Patent Publication Number: US-2006019074-A1

Title: Printed article having texture printing and a uniform surface gloss to simulate embossing and method of manufacturing same

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      This application is a continuation-in-part of U.S. patent application Ser. No. 10/239,691, filed Mar. 31, 2003. 
    
    
     BACKGROUND OF THE INVENTION  
      The present invention relates generally to a printed article, and more particularly to a printed article having a graphic design such as a trading card, greeting card, sign, poster, label, decal, book cover, decorative panel, name plate, a visual display or the like having a uniform gloss level with a textured pattern printed thereon by a printing method that makes the graphic design images come alive with depth, texture and three-dimensionality, thereby simulating an embossed image.  
      In order to attract the attention of consumers, many products are being manufactured with images that provide a unique and sensational visual presentation. To meet this demand, a variety of printing techniques have been developed to produce aesthetically pleasing visual effects, such as the appearance of depth and three-dimensionality. Various methods are known in the prior art that produce three-dimensional images on two-dimensional media.  
      One method involves printing two offset images in different colors on an opaque or transparent sheet, and viewing the images using special glasses having right and left lenses which correspond to the different image colors respectively. Holographic technology can also be used to produce am image on a flat sheet which appears three-dimensional when illuminated and viewed at the proper angles.  
      However, these methods have not been commercially popular for various reasons. The offset image method is undesirable in that special glasses are required to view the image. Holograms are difficult and expensive to produce. Therefore, processes have been developed to produce the illusion of three-dimensional images on two-dimensional media. One such process is conventional embossing, which forms a raised pattern on a substrate by physically deforming part of the substrate upwardly. However, embossing suffers from the drawback that an expensive press is necessary to perform the operation, and a die bearing the desired embossed pattern must be made for each application. Further, the materials that can be used for embossing are limited because of the deforming nature of the embossing process.  
      Therefore, a need exists for an economical printing method and resulting printed articles that offer the visual impact of embossing without the cost. The assignee of the present invention has developed a number of printing processes for printing a variety of visually stimulating vibrant images creating the illusion of depth, texture and three-dimensionality as disclosed in U.S. Pat. Nos. 5,762,379, 6,113,149 and 6,170,881, the disclosures of which are incorporated herein by reference. The present invention provides an improved printing method for printing vibrant images on printed articles having the illusion of depth, texture and three-dimensionality.  
     SUMMARY OF THE INVENTION  
      Therefore, it is an object of the present invention to provide a printed article and printing method that overcomes the drawbacks of the prior art. It is another object of the present invention to provide an economical printing method for printing images on a printed article creating the illusion of depth, texture, three-dimensionality, and simulated embossing. It is a further object of the invention to provide a printed article with a textured pattern printed over a graphic image printed on a reflective surface by a four-color offset printing process. It is yet another object of the invention to provide a printing process for printing images on a printed article creating visual impressions which change as the viewing angle of the printed article is changed.  
      The present invention is an improvement of U.S. Pat. No. 5,762,379, assigned to the assignee of the present invention, and incorporated herein by reference. The present invention provides a much less expensive method of producing a printed article having a uniform gloss appearance with a graphic design creating the illusion of an embossed article. The printed article of the present invention creates the illusion of an embossed article with a textured pattern printed over and/or around a graphic design or image that is printed on a reflective surface with a transparent layer of uniform gloss printed over or under the textured pattern. The visual effect simulating an embossed article is achieved with the texture ink effectively being hidden by the overall uniform gloss layer.  
      The present invention includes a substrate having a top surface and a bottom surface. The substrate may be formed of any suitable type of printable material. A reflective layer is preferably printed over the surface of the substrate. Alternatively, a reflective ink or foil may be deposited or laminated on the top surface of the substrate. A graphic design or image is printed over the reflective layer. The image may cover the entire portion of the reflective layer or only selected portions thereof. The image may comprise a plurality of ink layers in order to produce the desired graphic design. The graphic image is preferably applied to the reflective layer through a four-color offset printing process where a base layer is printed and a four-color image is printed over the base layer. Printed on top of the graphic image is a plurality of light bending textured lines to produce the desired visual effect of depth and three-dimensionality. These lines, convex in cross section, produce a reflective textured pattern on the surface of the printed article. A layer of transparent ink of uniform gloss is printed over the graphic layers and over the surface of the textured lines and graphic image. Alternatively, this transparent layer of uniform gloss can be printed over the graphic layers but under the textured lines as long as the uniform gloss of this clear layer is the same gloss level as the textured lines. If the human eye can not perceive the difference between the gloss level of the texture and the uniform gloss level of the transparent layer, then the article will appear to be embossed as opposed to simply printed with textured lines. The inks used in the present invention are preferably curable in response to the application of ultraviolet light.  
      The graphic image may be printed with opaque ink, semi-transparent ink, translucent ink, or any combination thereof. These inks are preferably curable in response to ultraviolet (UV) light. Methods of forming the graphic image include silk screening, lithography, flexography, gravure or other known printing methods.  
      The textured pattern includes raised portions for bending and reflecting light incident to the printed article. The textured pattern or textured lines are formed from a transparent ink printed on all or parts of the image by a printing process such as silk screening, lithography, flexography, coating or other known printing method. The printed lines create lenses that have a convex curvature to refract incident light in a manner to control the reflected light and magnify portions of the graphic image to create varying depths and dimensions to the finished part.  
      Various other features, objects, and advantages of the invention will be made apparent to those skilled in the art from the accompanying drawings and detailed description thereof.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is an enlarged cross-sectional view of an embodiment of a printed article produced in accordance with the present invention;  
       FIG. 1A  is an enlarged cross-sectional view of the printed article of  FIG. 1  with printing on both the top and bottom surfaces of the printed article;  
       FIG. 2  is an enlarged cross-sectional view of another embodiment of a printed article produced in accordance with the present invention;  
       FIG. 2A  is an enlarged cross-sectional view of a modification of the printed article of  FIG. 2  with printing on both the top and bottom surfaces of the printed article;  
       FIG. 3  is an enlarged cross-sectional view illustrating another embodiment of a printed article produced in accordance with the present invention;  
       FIG. 3A  is an enlarged cross-sectional view of the printed article of  FIG. 3  with printing on both the top and bottom surfaces of the printed article;  
       FIG. 4  is an enlarged cross-sectional view illustrating another embodiment of a printed article produced in accordance with the present invention;  
       FIG. 4A  is an enlarged cross-sectional view of the printed article of  FIG. 4  with printing on both the top and bottom surfaces of the printed article;  
       FIG. 5  is an enlarged cross-sectional view illustrating another embodiment of a printed article produced in accordance with the present invention;  
       FIG. 5A  is an enlarged cross-sectional view of the printed article of  FIG. 5  with printing on both the top and bottom surfaces of the printed article;  
       FIG. 6  is an enlarged cross-sectional view of another embodiment of a printed article produced in accordance with the present invention;  
       FIG. 6A  is an enlarged cross-sectional view of the embodiment of  FIG. 6  with printing on both the top and bottom surfaces of the printed article; and  
       FIG. 7  is a top plan view of a trading card having an image produced in accordance with the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring now to the drawings,  FIG. 1  illustrates an enlarged cross sectional view of an embodiment of a printed article produced in accordance with the present invention. The printed article  10  includes a substrate  12  having a top surface  14  and a bottom surface  16 . The substrate  12  can be formed of paper, cardboard, plastic, acrylic, glass, metal or any other suitable printable material.  
      A reflective or ink layer  18  is printed over all or a portion of the top surface  14  of the substrate  12 . The reflective layer  18  is preferably formed of reflective ink which is printed onto the substrate  12 . The reflective layer  18  can be clear or have color. The reflective layer  18  can be opaque, transparent, semi-transparent or translucent. The reflective layer  18  gives the printed article a shiny reflective or metallic appearance. Alternatively, the reflective layer  18  can be formed of a chrome film, diffraction film, metallic foil, holographic foil, roll leafing or any other metalized material having a reflective surface.  
      A graphic design or image  20  is printed over all or a portion of the reflective layer  18 . The image  20  can have any desired form, for example, a football player on a sports trading card as shown in  FIG. 6 , or any other image. The graphic design or image  20  may comprise a plurality of ink layers in order to provide the desired design. A preferred method of forming the graphic image  20  is through a four-color offset printing process where a base layer is printed and a four-color image is printed over the base layer. The graphic image  20  may be printed with opaque ink, semi-transparent ink, translucent ink, or any combination thereof. These inks are preferably curable in response to ultraviolet (UV) light. Methods of forming the graphic image  20  include silk screening, lithography, flexography, gravure or other known printing methods.  
      A textured pattern  23  is printed over and/or around the graphic design or image  20 . The textured pattern includes a plurality of convex rounded ridges, irregular textures, or lines  22  of transparent ink printed over and/or around the graphic design or image  20 . In the preferred embodiment, the height and thickness of the lines is approximately 0.5 mils to 2 mils. However, the thickness, height and spacing of the lines may vary depending upon the particular application and desired visual effect. The textured pattern  23  can be formed over the entire surface of the image  20  or over only a portion thereof. The textured pattern  23  of lines  22  is preferably formed from a transparent ink, such as Nasdar 3527, Radcure VM4SP, or the like, printed on top of the graphic design or image  20  by a printing method such as silk screening, lithography, flexography, offset printing, gravure, select coating or other known printing method. The transparent ink has rheological properties such that when it is applied, it flows into semi-cylindrical or other types of convex shapes when viewed in cross-section. This transparent ink is also preferably a UV curable ink. The transparent ink may also include flakes of glitter, pearls, or other materials to produce a “glittery” effect.  
      The textured pattern  23  gives the appearance of a raised or embossed effect, which simulates depth, three-dimensionality, and embossing. The semi-cylindrically shaped raised ridges, textures or lines  22 , bend and reflect light incident on the printed article  10 , producing the visual illusion of depth, texture, three-dimensionality and embossing in the printed article as it is viewed from different angles. Light incident on the printed article  10  is reflected off the reflective layer  18  back through the graphic design or image  20  and the textured pattern  23  to create a unique visual effect.  
      A transparent layer of uniform gloss  24 , is printed over the textured pattern  23 , of lines  22 , and the graphic design or image  20 . The transparent layer of uniform gloss  24 , must be thin enough not to diminish the light bending, magnification, and reflective properties of the textured pattern  23  and the lines  22  of the textured pattern  23 . The controlled gloss layer  24  is preferably formed of substantially transparent ink. This transparent layer of uniform gloss layer  24 , provides a uniform gloss appearance over the textured pattern and gives the printed article a uniform level of gloss over textured and non-textured areas as desired.  
      Light incident on the printed article  10  from above is reflected off the reflective layer back through the graphic design or image, the textured pattern and the uniform gloss layer, such that the printed article exhibits depth, texture, three-dimensionality, and appears to be embossed in those areas with texture patterns.  
       FIG. 1A  illustrates the printed article  10  of  FIG. 1  with printing on both the top  14  and bottom  16  surfaces of the substrate  12 . The printed article  10 A of  FIG. 1A  includes a second reflective layer  18 A printed on the bottom surface  16  of the substrate  12 , a second graphic design or image  20 A printed over and/or around the second reflective layer  18 A, a second textured pattern  23 A of lines  22 A printed on the second graphic design or image  20 A, and a second transparent layer of uniform gloss level ink  24 A printed on the second textured pattern  23 A and the second graphic design or image  20 A.  
       FIGS. 2 and 2 A, show another embodiment of the present invention. This embodiment demonstrates a change in the sequence of the layers to achieve an equivalent appearance as that obtained in  FIGS. 1 and 1 A. In this embodiment, the transparent layer of uniform gloss,  24  and  24 A, has been printed over the reflective layer  18  or  18 A, over the graphic design or image,  20  or  20 A, and under the texture pattern,  23  or  23 A. For the effect of simulated embossing to still be achieved as in  FIGS. 1 and 1 A, the gloss level of the transparent uniform gloss layer must be equal to the gloss level of the texture pattern. In the case of high gloss effects, the transparent layer and the texture pattern are both high gloss transparent layers and can be produced from the same raw materials. For an embossed appearance on a low gloss, matte, or velvet type appearance, the uniform transparent layer and the texture pattern would both be produced from materials that are low gloss, matte, or velvet type appearance, respectively.  
       FIGS. 3, 3A ,  4 ,  4 A,  5  and  5 A show different embodiments of printed articles  11 ,  11 A,  13 ,  13 A,  15  and  15 A of the embodiment shown in  FIGS. 1 and 1 A. For simplicity, the embodiments are shown based on the sequences presented in  FIGS. 1 and 1 A, but in all of these embodiments, the transparent layer of uniform gloss can alternatively be printed under the texture pattern, when the gloss level of the transparent and texture layer are equal.  
      As shown in  FIGS. 3 and 3 A, variations of printed articles  11  and  11 A include a graphic design or image  20 ,  20 A printed on selected portions of a reflective layer  18 ,  18 A with a textured pattern  23 ,  23 A of lines  22 ,  22 A printed on both the reflective layer  18 ,  18 A and graphic image  20 ,  20 A. A transparent layer of uniform gloss  24  is applied as the topmost layer or alternatively, as in  FIGS. 2, 2A  this transparent layer of uniform gloss can be printed underneath the texture lines  22 ,  22 A if the gloss level of the transparent layer of uniform gloss  24  is equal to the gloss level of the texture lines  22 ,  22 A. In  FIGS. 4 and 4 A, variations  13  and  13 A include a graphic design or image  20 ,  20 A printed on selected portions of a reflective layer  18 ,  18 A with a textured pattern  23 ,  23 A of lines  22 ,  22 A printed only on the graphic image  20 ,  20 A. And as shown in  FIGS. 5 and 5 A, variations  15  and  15 A includes a graphic design or image  20 ,  20 A printed on selected portions of a reflective layer  18 ,  18 A with a textured pattern  23 ,  23 A of lines  22 ,  22 A printed only on the reflective layer  18 ,  18 A.  
       FIG. 6  illustrates an enlarged cross sectional view of another embodiment of a printed article  26  produced in accordance with the present invention. The difference between this embodiment and the earlier described embodiments is that this embodiment does not include a reflective layer printed on the surface of the substrate.  
      The printed article  26  of the second embodiment includes a substrate  28  having a top surface  30  and a bottom surface  32 . A graphic design or image  34  is printed over all or a portion of the top surface  30  of the substrate  28 . The graphic design or image  34  may comprise a plurality of ink layers in order to provide the desired design. A preferred method of forming the graphic image  34  is through a four-color offset printing process where a base layer is printed and a four-color image is printed over the base layer. The graphic image  34  may be printed with opaque ink, semi-transparent ink, translucent ink, or any combination thereof. These inks are preferably curable in response to ultraviolet (UV) light. Other methods of forming the graphic image  34  include silk screening, lithography, flexography, gravure or other known printing methods.  
      A textured pattern of lines  36  is printed over the graphic design or image  34 . The textured pattern of lines  36  includes a plurality of convex ridges or curved lines of transparent ink. The textured pattern of lines is preferably printed over all or a portion of the graphic design or image  34 . The textured pattern of lines  36  creates an illusion of depth, texture and three-dimensionality in the printed article  26 .  
      A textured pattern  37  is printed over and/or around the graphic design or image  34 . The textured pattern  37  includes a plurality of parallel convex rounded ridges or lines  36  of transparent ink printed over and/or around the graphic design or image  34 . In the preferred embodiment, the height and thickness of the lines is approximately 0.5 mils to 2 mils. However, the thickness, height and spacing of the lines may vary depending upon the particular application and desired visual effect. The textured pattern  37  can be formed over the entire surface of the image  34  or over only a portion thereof. The textured pattern  37  of lines  36  is preferably formed from a transparent ink, such as Nasdar 3527, Radcure VM4SP, or the like, printed on top (or underneath) of the graphic design or image  34  by a printing method such as silk screening, lithography, flexography, offset printing, gravure, coating or other known printing method. The transparent ink has rheological properties such that when it is applied, it flows into a semi-cylindrical or other type of convex shape when viewed in cross-section. This transparent ink is also preferably a UV curable ink. The transparent ink may also include flakes of glitter, pearls, or other materials to produce a “glittery” effect.  
      The textured pattern  37  gives the appearance of a raised or embossed effect, which simulates depth and three-dimensionality. The semi-cylindrically shaped raised ridges or lines  36  bend and reflect light incident on the printed article  26  producing the visual illusion of depth, texture and three-dimensionality in the printed article as it is viewed from different angles. Light incident on the printed article  26  is reflected off the surface of the substrate  28  back through the graphic design or image  34  and the textured pattern  37  to create a unique visual effect.  
      A transparent layer of uniform gloss  38  is printed over the textured pattern  37  of lines  36  and the graphic design or image  34 , (or alternatively, the transparent layer of uniform gloss can be printed underneath the texture pattern  37  of lines  36 , if the gloss level is equal to gloss level of the texture pattern). The transparent layer of uniform gloss  38  must be thin enough not to diminish the glossy and reflective properties of the textured pattern  27 . The transparent layer of uniform gloss  38  is preferably formed of clear polyester by thermal lamination or by printing or coating with a clear plastic or ink. The transparent layer of uniform gloss  38  can also be formed of a pressure sensitive sheet using cold lamination. The transparent layer of uniform gloss  38  provides a level of gloss appearance matching that of the textured pattern  37  and gives the printed article  26  an overall gloss level that is not distinguished between textured and non-textured areas. It is this uniform gloss that deceives the eye to provide the appearance of an embossed article.  
       FIG. 6A  illustrates the printed article  26  of  FIG. 6  with printing on both the top  30  and bottom  32  surfaces of the substrate  28 . The printed article  26 A of  FIG. 6A  includes a second graphic design or image  34 A printed on the bottom surface  32  of the substrate  28 , a second textured pattern  37 A of lines  36 A printed on the second graphic design or image  34 A, and a second layer of uniform gloss transparent ink  38 A printed on the second textured pattern  37 A of lines  36 A and the second graphic design or image  34 A.  
       FIG. 7  illustrates an example of a sport trading card  40  manufactured in accordance with the present invention. The card  40  includes the image of a football player  42  printed over a reflective layer covering the top surface of the card. Printed on and around the image  42  is a plurality of textured pattern of lines  44 . The textured pattern of lines  44  are produced from transparent ink to create depth and three-dimensionality in the printed image and an overall shiny or glossy textured appearance of the printed article.  
      While the invention has been described with reference to preferred embodiments, those skilled in the art will appreciate that certain substitutions, alterations, and omissions may be made without departing from the spirit of the invention. Accordingly, the foregoing description is meant to be exemplary only and should not limit the scope of the invention set forth in the following claims.