Abstract:
Methods and Apparatus for Image Transfer to Multiple Articles Having Non-planar Surfaces are disclosed. Also disclosed is an apparatus that utilizes a modified microprocessor-based printer. The apparatus has end portions and at least one intermediate portion for holding two or more three-dimensional articles for printing images thereon. The apparatus further includes holding cups for securely gripping the ends of the three-dimensional articles while the images are being transferred thereto. The apparatus is further adjustable in order to accommodate articles having differing lengths.

Description:
This application is a continuation-in-part of application Ser. No. 09/877,828, filed Jun. 8, 2001 now U.S. Pat. No. 6,746,093, and the disclosure of that application is incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates generally to printing on non-planar surfaces and, more specifically, to Methods and Apparatus for Image Transfer to Multiple Articles Having Non-planar Surfaces. 
   2. Description of Related Art 
   Various types of image transfer techniques have been suggested in the past for imprinting images on a number of different material surfaces including cloth, wood, metal and ceramics. A very common technique, which has been widely used, is silk screening. The problem with silk screening is that it is generally limited to printing on smooth, flat surfaces. Furthermore, even on flat surfaces, the silk screening process produces a relatively low quality print when compared to that produced by lithography, gravure, letterpress sublimation and laser printing. 
   For imaging on metal surfaces, sublimation techniques are often used. An example of the prior sublimation processes can be found in Blake, U.S. Pat. No. 3,484,342 issued Dec. 16, 1969 and Fromson et al, U.S. Pat. No. 4,201,821 issued May 6, 1980; both Blake and Fromson suggest decorating unsealed and uncoated anodized aluminum using sublimation techniques. Sublimation processes, like screen printing, also suffer from being limited to flat, smooth surfaces. Transferring an image or graphic to a sphere or curved, cylindrically tapered surface by sublimation is extremely difficult, and such an approach, if achievable at all, would typically result in a poor quality, highly distorted image. 
   When printing on non-planar surfaces has been required, several techniques have been suggested. An example process is that disclosed by Stirbis et al, U.S. Pat. No. 4,941,266; the Stirbis apparatus (for decorating a cylindrical can) makes use of a multiple station ink supply and transfer apparatus for transferring ink from an in fountain to a rotatable inking blanket wheel through a plate cylinder. The Stirbis apparatus further includes an ink image registration adjustment apparatus and an axial and circumferential tightness control apparatus operatively associated with each plate cylinder and each ink supply and transfer apparatus. There have been additional prior techniques suggested for imprinting images on non-planar surfaces (including electro photographic imaging and magnetic imaging), but these techniques have met with limited commercial success. 
   Another prior system, Carlson, U.S. Pat. No. 5,831,641 discloses a method and apparatus for imprinting images on non-planar surfaces, including the surfaces of various types of three-dimensional articles, such as baseball bats. The Carlson apparatus includes a modified ink jet plotter coupled with an article positioning apparatus which functions to automatically maintain the surface of the article to be printed within a plane substantially parallel to and slightly spaced apart from the place within which the ink jet nozzles of the ink jet plotter reside. 
   Another prior art technique, which is frequently used to decorate surfaces, such as those from anodized aluminum, involves the use of transfer films. These films typically overlay the metal surface and undesirably, are subject to film deterioration and unattractive abrasion. A very popular prior art printing technique, which has found wide acceptance in recent years, is ink jet printing. Within the past several years, this technology has become the dominant technology for printing color images and graphics in the office and home markets. Ink jet printing basically involves a process whereby ink particles are projected in a continuous stream toward the surface to be imprinted using appropriate computer control to create text and graphics on the printing substrate. A number of different types of ink jet printers/plotters are readily commercially available from sources such as Calcomp, Packard Bell, NEC Technologies and Mutoh America, Inc. 
   As will be better understood from the discussion which follows, the method and apparatus of the present invention overcomes most of the problems encountered in prior art attempts to print high quality, detailed images on non-planar surfaces by employing a uniquely modified prior art ink jet image transfer technique. 
   SUMMARY OF THE INVENTION 
   In light of the aforementioned problems associated with the prior devices and methods, it is an object of the present invention to provide Methods and Apparatus for Image Transfer to Multiple Articles Having Non-planar Surfaces. The apparatus should utilize a modified microprocessor-based printer. The apparatus should have end portions and at least one intermediate portion for holding two or more three-dimensional articles for printing images thereon. The apparatus should further include holding cups for securely gripping the ends of the three-dimensional articles while the images are being transferred thereto. The apparatus should be adjustable to accommodate articles having differing lengths. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which: 
       FIG. 1  is front view of a conventional ink jet printer that has been modified to permit the printing on a pair of three-dimensional articles using a preferred embodiment of the present invention; 
       FIG. 2  is a top perspective view of the area of the first end portion of the device of  FIG. 1 ; 
       FIG. 3  is a top perspective view of the area of the intermediate portion of the device of  FIGS. 1 and 2 ; 
       FIG. 4  is a front perspective view of the device of  FIGS. 1-4 ; 
       FIG. 5  is a top view of a preferred drive means of the present invention; and 
       FIG. 6  is a perspective view of a holding cup of the device of  FIGS. 1-5 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide Methods and Apparatus for Image Transfer to Multiple Articles Having Non-planar Surfaces. 
   The present invention can best be understood by initial consideration of FIG.  1 .  FIG. 1  is front view of a conventional ink jet printer  10  that has been modified to permit the printing on a pair of three-dimensional articles using a preferred embodiment of the present invention. As was discussed in the parent application to the present application, the printer  10  has been modified to replace its original drive assemblies and mechanisms (i.e. those designed for printing on sheets of paper and the like) with the article positioning assembly  18  depicted herein. 
   The article positioning assembly  18  of this invention differs for that disclosed and claimed in the parent to this application at least two ways: (1) the apparatus for grasping the three-dimensional articles has been simplified; and (2) the present design can grasp at least two separate three-dimensional articles at the same time—this expedites the imaging process by allowing a single print run to create an image on two or more articles. 
   This new assembly  18  comprises a guide  20  running substantially along the entire width of the print zone  16  (and perhaps even beyond the print zone, as will be discussed below). The guide  20  is in a plane that is separate from the print zone&#39;s plane (the print guide  14  is in the print zone&#39;s plane), but parallel and in spaced relation thereto. Attached to, and extending upwardly from the guide  20  is a first end portion  22  for both holding one end of a first three-dimensional article (not shown). In this embodiment, the apparatus that drives the article positioning assembly  18  to rotate the articles is attached adjacent to the first end portion  22 , and thereby drives one end of one of the three-dimensional articles (not shown). 
   Approximately midway along the length of the guide  20  is located an intermediate portion  24 . The intermediate portion  24  includes, among other things, apparatus configured to grasp the second end of the aforementioned first three-dimensional article (not shown). The intermediate portion  24  also includes apparatus configured to grasp the first end of a second three-dimensional article (not shown). The intermediate portion  24  will permit the two article-ends that it is grasping to rotate freely at the same rate; in other words, if the drive means (not shown) causes the first article (not shown) to rotate, then this will drive the element(s) of the intermediate portion  24  that grasp the first three-dimensional article (not shown) to rotate, which in turn will cause the first end of the second three-dimensional article (not shown) to rotate. In embodiments where necessary, additional intermediate portions  24  may be added to the system in order to enable the article positioning assembly  18  to grasp and drive three or more three-dimensional articles to rotate. This would be particularly desirable for small three-dimensional articles such as bat-shaped pens among many, many others. If we now turn to  FIG. 2 , we can examine another novel and nonobvious portion of the system of the present invention. 
     FIG. 2  is a top perspective view of the area of the first end portion  22  of the device  18  of FIG.  1 . The guide  20  terminates at one end at the first end portion  22 . The first end portion  22  comprises, in pertinent part, a first adjustment block assembly  32  and a first carriage assembly  28 . The first adjustment block assembly  32  is a block, slidably engaged to the guide  20 , that further includes a set screw  34  or other braking means for preventing the adjustment block assembly  32  from sliding along the guide (i.e. to hold it in place firmly). 
   The first end portion  22  further comprises a first carriage assembly  28  that also slidingly engages the guide  20 . The first carriage assembly  28  further includes the means for grasping the first end of the first three-dimensional article (not shown). The first carriage assembly  28  further includes a handle  30  that conveniently extends outwardly from a set screw (not shown). The carriage assembly  28  set screw (not shown) performs the identical purpose as the adjustment block assembly  32  set screw  34  for the carriage assembly  28 . 
   Extending from the first adjustment block assembly  32 , in the direction of the first carriage assembly  28  is a alignment pin  35  and biasing device  37 , such as the spring shown. The alignment pin  35  serves to retain the biasing device  37  in position, as well as to engage an aperture (not shown) formed in the side of the carriage assembly  28 . Although outwardly a simple design, the adjustment block—carriage assembly interoperation is elegant and functional. 
   In operation, the user (after first having set the intermediate portion in its desired position), next sets the first carriage assembly  28  in position such that a first three-dimensional article (not shown) is held between the first carriage assembly  28  and the intermediate portion (not shown); the handle  30  is then turned to tighten the set screw (not shown) such that the carriage assembly  28  is held in place firmly along the guide  20 . Next, the user slides the first adjustment block  32  along the guide  20  until it is close to, yet separated somewhat from the first carriage assembly; the biasing device  37  is preferably in physical contact with the side of the first carriage assembly  28  (and the alignment pin  35  is most likely partially inserted into the aperture formed in the side of the carriage assembly  28 ). The set screw  34  is then turned to fix the first adjustment block assembly in place. 
   When it is time to remove and/or replace the three-dimensional article in the printing device (such as upon completion of the printing process), the user need simply loosen the set screw by turning the handle  30 , then grasp the handle  30 , and slide the first carriage assembly  28  to the left (as, shown here). When the carriage assembly moves a sufficient amount, the three-dimensional article will drop out of the grasping devices (see below). 
   In order to insert a new, like-sized three-dimensional article, the first carriage assembly  28  is held against the biasing device  35 ; the three-dimensional article is held in place between the grasping devices (see below), and the handle  30  is released. Once the handle  30  is released, the biasing device  37  will urge the first carriage assembly  28  to the right (in this drawing) until it is holding the three-dimensional article (not shown) in its grasping device (see below); the user then needs simply to turn the handle  30  until the set screw (not shown) holds the first carriage assembly  28  securely in place along the guide  20 . If we now turn to  FIG. 3 , we can examine yet another novel and nonobvious aspect of the present invention. 
     FIG. 3  is a top perspective view of the area of the intermediate portion  24  of the device of  FIGS. 1 and 2 . The intermediate portion  24  comprises two major sections: the second carriage assembly  36  and the second adjustment block assembly  38 . The second carriage assembly  36 , like the previously-described first carriage assembly includes a handle  30  extending from a set screw (not shown), that is operable to hold the carriage assembly  36  in place along the guide  20 . 
   Similar to the first adjustment block assembly (see above), the second adjustment block assembly  38  includes a set screw for holding the second adjustment block assembly  38  in place along the guide  30 . Also similarly, the second adjustment block assembly  38  has an alignment pin  40  extending therefrom for engagement with an aperture (not shown) formed in the side of the second carriage assembly  36 . Unlike the first adjustment block assembly (see above), however, there is no biasing device necessary between the second adjustment block  38  and the second carriage assembly  36 . The reason for this is that once a first three-dimensional article is placed between the first end portion (see  FIG. 2 ) and the intermediate portion  24 , the biasing device of the first end portion (see  FIG. 2 ) will provide the biasing force (through the first three-dimensional article) to the second carriage assembly  36 . 
   As with the first end portion (see FIG.  2 ), the adjustment block  38  is set in place with a slight gap between it and the set position of the first carriage assembly  36 ; in order to remove and replace the second three-dimensional article (not shown), the user need simply loosen the set screw using the handle  30 , and momentarily slide the second carriage assembly  36  to the left (as depicted here). Once the user has placed the fresh three-dimensional article in place, he or she need simply release the handle, resulting in the biasing action (translating through the first three-dimensional article) holding the second three-dimensional article (not shown) in the holding cups (see below). This action is extremely convenient and rapid. Having discussed these two important sections in detail independently, we shall now turn to  FIG. 4  to review their inter-relationship. 
     FIG. 4  is a front perspective view of the device  18  of  FIGS. 1-4 . As shown, the first three-dimensional article  44  (shown here as a miniature baseball-bat-shaped figure) is held by holding cups  54  at its first end  46  and its second end  48 . The first holding cup  54  (i.e. on the left) extends from the first end portion  22 ; the second holding cup (i.e. on the right) extends from the left side of the intermediate portion  24 . 
   A second three-dimensional article  50  (also shown here as a miniature baseball-bat-shaped figure) is held at its first end  51  by a holding cup  54  extending from the right side of the intermediate portion  24  and also being held at its second end  52  by a holding cup  54  extending from the second end portion  26 . 
   It should be clear that the two holding cups  54  extending from the intermediate portion  24  are attached to one another such that they rotate together. The result of this interconnection is that when the first three-dimensional article  44  rotates (i.e. when the drive means causes it to rotate), the second three-dimensional article  50  will also be driven to rotate. In order to focus on the drive mechanism, we shall now turn to FIG.  5 . 
     FIG. 5  is a top view of a preferred drive means  56  of the present invention. The drive means  56  could be created from a variety of conventional motor and gear arrangements that are adequate to provide steady, predictable rotation at the desired rate of speed. In this embodiment, the drive means  56  comprises a motor  60  for driving the plurality of interconnected drive gears  58 . Once the rotation has been stepped down to its desired velocity and resolution, the rotational output drives the holding cup  54  to rotate (and therefore to rotate the first three-dimensional article). If we finally turn to  FIG. 6 , we can examine a further novel and nonobvious advancement of the present invention. 
     FIG. 6  is a perspective view of a holding cup  54  of the device of  FIGS. 1-5 . As shown, the holding cup  54  comprises a body  55  from which a shaft  68  extends. The body  55  defines a generally circular outer peripheral surface  62  and a generally concave inner surface  64 . As discussed at length in the parent to this application, the ends of the three-dimensional article(s) are held in place by the inner surface of the holding cup  54 . What is truly unique is the projection of one or more ridges  66  from the inner surface  64 . These ridges  66  create a more positive rotational connection between the holding cup and the three-dimensional articles than if the inner surface  64  was left smooth (as was disclosed in the parent to this application). Furthermore, while the ridges  66  will provide substantial friction against rotation between the three-dimensional article and the holding cup  54 , they will not prevent the three-dimensional article from dropping right out of the holding cup  54  when the biasing force (see  FIG. 2 ) is relieved. 
   Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.