Patent Document

BACKGROUND 
     The disclosed embodiments relate generally to methods and systems for creating printed objects having three-dimensional structure. 
     Printing systems are no longer limited to devices that print text and images on two-dimensional substrates. Greeting cards, pop-up books, and packages are examples of printed substrates that can move from a flat structure to a three dimensional structure through manipulation of folds, creases, cuts and perforations. It is desirable that printing systems include or collaborate with variable structural data generating and finishing systems so that together they can print text and images on a substrate and also perform structural functions such as cutting, perforating, or scoring for folds so that the resulting substrate can be manipulated into a three-dimensional structure. 
     Personalized dimensional items are highly desirable, but expensive to produce, as the production must be done manually or with a support system that can be expensive or inefficient. Current structural printing systems implement a set of instructions and can mass-produce similar items, but the systems have limited ability to customize print jobs with structural features. These limitations can cause delays in assembly time as the system is reprogrammed or manually manipulated to change images and/or substrates, 
     Prior systems exist for the production of customized two-dimensional documents. For example, U.S. Pat. No. 6,948,115 to Aizikowitz et al., the disclosure of which is hereby incorporated by reference in its entirety, discloses a method of producing a personalized document using a variable information page description language output stream. However, such systems have limited ability to efficiently produce three-dimensional and/or structural information for the documents. 
     This document describes systems that solve one or more of the problems listed above. 
     SUMMARY 
     One embodiment described in this document is a system for producing a printed substrate having structural features. The production system includes a memory storing multiple recipient records. Each recipient record includes one or more customized or customizable objects to be printed on a substrate, thus yielding a customized substrate. The recipient records also may include data corresponding to at least one structural feature. This embodiment of the system includes a data iterator that selects a recipient record from the memory, and a document instance generator that generates an output sequence for rendering the customized substrate as a printed document. The output sequence includes instructions in object-oriented code for printing one or more objects from the selected recipient record on the customized substrate. Optionally, the object-oriented code may be compatible with the variable print specification (VPS) language, virtual reality modeling language (VRML) personalized print markup language (PPML), or portable document format (PDF). 
     This embodiment of the system also includes a rendering system that prints the object or objects on the customized substrate. This embodiment of the system also includes a structural design producer that generates a die line output code sequence in an object-oriented code based on the selected recipient record. This embodiment of the system also includes a converting system that applies structural features to the customized substrate based on the generated die line code sequence. Optionally, the structural features may include a crease, fold, cut, slit, application of an adhesive, insert, or perforation to the substrate along the die lines. 
     Optionally, the data iterator and the document instance generator may be a single device, such as a processor, or they may be different devices. If they are different devices, the system may also include a content buffer that enables the data iterator to operate as a producer and the document instance generator to operate as a consumer, so that the two devices operate together in a producer-consumer manner. 
     Optionally, the production system may include a definitions dictionary containing reusable object names and definitions for the names. If so, the document instance generator may also use information from the definitions dictionary to generate the document rendering output sequence. The system also may include a dies database comprising layout information for pages of dynamic structural document instances. If so, the structural design producer may also use information from the dies database dictionary to generate the die line output code sequence. 
     In an alternate embodiment, a method of printing a customized printed substrate includes receiving a structural design template for a first substrate to be printed; receiving a first recipient record; using the first recipient record to render one or more printed objects on the first printed substrate, and generating a first code sequence based on the first structural design template and the first recipient record. The first code sequence may include instructions for creating a first die line for the application of a structural feature on the first substrate, such that the first die line corresponds to data from the first recipient record. The method also may include appending the first code sequence to a first output code sequence in an object-oriented language, and using a converting system to apply at least one three-dimensional structural feature to the first substrate based on the first code sequence. The structural features may include items such as a crease, fold, cut, slit, insert, adhesive application, or perforation. 
     The method may be repeated for a second recipient record and a corresponding second printed substrate, as well as additional records and substrates. If so, the code sequences for each substrate may be included in a single code sequence or in separate code sequences. 
     Optionally, the method also may include identifying a computer-aided manufacturing definition for the converting system and ensuring that the instructions for creating the first die line are compatible with the computer-aided manufacturing definition. Generating each code sequence may include generating a customized set of instructions for the die line based on the data from the corresponding recipient record. 
     In some embodiments of the method, the rendering may include printing a unique identifier, such as a bar code, on the first substrate. If so, generating the code sequence may include using the unique identifier to identify and select the first die line. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exemplary system for producing customized, printed three-dimensional substrates. 
         FIG. 2  depicts an exemplary printed two-dimensional flat that can be transformed to a printed substrate by a finishing system. 
         FIG. 3  is a flowchart illustrating exemplary steps of a method of producing a three-dimensional substrate. 
     
    
    
     DETAILED DESCRIPTION 
     Before the present embodiments are described, it is to be understood that this invention is not limited to the particular systems, methodologies or protocols described, as these may vary. Also, the terminology used herein is for the purpose of describing particular embodiments and is not intended to limit the scope of the present disclosure, which will be limited only by the appended claims. 
     As used in this description and in the appended claims, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. As used herein, the term “comprising” means “including, but not limited to.”“document production device” is an electronic device that is capable of receiving commands and printing text and/or images on a substrate. Document production devices may include, but are not limited to, network printers, production printers, copiers and other devices that apply text and images using ink or toner. Printing devices may also perform a combination of functions such as printing and scanning, in which case such devices may be considered to be multifunctional devices. Printing devices may create two-dimensional documents, or they may create a graphical flat that can be converted to yield a three-dimensional item such as a package. 
       FIG. 1  illustrates a system for producing a printed substrate having structural features. Such substrates may include, for example, a three-dimensional package, a pop-up document, a greeting card, or another item. As shown in  FIG. 1 , the system includes a memory containing recipient data  10 , and a data iterator  20 , a document instance generator  30 , and a structural design producer  40  that accesses and/or receives recipient records from the memory  10 . 
     Each recipient record in the memory  10  includes data corresponding to one or more objects to be printed on a customized substrate, such as a document, package flat, card, or other substrate. The term “customized substrate,” when used in this patent document, refers to a substrate that contains printed material and/or structural features that are customized based on a received record such as a recipient data record. Each object represents an image or text, such as graphics, words, numbers, designs, colors, or other indicia that may be printed onto the substrate. The recipient records also may include data corresponding to at least one structural feature and/or data that can facilitate the creation of a structural feature. The data iterator  20  is a processor and/or a program instruction set running on a processor that selects a recipient record from the memory  10  and sends the object data from the record to the document instance generator  30  and the structural design producer  40 . Optionally, a content buffer  22  may hold the data before delivery to the document instance generator  30 . If so, the data iterator  20  may operate as a producer, the document instance generator  30  may operate as a consumer, and the data iterator  20  and document producer  30  may operate together in a producer-consumer relationship. If so, the data iterator  20  may determine the layouts and content objects for the output sequence  32 . 
     The document instance generator  30  is a processor and/or a program instruction set running on a processor that generates an output sequence  32  for rendering the customized substrate as a printed document. The output sequence  32  is generated in an object-oriented code, such as the variable print specification (VPS) language, personalized print markup language (PPML), or portable document format (PDF). Optionally, the document instance generator  30  may access a definitions dictionary  38  which contains reusable object names and definitions for the names, and the document instance generator  30  may use this information to generate the output sequence  32 . The definitions database may include the code formal or an image format specifying the object appearance. The output sequence is used by a rendering system  34  to print one or more objects from the output sequence onto a substrate to produce a customized flat substrate  50 . The rendering system  34  includes a computing device and a document production device, such as a processor and printer. 
     Referring to  FIG. 2 , an exemplary object printed on a substrate  60  may include any printed material, including but not limited to text  105  (such as a mailing address, a customized message, other text), custom graphics  110  (such as an image of an item to be placed inside a custom package or a corporate logo), a background  115 , or other material such as a unique identifier  120  such as a bar code, hash sequence, serial number, or other material. The printed objects also may include one or more reference marks  130  that other devices can use to identify known positions on the substrate and print additional material or apply structural features on the substrate. 
     Referring back to  FIG. 1 , the printed, flat substrate  50  exits the rendering system  34  and is received by a converting system  44 . A structural design producer  40  also receives the recipient record and uses the generator to generate a customized die line output code sequence  42 . The customized die line output code sequence also may be in an object-oriented code such as VPS, VRML, PPML, Adobe Illustrator (AI), or PDF. The structural design producer  40  is a processor and/or a program instruction set running on a processor that be either common with and part of, or separate from, the processor and/or instruction set used as the document instance generator  30 . Optionally, the structural design producer  40  may access a dies database  48  which contains layout information for pages of dynamic document instances, and the structural design producer  40  may use this information to generate the die line sequence  42 . 
     The converting system  44  is an electromechanical device that applies cuts, creases, perforations, folds, and/or other structural features along the die lines. The converting system  44  receives the die line output code sequence  42  and uses the die line code sequence to identify positions to apply cuts, perforations, punches, folds, slits, inserts, adhesive coatings, indentations, and/or other structural features, thus yielding a customized, finished substrate  72 . The converting system may perform this using any now or hereafter known methods, such as by using the reference objects to locate positions on the substrate and applying die lines based on specific data found in a recipient data file and/or the die line output code sequence, edge detection techniques to apply a cut or perforation around an image edge, die line files selected based on a unique identifier printed on the substrate, or other methods. 
     Referring to  FIG. 2 , the structural features applied to the customized substrate may include cut or perforation lines such as a document border cut line  152  and an image cut line  154 , a crease or fold line  162 ,  164 ,  166 , or other lines that apply structure to the substrate. For the substrate  60  in  FIG. 2 , after the border cut line  152  and image cut line  154  are applied, the converting system may cut the substrate along the border cut line  152  and image cut line  154 . The converting system may then apply folds along the fold lines  162  and  164 , as well as fold line  166 , so that when the document is folded, the image  110  dimensionally separates from the background  115  to exhibit a three-dimensional structure. 
     The system described above can thus produce multiple, customized printed three-dimensional documents, packages or other substrates for each recipient record in the recipients database. In some embodiments, the system can concurrently launch multiple production paths to concurrently generate individual parts of a three-dimensional object. 
       FIG. 3  is a process How illustrating an exemplary method of generating a customized, printed, three-dimensional substrate using a system such as that described above. Referring to  FIG. 3 , a method of printing a customized printed substrate includes receiving a structural design template (step  301 ) for a substrate to be printed; receiving a recipient record (step  303 ) from a recipients database or list; using the recipient record to render one or more printed objects (step  305 ) on the printed substrate; and generating a die line code sequence (step  307 ) based on the structural design template and the recipient record. The die line code sequence may include instructions for creating a first die line, such that the die line corresponds to data from the recipient record and a position on the substrate to which a structural feature will be applied. The method also may include appending the first code sequence to a first output code sequence in an object-oriented language (step  313 ), and using a converting system to apply (step  315 ) the structural features to the substrate along the die line or lines based on the code sequence. The application of structural features (step  315 ) may include applying a crease, fold, cut, insert, slit, adhesive, perforation or other structural feature to the first substrate along the first die line. 
     Optionally, the method also may include identifying (step  309 ) a computer-aided manufacturing definition for the converting system and ensuring (step  311 ) that the instructions for creating the first die line are compatible with the computer-aided manufacturing definition. Generating each die line code sequence (step  307 ) may include generating a customized set of instructions for the die line based on the data from the corresponding recipient record. 
     In some embodiments of the method, the rendering (step  305 ) may include printing a unique identifier, such as a bar code, on the first substrate. If so, generating the code sequence may include using the unique identifier to identify and select the first die line. 
     The method may be repeated for a second recipient record and corresponding second printed substrate, as well as additional records and substrates. If so, the code sequences for each substrate may be included in a single code sequence or in separate code sequences. Optionally, before repeating the document creation for a new recipient, the method may include determining whether the additional document(s) should use the same structural design template or a new structural design template (step  319 ). 
     It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Technology Category: 3