Abstract:
A method for material deposition employs a printing press, such as those used in cold foil transfers, that permits a greater usage of the foil web than traditional methods. This is achieved by increasing the number of times the foil web is passed through the press, while simultaneously taking into account the area that has not been used and adjusting the impacted area of the foil web accordingly. The foil web is adjusted by using a series of adjustable rollers and angular bars to change the length of the circumferential path the foil takes through the press. By modifying the angle of these rollers and the distance between them, the path can be lengthened or shortened to correspond to the particular needs for a particular print job. This allows the press to use the foil in such a way that reduces foil waste and manufacturer and consumer costs.

Description:
CLAIM OF PRIORITY 
       [0001]    This application is a continuation application of U.S. Ser. No. 14/463,724 filed on Aug. 20, 2014 which claims priority to U.S. Ser. No. 61/867,737 filed on Aug. 20, 2013, the contents of both of which are herein fully incorporated by reference in their entirety. 
     
    
     FIELD OF THE EMBODIMENTS 
       [0002]    The field of invention and its embodiments relates to printing presses, namely foil printing presses employing a cold foil methodology. In particular, using a specific methodology to reduce foil waste, thus implementing substantive cost saving measures to the manufacturer and consumer alike. 
       BACKGROUND OF THE EMBODIMENTS 
       [0003]    Historically, foil has been used for centuries as a means of adornment and decoration. A malleable metal, such as gold, was typically pounded into very thin sheets (i.e. foil) and then applied to armor, letters, and various types of furniture or artwork. What used to be reserved for the rich now has become a staple of the masses thanks to substantive improvements in technology. 
         [0004]    Foil is still expensive; however, it is now more common to find various types of foil with a base of aluminum in present mechanical processes. These foil works are ubiquitous and most often seen in commercial packaging, books, wedding announcements, cards, and the like. Notwithstanding the progression of foiling technology, the current foiling processes are not without their drawbacks. Most often, vast amounts of foil are wasted in the printing or stamping process. This is due to the high speed at which the presses run, which is typically referred to as “press speed.” This continuous foiling process is fast and simple, but as mentioned results in a substantial waste of foil and thus a waste of money. 
         [0005]    Even still, the cold foiling process has remained fairly unchanged for some time. Typically, a substrate is fed through a pair of rollers which apply an adhesive to the substrate. A separate foil web is then merged with the adhesive laden substrate and the two are pressed together through another set of rollers. The adhesive then cures on its own, or is cured by another means such as ultraviolet light. The excess foil is then stripped away from the substrate and the substrate continues down a conveyor for further treatment or packaging. The excess foil is collected by a collection core. Once the foil has run its course through the press, it cannot be reused. 
         [0006]    Thus, there is a need for a more efficient process in order to reduce said foil waste and manufacturing costs. The current invention meets and exceeds these needs and objectives. 
         [0007]    Review of Related Technology: 
         [0008]    U.S. Patent Application 2013/0075040 pertains to systems, machines and products for producing foil relief. The system includes apparatuses for placing a foil on a curable adhesive deposited on a substrate when the curable adhesive is substantially non-tacky, and applying energy to the adhesive deposited on the substrate while pressing the foil to the adhesive to cause the adhesive to become tacky and to adhere to the foil. The adhesive becomes substantially fully cured prior to completion of the pressing of the foil to the adhesive deposited on the substrate. In some embodiments, the system may further include one or more energy sources for pre-curing the curable adhesive prior to placing the foil on the adhesive to initiate the curing process of the adhesive and manipulate a viscosity level of the adhesive, with the pre-cured adhesive remaining substantially non-tacky. The curable adhesive includes one or more of, for example, a radical type adhesive and/or a cationic adhesive. 
         [0009]    U.S. Patent Application 2012/0193024 pertains to a material deposition technique for transferring material to a substrate. The material may be a foil on a carrier and the substrate may be printable paper. A computer-controlled, material application subsystem is provided having a material roller assembly including one or more material pressing rollers. The entire assembly is configured for controlled rotation such that the material pressing rollers alternately engage and disengage an impression cylinder. In a first rotatable position, the material roller assembly is rotated so that one of the material deposition rollers over which the material carrier is fed engages the impression cylinder and deposits the material onto the substrate as it passes beneath the roller. In a second rotatable position, the material roller assembly is rotated so as to disengage the material roller from the impression cylinder thereby precluding deposition of material onto the substrate as it passes beneath the roller. 
         [0010]    Various devices are known in the art. However, their structure and means of operation are substantially different from the present disclosure. The other inventions fail to solve all the problems taught by the present disclosure. The present invention and its embodiments enable a foil web to be used repeatedly on a single pass through a press. The foil web is positioned to minimize waste while not comprising the speed and effectiveness of the press. At least one embodiment of this invention is presented in the drawings below and will be described in more detail herein. 
       SUMMARY OF THE PREFERRED EMBODIMENTS 
       [0011]    The current invention and its embodiments disclose a material deposition method having the steps of unwinding a foil web from an unwind core; feeding the foil web through a press, wherein the press has a sync cartridge having a plurality of roller trays, the plurality of roller trays having at least two angular guide assemblies and being operably connected to a plurality of motors wherein, the plurality of motors provide differing angles to the at least two angular guide assemblies to manipulate the circumference of the foil web in relation to adherence to the substrate; using the sync cartridge to create at least two connected, substantially circular foil raceways for the foil web; applying a layer of adhesive to the substrate; bringing at least two sections of the foil web into contact with the substrate more than once; and separating the foil web from the layer of adhesive for a final time, wherein the foil web is collected upon a rewind core and the substrate continues through the press. 
         [0012]    The material deposition method uses a continuous foil web in the foiling process. The process itself is also continual, unlike other start/stop methodologies. This is done by looping the foil at least twice, and as many as 6 times or more, through the press and cold foiling attachment. The number of loops, typically referred to as “raceways,” is determined by the width of the foil web layout in relation to the maximum allowed width of the machine. The press can change the angle of the angular guide assemblies thereby changing the circumference of the foil web. If one desires to increase the circumference of the foil raceways, then the angle of the angular guide assemblies and distance between them is increased, and to decrease the circumference of the foil web the angle of the angular guide assemblies and the distance between them is decreased. The method may further comprise repeating the aforementioned steps using a second foil web. In this instance, the above described methodology can be combined with multiple foils of varying widths and types of foils to accommodate the various foiled areas needed for a particular project. 
         [0013]    In another embodiment, a material deposition method is described having the steps of unwinding a foil web from an unwind core; feeding the foil web through a press wherein the press has a sync cartridge wherein, the sync cartridge has a plurality of roller trays, the roller trays having at least two angular guide assemblies, the at least two angular guide assemblies having the capability to be manually manipulated to a particular angle and distance in order to change the circumference of the foil web in relation to the adherence to the substrate; using the sync cartridge to create at least two connected, substantially circular foil raceways for the foil web; applying a layer of adhesive to the substrate; bringing at least two sections of the foil web into contact with the substrate more than once; and separating the foil web from the layer of adhesive for a final time, wherein the foil web is collected upon a rewind core and the substrate continues through the press. This embodiment comprises generally the same principles as the previous embodiment described above; however, here one must manually change the angles and distances of the angular guide assemblies to achieve the varying circumferences for the foil web. 
         [0014]    In general, the present invention succeeds in conferring the following, and others not mentioned, benefits and objectives: 
         [0015]    It is an object of the present invention to provide a material deposition method for reducing waste in cold foil printing. 
         [0016]    It is an object of the present invention to provide a material deposition method that enables multiple foil webs of varying widths to be run through a press simultaneously. 
         [0017]    It is an object of the present invention to provide a material deposition method that provides a cost effective solution for reducing waste and its associated costs. 
         [0018]    It is an object of the present invention to provide a material deposition method that reduces manufacturer and consumer cost. 
         [0019]    It is an object of the present invention to provide a material deposition method that enables one to manually manipulate the length of the foil raceway. 
         [0020]    It is another object of the present invention to provide a material deposition method that enables one to automatically change the length of the foil raceway. 
         [0021]    It is another object of the present invention to provide a material deposition method for a cold foil press that permits multiple, continuous raceways for a foil web. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0022]      FIG. 1  is a diagram demonstrating a prior art method of depositing a material using a cold foil press. 
           [0023]      FIG. 2  is a flow chart illustrating a method of depositing a material as described by the present invention and its embodiments. 
           [0024]      FIG. 3  is perspective back view of an example of a press employing at least the methodology as described in  FIG. 2 . 
           [0025]      FIG. 4  is a perspective view of a sync cartridge assembly in accordance with the methodology of the present invention. 
           [0026]      FIG. 5  is a perspective view of a roller tray of a sync cartridge assembly. 
           [0027]      FIG. 6  is a perspective view of an angular guide assembly of a sync cartridge assembly. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified, as far as possible, with the same reference numerals. 
         [0029]    Reference will now be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto without deviating from the innovative concepts of the invention. 
         [0030]    As defined herein, “circumference” refers to the distance traveled by the foil web by way of a number of looped passes, or raceways, through the complete press. The overall distance is calculated and can be changed to suit the job at hand based on the number and size of images that must be printed. 
         [0031]    In  FIG. 1 , there is a typical prior art apparatus/method for depositing a material, such as a foil web  16 , onto a substrate  25 . The foil web  16  is unwound from a foil unwind core  18 . It moves along through the press and meets an alignment roller  20 . The foil web  16  passes through the alignment roller  20  and alignment nip  31  meeting the substrate  25  laden with an adhesive  26 . The foil web  16  and substrate  25  combination pass through a roller assembly  28  and  32 . 
         [0032]    Here, the foil web  16  is pressed into the adhesive laden substrate  25  fusing the foil web  16  to the adhesive  26 . The unadhered foil web  16  and substrate  25  are separated by a separation nip  34  and the leftover foil web  16  goes to a foil rewind core  24 . The substrate  25 , typically in an individual sheet form, goes to the next transfer cylinder (not shown) and continues through the press to have various transparent colors printed on top of foiled and non foiled areas of the sheet This method creates a large amount of wasted foil web  16 , as the operational press speed is such that it allows for small percentages of the foil web  16  to be adhered to the substrate  25 . The process is typically driven by a number of servo motors  40 . The current method, as described, greatly reduces the waste experienced with the aforementioned prior art methodology. 
         [0033]      FIG. 2  generally illustrates the preferred material deposition method  200  as described by the current invention and its embodiments. 
         [0034]    In step  201 , a foil web is unwound from the foil unwind core. This is a continuous foil web which is used from start to finish for the job. 
         [0035]    In step  205 , the foil web is fed through the press fitted with a sync cartridge. The sync cartridge permits the foil web to form multiple raceways through the press thereby increasing the amount of foil web used and decreasing the amount of foil web waste. The sync cartridge and its components are further described in  FIGS. 3-6 . 
         [0036]    In step  210 , the angle of the angular guide assemblies are set to a particular angle. The exact angle setting of the angular guide assemblies will be dependent on the specifications of the particular print job. Further, the angle settings of the angular guide assemblies can be manipulated independent of one another. In some instances, this step may be performed before the foil web is fed through the press in step  205 . 
         [0037]    In step  250 , the angle adjustments of the angular guide assemblies may be performed manually. Alternatively, the angle adjustments of the angular guide assemblies may be performed automatically by servo motors or the like in step  255 . 
         [0038]    In step  215 , there are at least two continuous raceways that have been created using the press and the sync cartridge. The press used in this methodology is preferably fitted with a cold foil attachment such as the one manufactured by KBA of Germany. Such a press enables one to retrofit a sync cartridge (see  FIG. 4 ) into the existing cold foil attachment. 
         [0039]    In step  220 , the substrate is then transported with at least one roller to the press. 
         [0040]    In step  225 , a layer of adhesive is applied to the surface of the substrate. The adhesive used is dependent on the specifications of the job but is nonetheless known in the art. 
         [0041]    In step  230 , the foil web and the substrate are advanced to a material roller assembly. 
         [0042]    In step  235 , the two materials are brought together and the foil contacts the adhesive and the two components are pressed together via rollers to ensure a proper adhesion. 
         [0043]    In step  240 , the remaining unadhered foil is separated from the substrate and rewound on a rewind drum and then disposed. 
         [0044]    Referring now to  FIG. 3 , there is an example of a complete press  50  comprising of a cold foil attachment  55  and a press unit  60 . The press unit  60  can be a number of different styles or brands that are receptive to any type of cold foil attachment  55 . The cold foil attachment  55  primarily dictates the alignment of the foil web, while the press unit  60  primarily dictates on the impression and adhesion properties of the process. Area A-A′ is the area that is receptive to the sync cartridge further described in  FIGS. 4-6 . 
         [0045]    In making determinations of cost/cost savings and the number of raceways to be run, a number of calculations can be completed. For example, the complete press  50  may accommodate up to about a 1.00 m (40 inch) foil web. Thus, if one desired to run four (4) lanes, or raceways, the maximum foil web width is about 25.4 cm (10 inches). 
         [0046]    In general, the cost for a 2.54 cm (1 inch) web is USD$60 for 8000 sheets. Thus, the cost for an about 1.00 m (40 inch) web is USD$2400 for 8000 sheets. By permitting a second raceway, or pass through the complete press  50 , the cost for the about 1.00 m (40 inch) foil web is reduced by half or USD$1200. There are multiple iterations where this holds true and the number of passes and widths of the foil web can vary. The one constant in this methodology is the increased foil usage and increased monetary savings. 
         [0047]    The complete press  50  typically ranges from about 0.4 m (15 inches) to about 2.3 m (90 inches) and the number of raceways is determined by the amount of space by dividing into the printing press width down to about 5 cm (2 inches) wide of the maximum size. For example, a 0.4 m (15 inch) machine could theoretically have seven (7) raceways that are about 5 cm (2 inches) wide and an about 2.3 m (90 inch) machine could have as much as forty-five (45) raceways if the layouts of the actual foiling job(s) allowed. 
         [0048]      FIG. 4  is perspective view of a sync cartridge  50  that is received in area A-A′ of  FIG. 3 . The sync cartridge  150  has a frame  100  generally defined by a number, typically four, lateral perimeters. The frame  100  may have a number of locking mechanisms that interact with the press thereby securing the sync cartridge  150  to the press. 
         [0049]    There is also a locking track  135  for the roller trays  110 . The locking track  135  permits the movement of the roller trays  110 . The locking track  135  is positioned to generally run laterally to the width of the frame. The locking tray  135  has a groove which receives the roller trays  110 . In some embodiments, the locking tray  135  only permits lateral movement of the roller trays  110 . However, in some instances, one can lift a roller tray  110  out of the locking tray  135  thereby allowing one to change the number of roller trays  110  present in the sync cartridge  150 . 
         [0050]    In order to move a roller tray  110 , one must first loosen the fasteners holding the roller trays  110  in place. The roller trays  110  then can be moved and positioned at specific points along the locking track  135 . The points at which the roller trays  110  may be secured to the locking track  135  may be fixed (i.e. set points along the track) or the locking tray  135  may enable the roller trays  110  to be positioned at any point along the locking tray  135 . Each of the roller trays  110  is further described in  FIG. 5  in more detail. 
         [0051]    The sync cartridge  150  generally interacts with at least one foil web as described by  FIGS. 3 &amp; 4 . First, a foil web passes over one of the roller assemblies  115 . It passes underneath one of the angular guide assemblies  125  and around over the top of the same angular guide assembly  125 . The particular angle of the angular guide assembly  125  dictates the direction the foil web takes thereon. Usually, the foil web will then pass underneath another angular guide assembly  125  and then pass over the top of the same angular guide assembly  125 . The foil web will then pass over a roller assembly  115  and travel down into the press unit  60 . The general process and orientation of passing the foil web through the angular guide assemblies  125  and roller assemblies  115  is repeated based on the number of raceways being run at a particular time. 
         [0052]      FIG. 5  is a perspective view of an example of an individual roller tray  110  from the sync cartridge  150  described in  FIG. 4 . The roller tray  110  has a base  175  on which the individual components of the tray  110  are disposed. On one end of the base  175  is a roller assembly  115  with a lock block  165 . The lock block  165  permits attachment of the roller assembly  115  while still permitting movement of the roller tray  110 . 
         [0053]    The roller assembly  115  helps with the alignment and tension in the foil web. As shown, there is a roller assembly  115  on the top side of the roller tray  110  and a roller assembly  115  attached to the lower side of the roller tray  110 . This provides proper tensioning for the foil web as it travels up and over the roller tray  110  and down the roller tray  110 . In some instances, there may be only one roller assembly  115  whereas in other instances the layout may require more than two roller assemblies  115 . 
         [0054]    The base  175  may also have a slidable track  140 . The slidable track  140  permits the angular guide assembly  125  to change angles and distance in relation to the roller assembly  115 . The slidable track  140  is a series of channels or grooves in an upper surface of the roller tray  110 . Each of the two ends of the angular guide assembly  125  can be adjusted independent the other side via the slidable channel  140 . This allows for virtually innumerable angular differences to be created. 
         [0055]    The angular guide assembly is held in place by the angle roller pivot lock  160 , which further enables the pivoting motion necessary to independently adjust the ends of the angular guide assembly  125 . Further, the angle roller pivot lock  160  prevents movement of the angular guide assembly  125  by way of at least one securement mechanism. 
         [0056]      FIG. 6  is an example of an angular guide assembly  125  as described above. The angular guide assembly  125  changes angles and positions relative to the sync cartridge  150  in order to change the circumference of the foil web. The circumference of the foil web can be decreased by decreasing the angle and distance between at least two of the angular guide assemblies  125 . The circumference of the foil web can be increased by increasing the angle and distance between at least two of the angular guide assemblies  125 . A base  190  of the angular guide assembly  125  supports a bar and locking mechanism  180 . 
         [0057]    As the circumference of the foil web is manipulated by the angular guide assemblies  125 , the foil web impacts the substrate at different points on each pass. Thus, the position of the foil web can be such that multiple areas of the foil web can be used in close proximity to one another rather than the wide gaps and wasted foil that is seen with the current cold foiling methodologies.