Printable film layer with carrier layer and method of use

Described herein is a printing template for use during an aqueous inkjet printing process in which ink is transferred onto a printable layer. The printing template includes a printable layer having a first side, a second side opposite the first side, and a shaped perimeter, the first side defining a printable surface. The printing template further includes a carrier layer sized and configured to entirely encompass the shaped perimeter of the printable layer. The carrier layer includes a first side and a second side opposite the first side. The first side includes an adhesive coating causing the first side of the carrier layer securely associated with the second side of the printable layer during the printing process, and is thereafter allowing removal of the carrier layer from the printable layer after completion of the printing process. Further, a predefined number of parts in a desired shape are die cut through the printable layer up until the carrier layer.

TECHNICAL FIELD

The present disclosure relates generally to the field of printing, and more specifically to printing photographs on a printable film layer which is removably associated with a carrier layer.

BACKGROUND

Printing photos on a printing template is not a new technique of creating attractive photographs. The prior art provides several methods of ways of printing on the printing template using latex or UV printers/inks. The prior art also discloses the use of sublimation inks, which are used to initially print on a transfer material, then using a heat press, sublimate or transfer the image from the transfer material onto a piece of printing template that has been coated to receive these sublimation/heat transfer inks. There is also prior art on creating the printing templates for printing on them, where the printing template has to be covered with some sort of clear plastic coating to seal in the ink.

While these methods are effective in transferring an image onto a printing template, many aqueous inkjet printers “read” the edges of the printing template and print up to the edge—rather than over the edge—leaving an undesired “margin” around the edge of the printing template. These printers do not offer the “edge to edge” printing capabilities that result in top quality, attractive finished products. This is particularly true when printing on rigid substrates, but even when printing on non-rigid substrates, these printers do not produce truly “edge to edge” finished products. The requirement that the picture be covered with a plastic sheet to seal in the ink is also cumbersome and requires a person to make sure there are no bubbles under the plastic covering. Thus, there is a long-felt need for a product that can produce a borderless picture without the need for additional covering, and a method by which it can be made. This class of printer is often found at retail locations that will print pictures for the customer on demand.

SUMMARY

The current disclosure provides a solution to this problem by describing a combination of a printable coating on a printable layer and a carrier layer that are connected to each other such that an inkjet printer prints beyond the edge of the printable layer, rather than up to the edge of the printable layer as is the current state-of-the-art. Another key inventive step to this invention is the ability to print directly onto a printable layer without the need to place any layer of material over the finished product. The carrier layer also has a square or rectangular shape that has been pre-cut into the carrier layer so that it can be easily removed, for example, from the printable layer after the printing is completed.

The printing template and related method described herein achieves the stated goals by basically tricking certain aqueous inkjet printers to think that the desired “edge” of the print (e.g. photograph) to be transferred to the printable surface of the printable layer is outside the perimeter of the printable surface receiving the print, so that there is no “margin” or “border” left between the edge of the print and the edge of a printable surface after the printing is completed. The printable surface of the printable layer in the current invention has a special “coating” that accepts the aqueous inks that are common in these printers, as described above, so there is no need to add any plastic sealer or covering after the print leaves the printer. The printable layer is not printed on as a single unit, but rather comes on a “carrier layer” that is having same dimensions as that of the printing layer. The printable layer also utilizes a printable coating so that the ink does not run. By way of example, this printable coating may be a film such as PET, BOPP, Polypropylene, or Polycarbonate that has been coated with a microporous aqueous inkjet-adhering layer. The coating technique can be accomplished with slot die, curtain, gravure, or Mayer rod techniques (for example).

As previously mentioned, the aqueous inkjet printers will not print edge to edge on the printable surface of the printable layer to receive the print, a carrier layer is used in the printing process. The carrier layer is equal to the printable layer; however, a printable surface defined on the printable layer is smaller than the printable layer and thus allows the printer to print completely across all the edges of the printable surface to create a borderless photograph on the printable surface of the printable layer. For example, if one were to print on an 11″×14″ printable surface using the prior art methods, a resulting picture would have a border of unprinted metal showing the deficiencies of that method. However, by associating the 11″×14″ printable surface with a 16″×20″ printable layer, the printer can print the 11″×14″ printable surface without a border. To “trick” the printer into printing beyond the edges of the 11″×14″ printable surface, the printable surface is defined within shaped parameters of the printable layer. This “tricks” printer sensors that detect the end of the printable layer for example by detecting a change in surface reflectivity as the printer encounters the edge of the printable layer.

Thus, the problem of how to create borderless metal prints is solved by providing a printable layer upon which the printable surface is defined. The carrier layer has an adhesive coating that holds the printable layer on top of the carrier layer during transport and printing processes.

It is a principal object of the disclosure to provide a means by which a printable layer can have a picture printed on its printable surface by a standard industry inkjet printer using standard industry ink, without a border or margin.

A further object of the disclosure is to provide a number of different products by die cutting a predefined number of parts in a desired shape through the printable layer until the carrier layer.

A further object of the disclosure is to provide the printable layer with a core layer having bottom side removably associated with the carrier layer. By changing the die cut shape, the thickness of the core layer, the shape of the printable surface, a printed product can be used to make disposable bar coasters, puzzles, board prints where the image is printed to the edge of the board, playing cards, sports trading cards, greeting cards, and so forth.

Another object of the disclosure is to provide a silicon release liner attached to the bottom side of the printable layer to prevent the carrier layer from bonding permanently or at least too securely to the bottom of the predefined number of parts.

It is another object of the disclosure to provide at least two portions on the printable surface of the printable film. Each of the at least two portions includes a predefined number of parts which are die cut in same or different shapes and sizes.

There has thus been outlined, rather broadly, the more important features of the metal photographic plate and carrier in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present disclosure will become better understood with reference to the following description and appended claims.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIGS. 1-5illustrate a first example of a printing template10for use in aqueous inkjet printing onto a metal substrate, according to one embodiment of the disclosure. By way of example only, the printing template10of the instant embodiment includes a printable metal plate12, a carrier14, and a hanging element16. The printable metal plate12has front face18, a back face20, and a perimeter22. In the example shown inFIGS. 1-5, the printable metal plate12has a generally rectangular shape having four opposing edges24, however it should be understood that the metal plate12may have any shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure. Preferably, the metal plate12is made of aluminum, however other any other suitable metal may be used.

The front face18is completely covered by a printable film layer26, and defines the printable surface of the metal plate12. The printable film layer26may be any material that is capable of accepting aqueous inkjet ink, including but not limited to (and by way of example only) polyester, polyethylene, Mylar, vinyl, PVC, PET, BOTT, polypropylene, polycorbonate, and acrylics. The key to the selection of the film is that it can accept and retain the aqueous ink from an inkjet printer. According to a preferred embodiment, an inkjet ink-retaining microporous coating may be applied on top of the printable film layer26to enhance the ink retention properties of the printable film layer26. The coating technique can be accomplished (by way of example) with slot die, curtain, gravure or Mayer rod techniques. It should be noted, however, that the key characteristics of the printable film layer26include, but are not limited to, ink adhesion and retention properties, cost, and optical clarity. With the use of this specialized printable film26, there is no need for any “final” covering sheet or other process to seal in the ink after the metal print leaves the printer.

The carrier14has front face28, a back face30, and a perimeter32. The carrier14is sized and configured such that carrier14is larger than the metal plate12, and more specifically such that the entire perimeter32of the carrier14is outside of the entire perimeter22of the metal plate12when the metal plate12is associated with the carrier14. The respective perimeter shapes of the metal plate12and carrier14do not have to match. In the example shown inFIGS. 1-5, the carrier14has a generally rectangular shape having four opposing edges34. Although the generally rectangular shape is preferable since the carrier14interacts with the printer and therefore consistency of size and shape is advantageous, nevertheless it should be understood that the carrier14may have any perimeter shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure, so long as the entire perimeter32of the carrier is14is outside of the entire perimeter22of the metal plate12. That is because a portion of the front face28(e.g. the portion of the front face28that is immediately adjacent the perimeter22of the metal plate12) represents a “print zone”36that receives ink from the ink dispensing element of the printer when the ink dispensing element traverses beyond the perimeter22of the metal plate12during the printing process.

The front face28of the carrier14has an external coat that mimics the printable film layer26of the metal plate12such that the printer prints over the edges24of the metal plate12onto the carrier14. This results in the metal plate12having printing37over its entire front face18, and then leaving a narrow strip of overlap printing38in the print zone36of the carrier14that surrounds the edges24of the metal plate12, while leaving an unprinted section40of the carrier14that was not printed upon, as shown inFIGS. 4-5.

The carrier14further includes at least one metal plate engaging element42configured to engage the metal plate12and maintain the association of the metal plate12and carrier14through the printing process. By way of example, the plate engaging element42of the instant embodiment comprises adhesive strips that secure the metal plate12to the front surface28of the carrier14during the printing process, as shown inFIGS. 1 and 3. The adhesive strips42allow for removal of the metal plate12from the carrier14by exerting sufficient force on the metal plate12to overpower the adhesive strip.

The back face30of the carrier14includes at least one perforated section that is removable to create a cutout opening44through which the hanging element16may be attached to the back face20of the metal plate12prior to disassociating the metal plate12and carrier14. By way of example, the cutout opening44is shown as having a generally rectangular (or square) shape, however any shape is possible that allows passage of the hanging element16therethrough. The back face20of the metal plate12includes a leveling indicia46that serves as an alignment guide for placing the hanging element16on the back of the metal plate12as the hanging element16is inserted into the cutout opening44of the carrier14.

The hanging element16of the present disclosure may be any attachable element or object that enables a user to hang the metal plate12on a wall. By way of example only, the hanging element16shown inFIG. 2is a generally rectangular (or square) piece of material (e.g. metal) having a front side48and a back side50. The back side50includes an adhesive layer (not shown) that enables the hanging element16to be attached to the back face20of the metal plate12through the cutout opening44in the carrier14. The hanging element16further includes a through-hole52(for example) sized and configured to receive at least a portion of a wall-mounted hanging element (not shown) so that the printed metal plate12may be displayed on a wall (see e.g.FIG. 18).

FIGS. 6-11illustrate a second example of a printing template110for use in aqueous inkjet printing onto a metal substrate, according to one embodiment of the disclosure. By way of example only, the printing template110of the instant embodiment includes a printable metal plate112, a carrier114, and a hanging element (not shown). The printable metal plate112has front face118, a back face120, and a perimeter122. In the example shown inFIGS. 6-11, the printable metal plate112has a generally rectangular shape having four opposing edges124, however it should be understood that the metal plate112may have any shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure. Preferably, the metal plate112is made of aluminum, however other any other suitable metal may be used.

The front face118is completely covered by a printable film layer126, and defines the printable surface of the metal plate112. The printable film layer126may be any material that is capable of accepting aqueous inkjet ink, including but not limited to (and by way of example only) polyester, polyethylene, Mylar, vinyl, PVC, PET, BOTT, polypropylene, polycorbonate, and acrylics. The key to the selection of the film is that it can accept and retain the aqueous ink from an inkjet printer. According to a preferred embodiment, an inkjet ink-retaining microporous coating may be applied on top of the printable film layer126to enhance the ink retention properties of the printable film layer126. The coating technique can be accomplished (by way of example) with slot die, curtain, gravure or Mayer rod techniques. It should be noted, however, that the key characteristics of the printable film layer126include, but are not limited to, ink adhesion and retention properties, cost, and optical clarity. With the use of this specialized printable film126, there is no need for any “final” covering sheet or other process to seal in the ink after the metal print leaves the printer.

The carrier114has front face128, a back face130, and a perimeter132. The carrier114is sized and configured such that carrier114is larger than the metal plate112, and more specifically such that the entire perimeter132of the carrier114is outside of the entire perimeter122of the metal plate112when the metal plate112is associated with the carrier114. The respective perimeter shapes of the metal plate112and carrier114do not have to match. In the example shown inFIGS. 6-11, the carrier114has a generally rectangular shape having four opposing edges134. Although the generally rectangular shape is preferable since the carrier114interacts with the printer and therefore consistency of size and shape is advantageous, nevertheless it should be understood that the carrier114may have any perimeter shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure, so long as the entire perimeter132of the carrier is114is outside of the entire perimeter122of the metal plate112. That is because a portion of the front face128(e.g. the portion of the front face128that is immediately adjacent the perimeter122of the metal plate112) represents a “print zone”136that receives ink from the ink dispensing element of the printer when the ink dispensing element traverses beyond the perimeter122of the metal plate112during the printing process.

The front face128of the carrier114has an external coat that mimics the printable film layer126of the metal plate112such that the printer prints over the edges124of the metal plate112onto the carrier114. This results in the metal plate112having printing137over its entire front face118, and then leaving a narrow strip of overlap printing138in the print zone136of the carrier114that surrounds the edges124of the metal plate112, while leaving an unprinted section140of the carrier114that was not printed upon, as shown inFIGS. 10-11.

The carrier114further includes at least one metal plate engaging element142configured to engage the metal plate112and maintain the association of the metal plate112and carrier114through the printing process. By way of example, the plate engaging element142of the instant embodiment comprises adhesive strips142that secure the metal plate112within a cutout opening144formed through the carrier114during the printing process, as shown inFIGS. 6 and 9. The adhesive strips142allow for removal of the metal plate112from the carrier114by exerting sufficient force on the metal plate112to overpower the adhesive strip. As shown inFIGS. 7-8, preferably the adhesive strips142are positioned such that a first portion of each adhesive strip is attached to the back face130of the carrier114, and a second portion of each adhesive strip extends into the cutout opening144to enable engagement with the metal plate112.

The cutout opening144is sized and configured to receive the entire perimeter122of the metal plate112thereby creating a recessed association between the metal plate112and carrier114. By way of example, the cutout opening144is shown as having a generally rectangular (or square) perimeter shape, however any shape is possible that receives and securely engages the metal plate112during printing. In order to be able to receive the metal plate112therein, the perimeter of the cutout opening144must be larger than the perimeter122of the metal plate112. Preferably, the distance between any part of the perimeter122of the metal plate112and the perimeter edge of the cutout opening144is within the range of 0.005-0.015″. Gaps larger than 0.015″ may cause the printer to detect the edge of the metal plate112and stop printing. Gaps smaller than 0.005″ may cause the metal plate112to not fit within the cutout opening144, especially in warm and/or humid climates.

The recessed association between the metal plate112and carrier114is advantageous in that it decreases the overall thickness of the plate/carrier combination, which in turn reduces the risk of metal plate112making contact with any of the internal components of the printer. Since most of the commercially available wide format aqueous inkjet printers that are compatible with the printing template110disclosed herein have a maximum allowable material thickness of approximately1.5mm, a recessed association between the plate112and carrier114enables a decrease in overall thickness of the printing template110and/or and increase in the thickness of the metal plate112to be printed on.

The hanging element (not shown) of the present embodiment is identical to the hanging element16described above, and may be attached to the back face120of the metal plate112through the cutout opening144.

FIGS. 12-17illustrate a third example of a printing template210for use in aqueous inkjet printing onto a metal substrate, according to one embodiment of the disclosure. By way of example only, the printing template210of the instant embodiment includes a printable metal plate212, a carrier214, and a hanging element (not shown). The printable metal plate212has front face218, a back face220, and a perimeter222. In the example shown inFIGS. 12-17, the printable metal plate212has a generally rectangular shape having four opposing edges224, however it should be understood that the metal plate212may have any shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure. Preferably, the metal plate212is made of aluminum, however other any other suitable metal may be used.

The front face218is completely covered by a printable film layer226, and defines the printable surface of the metal plate212. The printable film layer226may be any material that is capable of accepting aqueous inkjet ink, including but not limited to (and by way of example only) polyester, polyethylene, Mylar, vinyl, PVC, PET, BOTT, polypropylene, polycorbonate, and acrylics. The key to the selection of the film is that it can accept and retain the aqueous ink from an inkjet printer. According to a preferred embodiment, an inkjet ink-retaining microporous coating may be applied on top of the printable film layer226to enhance the ink retention properties of the printable film layer226. The coating technique can be accomplished (by way of example) with slot die, curtain, gravure or Mayer rod techniques. It should be noted, however, that the key characteristics of the printable film layer226include, but are not limited to, ink adhesion and retention properties, cost, and optical clarity. With the use of this specialized printable film226, there is no need for any “final” covering sheet or other process to seal in the ink after the metal print leaves the printer.

The carrier214comprises a plate-holding portion215and a plate-protecting element217. By way of example, the plate-holding portion215is similar to the carrier114described above, and has front face228, a back face230, and a perimeter232. The carrier214is sized and configured such that plate-holding portion215is larger than the metal plate212, and more specifically such that the entire perimeter232of the plate-holding portion215is outside of the entire perimeter222of the metal plate212when the metal plate212is associated with the carrier214. The respective perimeter shapes of the metal plate212and plate-holding portion215do not have to match. In the example shown inFIGS. 12-17, the plate-holding portion215has a generally rectangular shape having four opposing edges234. Although the generally rectangular shape is preferable since the carrier214interacts with the printer and therefore consistency of size and shape is advantageous, nevertheless it should be understood that the plate-holding portion215may have any perimeter shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure, so long as the entire perimeter232of the plate-holding portion215is outside of the entire perimeter222of the metal plate212. That is because a portion of the front face228(e.g. the portion of the front face228that is immediately adjacent the perimeter222of the metal plate212) represents a “print zone”236that receives ink from the ink dispensing element of the printer when the ink dispensing element traverses beyond the perimeter222of the metal plate112during the printing process (see e.g.FIG. 16).

The front face228of the plate-holding portion215has an external coat that mimics the printable film layer226of the metal plate212such that the printer prints over the edges224of the metal plate212onto the carrier214. This results in the metal plate212having printing237over its entire front face218, and then leaving a narrow strip of overlap printing238in the print zone236of the plate-holding portion215that surrounds the edges224of the metal plate212, while leaving an unprinted section240of the carrier214that was not printed upon, as shown inFIGS. 16-17.

The plate-holding portion215of the carrier214further includes at least one metal plate engaging element242configured to engage the metal plate212and maintain the association of the metal plate212and carrier214through the printing process. By way of example, the plate engaging element242of the instant embodiment comprises adhesive strips242that secure the metal plate212within a cutout opening244formed through the plate-holding portion215during the printing process, as shown inFIGS. 12-15. The adhesive strips242allow for removal of the metal plate212from the carrier214by exerting sufficient force on the metal plate212to overpower the adhesive strips. As shown inFIGS. 13-14, preferably the adhesive strips242are positioned such that a first portion of each adhesive strip is attached to the back face230of the plate-holding portion215, and a second portion of each adhesive strip extends into the cutout opening244to enable engagement with the metal plate212.

The cutout opening244is sized and configured to receive the entire perimeter222of the metal plate212thereby creating a recessed association between the metal plate212and carrier214. By way of example, the cutout opening244is shown as having a generally rectangular (or square) perimeter shape, however any shape is possible that receives and securely engages the metal plate212during printing. In order to be able to receive the metal plate212therein, the perimeter of the cutout opening244must be larger than the perimeter222of the metal plate212. Preferably, the distance between any part of the perimeter222of the metal plate212and the perimeter edge of the cutout opening244is within the range of 0.005-0.015″. Gaps larger than 0.015″ may cause the printer to detect the edge of the metal plate212and stop printing. Gaps smaller than 0.005″ may cause the metal plate212to not fit within the cutout opening244, especially in warm and/or humid climates.

The recessed association between the metal plate212and carrier214is advantageous in that it decreases the overall thickness of the plate/carrier combination, which in turn reduces the risk of metal plate212making contact with any of the internal components of the printer. Since most of the commercially available wide format aqueous inkjet printers that are compatible with the printing template210disclosed herein have a maximum allowable material thickness of approximately 1.5 mm, a recessed association between the plate212and carrier214enables a decrease in overall thickness of the printing template210and/or and increase in the thickness of the metal plate212to be printed on.

The plate-protecting portion217may be any feature or element that protects the printable surface218(including the printable film226) of the metal plate212before and/or after the printing process has been completed. By way of example only, the plate-protecting portion217of the present embodiment comprises a foldable flange217extending from one edge234of the plate-holding portion215. The flange217includes a front face219, a back face225, and a perimeter edge221. Because the flange217does not receive any ink during the printing process, the front face219doest not need to be coated with the same external coat (mimicking the printable film layer226) used on the plate-holding portion215. The perimeter edge221is sized and configured such that the plate-protecting portion217is large enough to cover the metal plate212within the cutout opening244, and preferably is the same size and shape as the perimeter232of the plate-holding portion215. The plate-protecting portion217is joined to the plate-holding portion at an interface223, that allows the plate-protecting portion217to fold (or pivot) over the plate-holding portion215such that the front face219of the plate-protecting portion217contacts the front face218of the plate-holding portion215. By way of example, the interface223may be any feature or element that enables this folding, including but not limited to a hinge, groove, adhesive, etc.). In any event, the plate-protecting portion217is in an “open” or “unfolded” configuration during the printing process, in which the plate-protecting portion217is located to the side of and is generally coplanar with the plate-holding portion215to enable seamless passage of the carrier214through the printer.

The hanging element (not shown) of the present embodiment is identical to the hanging element16described above, and may be attached to the back face220of the metal plate212through the cutout opening244.

FIG. 18illustrates an example of a finished picture60on a wall62. Because the printing has been done such that the printer head prints over the edges of the metal plate12/112/212, the resulting picture60is borderless.

FIG. 19is a schematic drawing showing an example process70by which the metal plates12/112/212are prepared according to one embodiment of the disclosure. By way of example, the process70begins with a sheet of metal72(e.g. aluminum) that is unrolled from a coil73and directed to a nip point74that crimps a layer of printable film76(e.g. the printable film layer26/126/226described above) to one surface of the metal sheet72. The printable film layer76originates from a liner roll78, and has a printable side80and an adhesive side82, which is initially covered with an adhesive cover84. Prior to crimping with the metal sheet72, the adhesive cover84is removed from the adhesive side82and taken in by a release liner uptake coil86. With the adhesive cover84removed, the adhesive side82is brought into contact with the metal sheet72at the nip point74(e.g. between a pair of nip rollers88) so that the printable film layer76can adhere to the metal sheet72. After the printable film layer76and metal sheet72are adhered to one another at the nip point74, the metal sheet72passes through a metal flattening machine90(e.g. comprising a plurality of roller elements that apply compressive force to the metal sheet72with printable film layer76to ensure adhesion and also remove potential air bubbles caught between the printable film layer76and metal sheet72. Finally, the individual metal plates12/112/212may be stamped out of the metal sheet72in a stamping press92. Once this occurs, the metal plates12/112/212are ready to use with the carriers14/114/214as described above. With the use of this specialized printable film76, there is no need for any “final” covering sheet or other process to seal in the ink after the metal plates go through printing process.

FIGS. 20-22illustrate a fourth example of a printing template410for use in aqueous inkjet printing onto a printing substrate, according to one embodiment of the disclosure. By way of example only, as shown inFIG. 20, the printing template410of the instant embodiment includes a printable layer412, a core layer414, a silicon release liner416, and a carrier layer416.

In the example shown inFIGS. 20-22, the printable layer412has a generally rectangular shape having four opposing edges, however it should be understood that the printable layer412may have any shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure.

The front face of the printable layer412defines the printable surface. The printable layer412may be any material that is capable of accepting aqueous inkjet ink, including but not limited to (and by way of example only) polyester, polyethylene, Mylar, vinyl, PVC, PET, BOTT, polypropylene, polycorbonate, and acrylics. The key to the selection of the printable layer is that it can accept and retain the aqueous ink from an inkjet printer. According to a preferred embodiment, an inkjet ink-retaining microporous coating may be applied on top of the printable layer412to enhance the ink retention properties of the printable layer412. The coating technique can be accomplished (by way of example) with slot die, curtain, gravure or Mayer rod techniques. It should be noted, however, that the key characteristics of the printable layer412include, but are not limited to, ink adhesion and retention properties, cost, and optical clarity. With the use of this specialized printable layer412, there is no need for any “final” covering sheet or other process to seal in the ink after the metal print leaves the printer.

The core layer414is having a bottom side removably associated with a top layer of the carrier layer418. Also, in an example, the core layer414has a predetermined thickness and is thicker than other layers of the printing template410. In other words, the core layer414is provided between the printable layer412and the carrier layer418to just add thickness where necessary (like in case of puzzle manufacturing).

The carrier layer418is sized and configured to entirely encompass the shaped perimeter of the printable layer412. By way of example, the carrier layer418has a front face and a back face opposite to the front face. The front face of the carrier layer418is coated with an adhesive coating causing the front face of the carrier layer418securely associated with the back face of the printable layer412or the core layer414, during the printing process. After the completion of the printing process, the adhesive coating allows easy removal of the carrier layer418from the printable layer412or the core layer418.

In an example, a silicon release liner416is attached to the bottom side (back face) of the printable layer412or the core layer418to prevent the carrier layer418from bonding permanently or at least too securely to the bottom of the predefined number of parts die cut in the printable layer412or the core layer418. Further, those skilled in the art can appreciate that this layer (silicon release liner416) is potentially not necessary with very specialized adhesives (which are easily removable).

Although the generally rectangular shape is preferable for the printing template410since the carrier layer418interacts with the printer and therefore consistency of size and shape is advantageous, nevertheless it should be understood that the carrier layer418or the printing template410may have any perimeter shape (e.g. circular, oval, triangular, etc.) without departing from the scope of the disclosure, so long as the entire perimeter of the carrier layer418is outside of the entire perimeter of the printable layer412.

Further, as can be seen fromFIG. 20, a shape is die cut420through the printable layer412, the core layer414, the silicon release liner416, except the carrier layer. Although the shape of the die cut420is shown rectangular, other shapes can also be adapted without deviating from the scope of the present disclosure. In examples shown inFIGS. 22A-22C, a predefined number of parts in a desired shape are die cut through the printable layer412until the carrier layer418. In the examples shown inFIGS. 22A-22c, the predefined number of parts are categorized in at least two portions420and422, where first portion420includes a number of parts die cut in same shape and size, while second portion422includes only one-part die cut in the printable layer412. Although a number of parts die cut in same shape and size in the first portion, the number of parts can be die cut in different shape and size without deviating from the scope of the present matter. For instance, the first portion420of example shown inFIG. 22Ahas 48 parts die cut in same shape. The first portion420of example shown inFIG. 22Ahas 110 parts die cut in same shape. The first portion420of example shown inFIG. 22Ahas 252 parts die cut in same shape. Such examples are used to create a puzzle of a photograph printed on the first portion420.

Accordingly, the first portion420and the second portion422defines areas in which the printer fills the printed image. In case of puzzle manufacturing as shown with example inFIGS. 22A and 22B, the first portion420is utilized to printing an image to create puzzle die cuts, while the second portion422is used for printing a reference image to solve the puzzle. Also, the reference image may be pasted or mounted on a cover424of a box426, which is used to store the puzzle die cuts formed from the first portion420.

As mentioned above, by changing the die cut shape, the thickness of the core layer414, the shape of the printable surface, a printed product can be used to make disposable bar coasters, puzzles, board prints where the image is printed to the edge of the board, playing cards, sports trading cards, greeting cards, and so forth,

It should be understood that while preferred embodiments are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof.