodiments, the first colored layer 460 may printed in a dithered pattern with a partially textured representation of the image being printed. In such embodiments any pixels that are not covered by any subsequent ink layers will form a portion of the finished print.

FIG. 7 illustrates a second fill layer 470 being printed on at least a portion of the first colored layer 460. Similar to the first fill layer 450, the second fill layer 470 may have multiple fill ink applications stacked on one another to increase the pixel height. As described previously, the fill ink applications may be stacked one pixel at a time or they may be stacked in subsequent passes of the print head.

FIG. 8 illustrates a top layer 480 of colored ink printed on the last layer of fill ink, which may be the second fill layer 470. The top layer 480 may be dithered to be representative of the printed image and is textured by the varying pixel height of the fill layers below. In some embodiments, the top layer 480 may be printed over only pixels having exposed fill ink. For instance, instead of printing on every pixel as shown in FIG. 8, the top layer 480 may be printed only on pixels 406, 408, and 410, since pixels 402, 404, and 412 have exposed fill ink.

In another embodiment, the printed image may be printed one pass at a time combining the different fill layers and colors layers in each pass. For example, the textured print of FIG. 8 may be printed using nine passes of the print head with nine ink applications 491 -499. The first application 491 forms the base layer 416. The second application 492 forms the top layer 480 at pixel 402 and the first fill layer 450 at pixels 404, 406, 408, 410, and 412. The third application 493 forms the first colored layer 460 at pixels 404 and 412, and the first fill layer 450 at pixels 406, 408, and 410. The fourth application 494 forms the top layer 480 at pixels 404 and 412, the first colored layer 460 at pixel 406, and the first fill layer 450 at pixels 408 and 410. The fifth application 495 forms the second fill layer 470 at pixel 406, the first fill layer 450 at pixel 408, and the first colored layer 460 at pixel 410. The sixth application 496 forms the top layer 480 at pixel 406, the first colored layer 460 at pixel 408, and the second fill layer 470 at pixel 410. The seventh application 497 forms the second fill layer 470 at pixel 408 and the top layer 480 at pixel 410. The eighth application 498 forms the second fill layer 470 at pixel 408 and the ninth application 499 forms the top layer 480 at pixel 409. This embodiment may be advantageous in that the print head may be kept at a single height during each pass.

FIG. 9 illustrates an embodiment having a finish coat 490 applied to the top layer 480. The finish coat 490 may protect the ink underneath and may provide a glossy or matte finish depending on the coat chosen. In some embodiments, a finish coat 490 may be applied through a print head having two nozzles, one for a clear matte and one for a clear gloss finish coating. The degree of specularity may then be controlled during application by varying the relative density of the dots being printed. In the embodiment of FIG. 9, the finish coat 490 includes an area having a glossy finish 492 and an area having a matte finish 494. The finish coat 490 may be applied as part of the printing process, or may be applied after the print is finished. The presence of matte and glossy finishes may enhance the appearance of the print or emphasize portions of the print.

The preceding description of the ink layers of the textured print may be modified such that the number of ink layers varies in number. For example, if minimal texture is required, only one fill layer may be necessary. Or, in embodiments requiring greater texturing, the number of fill layers may be increased and alternate with the colored layers. For example, a print may have a base layer, a first fill layer in contact with the base layer, a first colored layer in contact with the first fill layer, a second fill layer in contact with the first colored layer, a second colored layer in contact with the second fill layer, a third fill layer in contact with the second colored layer, and the top layer in contact with the third fill layer.

In some embodiments, the edges of the fill layers may be printed to have a beveled edge. The beveled edge may decrease the possibility of the fill layer catching and peeling from a layer underneath it. FIG. 10 illustrates an example of a layer of fill pixels having a beveled edge. A non-beveled fill layer may have edges 502, 504, and 506. Edge 502 is an example of a beveled edge being built up below edge 502. During printing, instead of jumping five pixel heights from pixel 508 to pixels 510, the pixels gradually step up one pixel height at a time until the correct pixel height is reached at the edge. In some embodiments, the edges may be interpolated as shown at edge 504. Edge 504 has two pixels to the left that each increase 1 pixel height between adjacent pixels and two pixels to the right that each increase 1 pixel height. Thus, instead of increasing 4 pixel heights between pixel 512 and pixels 514 the pixels each step one pixel height at a time with the original edge being near the center of the bevel. Edge 506 is an example of a bevel being place above the edge 506. In contrast to edge 502, in place of printing extra pixels to gradually increase the height, the edge is printed in a at edge 504, each pixel increases one pixel height starting at the edge until the height of the edge is reached.

In some embodiments, the substrate may have at least two sides. The described printing process may be printed on a first side of the substrate and the process may be repeated on a second side of the substrate. The printing on the first side of the substrate may be of the print and the printing on the second side of the substrate may include information about the print or include an authenticating identifier such as a seal or signature.

FIG. 1 1 illustrates an embodiment of a textured print 1000 having a tag 1002 embedded within the textured print 1000. On substrates having more than one side, the tag 1002 may be embedded on any side of the print. The tag 1002 contains information related to the textured print 1000. The tag 1002 may be a radio frequency identification (RFID) tag. The tag 1002 may be embedded between the substrate and the top layer of the print 1000. There may be more than one tag embedded in the print 1000. For example, a print 1000 may have a first tag 1002 embedded at a first location of the print 1000 and a second tag 1004 embedded at a second location of the print 1000. The first tag 1002 might contain information related to the first location of the print 1000 and the second tag 1004 may include information related to the second location of the print 1000. For example, the first location may correspond to a detail such as a first historic figure 1006 and the second location may correspond to a second historic figure 1008. The first tag would contain information related to the first historic figure 1006 and the second tag would contain information related to the second historic figure 1008. The tags 1006, 1008 may be localized, such that a tag reader would read tag 1002 when near the first location and would read tag 1004 when near the second location.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. For example, the beveled edges described in relation to FIG. 10 are applicable to the print of FIG. 8. Additionally, embodiments are not limited to the described figures. It should be understood that the figures are simplified and that the described techniques are applicable to prints having much greater numbers of pixels.

Claims

1 . A method for printing a textured image, comprising:

printing a base layer comprising colored ink on a substrate;

printing a first fill layer of fill ink in contact with at least a portion of the base layer;

printing a first colored layer comprising colored ink in contact with the first fill layer;

printing a second fill layer of fill ink in contact with at least a portion of the first colored layer; and

printing a top colored layer comprising a colored ink representation of an image.

2. The method of claim 1 , wherein the base layer has a uniform thickness.

3. The method of claims 1 , wherein the first colored layer has a uniform thickness.

4. The method of claim 1 , further comprising printing alternating additional colored and fill layers between the second fill layer and the top colored layer.

5. The method of claim 1 , wherein the first fill layer is printed with a beveled edge, and wherein the first colored layer extends laterally beyond the first fill layer's beveled edge.

6. The method of claim 1 , wherein the first fill layer is printed with an edge comprising colored ink.

7. The method of claim 1 , wherein the colored ink comprises at least one of cyan, magenta, yellow, and black inks.

8. The method of claim 1 , wherein the fill ink consists substantially of white ink.

9. The method of claim 1 , wherein the base layer is an untextured representation of the textured image.

10. The method of claim 1 , wherein the substrate has first and second sides, and the textured image is printed on the first side and a second textured image is printed on the second side.

1 1 . The method of claim 1 , further comprising placing a tag between the substrate and the top colored layer, wherein at least one layer of colored or fill ink is printed over the tag.

12. The method of any one of claims 1 -1 1 , wherein the tag is a radio frequency identification tag.

13. The method of claim 1 , further comprising:

printing a glossy finish on a first portion of the top colored layer; and printing a matte finish on a second portion of the top colored layer.

14. A printed, textured image comprising:

a substrate;

a base layer of colored ink in contact with the substrate;

a first fill layer of fill ink in contact with the base layer;

a first colored layer of colored ink in contact with the first fill layer; a second fill layer of fill ink in contact with the first fill layer;

a top colored layer comprising a colored ink representation of an image.

15. The image of claim 14, wherein the base layer is a two dimensional representation of the textured image.

16. The image of claim 14, wherein the fill ink consists substantially of white ink.

17. The image of claim 14, wherein the first colored layer of colored ink is a representation of the image.

18. The image of claim 14, further comprising alternating layers of colored ink and fill ink between the first colored layer and the top colored layer.

19. The image of claim 14, further comprising a tag embedded between the substrate and the top colored layer.

20. The image of claim 14, wherein the substrate has first and second sides, wherein the base, first fill, first colored, second fill, and top colored layers are printed on the substrate's first side and the substrate's second side has a second side base layer, a second side fill layer, and a second side colored layer.

21 . The image of any one of claims 14-20, wherein the first fill layer has a beveled edge, and wherein the first colored layer extends beyond the first fill layer's beveled edge.