Note: Descriptions are shown in the official language in which they were submitted.
85362-76
VARIABLE PRINTING PROCESS USING
FLEXIBLE SECONDARY PLATES AND SPECIALTY INKS
[0001]
FIELD OF THE INVENTION
[0002] The present invention relates to using flexible secondary plates in a
printing process for
cylindrical substrates. More specifically, the present invention relates to a
method and apparatus
which use flexible secondary plates made of novel materials to decorate the
exterior surface of
cylindrical metallic containers and provide product differentiation in a
printing process.
BACKGROUND
[0003] Metallic containers are frequently decorated with an image or indicia,
such as a brand name,
logo, product information, or design, using a lithographic printing process.
In lithographic printing,
one or more printing plates (or primary plates) with image regions are
attached to a plate cylinder
(or press cylinder) of a decorator. The decorator may include a plurality of
plate cylinders. The
image regions of each printing plate can include both ink receiving regions
and areas that do not
receive ink. An inker applies ink to the printing plates and the ink adheres
to the ink receiving
regions. Usually the printing plates of each plate cylinder receive a
particular color of ink from the
inker. The decorator also has a blanket cylinder (also known as an offset
cylinder, a printing
cylinder, or a segment wheel). Secondary plates (or secondary transfer plates
or printing blankets)
are attached to the blanket cylinder.
[0004] Decorators used in the metallic container industry typically have from
4 to 12 secondary
plates on the blanket cylinder. As the plate cylinder and blanket cylinder are
rotated in unison, each
of the one or more printing plates contacts a secondary plate and transfers a
particular color of ink
to the secondary plate. When all of the printing plates have transferred their
ink colors and images
to the secondary plate, the final lithographic image is formed on the
secondary plate. A cylindrical
metallic container is then brought into rotational contact with one of the
secondary plates of the
blanket cylinder and the lithographic image is transferred from the secondary
plate to the exterior
surface of the cylindrical metallic container.
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[0005] Lithographic printing methods are generally described in U.S. Patent
No. 3,766,851, U.S.
Patent No. 4,384,518, U.S. Patent No. 6,550,389, and U.S. Patent No.
6,899,998. The methods
described in these references generally only allow a single lithographic image
to be produced from
a single set of printing plates. Thus, the methods described in these patents
are only efficient for
printing the same image onto a large number of cylindrical metallic
containers. In order to print a
different image on a plurality of cylindrical metallic containers, a new set
of printing plates must be
installed on the plate cylinder of the decorator, resulting in downtime and
decreased efficiency of a
production line. Because only one image can be printed without changing the
printing plates, it is
economically challenging to produce small batches of decorated cylindrical
metallic containers
with different images.
[0006] One example of providing multiple different images from a single set of
printing plates is
provided in U.S. Patent No. 5,181,471 to Sillars. Sillars generally describes
a printing system with
engraved images formed in flexographic regions of printing plates attached to
the blanket cylinder.
[0007] Prior art printing blankets are comprised of several laminated layers
that generally include a
face portion, a first fabric layers, a compressible layer, and a second fabric
layer. The face portion
comprises a relatively thin rubber material that is adapted to receive a
maximum amount of ink
from the printing plates without distorting the ink image transferred from the
printing plates.
However, the material of the face portion burns or melts relatively easily
when images are formed
thereon, for example, by laser engraving, preventing the formation of images
with fine dots on
prior art printing blankets.
Accordingly, images formed in the face portion of prior art blankets are not
effective to transfer
high quality ink images to metallic containers.
[0008] Another method of providing multiple distinct images using a single set
of printing plates is
described in International Patent Publication No. WO 2014/008544 by Treloar.
Treloar generally
describes a blanket cylinder with secondary plates that are adapted to have
inked regions and non-
inked regions. Other methods of providing multiple distinct images in
lithographic printing
processes are described in International Patent Publication No. WO 2014/006517
by Vilas Boas et
al. (Vilas Boas) and International Patent Publication No. WO 2014/128200 by
Grahame et al.
(Grahame). However, the lithographic images described by Sillars. Treloar,
Vilas Boas, and
Grahame using these various techniques do not have sufficient detail to be
considered a high
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quality, high-definition image. Further, none of these patents or patent
publications describes the
use of specialty inks in the printing process or novel materials used for the
secondary plates to
create high image quality in a mass production process. The commercial
metallic container
industry requires high-definition printing in unique applications and requires
distinct graphical
elements formed by specialty inks that can efficiently be printed with high
resolution and detail on
the exterior surface of a cylindrical metallic container. These high-
definition images and the use of
specialty inks are necessary to differentiate products at the point of sale
and to attract consumers.
[00091 U.S. Patent Application Publication 2014/0210201 to Owen et al. (Owen)
generally
describes the use of thermochromic and photochromic inks to decorate beverage
cans. However,
Owen teaches the use of ink jet printing to apply the inks to the cans. Inkjet
printing has been found
to be subject to unwanted placement or positioning of ink. For example, inkjet
printing can result in
a mist of ink which can interfere with the printing process, cause undesired
markings on containers,
or cause equipment malfunction. In some cases, the use of an inkjet printing
process can result in
the loss of up to 20% or more of potential production time due to the need for
clean up,
maintenance, and/or repair. Additionally, inkjet printing processes have been
difficult to provide at
high speed and while maintaining print quality without distortion. Thus,
inkjet print processes are
general non-economical for use in the commercial container industry. In
contrast, the commercial
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container industry requires an apparatus and method capable of decorating
beverage
containers at significant production speeds of at least several thousand
cylindrical metallic
containers per minute.
[0010] Accordingly, there is an unmet need for a high-definition
lithographic printing
process that allows multiple images to be printed on an exterior surface of a
cylindrical
metallic container from a single set of printing plates and secondary plates
that uses
specialty inks and/or improved plate materials without sacrificing production
efficiency or
image quality and detail.
SUMMARY OF THE INVENTION
[0011] The present process uses flexible secondary plates affixed to a
blanket cylinder
of a decorator to significantly enhance the image quality and detail of
lithographic images
printed on metallic containers. It is one aspect of the present invention to
provide flexible
secondary plates comprised of a photopolymer material. In another aspect of
the present
invention, the flexible secondary plates are comprised of a compound
comprising at least
in part a saturated chain of polymethylene. In one embodiment, the saturated
chain of
polymethylene is an M-class rubber. In another embodiment, the saturated chain
of
polymethylene is an ethylene propylene diene monomer. Yet another aspect of
the present
invention is to provide a decorator that uses at least one specialty ink to
form a high-
definition image on an exterior surface of a metallic container. It is still
another aspect of
the present invention to provide flexible secondary plates for use in a
decorator that is
operable to decorate at least 2,200 metallic containers per minute.
[0012] More specifically, in one embodiment of the present invention, the
flexible
secondary plate is comprised of photopolymer material. An image is transferred
to, or
formed on, a face of the flexible photopolymer plate by exposing the
photopolymer
material with light. The image can be transferred using a computer to plate
process or a
conventional plate exposure process. This results in a flexible secondary
plate which has
relief areas that do not receive ink and hardened areas forming precise and
detailed image
areas that will receive ink and transfer the ink to an exterior surface of a
metallic
container.
[0013] In another embodiment of the present invention, the flexible
secondary plate is
comprised at least in part of a compound of a saturated chain of polymethylene
or other
related materials with similar physical properties. Alternatively, certain
pliable plastic
materials may be used for the same purpose. Images are formed in the flexible
secondary
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plate by direct laser engraving or other methods known in the art. Variable
types and
colors of inks are applied by inkers to one or more different portions of a
printing plate to
form a first image. The printing plate is then brought into rotational contact
with the
flexible secondary plates and transfers the various types and colors of inks
to the flexible
secondary plates. A container body is then moved into rotational contact with
the flexible
secondary plates and the inks are transferred to the exterior surface of the
container body.
In some embodiments of the process, the flexible secondary plates may also be
etched or
engraved on the face before, during, or after an image is formed thereon to
form one or
more recessed portions that do not receive ink. In other embodiments, a
varnish may also
be applied to one or more portions of the exterior surface of the container
body by the
flexible secondary plates or by a separate varnishing unit. These and other
advantages will
be apparent from the disclosure of the invention(s) contained herein.
[0014] Another aspect of the present invention is an apparatus, method, and
flexible
secondary plate for use in dry offset printing of metallic containers. In one
embodiment,
printing plates with a physical relief transfer multiple colors or types of
inks to flexible
secondary plates affixed to a blanket cylinder. The physical reliefs of the
printing plates
create inked and uninked regions on the surfaces of the printing plates that
are transferred
to the flexible secondary plates. The flexible secondary plates subsequently
transfer the
ink to an exterior surface of a metallic container in a high speed decorating
process. In
one embodiment, the flexible secondary plates are comprised of a material
comprising a
saturated chain of polymethylene. In another embodiment, the flexible
secondary plates
are comprised of a photopolymer material. Optionally, at least one of the
flexible
secondary plates includes an image. The image receives at least some ink from
one or
more of the printing plates and is transferred to a metallic container by
contact between the
exterior surface of the metallic container and the flexible secondary plate.
In another
embodiment, each of the flexible secondary plates include images. In one
embodiment,
the images on the flexible secondary plates are identical. In another
embodiment, the
images on the flexible secondary plates are each different.
[0015] As will be appreciated by one skilled in the art, in dry offset
printing, the
printing plates are not dampened with water. The images formed on the printing
plates
receive ink from inkers. The printing plates then transfer their inked images
to the flexible
secondary plates which subsequently transfer the ink to a metallic container.
In contrast,
in wet offset lithographic processes, the printing plates are chemically
treated to form
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image areas that will accept ink but repel water. Water and ink are then
applied to the
printing plates. Because of the chemical treatment of the printing plates,
only the ink
adheres to the images and the water is repelled. Additionally, the ink does
not adhere to
the non-image areas of the printing plates.
[0016] In accordance with one aspect of the present invention, a novel
method of
using a flexible secondary plate in a lithographic printing process to
decorate an exterior
surface of a metallic container is provided. This includes, but is not limited
to, a method
generally comprising: (1) forming a first image on a predetermined portion of
a top or
face portion of the flexible secondary plate; (2) removably affixing the
flexible secondary
plate with the first image onto a blanket cylinder of a decorator; (3)
attaching a plurality of
printing plates to a plate cylinder of the decorator; (4) applying an ink from
an inker to at
least one of the plurality of printing plates; (5) transferring at least some
of the ink from
the at least one of the plurality of printing plates to at least a portion of
the flexible
secondary plate; and (6) transferring the ink from the flexible secondary
plate to the
exterior surface of the metallic container, wherein the metallic container is
decorated. The
flexible secondary plate is comprised of one of a compound of a saturated
chain of
polymethylene, a photopolymer material, and a pliable plastic material. In one
embodiment, the flexible secondary plate is formed of a single homogeneous
material.
Said another way, the flexible secondary plate is not comprised of layers of
different
materials.
[0017] In one embodiment, forming the first image on the flexible secondary
plate
comprises removing at least some of a material of the face portion of the
flexible
secondary plate in a direct laser engraving process. In another embodiment, at
least some
of the material of the face portion of the flexible secondary plate is removed
to form the
first image in one or more of a direct laser engraving process, a mechanical
or chemical
etching or engraving process, an ink repelling process, a pressure forming
process, or by a
combination of one or more processes. In one embodiment, the first image
formed on the
flexible secondary plate has a depth of from about 0.0009 inch to about 0.089
inch. In
another embodiment, at least some of the material of the face portion is
removed to
produce a raised first image with a height of from about 0.0009 inch to about
0.089 inch
above the face portion of the flexible secondary plate.
[0018] The flexible secondary plate may be of any shape or size. In one
embodiment,
the flexible secondary plate is from about 0.04 inch to about 0.1 inch thick.
Optionally,
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the flexible secondary plate is formed of a non-laminated material. Thus, in
one
embodiment, the flexible secondary plate is devoid of clothe or fabric layers
and
intermediate layers including threads.
[0019] In one embodiment, the ink comprises a specialty ink. The specialty
ink may
comprise one or more of a thermochromic ink, a photochromic ink, a scented
thermochromic ink, a fluorescent ink, a UV ink, a black light ink, an infrared
ink, a
phosphorescent ink, a pressure sensitive ink, a tactile ink, a thermo-tactile
ink, a leuco dye,
and a matte ink.
[0020] In one embodiment, the saturated chain of polymethylene of the
flexible
secondary plate comprises an M-class rubber. In another embodiment, the
saturated chain
of polymethylene of the flexible secondary plate comprises an ethylene
propylene diene
monomer (EPDM) compound. In yet another embodiment, the saturated chain of
polymethylene of the flexible secondary plate comprises an ethylene propylene
monomer
(EPM) compound.
[0021] The blanket cylinder may include any number of flexible secondary
plates. In
one embodiment, from 8 to 12 flexible secondary plates are removably affixed
to the
blanket cylinder. In another embodiment, from 6 to 24 flexible secondary
plates are
removably affixed to the blanket cylinder. Optionally, the method may further
comprise
removably affixing from about 4 to about 24 flexible secondary plates onto the
blanket
cylinder. Each of the about 4 to the about 24 flexible secondary plates may
have different
images. Ink transferred from the about 4 to the about 24 flexible secondary
plates
produces 4 to 24 decorated metallic containers with different images. In still
another
embodiment, the flexible secondary plates are operable in a decorator to
decorate up to
about 2,200 metallic containers per minute.
[0022] In one embodiment, the method may optionally further include
removably
attaching a plurality of second printing plates to a second plate cylinder of
the decorator.
A second ink from a second inker is applied to at least one of the plurality
of second
printing plates. The second ink is a different type or color of ink than the
first ink applied
by the inker. At least some of the second ink is transferred from the at least
one of the
plurality of second printing plates to at least a portion of the flexible
secondary plate.
Optionally, at least some of the second ink is transferred from the at least
one of the
plurality of second printing plates to at least a portion of the first image.
In another
embodiment, none of the second ink is transferred to the first image. For
example, the
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second printing plates may optionally include relief areas that align with the
first image of
the flexible secondary plate. The relief areas do not receive ink from the
inkers. The first
ink and the second ink are then transferred from the flexible secondary plate
to the exterior
surface of the metallic container. Accordingly, the metallic container is
decorated with at
least some of the first ink and at least some of the second ink.
[0023] In one embodiment, the decorator may include from four to eighteen
plate
cylinders with printing plates attached thereto. In another embodiment, the
decorator
includes about eight plate cylinders. Each of the plate cylinders is operable
to transfer a
different type or color of ink to the flexible secondary plates affixed to the
blanket
cylinder. In one embodiment, the printing plates of each of the one to eight
plate cylinders
may optionally transfer unique images to the flexible secondary plates.
[0024] In accordance with another aspect of the present invention, an
apparatus for
forming a high-definition lithographic image on an exterior surface of a
metallic container
is disclosed, the apparatus is operable to create multiple lithographic images
from a single
set of printing plates. The apparatus generally comprises: (1) at least one
plate cylinder
with an inker; (2) a blanket cylinder; and (3) a support cylinder. In one
embodiment, the
apparatus is operable to decorate at least 2,200 metallic containers per
minute.
[0025] The inker is operable to transfer an ink to predetermined portions
of one or
more printing plates attached to a circumference of the at least one plate
cylinder. In one
embodiment, one or more of the printing plates are comprised of at least one
of a
compound comprising a saturated chain of polymethylene, a photopolymer
material, and a
pliable plastic material.
[0026] One or more flexible secondary plates are removably affixed to a
circumference of the blanket cylinder. Each of the one or more flexible
secondary plates
is comprised of one of: a compound comprising at least in part a saturated
chain of
polymethylene; a photopolymer material; and a pliable plastic material. In one
embodiment, at least one of the flexible secondary plates has an image formed
thereon.
The blanket cylinder is operable to move the flexible secondary plates into
rotational
contact with the one or more printing plates attached to the at least one
plate cylinder.
When the flexible secondary plates contact the printing plates, ink is
transferred from the
predetermined portions of the one or more printing plates to at least a
portion of the
flexible secondary plates. Optionally, the flexible secondary plates are
formed of a single
homogeneous material. The flexible secondary plates may be affixed to the
blanket
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cylinder with an adhesive. In one embodiment, the adhesive includes a peel-off
backing
material. In one embodiment, the flexible secondary plate does not include a
clothe or
fabric layer.
[0027] The support cylinder includes a plurality of stations adapted to
receive metallic
containers. Each station is operable to receive a metallic container from a
conveyor and
move the metallic container into contact with a flexible secondary plate
affixed to the
blanket cylinder. Ink is then transferred from the flexible secondary plate to
the metallic
container to form the high-definition lithographic image on the exterior
surface of the
metallic container.
[0028] In one embodiment, the at least one plate cylinder comprises from
about 4 to
about 18 plate cylinders. Each of the plate cylinders includes an inker
operable to transfer
a different color of ink or a different type of specialty ink to predetermined
portions of one
or more printing plates attached to each of the plate cylinders In one
embodiment, the
specialty ink comprises one or more of a thermochromic ink, a photochromic
ink, a
scented thermochromic ink, a fluorescent ink, a UV ink, a black light ink, an
infrared ink,
a phosphorescent ink, a pressure sensitive ink, a tactile ink, a thermo-
tactile ink, a leuco
dye, and a matte ink. In another embodiment, the printing plates attached to a
first of the
plate cylinders transfer a first image to the flexible secondary plates that
is different than
images transferred by the printing plates attached to the other plate
cylinders.
[0029] In one embodiment, the saturated chain of polymethylene of the
flexible
secondary plates is an M-class rubber compound. In another embodiment, the
saturated
chain of polymethylene of the flexible secondary plates is an ethylene
propylene diene
monomer compound. In still another embodiment, the saturated chain of
polymethylene
of the flexible secondary plates is an ethylene propylene monomer compound.
100301 In one embodiment, each of the one or more flexible secondary plates
affixed
to the blanket cylinder has a distinct image formed thereon. The images are
fot tned on the
face portion of the flexible secondary plates by one or more of: a direct
laser engraving
process; a mechanical or chemical etching or engraving process; an ink
repelling process;
a pressure forming process; or by a combination of one or more processes. In
one
embodiment, when the flexible secondary plates are comprised at least
partially of a
photopolymer material, the images may also be formed using a computer to plate
(CTP)
process, a conventional plate exposure process, or any other suitable method.
The images
formed on the flexible secondary plates may have a depth of from about 0.0009
inch to
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about 0.089 inch. In another embodiment, an image formed on the flexible
secondary
plate may have a height of from about 0.0009 inch to about 0.089 inch above
the face
portion of the flexible secondary plate.
[0031] It is another aspect of the present invention to provide a flexible
secondary
plate adapted to form a high-definition lithographic image on an exterior
surface of a
metallic container in a printing process. The flexible secondary plate
generally comprises
a plate body of a predetermined size. The plate body has a face portion and a
back
portion. The back portion is adapted to be removably attached to a blanket
cylinder of a
decorator. In one embodiment at least the face portion of the flexible
secondary plate
comprises a compound comprised at least in part of a saturated chain of
polymethylene, a
photopolymer material, and a pliable plastic material. In one embodiment, the
plate body
is from about 0.04 inch to about 0.1 inch thick. In another embodiment, the
plate body is
formed of a single homogeneous layer. Accordingly, the flexible secondary
plate is
formed of a non-laminated material. In one embodiment, the plate body is
comprised at
least in part of a compound comprising a saturated chain of polymethylene. In
another
embodiment, the plate body is formed of a single homogeneous layer of a
photopolymer
material.
[0032] In one embodiment, the saturated chain of polymethylene is an M-
class rubber.
In another embodiment, the saturated chain of polymethylene is an ethylene
propylene
diene monomer compound. In still another embodiment, the saturated chain of
polymethylene is an ethylene propylene monomer compound.
[0033] In one embodiment, an image is formed on the face portion of the
flexible
secondary plate. The image may be formed by at least one of a direct laser
engraving
process, a mechanical etching or engraving process, an ink repelling process,
and a
pressure forming process. The direct laser engraving process may ablate or
otherwise
remove at least some material from the face portion of the flexible secondary
plate. When
the flexible secondary plate is comprised at least partially of a photopolymer
material, the
image may also be formed using a computer to plate process, a conventional
plate
exposure process, or any other suitable method. The image may have a depth of
from
about 0.0009 inch to about 0.089 inch below a plane formed by the face
portion. In
another embodiment, the image may have a height of from 0.0009 inch to about
0.089
inch above the plane formed by the face portion.
[0034] Still another aspect of the present invention is a novel method of
engraving a
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flexible transfer plate with a laser to form an image adapted to print on an
exterior surface
of a metallic container. The method generally includes, but is not limited to:
(1)
providing a flexible transfer plate comprised of a saturated chain of
polymethylene; and
(2) engraving a face portion of the flexible transfer plate with the laser to
remove at least
some of the face portion to form the image. A back portion of the flexible
transfer plate is
configured to be affixed to a blanket cylinder of a decorator. Accordingly,
when a printing
plate attached to a plate cylinder of the decorator transfers ink to the
image. An exterior
surface of a metallic container is subsequently brought into contact with the
face portion
of the flexible transfer plate. In this manner, at least some of the ink is
transferred to the
exterior surface of the metallic container. In one embodiment, the saturated
chain of
polymethylene of the flexible transfer plate is one of an ethylene propylene
rubber, an M-
class rubber, and an ethylene propylene diene monomer.
[0035] In accordance with one aspect of the present invention, a novel
method of
using a flexible secondary plate in a lithographic printing process to
decorate an exterior
surface of a metallic container is provided. This includes, but is not limited
to, a method
generally comprising: (1) forming a first image to be printed onto an exterior
surface of
the metallic container; (2) transferring the first image to a predetermined
portion of a face
portion of the flexible secondary plate, wherein the flexible secondary plate
is comprised
of one of a photopolymer material, a compound comprising a saturated chain of
polymethylene, and a pliable plastic material; (3) removably affixing the
flexible
secondary plate with the first image onto a blanket cylinder of a decorator;
(4) attaching a
plurality of printing plates to at least one plate cylinder of the decorator;
(5) applying an
ink from an inker to at least one of the plurality of the printing plates; (6)
transferring at
least some of the ink from the at least one of the plurality of printing
plates to at least a
portion of the flexible secondary plate; and (7) transferring the ink from the
flexible
secondary plate to the exterior surface of the metallic container, wherein the
metallic
container is decorated
[0036] Additionally or alternatively, the method may further comprise
removably
affixing from about 4 to about 24 flexible secondary plates onto the blanket
cylinder. The
about 4 to the about 24 flexible secondary plates may each have different
images. Ink
transferred from the about 4 to the about 24 flexible secondary plates
produces 4 to 24
different images on about 4 to the about 24 metallic containers
[0037] In one embodiment, the face portion of the flexible secondary plate
may be
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etched or engraved to form one or more recessed portions. In another
embodiment, a
second image to be printed onto an exterior surface of the metallic container
is founed on
the printing plates. The metallic container is then decorated with the first
image and the
second image.
[0038] In one embodiment in which the flexible secondary plate comprises a
photopolymer material, transferring the first image to the predetermined
portion of the
face portion of the flexible secondary plate generally comprises: (1) creating
a film
negative of the first image; (2) placing the film negative on the
predetermined portion of
the face portion of the flexible secondary plate; (3) exposing the flexible
secondary plate
and the film negative to a light source, wherein the photopolymer material of
the flexible
secondary plate hardens in predetermined locations where light passes through
the film
negative, and wherein the photopolymer material of the secondary plate remains
unexposed and soft in predetermined locations where the light is blocked by
the film
negative; (4) removing the film negative from the flexible secondary plate;
and (5) placing
the flexible secondary plate in a washing station and cleaning the flexible
secondary plate
to remove the soft, unexposed photopolymer material of the flexible secondary
plate to
reveal the transferred first image.
[0039] Additionally or alternatively, transferring the first image to the
predetermined
portion of the face portion of the flexible secondary plate may generally
comprise: (1)
creating the first image; (2) ablating portions of an opaque mask coating on
the face
portion of the flexible secondary plate to form a negative of the first image;
(3) exposing
the flexible secondary plate to a light source, wherein a polymer material of
the flexible
secondary plate hardens in predetermined locations where the masking coating
has been
ablated, and wherein the polymer material of the flexible secondary plate
remains
unexposed and soft in predetermined locations where the light is blocked by
the mask
coating; and (4) removing the soft, unexposed polymer material of the flexible
secondary
plate to reveal the transferred first image.
[0040] In one embodiment, the light source is an ultraviolet light source.
In another
embodiment, the flexible secondary plate and the film negative are exposed to
the light
source for from about 0.01 minute to about 10 minutes. In one embodiment, the
washing
station uses a solvent to clean the flexible secondary plate. In another
embodiment, the
washing station uses water to clean the flexible secondary plate.
[0041] The flexible secondary plate comprised of a photopolymer material
may be
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formed of any mixture of materials that harden or form a different texture
after exposure to
ultraviolet or visible light. In one embodiment, the flexible secondary plate
is comprised
of one of elastomers which are cured using a light-catalyzed
photopolymerization process,
chloroprene crosslinked with trimethylolpropane triacrylate, and styrene-
isoprene rubber
with a polyacrylate. In one embodiment, before the first image is transferred
to the
flexible secondary plate, the flexible secondary plate has a hardness of from
about 40
Shore A durometers to about 110 Shore A durometers. In another embodiment, the
hardness of the flexible secondary plate is from about 67 Shore A durometers
to about 90
Shore A durometers. In still another embodiment, the flexible secondary plate
has a
hardness of from about 69 Shore A durometers to about 81 Shore A durometers
before the
first image is transferred to the flexible secondary plate. In yet another
embodiment, the
flexible secondary plate has a hardness of from about 65 Shore A durometers to
about 73
Shore A durometers before the first image is transferred to the flexible
secondary plate. In
still another embodiment, the photopolymer flexible secondary plate has a
Shore A
durometer harness of between about 25 and 55. In another embodiment, at least
one of the
flexible secondary plates may have a Shore A hardness of between about 76 and
about 82
durometers. In still another embodiment, at least one of the flexible
secondary plates may
have a Shore A hardness of between about 68 and about 74 durometers. In yet
another
embodiment, at least one of the flexible secondary plates optionally has a
Shore A
hardness of between about 62 and about 68 durometers.
[0042] In one embodiment, the saturated chain of polymethylene of the
flexible
secondary plate is an M-class rubber. In another embodiment, the saturated
chain of
polymethylene of the flexible secondary plate is an ethylene propylene diene
monomer
compound. In yet another embodiment, the saturated chain of polymethylene of
the
flexible secondary plate is an ethylene propylene monomer compound.
[0043] In one embodiment, at least some of a material of the face portion
of the
flexible secondary plate is removed to form the first image in one or more of
a direct laser
engraving process, a mechanical or chemical etching or engraving process, an
ink
repelling process, a pressure forming process, or by a combination of one or
more
processes. In one embodiment, the first image foimed on the flexible secondary
plate has
a depth of from about 0.0009 inch to about 0.089 inch compared to a plane
formed by the
face portion. In another embodiment, the first image has a height of from
about 0.0009
inch to about 0.089 inch above the plane formed by the face portion.
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[0044] In one embodiment, the ink comprises a specialty ink. The specialty
ink may
comprise one or more of a thermochromic ink, a photochromic ink, a scented
thermochromic ink, a fluorescent ink, a UV ink, a black light ink, an infrared
ink, a
phosphorescent ink, a pressure sensitive ink, a tactile ink, a thermo-tactile
ink, a leuco dye,
and a matte ink.
[0045] In one embodiment, each of the different images are formed in a same
location
on each of the flexible secondary plates. In another embodiment, only the
printing plates
attached to a first one of the at least one plate cylinder transfers ink to
the different images
formed on each of the flexible secondary plates. Printing plates attached to a
second one of
the at least one plate cylinder do not transfer ink to the different images
formed on each of
the flexible secondary plates. Instead, the printing plates attached to the
second of the at
least one plate cylinder transfer ink to other predetermined portions of each
of the flexible
secondary plates.
[0046] In one embodiment, the metallic container is generally cylindrical
in shape.
The first image is transferred to a curved exterior surface of the metallic
container. In
another embodiment, the metallic container is generally cylindrical in shape
and the first
image is transferred to a substantially flat exterior surface of the metallic
container. In yet
another embodiment, the metallic container is not cylindrical in shape and the
first image
is transferred to a flat exterior surface of the metallic container.
[0047] In accordance with another aspect of the present invention, an
apparatus for
forming a high-definition lithographic image on an exterior surface of a
metallic container
is disclosed, the apparatus operable to create multiples lithographic images
from a single
set of printing plates. The apparatus generally comprises: (1) at least one
plate cylinder
with an inker to transfer ink to predetermined portions of one or more
printing plates
attached to a circumference of the at least one plate cylinder; (2) a blanket
cylinder having
one or more flexible secondary plates affixed to a circumference of the
blanket cylinder,
the blanket cylinder operable to move the flexible secondary plates into
rotational contact
with a printing plate attached to the at least one plate cylinder, wherein ink
is transferred
from the predetermined portions of the printing plate to at least a portion of
the flexible
secondary plates, and wherein the flexible secondary plates optionally each
have an image
formed thereon; and (3) a support cylinder including a plurality of stations
adapted to
receive metallic containers, the support cylinder operable to receive the
metallic container
from a conveyor and move the metallic container into contact with a flexible
secondary
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plate affixed to the blanket cylinder, wherein ink is transferred from the
flexible secondary
plate to the metallic container to form the high-definition lithographic image
on the
exterior surface of the metallic container.
[0048] In one embodiment, the flexible secondary plates are comprised of a
compound
comprising at least in part a saturated chain of polymethylene. In another
embodiment,
the flexible secondary plates are comprised of a photopolymer material. In
still another
embodiment, the flexible secondary plates are comprised at least in part of a
pliable plastic
material. In another embodiment, one or more of the printing plates are
comprised of a
compound of one of: a saturated chain of polymethylene; a photopolymer
material; and a
pliable plastic material. Additionally, the flexible secondary plates may
optionally be
formed of a single layer of material without an intermediate fabric layer. In
another
embodiment, the flexible secondary plates are formed without a layer of a
different
material.
[0049] In one embodiment, the at least one plate cylinder and the support
cylinder
rotate in a first direction and the blanket cylinder rotates in an opposite
second direction.
In another embodiment, from about 4 to about 24 flexible secondary plates are
affixed to
the circumference of the blanket cylinder.
[0050] In one embodiment, each of the flexible secondary plates has a
different image
formed thereon. In one embodiment, each of the different images are formed in
a same
location on each of the flexible secondary plates. In another embodiment, only
first
printing plates attached to a first plate cylinder of the at least one plate
cylinder transfer
ink to the different images formed on each of the flexible secondary plates.
Second
printing plates attached to a second plate cylinder of the at least one plate
cylinder do not
transfer ink to the images formed on the flexible secondary plates. The second
printing
plates may optionally transfer ink to other predetermined portions of each of
the flexible
secondary plates.
[0051] In one embodiment, a second image is formed on the printing plates
Ink is
transferred from the second image to the flexible secondary plates and then to
the exterior
surface of the metallic container. In another embodiment, no image is formed
on the
printing plates but the printing plates convey ink to the flexible secondary
plates. For
example, in one embodiment, the face portion of a printing plate receives a
continuous
coating of ink. The continuous coating of ink is transferred to each portion
of the face
portion of flexible secondary plate that makes contact with the face portion
of the printing
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plate.
[0052] In one embodiment, the metallic container is generally cylindrical
in shape. In
yet another embodiment, the metallic container is not cylindrical in shape. In
one
embodiment, the ink is transferred from the flexible secondary plate to one or
more of a
generally cylindrical exterior surface and a non-cylindrical exterior surface
of the metallic
container.
[0053] In one embodiment, when the flexible secondary plate is comprised of
a
photopolymer material, the images are generally formed on the flexible
secondary plates
by: (1) creating a film negative of each different image; (2) placing the film
negatives on
predetermined portions of the flexible secondary plates; (3) exposing the
flexible
secondary plates and the film negatives to a light source; (4) removing the
film negatives
from the flexible secondary plates; and (5) washing the flexible secondary
plates to
remove unexposed soft photopolymer material of the flexible secondary plates
to reveal
the different images. In another embodiment, the images are generally formed
on the
flexible secondary plates by at least one of: a direct laser engraving
process; a mechanical
or chemical etching or engraving process; an ink repelling process; a pressure
founing
process; and a combination of one or more processes.
[0054] In one embodiment, the ink comprises a specialty ink. The specialty
ink may
be one or more of a thermochromic ink, a photochromic ink, a scented
thermochromic ink,
a fluorescent ink, a UV ink, a black light ink, an infrared ink, a
phosphorescent ink, a
pressure sensitive ink, a tactile ink, a thermo-tactile ink, a leuco dye, and
a matte ink.
[0055] In another embodiment, the at least one plate cylinder comprises
from about
four to about eighteen plate cylinders. In another embodiment, the apparatus
includes
about 8 plate cylinders. An inker is associated in a predetermined alignment
with each of
the four to eighteen plate cylinders. In still another embodiment, first
printing plates
attached to a first of the four to eighteen plate cylinders have an ink
receiving area
aligning with, and operable to transfer ink to, the different images on each
of the flexible
secondary plates. Each of the second printing plates attached to the other of
the four to
eighteen plate cylinders have a relief area aligning with the different images
on each of the
flexible secondary plates. The relief areas will not transfer ink to the
different images of
the flexible secondary plates. The ink receiving area of the first printing
plates attached to
the first of the four to eighteen plate cylinders and the relief areas of the
second printing
plates attached to the other of the four to eighteen plate cylinders are
located in
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corresponding locations on all of the printing plates and have the same
general size and
shape. In one embodiment, the ink receiving areas and the relief areas have a
shape
selected from the group consisting of a parallelogram, a square, a rectangle,
a circle, or
any combination thereof. In a more preferred embodiment, the ink receiving
areas and the
relief areas have a generally rectangular shape. In still another embodiment,
the ink
receiving areas and the relief areas are at least slightly larger than the
different images of
the flexible secondary plates. In this manner, the position of the flexible
secondary plates
on the blanket cylinder may vary by a predetermined amount axially and
radially of a
predetermined position to maintain a predetermined alignment with the ink
receiving areas
of the first printing plates and with the relief areas of the second printing
plates.
[0056] It is another aspect of the present invention to provide flexible
secondary plate
adapted to form a high-definition lithographic image on an exterior surface of
a metallic
container in a printing process. In one embodiment, the flexible secondary
plate generally
comprises a plate body comprised of a photopolymer material of a predetermined
size and
hardness, the plate body having a face portion and a back portion, wherein the
back
portion is adapted to be attached to a blanket cylinder of a decorator. In
another
embodiment, the flexible secondary place is comprised at least partially of a
compound
comprising saturated chain of polymethylene. In one embodiment, the plate body
is from
about 0.04 inch to about 0.1 inch thick. Optionally, the flexible secondary
plate may be
formed of a single material. Accordingly, in one embodiment the flexible
secondary plate
is devoid of threads and/or intermediate layers of different materials. In one
embodiment,
the metallic container has a body with a generally cylindrical shape.
[0057] Optionally, an image may be formed on the face portion of the
flexible
secondary plate by creating a film negative of the image. The film negative is
placed on a
predetermined portion of the face portion. The face portion and the film
negative are
exposed to a light source. The film negative is removed from the face portion,
and
subsequently the flexible secondary plate is cleaned to remove unexposed soft
material
from the face portion. In one embodiment, before the image is formed on the
face portion,
the flexible secondary plate has a hardness of from about 40 Shore A
durometers to about
110 Shore A durometers. In addition, images may be formed on the face portion
of the
flexible secondary plate by one or more of a direct laser engraving process, a
mechanical
or chemical etching or engraving process, an ink repelling process, a pressure
forming
process, or by a combination of one or more processes.
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[0058] It is another aspect of the present invention to provide a method of
using a
decorator in a printing process to decorate an exterior surface of a plurality
of metallic
containers with different images. The method generally comprises: (1)
providing a first
printing plate positioned on a first plate cylinder of the decorator which
includes a first ink
receiving region and a relief area that will not receive ink; (2) providing a
second printing
plate positioned on a second plate cylinder of the decorator which includes a
second ink
receiving region that aligns with the relief area of the first printing plate;
(3) providing a
first flexible transfer plate positioned on a blanket cylinder of the
decorator, a face portion
of the first flexible transfer plate defining a first plane, the first
flexible transfer plate
including a first image in a first predetermined portion of the face portion;
(4) providing a
second flexible transfer plate positioned on the blanket cylinder, a face
portion of the
second flexible transfer plate defining a second plane, the second flexible
transfer plate
including a second image in a second predetermined portion of the face
portion; (5)
applying a first ink to the first ink receiving region of the first printing
plate; (6)
transferring the first ink from the first printing plate to other
predetermined portions of the
face portions of each of the first and second flexible transfer plates; (7)
applying a second
ink to the second ink receiving region of the second printing plate; (8)
transferring the
second ink from the second ink receiving region of the second printing plate
to the first
image of the first flexible transfer plate and to the second image of the
second flexible
transfer plate; (9) transferring the first and second inks from the first
flexible transfer plate
to an exterior surface of a first metallic container, wherein the first
metallic container is
decorated with the first ink and with the first image formed of the second
ink; and (10)
transferring the first and second inks from the second flexible transfer plate
to an exterior
surface of a second metallic container, wherein the second metallic container
is decorated
with the first ink and with the second image formed of the second ink. In one
embodiment, the first and second flexible transfer plates are comprised of one
of a
compound comprising at least in part a saturated chain of polymethylene, a
photopolymer
material, and a pliable plastic material Optionally, the first and second
flexible transfer
plates are formed of a monolithic layer of material with no intermediate
layers of other
materials. In one embodiment, an adhesive transfer tape on a back portion of
the first and
second flexible transfer plates is used to affix the transfer plates to the
blanket cylinder.
[0059] In one embodiment, at least a portion of the first image has a depth
that is
lower than the first plane and no portion of the first image projects above
the first plane.
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In another embodiment, at least a portion of the second image has a depth that
is lower
than the second plane and no portion of the second image projects above the
second plane.
In still another embodiment, at least a portion of one of the first and second
images
projects above the first and second planes.
[0060] Optionally, in another embodiment, the first predetermined portion
of the first
flexible transfer plate and the second predetermined portion of the second
flexible transfer
plate each align with the relief area of the first printing plate and with the
second ink
receiving region of the second printing plate during the transfer of ink from
the first and
second printing plates to the first and second flexible transfer plates. In
still another
embodiment, the first image of the first flexible transfer plate is surrounded
by a relief area
that will not receive ink from the first and second printing plates. In this
manner the first
image formed on the first metallic container is surrounded by a non-inked
area. In another
embodiment, the second image of the second flexible transfer plate comprises
relief areas
that will not receive ink from the second printing plate and raised areas that
will receive
ink from the second printing plate. Accordingly, the second image formed on
the second
metallic container includes non-inked portions and inked portions.
[0061] Optionally, the second ink receiving region of the second printing
plate is
surrounded by a non-ink region. Additionally, the relief area of the first
printing plate may
optionally have a shape that aligns with a shape of the second ink receiving
region of the
second printing plate. In another embodiment, the depth of at least one of the
first image
on the first flexible transfer plate and the second image on the second
flexible transfer
plate is from about 0.0009 inch to about 0.089 inch. In still another
embodiment, the
height of at least one of the first image on the first flexible transfer plate
and the second
image on the second flexible transfer plate is from about 0.0009 inch to about
0.089 inch
above a plane defined by ink receiving surfaces of the flexible transfer
plates.
[0062] In one embodiment, the first and second flexible transfer plates are
comprised
of at least one of an elastomer which is cured using a light-catalyzed
photopolymerization
process, a chloroprene crosslinked with trimethylolpropane triacrylate, and a
styrene-
isoprene rubber with a polyacrylate. In another embodiment, the saturated
chain of
polymethylene of the first and second flexible transfer plates is an M-class
rubber. In
another embodiment, the saturated chain of polymethylene of the first and
second flexible
transfer plates is an ethylene propylene diene monomer compound. In yet
another
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embodiment, the saturated chain of polymethylene of the first and second
flexible transfer
plates is an ethylene propylene monomer compound.
[0063] In one embodiment, the first ink is a different type or a different
color of ink
than the second ink. In another embodiment, at least one of the first ink and
the second
ink comprises a specialty ink. The specialty ink may comprise one or more of a
thermochromic ink, a photochromic ink, a scented thermochromic ink, a
fluorescent ink, a
UV ink, a black light ink, an infrared ink, a phosphorescent ink, a pressure
sensitive ink, a
tactile ink, a thermo-tactile ink, a leuco dye, and a matte ink.
[0064] Still another aspect of the present invention is a method of using a
flexible
secondary plate in a printing process to decorate an exterior surface of a
generally
cylindrical container. The method includes, but is not limited to: (1)
providing a first
flexible secondary plate with a first image formed thereon, at least a portion
of the first
image having a depth that is lower than a first plane defined by a face
portion of the first
flexible secondary plate, wherein no portion of the first image projects above
the first
plane; (2) affixing the first flexible secondary plate with the first image to
a blanket
cylinder of a decorator; (3) transferring a first ink from a first printing
plate to at least a
portion of the first flexible secondary plate, wherein the first printing
plate is
interconnected to a first plate cylinder of the decorator; and (4)
transferring the first ink
from the first flexible secondary plate to the exterior surface of a first
container to form the
first image on the first container. Accordingly, the first image on the first
container is of
the first ink. In one embodiment, the first image formed on the first flexible
secondary
plate is three dimensional and includes predetermined portions with different
depths.
[0065] Optionally, in another embodiment, the method may further include
transferring a second ink from a second image on a second printing plate to at
least a
portion of the first flexible secondary plate, wherein the second printing
plate does not
transfer the second ink to the first image, and wherein the second printing
plate is
interconnected to a second plate cylinder of the decorator. Subsequently, the
first and
second inks are transferred from the first flexible secondary plate to the
exterior surface of
a first container to form the first and second images on the first container.
In this manner,
the first image on the first container is of the first ink and the second
image on the first
container is of the second ink. In one embodiment, the first image formed on
the first
flexible secondary plate is three dimensional and includes predetermined
portions with
different depths.
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[0066] In one embodiment, the first image on the first flexible secondary
plate is a
negative comprising relief areas that will not receive ink (or that will only
receive a very
small amount of ink) from the first printing plate. In another embodiment, the
first image
formed on the first container includes non-inked areas.
[0067] In another embodiment, the first image on the first flexible
secondary plate
comprises a combination of relief areas that will not receive ink from the
first printing
plate and raised areas that will receive ink from the first printing plate. In
another
embodiment, the first image formed on the first container includes non-inked
areas and
inked areas.
[0068] Optionally, the method may further include: (a) providing a second
flexible
secondary plate with a third image formed thereon; (b) affixing the second
flexible
secondary plate to the blanket cylinder; (c) transferring the first ink from
the first printing
plate to at least a portion of the second flexible secondary plate; (d)
transferring the second
ink from the second image on the second printing plate to the second flexible
secondary
plate, wherein the second printing plate does not transfer the second ink to
the third image,
and (e) transferring the first and second inks from the second flexible
secondary plate to
the exterior surface of a second container to form the second and third images
on the
second container. Accordingly, the third image on the second container is
comprised at
least partially of the first ink and the second image on the second container
is comprised at
least partially of the second ink.
[0069] In one embodiment, the first and second flexible secondary plates
are
comprised of one of a composition at least in part comprising a saturated
chain of
polymethylene, a photopolymer material, and a pliable plastic material. In
another
embodiment, the first and second flexible secondary plates are comprised of at
least one of
an elastomer which is cured using a light-catalyzed photopolymerization
process, a
chloroprene crosslinked with trimethylolpropane triacrylate, and a styrene-
isoprene rubber
with a polyacrylate. In another embodiment, the saturated chain of
polymethylene is an
M-class rubber. In another embodiment, the saturated chain of polymethylene is
an
ethylene propylene diene monomer compound. In yet another embodiment, the
saturated
chain of polymethylene is an ethylene propylene monomer compound.
Additionally, the
first and second flexible secondary plates may be formed of homogeneous layer
of
material. In another embodiment, interior portions of the first and second
flexible
secondary plates are devoid of threads or fabrics.
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[0070] In one embodiment, the first ink is a different type or a different
color of ink
than the second ink. In another embodiment, at least one of the first ink and
the second
ink comprises a specialty ink. The specialty ink may comprise one or more of a
thermochromic ink, a photochromic ink, a scented thermochromic ink, a
fluorescent ink, a
UV ink, a black light ink, an infrared ink, a phosphorescent ink, a pressure
sensitive ink, a
tactile ink, a thermo-tactile ink, a leuco dye, and a matte ink.
[0071] Another aspect of the present invention is a method of decorating an
exterior
surface of a plurality of cylindrical metal containers in a continuous
decorating process.
The method comprises: (I) affixing a plurality of flexible secondary plates to
a blanket
cylinder of a decorator; (2) attaching a first printing plate with a first ink
receiving region
to a first plate cylinder of the decorator, the first ink receiving region
aligning with a
predetermined portion of each of the plurality of flexible secondary plates;
(3) attaching a
second printing plate with second ink receiving region and a relief area to a
second plate
cylinder of the decorator, the relief area aligning with the predetermined
portion of each of
the plurality of flexible secondary plates; (4) applying a first ink to the
first ink receiving
region of the first printing plate; (5) applying a second ink to the second
ink receiving
region of the second printing plate; (6) transferring at least some of the
first ink and the
second ink from the first and second printing plates to at least a portion of
each of the
plurality of flexible secondary plates; and (7) transferring the first ink and
the second ink
from the plurality of flexible secondary plates to an exterior surface of the
each of the
plurality of cylindrical metal containers, wherein each of the plurality of
cylindrical metal
containers is decorated with the first ink and the second ink.
[0072] In one optional embodiment, each of the flexible secondary plates
has a
different image formed within at least a portion of the predetermined portion
of each of the
plurality of flexible secondary plates. In one embodiment, at least a portion
of each
different image formed on the flexible secondary plates has a depth that is
lower than a
plane defined by a face portion of each flexible secondary plate. In another
embodiment,
no portion of each different images formed on the flexible secondary plates
projects above
the plane of the face portion of each flexible secondary plate.
[0073] In one embodiment, the second printing plate transfers an image with
the
second ink to each of the plurality of flexible secondary plates. The image is
then
transferred from the flexible secondary plates to each of the plurality of
cylindrical metal
containers. In this manner, each of the plurality of cylindrical metal
containers is
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decorated with the image from the second printing plate in the second ink and
with one of
the different images of the flexible secondary plates in the first ink.
[0074] In one embodiment, the flexible secondary plates are comprised of a
homogeneous layer. The homogeneous layer may be one of a composition
comprising at
least in part a saturated chain of polymethylene, a photopolymer material, and
a pliable
plastic material. In one embodiment, at least one of the flexible secondary
plates is
comprised of at least one of an elastomer which is cured using a light-
catalyzed
photopolymerization process, a chloroprene crosslinked with trimethylolpropane
triacrylate, and a styrene-isoprene rubber with a polyacrylate. In another
embodiment, the
saturated chain of polymethylene is an M-class rubber. In another embodiment,
the
saturated chain of polymethylene is an ethylene propylene diene monomer
compound. In
yet another embodiment, the saturated chain of polymethylene is an ethylene
propylene
monomer compound. In still another embodiment, the flexible secondary plates
are
devoid of threads.
[0075] In another embodiment, a first inker applies the first ink to the
first printing
plate and a second inker applies the second ink to the second printing plate.
In one
embodiment, the first ink is a different type or a different color of ink than
the second ink.
In another embodiment, at least one of the first ink and the second ink
comprises a
specialty ink. The specialty ink may comprise one or more of a thermochromic
ink, a
photochromic ink, a scented thermochromic ink, a fluorescent ink, a UV ink, a
black light
ink, an infrared ink, a phosphorescent ink, a pressure sensitive ink, a
tactile ink, a thermo-
tactile ink, a leuco dye, and a matte ink.
[0076] In yet another embodiment, the decorator comprises additional
printing plates
attached to additional plate cylinders. In one embodiment, the additional
plate cylinders
comprises from four to eighteen plate cylinders. Each of the four to eighteen
plate
cylinders operable to apply additional colors or types of ink to the plurality
of flexible
secondary plates affixed to the blanket cylinder.
[0077] One aspect of the present invention is a decorator to decorate an
exterior
surface of a plurality of metallic containers with different images. The
decorator includes,
but is not limited to: (1) a first plate cylinder which includes a first
printing plate with a
first ink receiving region; (2) a first inker arranged in a predetermined
position with
respect to the first plate cylinder, the first inker to apply a first ink to
the first ink receiving
region of the first printing plate; (3) a second plate cylinder which includes
a second
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printing plate with a second ink receiving region; (4) a second inker arranged
in a
predetermined position with respect to the second plate cylinder, the second
inker to apply
a second ink to the second ink receiving region of the second printing plate;
(5) a blanket
cylinder with a first flexible transfer plate comprised at least in part of a
compound
including a saturated chain of polymethylene, the blanket cylinder aligned in
a
predetermined position with respect to the first and second plate cylinders
such that the
first flexible transfer plate receives the first ink from the first printing
plate and the first
flexible transfer plate receives the second ink from the second printing
plate; (6) a support
cylinder aligned in a predetermined position with respect to the blanket
cylinder, the
support cylinder including a plurality of stations to receive metallic
containers and hold
the metallic containers in a predetermined position with respect to the first
transfer plate of
the blanket cylinder, the support cylinder operable to move the metallic
containers into
contact with the first flexible transfer plate to transfer the first and
second inks from the
first flexible transfer plate to the metallic containers. In one embodiment,
the first flexible
transfer plate is a homogeneous material. In another embodiment, the first
flexible
transfer plate is devoid of a fabric layer. In yet another embodiment, the
first flexible
transfer plate is devoid of threads.
[0078] In one embodiment, the first flexible transfer plate further
comprises a face
portion defining a first plane. A first image is formed in a first
predetermined portion of
the face portion. At least a portion of the first image has a depth that is
lower than the first
plane. In one embodiment, no portion of the first image projects above the
first plane.
Optionally, in another embodiment, the first flexible transfer plate is formed
of a single
layer of material.
[0079] In another embodiment the blanket cylinder further includes a second
flexible
transfer plate comprised at least in part of a compound including a saturated
chain of
polymethylene. In one embodiment, the second flexible transfer plate further
comprises a
face portion defining a second plane. Optionally, a second image is formed in
a second
predetermined portion of the face portion. At least a portion of the optional
second image
has a depth that is lower than the second plane. In one embodiment, no portion
of the
second image projects above the second plane. In one embodiment, each of the
first image
of the first flexible transfer plate and the second image of the second
flexible transfer plate
have a depth that is from about 0.0009 inch to about 0.089 inch below the
first and second
planes. Alternatively, at least one of first image of the first flexible
transfer plate and the
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second image of the second flexible transfer plate may have a height that is
from about
0.0009 inch to about 0.089 inch above the first and second planes.
[0080] In another embodiment, the first printing plate further comprises a
relief area
that will not receive the first ink from the first inker. The relief area
aligns with the first
image of the first flexible transfer plate and with the second image of the
second flexible
transfer plate. The second ink receiving region of the second printing plate
also aligns
with the first and second images of the first and second flexible transfer
plates.
Optionally, the second ink receiving region of the second printing plate may
be
surrounded by a non-ink region. In one embodiment, the first predetermined
portion of
the first flexible transfer plate and the second predetermined portion of the
second flexible
transfer plate each align with the relief area of the first printing plate and
the second ink
receiving region of the second printing plate. In this manner, during the
transfer of ink
from the first and second printing plates to the first and second flexible
transfer plates, the
first ink is not transferred to the first and second images formed on the
first and second
flexible transfer plates.
[0081] In one embodiment, an adhesive transfer tape on a back portion of
the first and
second flexible transfer plates is used to affix the first and second transfer
plates to the
blanket cylinder.
[0082] In another embodiment, the first image of the first flexible
transfer plate is
surrounded by a relief area that will not receive ink from the first and
second printing
plates. Accordingly, the first image formed on the metallic containers is
surrounded by a
non-inked area.
[0083] Optionally, in another embodiment, the second image of the second
flexible
transfer plate comprises relief areas that will not receive the second ink
from the second
printing plate and raised areas that will receive the second ink from the
second printing
plate. Accordingly, the second image formed on the metallic containers
includes non-
inked portions and inked portions.
[0084] In one embodiment, the saturated chain of polymethylene of at least
one of the
first and second flexible transfer plates is an M-class rubber. In another
embodiment, the
saturated chain of polymethylene of at least one of the first and second
flexible transfer
plates is an ethylene propylene diene monomer compound. In yet another
embodiment,
the saturated chain of polymethylene of at least one of the first and second
flexible transfer
plates is an ethylene propylene monomer compound.
85362-76
[0085] In one embodiment, the first ink is a different type or a different
color of ink than the
second ink. In another embodiment, at least one of the first ink and the
second ink comprises a
specialty ink. The specialty ink may comprise one or more of a thermochromic
ink, a photochromic
ink, a scented thermochromic ink, a fluorescent ink, a UV ink, a black light
ink, an infrared ink, a
phosphorescent ink, a pressure sensitive ink, a tactile ink, a thermo-tactile
ink, a leuco dye, and a
matte ink.
10085A1 In another embodiment, a method of using a flexible secondary plate in
a printing
process to decorate an exterior surface of a metallic container is provided,
comprising:
forming a first image on a predetermined portion of a face portion of the
flexible secondary
plate by removing at least some of the face portion in a laser engraving
process, wherein the face
portion is comprised of a saturated chain of polymethylene;
removably affixing the flexible secondary plate with the first image onto a
blanket cylinder
of a decorator;
attaching a printing plate to a plate cylinder of the decorator;
applying an ink from an inker to the printing plate;
transferring at least some of the ink from the printing plate to at least a
portion of the
flexible secondary plate; and
transferring the ink from the flexible secondary plate to the exterior surface
of the metallic
container, wherein the metallic container is decorated.
[0085131 In another embodiment, an apparatus for forming a high-definition
lithographic image
on an exterior surface of a metallic container is provided, comprising:
a plate cylinder;
a printing plate attached to a circumference of the plate cylinder;
an inker operable to transfer an ink to the printing plate;
a blanket cylinder;
a flexible secondary plate affixed to the blanket cylinder, the flexible
secondary plate
having a face portion comprised of a saturated chain of polymethylene that
includes an image
formed by a laser engraving process, wherein the blanket cylinder is operable
to move the
flexible secondary plate into contact with the printing plate such that the
ink is transferred from
the printing plate to the image of the flexible secondary plate; and
26
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a support cylinder, operable to move the metallic container into contact with
the flexible
secondary plate affixed to the blanket cylinder, wherein the ink is
transferred from the flexible
secondary plate to the metallic container to form the high-definition
lithographic image on the
exterior surface.
[0085C] In another embodiment, a flexible secondary plate adapted to form a
high-definition
lithographic image on an exterior surface of a metallic container in a
printing process is provided,
the flexible secondary plate comprising:
a plate body of a predetermined size, the plate body formed of a single layer
of material
comprising a saturated chain of polymethylene and having a face portion and a
back portion,
wherein the back portion is adapted to be removably attached to a blanket
cylinder of a decorator,
and wherein an image is formed on the face portion by removing some of the
material comprising
the saturated chain of polymethylene.
[0086] The Summary of the Invention is neither intended nor should it be
construed as being
representative of the full extent and scope of the present invention.
Moreover, references made
herein to "the present invention" or aspects thereof should be understood to
mean certain
embodiments of the present invention and should not necessarily be construed
as limiting all
embodiments to a particular description. The present invention is set forth in
various levels of
detail in the Summary of the Invention as well as in the attached drawings and
the Detailed
Description of the Invention and no limitation as to the scope of the present
invention is intended
by either the inclusion or non-inclusion of elements, components, etc. in this
Summary of the
Invention. Additional aspects of the present invention will become more
readily apparent from the
Detail Description, particularly when taken together with the drawings.
[0087] These and other advantages will be apparent from the disclosure of the
invention(s)
contained herein. The above-described embodiments, objectives, and
configurations are neither
complete nor exhaustive. As will be appreciated, other embodiments of the
invention are possible
using, alone or in combination, one or more of the features set forth above or
described below.
Further, the Summary of the Invention is neither intended nor should it be
construed as
representing the full extent and scope of the present invention. The present
invention is set forth in
various levels of detail in the Summary of the Invention, and, in the attached
drawings and the
26a
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Detailed Description of the invention and no limitation as to the scope of the
present invention is
intended to either the inclusion or non-inclusion of elements, components,
etc. in this Summary of
the Invention. Additional aspects of the present invention will become more
readily apparent from
the detailed description, particularly when taken with the drawings.
[0088] Although generally referred to herein as "metallic can," "metallic
containers,'' and/or
"cylindrical metallic containers," it should be appreciated that the current
process may be used to
decorate any variety or shape of containers or other articles of
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manufacture, including generally cylindrical surfaces and non-cylindrical
surfaces
(including flat substrates) whether made of metal or other materials.
[0089] As used herein, the phrase "specialty inks" may include, but is not
limited to,
one or more colors or types of thermochromic ink, photochromic ink, scented
thermochromic ink, fluorescent ink, UV ink, black light ink, infrared ink,
phosphorescent
ink, pressure sensitive ink, tactile ink, thermo-tactile ink, leuco dye, matte
ink, and any
other type of ink, dye, or varnish that changes appearance, color, phase,
and/or texture in
response to temperature changes or exposure to light or pressure.
[0090] A "thermochromic ink," as used herein, may include, but is not
limited to, any
ink of a first predetermined color that can undergo reversible or irreversible
change to a
second and/or third predetermined color in response to temperature changes.
[0091] As used in the present application, a "photochromic ink" may
comprise, but is
not limited to, any ink of a first predetermined color that can undergo
reversible or
irreversible change to a second and/or third predetermined color in response
to the
exposure of light of various wavelengths.
[0092] A "scented thermochromic ink," by way of illustration only,
includes, but is not
limited to, any ink of any color that releases a predetermined scent in
response to
temperature changes.
[0093] A "fluorescent ink," as used in the present application, may
include, but is not
limited to, any ink that absorbs ultraviolet energy (light) of various
wavelengths and, in
response, transmits longer waves in a visible spectrum producing light (or
"glow") in a
predetermined color. Fluorescent inks glow under black light and provide a
"day glow."
[0094] As used herein, a "phosphorescent ink" includes, but is not limited
to, any ink
that absorbs light of various wavelengths and produces light of a
predetermined color in
response. Phosphorescent inks produce light in a manner similar to fluorescent
inks;
however, phosphorescent inks continue to produce light, or "glow," once
charged by light
source even if the light source is removed Phosphorescent inks may also be
known as
"glow in the dark ink."
[0095] As used herein, a "black light ink" includes, but is not limited to,
any ink that
includes a phosphor that absorbs energy from UV radiation and, in response,
emits visible
light.
[0096] A "pressure sensitive ink" as used in the present application may
include, but is
not limited to, any ink of a first predetermined color that can change to a
second and/or
27
85362-76
third predetermined color upon receiving a predetermined amount of pressure.
The pressure
sensitive ink may include capsules containing inks of different colors. When a
pre-determined
amount of pressure is applied to the pressure sensitive ink, the capsules
rupture and the different
colors released from the capsules mix, changing the color of the pressure
sensitive ink.
[0097] As used in the present application. a "matt ink" may include, but is
not limited to, any ink of
any predetermined color that has a finish that scatters rays of light more (or
has less "gloss") when
applied to a substrate than other non-matt inks (or "glossy" inks) that
reflect more light as parallel
rays.
[0098] References made herein to ''lithographic printing" or aspects thereof
should not necessarily
be construed as limiting the present invention to a particular method or type
of printing. It will be
recognized by one skilled in the art that the present invention may be used in
other printing
processes such as offset printing, dry offset printing, gravure printing,
intaglio printing, screen
printing, and inkjet printing.
[0099] As used herein, a flexible secondary plate may be comprised of
photopolymer material, a
composition comprising at least in part a saturated chain of polymethylene,
various forms of
pliable plastic materials, or any other related materials with similar
physical properties. The
flexible secondary plate may be or any size or shape and may be round or a
sleeve adapted to fit
around a circumference of a blanket cylinder.
[0100] The phrases "photopolymer plates," "flexible photopolymer plates,"
"flexible photopolymer
material," and "flexible photopolymer blankets" may be used interchangeably
and generally refer
to plates or blankets including a photopolymer material. Thus, the flexible
photopolymer plate may
be a photopolymer printing plate that is a digital plate, a conventional
analog plate, or a cylinder
coated with a photopolymer.
[0101] The term "a" or "an" entity, as used herein, refers to one or more of
that entity. As such, the
terms "a" (or "an"). "one or more," and "at least one" can be used
interchangeably herein.
[0102] The use of "including," "comprising," or "having" and variations
thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as well as
additional items.
Accordingly, the terms "including," "comprising," or "having" and variations
thereof can be used
interchangeably herein.
[0103]
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BRIEF DESCRIPTION OF THE DRAWINGS
[0104] The accompanying drawings, which are incorporated in and constitute a
part of the
specification, illustrate embodiments of the invention and together with the
Summary of the
Invention given above and the Detailed Description of the drawings given
below, serve to explain
the principles of these embodiments. In certain instances, details that are
not necessary for an
understanding of the disclosure or that render other details difficult to
perceive may have been
omitted. It should be understood, of course, that the invention is not
necessarily limited to the
particular embodiments illustrated herein. Additionally, it should be
understood that the drawings
are not necessarily to scale.
[0105] Fig. 1 A is a top plan view of a printing plate with an engraved or
etched area according to
one embodiment of the present invention;
[0106] Fig. TB is a cross-sectional elevation view of the printing plate of
Fig. 1 A taken along line
IB;
[0107] Fig. 2A is a top plan view of a printing plate with a relief area
according to an embodiment
of the present invention;
[0108] Fig. 2B is a cross-sectional elevation view of the printing plate of
Fig. 2A taken along line
2B;
[0109] Fig. 3 A is a top plan view of a flexible secondary plate before an
image is formed thereon;
[0110] Fig. 38 is a side elevation view of the flexible secondary plate of
Fig. 3 A;
[0111] Fig. 4A is a top plan view of a flexible secondary plate with an image
formed thereon
according to one embodiment of the present invention;
[0112] Fig. 4B is a top plan view of a flexible secondary plate with a second
image formed thereon
according to another embodiment of the present invention;
[0113] Fig. 4C is a cross-sectional elevation view of the flexible secondary
plate of Fig. 4B taken
along line 4C;
[0114] Fig. 5 is a schematic illustration of one embodiment of a decorator of
the present invention
using flexible secondary plates to decorate metallic containers;
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[0115] Fig. 6A is a photograph of a flexible secondary plate comprised of a
photopolymer material with an image formed thereon according to various
embodiments
of the present invention;
[0116] Fig. 6B is an enlarged photograph of the image formed on the flexible
secondary
plate of Fig. 6A;
[0117] Fig. 7A is a photograph of a metallic container decorated according to
various
embodiments of the present invention using the flexible secondary plate of
Fig. 6A;
[0118] Fig. 7B is an enlarged photograph of the metallic can of Fig. 7A;
[0119] Fig. 8 is a photograph of another flexible secondary plate comprised of
a
photopolymer material with images formed thereon according to various
embodiments of
the present invention;
[0120] Fig. 9 is a photograph of a metallic container decorated according to
various
embodiments of the present invention using the flexible secondary plate of
Fig. 8;
[0121] Fig. 10A is an enlarged photograph of a first image formed on the
metallic
container of Fig. 9 using the flexible secondary plate of Fig. 8;
[0122] Fig. 10B is a second enlarged photograph of a second image formed on
the
metallic container of Fig. 9 using the flexible secondary plate of Fig. 8;
[0123] Fig. 11 is a photograph of another flexible secondary plate comprised
of a
photopolymer material with images formed thereon according to various
embodiments of
the present invention;
[0124] Fig. 12 is a photograph of a metallic container decorated according to
various
embodiments of the present invention using the flexible secondary plate of
Fig. 11;
[0125] Fig. 13 is yet another photograph of a flexible secondary plate
comprised of a
photopolymer material with images formed thereon according to various
embodiments of
the present invention;
[0126] Figs. 14A-14B are photographs of a metallic container decorated
according to
various embodiments of the present invention using the flexible secondary
plate of Fig.
13;
[0127] Figs. 15A-15B are photographs of a flexible secondary plate comprising
a
composition including a saturated chain of polymethylene with images founed
thereon
according to various embodiments of the present invention;
[0128] Figs. 16A-16C are photographs of a metallic container decorated using
the
flexible secondary plate of Fig. 15 according to an embodiment of the present
invention;
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[0129] Fig. 17A is a photograph of a face portion of a prior art printing
blanket with
images formed thereon;
[0130] Fig. 17B is a photograph of an edge of the prior art printing blanket
of Fig. 17A
showing layers of the prior art printing blanket;
[0131] Fig. 17C is a schematic side elevation view showing the layers of a
prior art
printing blanket;
[0132] Figs. 18A-18B are photographs of a metallic container decorated using
the prior
art printing blanket of Fig. 17; and
[0133] Figs. 19A-19B are photographs of another metallic container decorated
using
another prior art printing blanket.
[0134] To assist in the understanding of one embodiment of the present
invention the
following list of components and associated numbering found in the drawings is
provided
herein:
Number Component
2 Printing plate
4 Face portion
6 Back portion
8 Ink receiving region
Non-ink region
12 Relief area
14 Flexible secondary plate
16 Ink receiving region
18 Image
Relief area
22 Screened area
24 Decorator
26 Plate cylinder
28 Inker
Rollers
32 Blanket cylinder
33 Common image
34 Metallic container
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36 Conveyor
38 Support cylinder
40 Station for metallic container
42 Storage facility
44 Container surface
46 Non-inked portion
48 Varnish unit
50 Curing unit
52 Flexible secondary plate of photopolymer material
54 Image on flexible secondary plate
56 Image on flexible secondary plate
58 Ink receiving region
60 First portion of ink receiving region
62 Second portion of ink receiving region
64 Third portion of ink receiving region
65 Fourth portion of ink receiving region
66 Decorated metallic container
68 Image
70 Flexible secondary plate of photopolymer material
72 Black sheet
74 Image of dog
76 Image of feline
78 Decorated metallic container
80 Flexible secondary plate of photopolymer material
82 Backing material
84 Image of building
88 Decorated metallic container
90 Flexible secondary plate comprised of a composition of a saturated
chain
of polymethlene
94 First image
96 Second image
98 Depth scale
100 Decorated metallic container
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102 Base coat
106 Printing blanket comprised of known materials
108 Image formed on face portion of a prior art printing blanket
110 Face portion
112 First fabric layer
114 Compressible layer
116 Second fabric layer
118 Paper backing
120 Decorated metallic container
122 Decorated metallic container
124 Image transferred to a container from a prior art printing blanket
DETAILED DESCRIPTION
[0135] The present invention has significant benefits across a broad spectrum
of
endeavors. It is the Applicant's intent that this specification and the claims
appended
hereto be accorded a breadth in keeping with the scope and spirit of the
invention being
disclosed despite what might appear to be limiting language imposed by the
requirements
of referring to the specific examples disclosed. To acquaint persons skilled
in the
pertinent arts most closely related to the present invention, a preferred
embodiment that
illustrates the best mode now contemplated for putting the invention into
practice is
described herein by, and with reference to, the annexed drawings that form a
part of the
specification. The exemplary embodiment is described in detail without
attempting to
describe all of the various forms and modifications in which the invention
might be
embodied. As such, the embodiments described herein are illustrative, and as
will become
apparent to those skilled in the arts, may be modified in numerous ways within
the scope
and spirit of the invention.
[0136] Although the following text sets forth a detailed description of
numerous
different embodiments, it should be understood that the detailed description
is to be
construed as exemplary only and does not describe every possible embodiment
since
describing every possible embodiment would be impractical, if not impossible.
Numerous
alternative embodiments could be implemented, using either current technology
or
technology developed after the filing date of this patent, which would still
fall within the
scope of the claims. To the extent that any term recited in the claims at the
end of this
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patent is referred to in this patent in a manner consistent with a single
meaning, that is
done for sake of clarity only so as to not confuse the reader, and it is not
intended that such
claim term by limited, by implication or otherwise, to that single meaning.
101371 Referring now to Figs. lA and 1B, a printing plate 2A is illustrated.
The printing
plate 2A has a face portion 4 and a back portion 6. One or more ink receiving
regions 8
adapted to receive ink are formed in the face portion 4 by any means known to
those of
skill in the art. The ink receiving regions 8 are adapted to transfer ink to a
flexible
secondary plate 14 (illustrated in Figs. 3-4). The ink receiving regions 8 of
the printing
plate 2A transfer a single tone, image, type of ink, or text to the flexible
secondary plate
14 during a printing process.
101381 One or more non-ink regions 10 may be formed in the printing plate 2A.
The
non-ink regions 10 may be formed by engraving, cutting, etching, and/or
removing
selected portions from the face portion 4 of the printing plate 2A to form
depressions in
the face portion. Additionally or alternatively, non-ink regions 10 may be
treated to be
hydrophilic to prevent ink from adhering to the printing plate 2A as is known
by those of
skill in the art. The non-ink regions 10 will not receive or transfer ink to
the flexible
secondary plate 14. Although the non-ink region 10 illustrated in Fig. lA is
rectangular,
one skilled in the art will recognize that any shape of non-ink region 10 can
be formed on
the printing plate 2A, such as a circle, square, or star, an irregular shape
and/or
combinations thereof. The size and the location of the non-ink region 10 may
also be
varied. The printing plate 2A may have a common content with the other
printing plates 2
used in the printing process to form a final image that will be transferred
first to the
flexible secondary plate and then to a metallic container 34. Additionally, in
one
embodiment, the size, location, and shape of the ink receiving region 8A
within the non-
ink region 10 aligns with the size, location, and shape of images 18 formed on
the flexible
secondary plates 14. Accordingly, the ink receiving region 8A will transfer
ink to the
images 18 formed on the flexible secondary plates 14. In one embodiment, the
ink
receiving region 8A is up to about 0.5 inches larger in all dimensions than
the images 18
formed on the flexible secondary plates 14.
101391 Printing plates 2B may also be formed with a relief area 12, as
illustrated in Figs.
2A and 2B. The relief area 12 can be formed by removing a portion of the face
portion 4
of the plate 2B. Additionally or alternatively, the relief area 12 can be
formed or treated to
be hydrophilic to prevent ink from adhering to the printing plate 2B. The
relief area 12
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will not accept ink and therefore will not transfer ink to the flexible
secondary plates 14.
The size, location, and shape of the relief area 12 may align with the size,
location, and
shape of the non-ink region 10 of the printing plate 2A illustrated in Figs.
1A and 1B. In
one embodiment, the size, location, and shape of the relief area 12 aligns
with the size,
location, and shape of the ink receiving region 8A of the printing plate 2A.
Said another
way, the relief area 12 is formed in substantially the same location of
printing plate 2B as
the ink receiving region 8A of printing plate 2A. However, in operation,
printing plate 2A
does not contact printing plate 2B as they are affixed to different plate
cylinders 26B, 26A
of decorator 24. Further, in another embodiment, the size, location, and shape
of the relief
area 12 aligns with the size, location, and shape of images 18 formed on the
flexible
secondary plates 14. Accordingly, the relief area 12 will not transfer ink to
the images 18
formed on the flexible secondary plates 14. In one embodiment, the relief area
12 is up to
about 0.5 inches larger in all dimensions than the images 18 formed on the
flexible
secondary plates 14.
[0140] More than one relief 12 area may be formed in each printing plate 2.
Additionally or alternatively, printing plates 2 may include both relief areas
12 and non-
ink regions 10. In one embodiment, one or more of the printing plates 2
include a face
portion 4 comprising a photopolymer material. Images, non-ink regions 10, and
relief
areas 12 may be formed on the face portion 4 of a printing plate 2 comprising
the
photopolymer material as described below in conjunction with Figs. 3 and 4.
[0141] After one or more of the ink receiving regions 8, non-ink regions 10,
and/or relief
areas 12 are formed on a printing plate 2, the plate 2 is attached to a plate
cylinder 26 of a
decorator 24, discussed below in conjunction with Fig. 5. Optionally, more
than one color
of ink and one or more specialty inks may be used in conjunction with a
corresponding
inker 28 in the printing process to form the final image. Each individual
color of ink and
type of specialty ink is applied by different plate cylinders 26. The printing
plates 2 of
each plate cylinder 26 will only receive one color or type of ink from an
inker 28
associated with each plate cylinder 26. As will be appreciated by one of skill
in the art,
the decorator 24 may include from about four plate cylinders 26 to about
eighteen plate
cylinders 26. Each plate cylinder 26 of the decorator 24 is operable to
transfer an image
comprising a different color or type of ink to the flexible secondary plates
14 of the
blanket cylinder 32.
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[0142] Figs. 3A and 3B illustrate a flexible secondary plate 14 before an
image has been
formed on the face portion 4 of the plate. In one embodiment, the flexible
secondary plate
14 is comprised of a single material. Said another way, the flexible secondary
plate is a
homogeneous structure that is not formed of a laminate (or layers) of
different materials.
In one embodiment, the flexible secondary plate 14 is devoid of fabrics. In
another
embodiment, the flexible secondary plate is devoid of threads within the
single material of
the flexible secondary plate 14. In contrast, prior art printing blankets
(shown in Figs.
17A-17C) are a composite comprised of several layers, each layer comprising
different
materials. Although the flexible secondary plate 14 illustrated in Figs. 3A
and 3B has a
generally rectangular shape, flexible secondary plates may be supplied in a
variety of sizes
and shapes that are suitable for use with the present invention. In one
embodiment of the
present invention, the flexible secondary plate 14 has a thickness of about
0.04 inch to
about 0.1 inch. In another embodiment, the thickness of the flexible secondary
plate is
from about 0.060 inch to about 0.090 inch. In another embodiment, the flexible
secondary
plate is about 0.05 inch thick. In still another embodiment, the flexible
secondary plate is
about 0.0725 inch thick. As will be appreciated by those of skill in the art,
flexible
secondary plates of any other suitable thicknesses may also be used with the
present
invention. Optionally, the flexible secondary plates may include a Mylar
backing.
However, one of skill in the art will appreciate that backings of other
materials, or no
backing, may be used with the flexible secondary plates 14. Further, an
adhesive transfer
tape or adhesive stickyback may be added to the back portion 6 of the flexible
secondary
plate 14.
[0143] In one aspect of the present invention, the flexible secondary plate 14
may be
comprised at least in part of a composition of a saturated chain of
polymethylene or other
similar materials with similar physical properties. The flexible secondary
plate 14
comprised of the composition of a saturated chain of polymethylene has a
hardness of
between about 67 Shore A durometers and about 90 Shore A durometers. In
another
embodiment, the flexible secondary plate 14 comprised of the composition of a
saturated
chain of polymethylene has a hardness of between about 70 Shore A durometers
and about
74 Shore A durometers, and in a more preferred embodiment, about 72 Shore A
durometers.
[0144] In one embodiment, the saturated chain of polymethylene of the flexible
secondary plate 14 comprises at least in part an M-class rubber. It will be
appreciated by
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85362-76
those of skill in the art that an M-class rubber refers to rubbers in American
Society for Testing and
Materials (ASTM) standard D-1418. In another embodiment, the saturated chain
of polymethylene
of the flexible secondary plate 14 comprises at least in part an ethylene
propylene diene monomer
compound, known to those of skill in the art as EPDM rubber. EPDM rubber is a
durable, synthetic
rubber. In yet another embodiment, the saturated chain of polymethylene of the
flexible secondary
plate 14 comprises at least in part an ethylene propylene monomer compound and
is known to
those of skill in the art as EPR and/or EPM rubber. In another aspect of the
present invention, at
least the face portion 4 of the flexible secondary plate 14 may be comprised
of pliable plastic
materials.
[0145] In another aspect of the present invention, the flexible secondary
plate 14 may be comprised
of a photopolymer material. Suitable flexible photopolymer plates are
commercially available from
a variety of sources as will be appreciated by one skilled in the art.
Examples of flexible
photopolymer plates used for high quality printing on flexible packaging are
the Cyrelt NOWS
and the Cyrelt DPR plates made by DuPontTm .
[0146] In one embodiment, the flexible photopolymer plates have a hardness of
from about 40
Shore A durometers to about 110 Shore A durometers. In a preferred embodiment,
the hardness of
the flexible photopolymer plates is from about 60 Shore A durometers to about
100 Shore A
durometers. In another preferred embodiment, the
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hardness of the flexible photopolymer plates is from about 50 Shore A
durometers to
about 90 Shore A durometers. Optionally, the hardness may be between about 67
Shore A
durometers and about 90 shore A durometers. One more preferred flexible
photopolymer
plate has a hardness of between about 71 Shore A durometers and about 81 Shore
a
durometers. Another preferred flexible photopolymer plate has a hardness of
between
about 64 Shore A durometers and about 74 Shore A durometers. In still another
embodiment, the photopolymer flexible secondary plate has a Shore A durometer
harness
of between about 25 and 55. Optionally, at least one flexible secondary plate
comprised of
a photopolymer material may have a Shore A hardness of between about 76 and
about 82
durometers. In another embodiment, at least one flexible secondary plate
comprised of a
photopolymer material may have a Shore A hardness of between about 68 and
about 74
durometers. In still another embodiment, at least one flexible secondary plate
comprised
of a photopolymer material may have a Shore A hardness of between about 62 and
about
68 durometers. However, flexible secondary plates comprised of a photopolymer
material
that are harder or softer may be used with the method of the present
invention. In one
embodiment, the hardness of the flexible photopolymer plates is measured after
the plates
have been cured and an image formed thereon as described below.
[0147] The flexible photopolymer plate may be made of any photo-curable
material,
whether made of a polymer or not. One example is a UV-curable material.
Another
example is made of a material cured by light of a different wavelength, not
necessarily UV
light. Although many such plates are made of polymer compositions today, the
current
invention is applicable to plates made of any material and composition that
are curable by
light of a desired wavelength. In one embodiment, the photopolymer plate is
comprised of
elastomers which are cured using a light-catalyzed photopolymerization
process. In
another embodiment, the photopolymer plate is comprised of chloroprene cross-
linked
with trimethylolpropane triacrylate. In still another embodiment, the
photopolymer plate
is comprised of styrene-isoprene rubber with a polyacrylate. Still other
embodiments may
use flexible photopolymer plates comprised of other suitable light-curable
materials
known to those skilled in the art or developed in the future.
[0148] Flexible photopolymer plates have primarily been used for creating high
resolution graphics on flexible plastic packaging (such as soft plastic
vegetable and
produce bags), tags, labels, folding cartons, and tissue wrappers. Flexible
photopolymer
plates are not known to have been used in the metallic container industry due
to the
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significant challenges of high speed printing on an exterior surface of a
metallic substrate.
More specifically, metallic container manufacturing facilities operate some of
the fastest,
if not the fastest, production lines in the container industry. Because of the
high speeds of
the production lines, decorating techniques or processes that may work in
other industries
or with containers formed of other materials do not necessarily work at the
high speeds
required for metallic container production lines.
[0149] Referring now to Figs. 4A - 4C, flexible secondary plates 14 are
illustrated with
images 18 formed thereon. The face portions 4 of the flexible secondary plates
14A, 14B
include ink receiving regions 16. In one embodiment, the ink receiving regions
16 define
a plane. Ink receiving regions 8 of printing plates 2 that contact the ink
receiving regions
16 will transfer at least some ink to the ink receiving regions of the
flexible secondary
plates 14. An image 18A of the word "BALL" is formed on the flexible secondary
plate
14A. An image 18B of a sports jersey is formed on the other flexible secondary
plate 14B.
In one embodiment, at least a portion of the images 18A, 18B has a depth that
is lower
than the plane of the ink receiving region 16. Said another way, in one
embodiment, no
portion of the images 18A, 18B projects above the plane defined by the ink
receiving
regions 16.
[0150] The process of forming the image 18 to be printed onto the exterior
surface of the
metallic container on the flexible secondary plates 14 depends on the material
of the
flexible secondary plate. When the flexible secondary plates 14 are comprised
at least
partially of a composition of a saturated chain of polymethylene, the image 18
is formed
on (or transferred to) the flexible secondary plate 14 by any process known to
one of skill
in the art (or developed in the future) including, without limitation, a
direct laser engraving
(DLE) process, a mechanical or chemical etching or engraving process, an ink
repelling
process, a pressure forming process, or by a combination of processes.
[0151] In the DLE process, a portion of the material comprising a saturated
chain of
polymethylene of the flexible secondary plate 14 is ablated, or otherwise
removed, by a
laser. The time required to form the image 18 on the flexible secondary plate
14 varies
based on the size and complexity of the image, the depth and shading of the
image, and
also upon the composition of the flexible secondary plate. In one embodiment,
the
processing time required to form the image 18 in the composition comprising a
saturated
chain of polymethylene using the DLE process is from approximately 10 minutes
to
approximately 3 hours.
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[0152] The flexible secondary plate 14 may be affixed to a cylindrical surface
(not
illustrated) while the image 18 is formed using the DLE process. The
cylindrical surface
has a radius of curvature approximately equal to the radius of curvature of
the blanket
cylinder 32 of the decorator 24 (illustrated in Fig. 5). Forming the image 18
in the
material comprising a saturated chain of polymethylene using the DLE process
is similar
to using a laser engraving and cutting system, such as an Epilog laser to burn
an image in a
substrate. However, the DLE process offers higher image resolutions and the
ability to
control the height of screened dots that compose the image 18 (known as the
"dot deck
height"). In contrast, prior art printing blankets, such as the blankets shown
in Fig. 17,
melt easily. Because of this, prior art printing blankets do not allow fine
dot images to be
formed thereon such as those formed by use of a flexible secondary blanket 14
comprising
at least in part a saturated chain of polymethylene.
[0153] In the etching or engraving process, predetermined portions of the
material
comprising a saturated chain of polymethylene of the flexible secondary plate
14 are
removed to form the image 18. In a mechanical etching or engraving process, a
tool is
used to remove the predetermined portions of the material of the flexible
secondary plate
14. The tool may include a cutting tool, a rotating bit, an abrasive tool, a
fluid tool, or any
other type of tool operable to remove a predetermined amount of material from
the face
portion 4 of the flexible secondary plate 14. The fluid tool may direct a high
pressure
stream into the face portion 4 of the flexible secondary plate 14. The high
pressure stream
of the fluid tool can include at least one of a gas, a liquid, and a solid
selected to remove
the rubber from the face portion 4 of the flexible secondary plate 14.
Optionally, the tool
may be heated to a predetermined temperature as the image 18 is formed on the
flexible
secondary plate 14.
[0154] In a chemical etching or engraving process, a chemical is used to
remove the
predetermined portions of the material of the flexible secondary plate 14 A
masking
material may be applied to the material of the flexible secondary plate 14 to
ensure that the
chemical only contacts and removes the predetermined portions of the material
comprising
a saturated chain of polymethylene to form the image 18. The masking material
is
selected to adhere to the material and is inert with respect to the chemical
to protect non-
image areas of the material comprising a saturated chain of polymethylene. In
one
embodiment, the masking material may be applied to the entire face portion 4
of the
flexible secondary plate 14. The masking material is then selectively removed
from the
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areas forming the image 18. In another embodiment, the masking material is
only applied
to non-image areas on the face portion 4 of the flexible secondary plate 14.
The chemical
is then applied to the face portion 4 and contacts the image areas not
protected by the
masking material. After a predetermined amount of time, the chemical is
removed or
neutralized and the masking material is removed from the flexible secondary
plate 14.
Optionally, the flexible secondary plate 14 may be at least partially immersed
in a bath of
the chemical. In another embodiment, no masking material is used and the
chemical is
selectively applied to the predetermined portions of the material comprising a
saturated
chain of polymethylene of the flexible secondary plate 14.
[0155] When the image 18 is formed using the ink repelling process,
predetermined
portions of the flexible secondary plate 14 are adapted to be receptive or
repellant to ink.
In one embodiment, a chemical or a material that repels or attracts ink is
applied to
predetermined portions of the flexible secondary plate 14 to form the image
18. In another
embodiment, before the image 18 is formed on the flexible secondary plate 14,
the face
portion 4 of the plate includes a coating that repels or attracts ink.
Predetermined portions
of the coating are selectively removed from the flexible secondary plate 14 to
form the
image 18. The image formed using the ink repelling process is comprised of
areas that
attract ink and other areas that repel ink. In one embodiment, the image 18
may include
areas that attract (or repel) at least one type of ink and repel (or attract)
at least one other
type of ink.
[0156] In the pressure forming process, the image 18 is first formed on a
surface of a
master material. The master material may comprise a metal, a plastic, a
photopolymer
material, or any other suitable material. The material comprising a saturated
chain of
polymethylene of the face portion 4 of the flexible secondary plate 14 is
pressed against
the image on the master material for a predetermined amount of time to
transfer the image
from the master material to the flexible secondary plate 14. The flexible
secondary plate
14 with the image 18 is then removed from the master material The rubber of
the flexible
secondary plate 14 and/or the master material may be heated before the
flexible secondary
plate 14 is pressed against master material. In one embodiment, the flexible
secondary
plate 14 and the master material are heated to a temperature of approximately
310 F. In
another embodiment, the flexible secondary plate 14 and the master material
are pressed
together at a pressure of approximately 1,000 psi.
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[0157] After the image 18 is formed on the flexible secondary plate 14, the
flexible
secondary plate 14 may be cleaned by any suitable method to remove debris from
the face
portion 4. In one embodiment, a pressurized gas is used to remove the debris
from the
flexible secondary plate 14. In another embodiment, the debris is removed from
the
flexible secondary plate 14 with a liquid, such as water or a solvent.
[0158] When the image 18 is formed on the face portion 4 of the flexible
secondary
plate 14, the face portion 4 may have relief areas 20 that will not receive
ink and images
18 that can receive ink. The image 18 formed on the flexible secondary plate
14 can be
three dimensional and have different depths in the face portion 4. As
described above, in
one embodiment, the ink receiving regions 16 of the face portion 4 define a
plane. At least
a portion of the image 18 has a depth that is lower than the plane defined by
the ink
receiving region 16. Said another way, in one embodiment, no portion of the
image 18
projects above the plane defined by the ink receiving region 16. In one
embodiment, the
image 18, or portions of the image, may have a depth of about 0.0009 inch to
about 0.089
inch in relation to the plane of the face portion 4. In a more preferred
embodiment, the
depth of the image 18, or within portions of an image 18, is from
approximately 0.001
inch to approximately 0.084 inch deep.
[0159] When the flexible secondary plates 14 are comprised at least partially
of a
photopolymer material, the images 18A, 18B are formed of exposed and hardened
material of the flexible photopolymer plates with a computer to plate (CTP)
process, a
conventional plate exposure process, or any other suitable method. A piece of
Mylar is
generally used as a backing for the flexible photopolymer plate 14, although
other
materials commonly known by one skilled in the art may also be employed as a
backing.
An image 18 to be printed onto an exterior surface of the metallic container
is formed.
[0160] In the conventional plate exposure process, a film negative of the
image 18 is
created. The film negative is placed on a predetermined portion of the face
portion 4 of
the flexible photopolymer plate 14. The flexible photopolymer plate 14 with
the film
negative is then placed into an exposure device that exposes the flexible
photopolymer
plate and the film negative to a light source. The film negative acts as a
negative mask
that blocks and prevents some of the light from reaching the face portion 4 of
the flexible
photopolymer plate 14. The light shines through the clear sections of the film
negative
and hardens the material of the flexible photopolymer plate 14. Exposure time
to an
42
85362-76
ultraviolet light source may range from approximately 0.01 minute to
approximately 10 minutes.
[0161] The material on the face portion 4 of the flexible photopolymer plate
14 hardens where light
passes through the film negative and strikes the face portion 4. Portions of
the flexible
photopolymer plate 14 that are not covered by the film negative are also
exposed to the light and
harden. The material on the face portion 4 of the flexible photopolymer plate
14 under the areas of
the film negative that block the light, or some of the light, remain unexposed
and soft.
[0162] Using the CTP process, the image 18 is transferred directly to the
flexible photopolymer
plate 14 in a digital imager apparatus. The digital imager apparatus ablates,
or otherwise removes,
portions of an opaque mask coating on the face portion 4 of the flexible
photopolymer plate 14 to
form a negative of the image 18. The flexible photopolymer plate 14 is then
placed into an
exposure device that exposes the flexible photopolymer plate 14 to a light
source. The exposure
device may be the same as, or similar to, the exposure device used in the
conventional plate
exposure process described above. Portions of the mask coating that were not
ablated at least
partially block light and prevent the light from reaching (or decrease the
amount of the light
reaching) the face portion 4 of the flexible photopolymer plate 14. The
polymer material of the
flexible photopolymer plate 14 under remaining portions of the mask coating
remains unexposed
and soft. Light from the exposure device contacts the polymer material of the
flexible
photopolymer plate 14 in the image areas where the mask coating has been
removed and hardens
the material of the flexible photopolymer plate 14. Exposure time to an
ultraviolet light source may
range from approximately 0.01 minute to approximately 10 minutes. An example
of the CTP
process is described in "Advancing Flexography, The Technical Path Forward" by
Ray Bodwell
and Jan Scharfenberg.
[0163] Once the image 18 is transferred to the flexible photopolymer plate 14
using either the CTP
process or the conventional plate exposure process, the soft, unexposed
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polymer material on the face portion 4 of the exposed flexible photopolymer
plate 14 is
removed. In one embodiment, the exposed flexible photopolymer plate 14 is
placed in a
washing station. The unexposed, soft polymer material on unexposed areas of
the face
portion 4 of the flexible photopolymer plate 14 is removed by washing and
scrubbing the
face portion 4. The washing station may include either water or a solvent,
such as Cyrel
Nutre-Clean. As will be appreciated, other solutions and solvents may be used
in the
washing station. In another embodiment, the unexposed polymer material is
removed
from the face portion 4 by a post processing apparatus that does not use
solvents and/or
other liquids. The post processing apparatus may use thermal energy and a
developer roll
to remove the unexposed polymer material. After the soft, unexposed polymer
material is
removed, the flexible photopolymer plate 14 may be exposed to light a second
time to
complete polymerization and ensure all areas of the flexible photopolymer
plate 14 have
been hardened and to attain maximum durability.
[0164] When the unexposed soft material on areas of the face portion 4 of the
flexible
photopolymer plate 14 have been removed, the face portion 4 will have relief
areas 20 that
will not receive ink and hardened areas forming images 18 that can receive
ink. The
image 18 formed on the flexible photopolymer plate can be three dimensional
and have
different depths in the face portion 4 depending on the amount of light that
passed through
the film negative or the masking coating. The image 18, or portions of the
image 18, have
a depth of about 0.0009 inch to about 0.089 inch. In a more preferred
embodiment, the
depth of the image 18, or within portions of an image 18, is from
approximately 0.001
inch to approximately 0.084 inch deep.
[0165] In some embodiments, the flexible photopolymer plates 14 may also be
etched or
engraved on the face portion 4 before, during, or after the curing process to
form one or
more additional recessed portions. The etched or engraved areas may be formed
using a
laser or any other means known by those of skill in the art.
[0166] For both soft secondary plates 14 comprised a saturated chain of
polymethylene
or comprised of a photopolymer material, the images 18 have a maximum
thickness equal
to the original thickness of the flexible secondary plate 14. For example, as
illustrated in
the cross-sectional side elevation view of Fig. 4C, in one embodiment, the
flexible
secondary plate 14B is comprised of a single material from the face portion 4
to the back
portion 6. In contrast, in prior art printing blankets 106, illustrated in
Figs. 17A - 17C, the
image depth is limited to only an exterior layer of the laminate material of
the blanket.
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Thus, flexible secondary plates 14 comprised of a composition comprising at
least in part a
saturated chain of polymethylene or comprised of a photopolymer material offer
more
options for forming images than prior art printing blankets.
[0167] The images 18 can be surrounded by relief areas 20. When the flexible
secondary plate 14 is comprised at least partially of a photopolymer material,
the relief
areas 20 comprise portions of the photopolymer material that were not exposed
and
therefore remained soft. The unexposed, soft material of the flexible
photopolymer plates
is subsequently removed to form the relief areas 20. The size, location, and
shape of the
relief area 20 formed in the flexible secondary plates 14 may align with the
size, location,
and shape of the non-ink region 10 of the printing plate 2A illustrated in
Fig. lA and the
relief area 12 of the printing plate 2B illustrated in Fig. 2A.
[0168] In one embodiment, the size, location, and shape of the image 18 formed
on the
flexible secondary plates 14 aligns with the size, location, and shape of the
ink receiving
region 8A of the printing plate 2A illustrated in Fig. 1. Said another way,
when the
flexible secondary plates 14 are affixed to a blanket cylinder 32 of a
decorator 24 and the
printing plate 2A is affixed to plate cylinder 26A, the ink receiving region
8A will contact,
and transfer at least some ink to, an image 18 on one of the flexible
secondary plates 14.
[0169] Additionally, the size, location, and shape of the image 18 formed on
the flexible
secondary plates 14 may optionally align with the size, location, and shape of
the relief
region 12 of the printing plate 2B illustrated in Fig. 2. Accordingly, when
the printing
plate 2B is affixed to a plate cylinder 26B of the decorator 24, the relief
region 12 will not
contact, and will not transfer ink to, the images 18 on the flexible secondary
plates 14.
[0170] The relief areas 20 of the flexible secondary plates 14 will not accept
ink from
the printing plates 4 and may be used to create unique, undecorated areas (or
non-inked
areas) on the metallic container. The image 18 can include a relief area 20C
that will not
receive ink and can also include screened areas 22 that receive less ink than
other portions
of the image as illustrated in Fig. 4B. Although Figs. 4A, 4B, and 4C
illustrate images 18
surrounded by relief areas 20, it should be understood that an image 18 may be
formed on
the flexible secondary plate 14 with no relief area surrounding the image 18,
as shown in
Figs 6A and 6B. Further, it will be understood by one of skill in the art that
a relief area
20 can be of any desired size or shape and more than one relief area 20 may be
formed on
the flexible secondary plate 14.
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[0171] After the image 18 has been founed on the face portion 4 of the
flexible
secondary plate 14, an adhesive transfer tape or adhesive stickyback may be
added to the
Mylar portion or other backing on the back portion 6 of the flexible secondary
plate 14.
Suitable adhesive stickyback is available from a variety of commercial
suppliers. In one
embodiment, the adhesive stickyback is about 2.0 mil (or about 0.002 inch)
thick. In
another embodiment, the adhesive stickyback is about 15 mil (or about 0.015
inch) thick.
The flexible secondary plate 14 with the stickyback on the back portion 6 is
then attached
to the blanket cylinder 32 of the decorator 24.
[0172] Although not illustrated in Figs. 1-4, it will be appreciated by one of
skill in the
art that one or more of the printing plates 2 and/or the flexible secondary
plates 14 may
have print registration areas that are used to monitor the registration of
different colors or
specialty inks printed by different plates 2, 14 to form an image on the
metallic container.
For example, print registration areas may be provided on the printing plates 2
and/or the
flexible secondary plates 14 to monitor the location and alignment of print
content on
metallic containers.
[0173] Referring now to Fig. 5, a decorator 24 using flexible secondary plates
14 and
specialty inks to form multiple images 18 on metallic containers 34 is
illustrated. The
decorator 24 includes at least one plate cylinder 26. It will be appreciated
that the
decorator 24 may have any number of plate cylinders 26. In one embodiment, the
decorator 24 includes from about four plate cylinders 26 to about eighteen
plate cylinders
26.
[0174] One or more printing plates 2 are attached to each of the plate
cylinders 26.
Additionally or alternatively, the printing plate 2 can be a sleeve or
cylinder that wraps
around a circumference of the plate cylinder 26. The plate cylinders 26 are
operable to
rotate in a first direction. Inkers 28 with rollers 30 are associated with
each plate cylinder
26. The rollers 30 of each inker 28 transfer one color of ink or type of
specialty ink to the
ink receiving regions 8 of the printing plates 2.
[0175] As discussed herein, specialty inks include, but are not limited to, a
thermochromic ink, a photochromic ink, a scented thermochromic ink, a
fluorescent ink, a
UV ink, a glow-in-the-dark ink, a black light ink, an infrared ink, a
phosphorescent ink, a
pressure sensitive ink, a tactile ink, a tactile thermochromic ink, a leuco
dye, a matte ink,
and any other type of ink, dye, or varnish that changes appearance, color,
and/or texture in
response to temperature changes or exposure to light or pressure. Specialty
inks and
46
85362-76
methods of using them are disclosed in U.S. Patent No. 4,889,560, U.S. Patent
No. 5,502,476, U.S.
Patent No. 5,591,255, U.S. Patent No. 5,919,839, U.S. Patent No. 6, 139,779,
U.S. Patent No. 6,
174,937, U.S. Patent No. 6, 196,675, U.S. Patent No. 6,309,453, U.S. Patent
No. 6,494,950, U.S.
Patent No. 7,810,922, U.S. Patent No. 8,409,698, U.S. Patent Application
Publication
2012/0238675, U.S. Patent Application Publication 2013/0075675, U.S. Patent
Application
Publication 2013/0105743, U.S. Patent Application Publication 2013/0231242,
U.S. Patent
Application Publication 2012/0315412, U.S. Patent Application Publication
2013/0340885, U.S.
Patent Application Publication 2014/0039091, U.S. Patent Application
Publication 2014/0072442,
U.S. Patent Application Publication 2014/0187668, U.S. Patent Application
Publication
2014/0210201, U.S. Patent Application Publication 2014/0212654, U.S. Patent
Application
Publication 2014/0272161, and International Publication No. WO 2014/096088.
[0176] A first color of ink or type of specialty ink may be applied to the
printing plates 2A of the
first plate cylinder 26A and a second color of ink or type of specialty ink
may be applied to the
printing plates 2B of the second plate cylinder 26B. More colors of ink and
types of specialty ink
may be used if additional plate cylinders 26 are provided. In one embodiment,
the decorator 24
includes from 4 to 18 plate cylinders 26 and from 4 to 18 inkers 28 each
operable to apply a
different color of ink or type of specialty ink to a predetermined portion of
a printing plate 2. In a
more preferred embodiment, the decorator 24 includes from 6 to 18 plate
cylinders and from 6 to
18 inkers each operable to apply a different color of ink or type of specialty
ink to a predetermined
portion of a printing plate 2.
[0177] In the example illustrated in Fig. 5, the printing plates 2B of the
second plate cylinder 26B
include common content, an image 33 in the form of the letters "Please
Recycle,'' in ink receiving
regions 8 that will be transferred to all of the flexible secondary plates 14.
However, as will be
appreciated by one of skill in the art, the printing plates 2B do not have to
include an image. For
example, the printing plates 2B can transfer ink to the flexible secondary
plates 14 without
transferring an image to the flexible secondary plates 14. Said another way,
printing plates 2 may
transfer ink without words or other indicia to the flexible secondary plates
14. The first and second
plate cylinder 26A, 26B can include printing plates 2 with one or more relief
areas 12 and non-ink
regions 10.
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[0178] In one embodiment, a relief area 12 may be folined in the same location
of all of
the printing plates 2B affixed to the second plate cylinder 26B. Another
portion of the
printing plates 2B forms an ink receiving region 8 that may include the image
33. In one
embodiment, the image 33 formed on the ink receiving region 8 of printing
plates 2B may
include text. For example, as illustrated in Fig. 5, an image 33 comprising
the letters
"Please Recycle" is formed on the ink receiving region 8 of printing plates
2B. It will be
appreciated by one of skill in the art that other text or images may be formed
on the ink
receiving region 8 of printing plates 2B.
[0179] The relief areas 12 formed in the printing plates 2B do not receive ink
from the
inkers 28B and will not transfer ink to the flexible secondary plates 14. The
ink receiving
region 8 of the printing plates 2B will receive and may transfer ink to the
flexible
secondary plates 14. Continuing this example, printing plates 2A affixed to
the first plate
cylinder 26A may include an ink receiving region 8A. Ink receiving region 8A
may be
formed on a predetermined position of the printing plates 2A such that ink
placed on
region 8A will be transferred to all images 18 of the flexible secondary
plates 14 that
contact the ink receiving region 8A of the face portion 4 of the printing
plates 2A.
[0180] In one embodiment, the ink receiving region 8A of printing plates 2A
aligns with
the relief area 12 of printing plates 2B. However, as will be appreciated by
one of skill in
the art, during operation of the decorator 24, the printing plates 2A affixed
to plate
cylinder 26A do not contact the printing plates 2B affixed to plate cylinder
26B. In
another embodiment, the ink receiving region 8A of printing plates 2A aligns
with images
18 formed on the flexible secondary plates 14. Accordingly, during operation
of the
decorator 24, portions of the ink receiving region 8A of printing plates 2A
that contact the
flexible secondary plates 14 will transfer at least some ink to the flexible
secondary plates
14. Optionally, the ink receiving region 8A of printing plates 2A and the
relief area 12 of
printing plates 2B may be larger than the images 18 of the flexible secondary
plates 14 by
a predetermined amount.
[0181] Additionally or alternatively, one or more printing plates 2 can
transfer different
colors of ink and types of specialty ink to the same location of the flexible
secondary
plates 14. Thus, different colors of ink and types of specialty ink may be
transferred from
one or more printing plates 2 to the same location of the flexible secondary
plates 14 in
overlapping layers.
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[0182] The decorator 24 also includes a blanket cylinder 32 to which one or
more
flexible secondary plates 14 are attached. Optionally, in one embodiment, the
position of
the flexible secondary plates 14 on the blanket cylinder 32 may be varied by
up to a
predetermined amount both axially and radially and still align with the ink
receiving
region 8A of printing plate 2A. Additionally or alternatively, the one or more
flexible
secondary plates 14 can be a sleeve or cylinder of a photopolymer material or
a sleeve of a
composition of a saturated chain of polymethylene that wraps around the
circumference of
the blanket cylinder 32.
[0183] The blanket cylinder 32 rotates in a second direction opposite to the
first
direction of the plate cylinders 26. Each flexible secondary plate 14 may have
a different
image 18 formed thereon. For example, the flexible secondary plates 14
illustrated in Fig.
include an image 18B of a sports jersey, an image 18C of a star, an image 18D
of an
"X," and an image 18E of a lightning bolt formed thereon
[0184] The images 18 on the flexible secondary plates 14 can be formed in
locations
corresponding to, or aligning with, the relief areas 12 of the printing plates
2B and the ink
receiving regions 8A of the printing plates 2A. The images 18 of the flexible
secondary
plates 18 may be negatives (formed by relief areas 20 that will not receive
ink) that leave
non-inked areas on the decorated metallic container 34. Alternatively, the
images 18 may
be positives that will receive ink when the images 18 contact one or more ink
receiving
regions 8 of the printing plates 2 that have received ink from an inker 28.
Examples of a
positive image 94 and a negative of the same image 96 transferred to a
metallic container
100 using a flexible secondary plate 90 comprised at least in part of a
composition
including a saturated chain of polymethylene are provided in Figs. 16A - 16C.
[0185] For a flexible secondary plate 14 formed at least partially of a
photopolymer
material, a positive portion of an image is formed by exposed, hardened areas
of the
flexible photopolymer plates 14. The positive portions of an image formed on a
flexible
secondary plate 14 formed at least partially of a composition comprising a
saturated chain
of polymethylene comprise the portions of the face 4 of a flexible secondary
plate 14 that
are not removed during the image forming process or areas adapted to attract
ink. The
images 18 can also include combinations of negative and positive areas. It
will be
understood by those of skill in the art that a positive image will apply ink
to a metallic
container 34 and a negative image means an absence of ink in a printed or
positive part of
an image.
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[0186] The plate cylinders 26 rotate in the first direction and the blanket
cylinder 32
rotates in the second opposite direction in unison to bring the printing
plates 2 into contact
with the flexible secondary plates 14. Ink is transferred to the ink receiving
regions 16 and
images 18 of the flexible secondary plates 14 that contact the inked ink
receiving regions
8, 8A of the printing plates 2. The main image exposure occurs on the inked
printing
plates 2 and a secondary image is produced by the flexible secondary plates
14. The
flexible secondary plates 14 may have ink receiving regions 16 that are common
for all of
the flexible secondary plates 14. The areas where images 18 are formed on the
flexible
secondary plates, such as the images 18A, 18B illustrated in Figs. 4A and 4B,
will create
unique inked areas for each flexible secondary plate 14. The process is
similar to a stamp
ink pad and rubber stamp where only the raised portion of the rubber stamp
collects ink
from the ink pad and transfers the ink to a substrate as an image Relief areas
20, if
present, of the flexible secondary plates 14 will not receive ink from the
printing plates 2.
Only the images 18 and/or the ink receiving regions 16 of the flexible
secondary plates 14
will receive ink from the printing plates 2 and transfer the ink onto the
surface of the
metallic containers 34. By using flexible secondary plates 14 with different
images 18
formed thereon a completely different image 18 will be printed on each
metallic container
34. This results in multiple lithographic images being produced from a single
set of
printing plates 2 on the plate cylinders 26 of the decorator 24. The process
uses high-
definition solid and screened images 18 formed on the flexible secondary
plates 14
resulting in unique ink transfer to metallic containers 34.
[0187] In operation, a metallic container 34 is fed to a support cylinder 38
by a conveyor
36 or other means from a storage location or facility 42. The support cylinder
38 has a
plurality of stations 40 adapted to receive and hold a metallic container 34
in a
predetermined position aligned with the flexible secondary plates 14. The
stations 40 can
hold the metallic containers 34 in a stationary position and can also rotate
the metallic
containers 34 about each container's longitudinal axis. As the blanket
cylinder 32 rotates
in the second direction, the flexible secondary plates 14 rotate into a
predetermined
alignment with respect to the printing plates 2 affixed to the plate cylinders
26. The
flexible secondary plates 14 receive at least some ink by contacting printing
plates 2A, 2B
of each plate cylinder 26A, 26B.
[0188] The blanket cylinder 32 continues to rotate in the second direction and
the
support cylinder 38 rotates in unison in the first direction to bring an
exterior surface 44 of
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the metallic container 34 into rotational contact with an inked flexible
secondary plate 14
attached to the blanket cylinder 32. The ink is then transferred from the
flexible secondary
plate 14 to the exterior surface 44 of the metallic container 34. Although a
support
cylinder 38 is illustrated in Fig. 5, it should be understood that other means
of supporting
the metallic containers 34 and bringing the exterior surface 44 of them into
contact with
the flexible secondary plates 14 may be used, such as a mandrel wheel or a
conveyor belt.
[0189] After the ink is transferred to the metallic container 34, a varnish
unit 48 may
optionally apply an over varnish to the metallic container 34. The over
varnish may
comprise a specialty ink. If necessary, the ink and/or the over varnish may be
cured by a
curing unit 50 by any method known to those of skill in the art. In one
embodiment, the
curing unit 50 may use one or more of thermal energy, ultraviolet energy, and
an electron
beam to cure the ink and/or the over varnish on the metallic container 34.
[0190] Two decorated metallic containers 34A, 34B are also illustrated in Fig.
5. The
decorated metallic containers 34 each include a common image 33 of "Please
Recycle"
which is transferred from the printing plate 2B. Container 34A includes unique
content,
the image 18B of a sports jersey, and container 34B includes a unique image
18C of a star.
In one embodiment, the images 18B, 18C are each formed of a first ink received
from the
ink receiving area 8A of printing plates 2A affixed to the first plate
cylinder 26A. The
common image 33 on each container 34A, 34B is formed of a second ink received
from
the printing plates 2B affixed to the second plate cylinder 26B. It will be
appreciated by
one of skill in the art that at least one of the first ink and the second ink
may comprise a
specialty ink as described herein.
[0191] Decorators 24 used in the commercial metallic container industry
generally have
blanket cylinders 32 with between about 4 to 12 individual flexible secondary
plates 14
attached. When each of the 4 to 12 individual flexible secondary plates 14 has
a unique
image 18 formed thereon, the decorator 24 can produce from 4 to 12 different
lithographic
images without changing the printing plates 2. The present invention will work
with a
blanket cylinder 32 with any number of flexible secondary plates 14 attached
to its
circumference. For example, in one embodiment the blanket cylinder 32 includes
from
about 4 to 24 different flexible secondary plates 14. In addition, although
the flexible
secondary plates 14 are illustrated in Fig. 5 as individual secondary plates,
in some
embodiments the blanket cylinder 32 may have one continuous blanket of a
photopolymer
material or a composition comprising at least in part a saturated chain of
polymethylene
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affixed to its circumference, the continuous blanket having multiple unique
images 18
formed thereon. In another embodiment, one or more flexible secondary plates
14
comprised at least partially of a saturated chain of polymethylene and one or
more flexible
secondary plates 14 comprised at least partially of a photopolymer material
may be
attached to the blanket cylinder 32 at the same time. Each of the flexible
secondary plates
14 may have one or more different images 18 formed thereon. In another
embodiment,
printing plates 2 formed of composition including a saturated chain of
polymethylene or a
soft photopolymer material may be attached to one or more of the plate
cylinders 26. Each
of the printing plates 2 comprised of a saturated chain of polymethylene or
the
photopolymer printing plates 2 may have one or more ink receiving regions 8,
non-ink
regions 10, and relief areas 12 that form an image 33.
[0192] Referring now to Fig. 6A, a photograph of a flexible secondary plate
14F
comprised of a photopolymer material is provided. The flexible secondary plate
14F
includes an image 18 of a sports jersey with the number "92" formed thereon
according to
various embodiments of the present invention. Fig. 6B is an enlarged
photograph of the
image 18 of Fig. 6A. In the embodiment illustrated in Figs 6A and 6B, the
image 18 is not
surrounded by a relief area.
[0193] Referring now to Fig. 7A, a photograph of a generally cylindrical
metallic
container 34F decorated according to various embodiments of the present
invention with
the flexible secondary plate 14F shown in Fig. 6A is provided. Fig. 7B is an
enlarged
portion of the photograph of Fig. 7A. The photographs show a generally
cylindrical
metallic container 34F decorated with an image 18 of a sports jersey which
includes the
number "92" formed in a non-inked portion 46 (or negative) of the decoration.
Other
numbers, shapes, words, or designs could be formed to decorate a substrate
using the
present invention.
[0194] Referring now to Fig. 8, a photograph of another flexible secondary
plate 52 with
two images 54, 55 formed thereon according to various embodiments of the
present
invention is provided. The flexible secondary plate 52 is comprised of a
photopolymer
material. More specifically, the flexible secondary plate 52 includes an image
54 of a face
of a child and an image 56 of a portion of a woman's face. The flexible
secondary plate
52 was photographed after receiving at least two different inks from printing
plates 2. The
inks were subsequently transferred to a metallic container 34. Accordingly,
the ink
receiving region 58 of the flexible secondary plate 52 includes portions 60,
62, 64, and 65
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that include dried ink received from printing plates 2 of a decorator 24. The
first portion
60 includes dried blue ink comprising inverted letters and a blue recycle
symbol. The
second portion 62 includes blue ink comprising inverted letters and numbers
comprising
"16oz". The third portion 64 includes a square filled with blue ink and white
ink of
inverted letters comprising "Ball". The fourth portion 65 includes white ink
of inverted
letters comprising "eat. drink. imagine."
[0195] Referring now to Fig. 9, a photograph of a generally cylindrical
metallic
container 66 decorated according to various embodiments of the present
invention using
the flexible secondary plate 52 of Fig. 8 is shown. More specifically, the
metallic
container 66 includes images 54, 56 of the face of the child and the portion
of the
woman's face transferred from the flexible secondary plate 52. The metallic
container
34G also includes a negative image 68 comprising in part the text "TEST IMAGE
12
FACES." The negative image 68 is formed on the metallic container 66 by
letters
comprising a relief area in a portion of blanket 52. The relief area do not
receive ink from
any printing plates 2. However, the relief area that formed image 66 is not
visible in the
photograph of flexible secondary plate 52 photographed in Fig. 8.
[0196] Figs. 10A, 10B provide enlarged photographs of the first image 54 of
the child's
face and the second image 56 of the portion of the woman's face formed on the
metallic
container 66 shown in Fig. 9. In addition, a portion of the recycle symbol
comprised of
blue ink transferred from the first portion 60 of the ink receiving 58 of
flexible secondary
plate 52 is visible in Fig. 10A.
[0197] Referring now to Fig. 11, another photograph of a flexible secondary
plate 70
comprised of a photopolymer material is provided. The flexible secondary plate
70 is
devoid of a backing or adhesive layer. More specifically, the photograph of
Fig. 11 was
taken from the back through the back portion 6 of the flexible secondary plate
70. This
illustrates that the flexible secondary plates of the present invention may be
formed of a
monolithic material in contrast to prior art printing blankets (illustrated in
Figs. 17A, 17B)
A black sheet 72 was placed under the flexible secondary plate 70 (against the
face portion
of the flexible secondary plate) to provide contrast for the photograph. The
black sheet 72
forms no part of the present invention and is not used with the flexible
secondary plate 70
during the decoration of containers.
[0198] Two images 74, 76 have been formed on the face portion of the flexible
secondary plate 70. The first image 74 is of a dog and the second image 76 is
of a feline.
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The images 74, 76 are reversed in the photograph of Fig. 11 because, as
mentioned above,
the photograph is taken from the back portion 6 of the flexible secondary
plate 70.
[0199] Referring now to Fig. 12, a photograph of a metallic container 78
decorated
using the flexible secondary plate 70 of Fig. 11 is provided. The metallic
container 78
includes images 74, 76 formed by ink received from the images 74, 76 of
flexible
secondary plate 70.
[0200] Referring now to Fig. 13, still another photograph of a flexible
secondary plate
80 comprised of a photopolymer material is provided. A variety of images have
been
formed on a face portion 4 of the flexible secondary plate 80. A backing
material 82 has
been affixed to the back portion of the flexible secondary plate 80 for
contrast. The
backing material 82 is not part of the present invention and is not used with
the flexible
secondary plate 80 during decoration of metallic containers. One image 84 of a
building
and city skyline are formed in three different sizes.
[0201] Referring now to Figs. 14A, 14B, photographs of a metallic container 88
decorated using the flexible secondary plate 80 of Fig. 13 are provided. More
specifically,
the images 84A, 84B, 84C are shown formed on the exterior surface of the
metallic
container by ink received from flexible secondary plate 80.
[0202] Referring now to Figs. 15A, 15B, two different photographs of a
flexible
secondary plate 90 comprised of a composition including at least in part a
saturated chain
of polymethylene are provided. Two images 94, 96 of the same woman have been
formed
on a face portion 4 of the flexible secondary plate 90. Image 94 is a negative
of image 96.
[0203] A depth scale 98 has also been formed in the face portion 4 of the
flexible
secondary plate 90. The depth scale 98 shows a relative depth of rubber
material that has
been removed from the face portion 4. The amount of rubber material removed
from the
face portion 4 increases from very little material removed proximate to
portion 98A of
depth scale 98 to a large amount of material removed proximate to portion 98B
of depth
scale 98. Accordingly, portion 98A (which is difficult to distinguish in the
photographs of
Figs. 15A, 15B) is about parallel to a plane formed by the face portion 4 and
will receive
and transfer a larger amount of ink than portion 98B of depth scale 98.
[0204] Referring now to Figs. 16A - 16C photographs of a metallic container
100
decorated using the flexible secondary plate 90 of Fig. 15 are provided. The
metallic
container 100 includes a base coat 102 of white ink which is most visible on
the portion of
the metallic container 100 shown in Fig. 16C associated with depth scale
portion 98B.
54
85362-76
Said another way, the white ink of the base coat 102 is most visible on
portions of the metallic
container 100 that received little or no ink from the flexible secondary plate
90. The metallic
container 100 has been decorated by black ink received from ink receiving
regions 16 and images
94, 96 of the flexible secondary plate 90 that contacted the exterior surface
of the metallic
container 100.
[0205] Referring now to Figs. 17A and 17B, photographs of a prior art printing
blanket 106
comprised of known materials are shown. Fig. 17A is a top plan view of the
printing blanket 106.
Images, including an image 108 of a woman, have been formed in the face
portion of the printing
blanket 106. As shown in Fig. 17B, which is an angled side elevation view of
the printing blanket
106, printing blanket 106 is comprised of several layers of different
materials in contrast to the
flexible secondary plates of the current invention, shown, for example, in the
cross-sectional side
elevation view of Fig. 4C. Some prior art printing blankets are formed of four
or more layers.
[0206] The printing blanket 106 generally comprises a face portion 110, a
first fabric layer 112, a
compressible layer 114, and a second fabric layer 116. A paper backing 118
covering an adhesive
material is also shown pulled away from the second fabric layer 116 for
clarity. A schematic side
elevation view of the layers 110, 112, 114, and 116 of the printing blanket
106 is provided in Fig.
17C.
[0207] The face portion 110 comprises a relatively thin rubber material that
is different than the
material of the flexible secondary plates comprising a saturated chain of
polymethlene of the
present invention. In one prior art printing blanket 106, the face portion 110
comprises Nitrile
butadiene rubber (NBR). As will be appreciated by one of skill in the art, NBR
is a family of
unsaturated copolymers of 2-propenenitrile and various butadiene monomers (1,2-
butadiene and
1,3 -butadiene). NBR is also known as Buna-N, Perbunan
acrylonitrile butadiene rubber, Nipol
0, Krynac and Europrene t.
[0208] More significantly, the material of the face portion 110 melts
relatively easily and does not
enable the formation of fine dot images requires to produce a high-definition
lithographic image on
a metallic container. In addition, compared to the homogeneous of the flexible
secondary plates 14,
52, 70, 80, and 90 of the present invention, the prior art printing blanket
106 of Fig. 17 is
comprised of several different materials arranged in discrete layers 110 -
116. As the face portion
110 is relatively thin, the depth of an image that may be formed in the
printing blanket 106 is
CA 2981189 2018-12-12
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limited compared to the homogeneous flexible secondary plates of the present
invention. Said
another way, the comparative thinness of the face portion 110 limits the depth
of material that may
be removed from the printing blanket 106 to form images.
[0209] The layers of a prior art printing blanket are described in a document
entitled "Blanket for
Offset Printing," (hereinafter "Offset Printing"). According to Offset
Printing, "The offset blanket
surface structure, profile, and hardness are extremely important and
contribute significantly to the
printing performance of an offset blanket. . . . It is not an easy task to
develop a suitable rubber
compound for the printing surface of an offset blanket utilized for high
quality offset printing. The
difficulty is due to the conflicting chemical and mechanical requirements
which can be found
during the printing operation."
[0210] Referring now to Fig. 18, photographs of a metallic container 120
decorated using the
printing blanket 106 of Fig. 17 are provided. The image 108 in Fig. 18B
includes notable dots and
less detail compared to the high resolution and detail of images 54, 56 of
Fig. 10 and images 94, 96
of Fig. 16 produced used flexible secondary plates of the present invention.
[0211] Photographs of another metallic container 122 decorated with a prior
art printing blanket are
provided in Fig. 19. Images 124 formed on the container 122 also do not have
the amount of detail
and clarity of images produced using flexible secondary plates of the present
invention.
[0212] The description of the present invention has been presented for
purposes of illustration and
description, but is not intended to be exhaustive or limiting of the invention
to the form disclosed.
Many modifications and variations will be apparent to those of ordinary skill
in the art. The
embodiments described and shown in the figures were chosen and described in
order to best
explain the principles of the invention, the practical application, and to
enable those of ordinary
skill in the art to understand the invention.
[0213] While various embodiments of the present invention have been described
in detail, it is
apparent that modifications and alterations of those embodiments will occur to
those skilled in the
art. However, it is to be expressly understood that such modifications and
alterations are within the
scope and spirit of the present invention, as set forth in the following
claims. Further, the
invention(s) described herein is capable of other
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embodiments and of being practiced or of being carried out in various ways. In
addition, it
is to be understood that the phraseology and terminology used herein is for
the purpose of
description and should not be regarded as limiting. The use of "including,"
"comprising,"
or "having" and variations thereof herein is meant to encompass the items
listed thereafter
and equivalents thereof as well as additional items.
57
