WO2025160081A1

WO2025160081A1 - Digitally printed substrates and methods thereof

Info

Publication number: WO2025160081A1
Application number: PCT/US2025/012445
Authority: WO
Inventors: Tom Odum; Brock CHAMPION; Jacob ATRAKAWI
Original assignee: Shaw Industries Group Inc
Current assignee: Shaw Industries Group Inc
Priority date: 2024-01-22
Filing date: 2025-01-21
Publication date: 2025-07-31
Anticipated expiration: 2026-07-22

Abstract

The invention is directed towards printed substrates and methods of creating printed substrates. Printed substrates include at least a base substrate and a printed layer where one or more areas of the printed layer are selectively omitted during printing. Additional layers can be coupled to printed substrates to provide a final product additional characteristics where the omitted areas of the printed layer enhance additional layer coupling.

Description

DIGITALLY PRINTED SUBSTRATES AND METHODS THEREOF

TECHNICAL FIELD OF THE INVENTION

[0001] The present disclosure relates to printed substrates and methods of creating, coating, adhering additional layers to, and combinations thereof printed substrates.

BACKGROUND OF THE INVENTION

[0002] Ultraviolet (UV) curable inks are used in digital printing. Once cured, UV curable inks can act as a barrier to adhesion thereto, thereby affecting lamination of other layers to the UV cured ink layer. As such, oftentimes, heat lamination to the top of UV cured inks presents a number of obstacles.

SUMMARY OF THE INVENTION

[0003] It is to be understood that this summary is not an extensive overview of the disclosure. This summary is not restrictive, and it is intended to neither identify key or critical elements of the disclosure nor delineate the scope thereof. The sole purpose of this summary is to explain and exemplify certain concepts of the disclosure as an introduction to the following complete and extensive detailed description.

[0004] The present disclosure relates to a printed substrate and products including printed substrates.

[0005] The present disclosure relates to a base substrate that includes a first and second surface where the two surfaces oppose each other. A base substrate may include a material of polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), paper, cellulosic materials, wood-based materials, high-density fiberboard (HDF), low- density fiberboard (LDF), metals, leathers, cloth-based materials, ceramics, glass, and the like. [0006] The present disclosure relates to a printed layer. The printed layer may be deposited onto a surface of the base substrate and cured. Materials deposited in the printed layer include but are not limited to inks, dyes, paints, soluble pigments, and the like. Inks further include but are not limited to UV-cured inks and electron-beam cured (e-beam cured) inks. Additional inks include but are not limited to aqueous inks, non-aqueous inks, powdered inks, such as PET-powdered inks, and the like. [0007] The printed layer is designed to include a plurality of selectively placed voids in a print design, as further described herein. Voids enhance coupling of additional layers to the printed substrate, via the voids, allowing at least a portion of the additional layers to contact the base substrate. Voids may be selectively introduced using a variety of methods. Said methods may result in void percentages of the printed layer relative to the area of the base substrate, ranging from about twenty percent to fifty percent.

[0008] The present disclosure relates to one or more additional layers. One or more additional layers are coupled to the printed layer on the base substrate. Voids in the printed layer enhance coupling of one or more additional layers by allowing at least a portion of the one or more additional layers to come into contact with a base substrate. Additional layers may serve as protective wear films. Additional layers may include materials of polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), polyurethane reactive (PUR), ultraviolet-cured (UV-cured) polyurethane, and the like.

[0009] In an aspect, the present disclosure relates to optional adhesive materials that can be used with printed layers that contain voids. Adhesives may be deposited on top of a printed layer and extending through the voids to the base substrate before coupling an additional layer to a printed substrate. The combination of voids and adhesives may further enhance the coupling of an additional layer to a printed substrate and the base substrate.

[0010] The present disclosure relates to adhesion promoters. Adhesion promoters may be deposited on a base substrate before a printed layer is deposited. Adhesion promoters may promote adhesion of a printed layer onto a base substrate. Adhesion promoters may also promote adhesion of an additional layer being coupled to a printed substrate.

[0011] The present disclosure relates to methods of creating printed substrates and products including printed substrates.

[0012] The present disclosure relates to methods of creating printed substrates by providing a base substrate and selectively depositing a print layer onto a surface of the base substrate to selectively create voids in the print layer. Once deposited, the print layer may undergo a curing process. In some examples, the base substrate is covered with a surface treatment before depositing the print layer to prevent the print layer from migrating before curing. In other examples, the base substrate and print layer can be exposed to a pinning lamp before curing to prevent migration. [0013] The present disclosure relates to methods of selectively creating voids in a print layer by omitting all pixels within a predetermined threshold of a chosen color from a print design while depositing the print layer. Voids may also be selectively configured to create higher concentrations of voids around one or more edges of a base substrate.

[0014] The present disclosure relates to methods of depositing an adhesion promoter onto a base substrate before depositing a print layer.

[0015] The present disclosure relates to methods of coupling an additional layer to a printed substrate. As a non-limiting example, an additional layer can be placed above a printed substrate and heat laminated. In one example, the additional layer may be film. As an additional, nonlimiting example, an additional layer can be deposited as a liquid onto a printed substrate and cured. As an additional, non-limiting example, an adhesive may first be deposited onto a printed substrate before placing an additional layer onto the deposited adhesive. The adhesive may then be cured to couple the additional layer to the printed substrate.

[0016] The present disclosure further relates to computer-implemented methods for creating printed substrates. Such methods include a user interface allowing a user to select a variety of inputs. Such inputs are then used to generate a print design according to the inputs. In an aspect, the print design can take the form of a vector file. Printing instructions can be generated from the print design which can include unique printing instructions to create the printed substrate. In an aspect, the printing instructions can include a raster file. A printer can then use printing instructions to deposit a uniquely designed print design onto a base substrate, according to the present disclosure.

BRIEF DESCRIPTION OF DRAWINGS

[0017] The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

[0018] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee. [0019] FIGS. 1 and 1 A display a printed substrate (FIG. 1) and a zoomed-in version of the printed substrate (FIG. 1A) printed according to traditional methods that do not selectively include voids.

[0020] FIGS. 2A-2D display a screen visual pixel view of removed pixels based on removal criteria (FIG. 2A), an estimated ink pattern based on the digital input from FIG. 2A (FIG. 2B), a printed substrate according digital input from FIG. 2A (FIG. 2C), and a black and white printed substrate according digital input from FIG. 2A (FIG. 2D).

[0021] FIGS. 3A-3B display a selection of pixels to be omitted via an image handling computer program (FIG. 3A) and an example of selectively omitted pixels according to the selection (FIG. 3B).

[0022] FIGS. 4A-4B display examples of a printed layer with missing pixels overlaying a colored background.

[0023] FIGS. 5 and 5A display a modified raster image file for a pattern with voids to be printed on a white substrate according to the present disclosure.

[0024] FIGS. 6 and 6A display the modified raster image file of FIGS. 5 and 5A printed on a brown substrate according to the present disclosure.

[0025] FIG. 7 is a cross-sectional schematic of a printed substrate according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0026] It should be appreciated that this disclosure is not limited to the devices, systems, components, and methods described herein. It is also to be understood that the terminology used herein is for the purpose of describing certain embodiments only, and is not intended to be limiting, since the scope of the present disclosure will be limited only by the appended claims. [0027] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Any devices, systems, components, and methods similar or equivalent to those described herein can be used in the practice or testing of the present invention. All publications mentioned are incorporated herein by reference in their entirety.

[0028] The use of the terms "a," "an," "the," and similar referents in the context of describing the presently claimed invention (especially in the context of the claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context.

[0029] Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

[0030] Use of the term "about" is intended to describe values either above or below the stated value in a range of approx. +/- 10%; in other embodiments the values may range in value either above or below the stated value in a range of approx. +/- 5%; in other embodiments the values may range in value either above or below the stated value in a range of approx. +/- 2%; in other embodiments the values may range in value either above or below the stated value in a range of approx. +/- 1%. The preceding ranges are intended to be made clear by context, and no further limitation is implied. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or example language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any nonclaimed element as essential to the practice of the invention.

[0031] As used herein, “adhesion promoter” refers to a material or surface treatment that can be applied to a base substrate, e g., before any deposition of a printed layer, to allow the substance deposited in a printed layer to better adhere to or wet (i.e., spread out on) the base substrate. The ability of a deposited substance, such as an ink, to adhere to or wet a base substrate may be measured according to ASTM D3359 standards. Where voids are present in a printed layer, an adhesion promoter may interact with an additional layer coupled to a printed substrate, increasing adhesion, though the adhesion promoter’s primary function is to enhance the adhesion of a printed layer to a base substrate. Adhesion promoter materials include but are not limited to primers, solvent-based primers, paint primers, acrylic-based primers, and the like. Surface treatments used as adhesion promoters include but are not limited to corona surface treatments, plasma surface treatments, ozone surface treatments, and the like.

[0032] As used herein, “adhesive” refer to materials that can be applied to a printed substrate, such as to a free surface of a partially- or fully-cured printed layer, to adhere an additional layer, such as a protective wear layer, to the printed substrate. Adhesives include solutions of polyurethane reactive (PUR), modified silanes, modified terminated polymers, various glues, and the like.

[0033] As used herein, “dyne” refers to a measurement that allows the comparison of the surface energy of an ink, dye, or other wetting agent to the surface energy of a substrate onto which the ink, dye, or other wetting agent is applied. “Dyne” tests demonstrate if an ink, dye, or other wetting agent is compatible with a substrate where compatibility means that the ink, dye, or other wetting agent will wet the substrate within a reasonable time once applied. “Dyne” may be measured by the dyne test, also known as the ink method. This method is based on the ASTM 2578/ISO 8296 standard for measuring surface energy. It can be performed using various specialized equipment, such as dyne pens where a dyne pen, in a non-limiting example, may be used to determine the wetting ability of a plastic sheet.

[0034] As used herein, a “pinning lamp” refers to a lamp with a low energy source that partially cures a deposited substance, including inks, to keep the substance in place after being deposited (i.e., to prevent the substance from migrating). A pinning lamp does not completely cure and cross-link the substance. This allows other color droplets to be added to the initially deposited droplet to create the proper color for a spot area being printed. In such an example, a first layer may be deposited, partially cured (i.e., “pinned”), and then have an additional layer of ink deposited onto the first layer. The additional layer can then be “pinned,” and the process can be repeated as needed. In examples using single-pass printers, “pinning” can occur between applications of colors. Once ready, a final combination of deposited substance layers and/or colors, such as multiple ink colors or multiple layers of ink, is then be exposed to a high-energy ultraviolet (UV) lamp to completely cross link the substance. Pinning can be applied to both UV- cured substances (e.g., inks), as well as hybrid substances including water-based and UV-curable components.

[0035] As used herein, “printed substrate” refers to a base substrate, such as a film, layer, or other aspect of a chosen material, onto which a printed layer of a substance has been deposited. In most examples, the deposited substance on a base substrate has undergone a curing process in the context of a “printed substrate.” In some examples, the deposited substance may not have undergone a curing process or at least a partial curing process. “Printed substrate” may also refer to aspects where there is an intervening layer between the base substrate and the printed layer. In such examples, the intervening layer may be an adhesion promoter or adhesive. In such examples, an adhesion promoter or adhesive may be layered onto a base substrate before a print layer is then deposited and at least partially cured, creating a “printed substrate.” As a nonlimiting example, a “printed substrate” may be a substrate including a UV-curable ink layered thereon, the UV-curable ink layer formed by printing or otherwise depositing a UV-curable ink layer on a substrate and at least partially curing the ink.

[0036] The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and their previous and following description. However, before the present devices, systems, components, and methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, components, and methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.

[0037] Digital printing of ultraviolet (UV) curable inks onto a variety of substrates may be used for various industrial applications, including but not limited to the flooring, walling, furniture, bill boards, trailer sides, building facades, decorative items, and other applications relating to uses and creations of surface materials. Digitally printing such inks directly onto a substrate creates a thermoset barrier on the substrate post-curing. This thermoset barrier (i.e., the ink) presents a number of issues when applying additional layers of material to the now-printed substrate, including, but not limited to, during application of additional layers by foil lamination, film lamination, heat lamination of films, adhering additional films with adhesives, and the like. As an example, UV-cured inks and electron-beam cured (e-beam cured) inks may create a thermoset layer on top of a substrate where the thermoset layer prevents an additional, thermoplastic layer from being heat laminated onto the substrate. In such an example, the heat lamination cannot achieve proper bond strength due to the adhesion barrier created by the thermoset layer.

[0038] The present disclosure relates to printed substrates and methods of creating, coating, adhering additional layers to, and combinations thereof such substrates. The present disclosure relates to selectively printing at least one layer of ink onto a base substrate to allow for addition of additional layers to the substrate after the ink layer has been cured, i.e., through the use of voids in the printed layer. [0039] The present disclosure relates to a base substrate 100 with a print layer 200 containing voids 230 that allows a top layer 300 (e.g., a protective coating) to adhere to both the print layer 200 and the base substrate 100, as shown in FIG. 7.

[0040] A base substrate 100 includes a first surface 110 and a second surface 120 where the first and second surfaces 110, 120 are on opposing sides of the base substrate 100. As non-limiting examples, a base substrate 100 may be made of a variety of materials depending on a desired application. Desired applications include but are not limited to flooring, walling, furniture, bill boards, trailer sides, building facades, decorative items, roofing, and the like. Materials of a base substrate 100 include but are not limited to a number of polymers. Polymers may include but are not limited to polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), other polymer films, any combinations thereof, and the like. Additional materials of a base substrate 100 may include any material on which a UV-cured layer of ink may be printed. Such additional materials may include but are not limited to paper, cellulosic materials, wood-based materials, high-density fiberboard (HDF), medium-density fiberboard (MDF), low-density fiberboard (LDF), coated fiberboards, including melamine-formaldehyde- coated or urea-formaldehyde-coated fiberboards, metals, leathers, cloth-based materials, ceramics, glass, and the like.

[0041] Material selection of a base substrate 100 may be made according to a desired dyne of the base substrate 100 material, as defined herein. As such, a material may be selected that will be compatible with a given ink to be printed, as denoted by a material’s dyne value. Materials with dynes that are too low may not properly be wetted by or otherwise interact with a printed material (e.g., an ink). Though adhesion promoters, as described herein, may be used to enhance wetting of a base substrate 100 with a printed substance, it may be desired to choose a material with a sufficient dyne to avoid use of adhesion promoters. As a non-limiting example, dynes above about 35 of a base substrate 100 material will allow the material to be properly wetted by UV-cured inks. In such examples, dynes may not need to be as high in certain areas where voids 230, as further discussed herein, may exist. In such areas, where an ink is not in contact with a base substrate 100 material, a higher dyne level may not be needed. In such areas, dyne levels do not affect the interaction between a base substrate 100 and additional layers, as further discussed herein. [0042] As a non-limiting example, PVC may be used as the material of a base substrate 100. In such an example, a PVC film with a dyne level of about 38 or more may be desired. Such dyne level may allow for better adhesion of an ink layer, described further below, to the base substrate 100. The dyne level of a base substrate 100 may not be as applicable to the adhesion of additional layers, such as a heat lamination layer, as discussed further herein. In an additional non-limiting example, a base substrate 100 of a PET material may require an adhesion promoter, including but not limited to an acrylic-based primer for better ink adhesion, due to a lower dyne value of PET compared to PVC. In such an example, the use of an adhesion promoter would also allow for better adhesion of additional layers in addition to promoting adhesion of ink to the base substrate 100. Additional layers include but are not limited to a heat laminated film, wear layers, layers applied using adhesives, curable polymeric layers, such as a polyurethane reactive (PUR) layers, and the like, as discussed further herein.

[0043] The present disclosure relates to one or more printed layers 200. A printed layer 200 is provided by printing a material onto a surface 110, 120 of a base substrate 100 and includes a first surface 210 and a second surface 220. A printed layer 200 may be printed onto a first surface 110, a second surface 120, or both surfaces 110, 120 of the base substrate 100. Materials printed onto the base substrate 100 to create a printed layer 200 include but are not limited to inks, UV-cured inks, electron-beam cured (e-beam cured) inks, aqueous inks, non-aqueous inks, dyes, latex inks, paints, soluble pigments, and various other inks and applications that create an adhesion barrier when cured is used. As a non-limiting example, ink may be printed onto a base substrate 100. Print layers 200 are cured after being applied to a base substrate 100 to set the print layer 200 and adhere it to the base substrate 100. Curing may occur through any appropriate process known in the art, including but not limited to UV-curing, heat curing, drying, and the like. Traditional methods of printing and curing print layers 200 create thermoset barriers on top of a base substrate 100, as shown in FIGS. 1-1 A. Such thermoset barriers prevent effective additions of additional layers. As a non-limiting example, a thermoset barrier may prevent effective heat lamination of an additional layer, such as a laminate.

[0044] The present disclosure relates to print layers 200 that overcome obstacles associated with traditional printing and curing techniques that create thermoset barrier layers by applying print layers with voids 230 within the print layer that leave exposure of a portion of the surface(s) 110, 120 of the base substrate 100. In such aspects, print layers 200 include a plurality of voids 230. Selectively creating voids 230 in a print layer 200 enhances the ability to bond or apply additional layers 300 to a printed substrate including a base substrate 100 and a printed layer 200 that has been printed on a first surface 110 or second surface 120 of a base substrate 100. Voids 230 enhance applications of additional layers 300, as further described herein, by allowing the additional layer 300 to interact directly with the base substrate 100, instead of the printed layer 200 where the printed layer 200 includes a thermoset barrier. While some bonding does occur with the printed layer 200, the voids 230 provide a direct connection between an additional layer 300 and a base substrate 100, or other substances that the additional layer 300 more readily bonds to compared to the additional layer 300 bonding to the print layer 200, that has better bonding properties for the coupling of the additional layer 300. In examples where the additional layer 300 does not directly contact the base substrate 100, an additional layer 300 may contact and bond, attach, or couple to an adhesive or adhesion promoter, as further described herein. [0045] In an aspect, especially with printed inks, printed ink is placed on the substrate based upon a raster image file, which is made up of an array of regularly sampled values, known as pixels. Each pixel (picture element) has one or more numbers associated with it, specifying a color which the pixel should display. In such aspects, the voids 230 can correspond to the removal of pixels in the raster image file. Pixel voids 230 refer to individual pixels or regions of pixels that would normally be printed, such as with a dye, onto a base substrate 100 but that have been selectively left empty, such as not being printed, according to the present disclosure. In some aspects, the voids 230 can be made from several adjacent pixels. As a non-limiting example, when the print layer 200 is created by depositing drops of a UV-cured ink onto a base substrate 100, voids 230 may be the same size as an omitted ink droplet. In such examples, individual voids 230 may range from about 25 micrometers up to about 120 micrometers in diameter or width. In such examples, the diameter or width of an individual void 230 may correspond to the diameter or width of a missing drop of ink. In other examples, the voids 230 may correspond to multiple individual drops of ink in adjacent pixels. Though voids 230 may be created in circular shapes, non-circular geometries are also possible according to the present disclosure. Voids 230 can include various shapes. Such shapes can be created using the methods described herein while also using a filter to make the voids 230 and the image created by a printed layer 200 have various shapes. Using various shapes may also allow creating gradients and organic or geometric shapes in the printed image. [0046] As a non-limiting example, an additional layer may effectively bond with the material of a base substrate 100 but may not effectively bond with a thermoset barrier of a printed layer 200. In such an example, introducing voids 230 into the printed layer 200 allows the two materials that are capable of binding together (i.e., the base substrate 100 and the additional layer) to come into contact. This overcomes obstacles in the prior art where an additional layer can only come into contact with the printed layer 200 with which the additional layer cannot bind. As such, the introduction of voids 230 according to the present disclosure allows enhanced binding of an additional layer onto a printed substrate.

[0047] Voids 230 may be selectively created using a number of techniques. When raster image files are used to for the print layer 200, pixel voids 230 will typically be selectively created to create voids 230 without lowering the image quality and still maintaining the overall/general recognizability or appearance of the image/image pattern. As a non-limiting example, one or more colors to be printed onto a base substrate 100 may intentionally be omitted using a digital imaging software prior to printing the print layer 200. The removal of the pixels may be accomplished by adjusting a script or print design used for digital printing.

[0048] As a non-limiting example, FIG. 2A displays a pixel view of a virtual representation of a print design that includes several omitted pixels. In such an example, FIG. 2B then displays the estimated ink pattern that would be printed by implementing the print design of FIG. 2A. The estimated ink pattern of FIG. 2B includes simulated rounding effects associated with voids 230. Such rounding effects occur where introducing voids 230 into a print layer 200 may not create voids 230 that match omitted pixels (e.g., square pixels) in a one-to-one aspect. Actual voids 230 may instead be rounded, not square, unlike pixels in a digital print design. Rounding effects may be caused by printed substances migrating prior to being fixed (e.g., by a UV light source), as discussed further herein. FIGS. 2C-2D display an actual ink pattern printed by implementing the print design of FIG. 2A.

[0049] As a non-limiting example, FIG. 3A displays an example of where pixels are being selected by a computer program to produce the print design in FIG. 3B, which includes a void pattern also seen in FIG. 2A. FIG. 3B provides an example printed substrate where a void pattern may be printed in addition to the pattern seen in FIG. 2A.

[0050] In addition, the removal of the pixel colors can be done based upon a threshold of a selected color. For example, if a pixel selected with a given RBG value (e.g., R: 123, B: 123, G:123) is selected, and a threshold of 6 is utilized, the software can remove all pixels with values that fall within the threshold (e.g., R:117-129; B: 117-129; G: 117-129); otherwise, without selecting a threshold range, it is possible that not enough pixels are eliminated to create voids 230 to ensure adhesion between the upper layer 300 and the substrate via the voids 230. By omitting one or more colors, the print layer 200 will include a plurality of voids 230 where pixels of the omitted color would have been printed. As a non-limiting example, an image program including minor scripts or input requests may be used to allow a user to select a color and amount of such color to remove. Selections of color and amount of color to be removed may be based on the image or design to be printed and the color of the base layer film, as further discussed herein. As non-limiting examples, image programs such as Gimp may be used.

[0051] As a non-limiting example, voids 230 may be selectively created by removing the lightest color in a digital image to be printed using a digital image program, as described above, though any color may be omitted. In such an example, in addition to removing the lightest image color, the color of the base substrate 100 may be selected to minimize aesthetic deficiencies caused by removal of a color from the printing design. In such an example, a base substrate 100 of the same color, or a similar color, as the color omitted from the printing design may be selected. Such selection may mitigate any potential lack of color at voids 230 caused by omitting a printed material, such as an ink, as shown in FIGS. 4A-4B. FIGS. 4A-4B show the effect of choosing a base substrate 100 of a color similar or identical to a color being omitted where overlaying the print layer 200 on the base substrate 100 mitigates deficiencies in the print design. Such selection may reduce any apparent contrast or distortion in a final product. Omitting light colors may be advantageous where omitting dark colors may require the use of a dark substrate 100. Dark substrates 100 may be costlier and may cause more distortion in a final image due to higher energy absorption by a base substrate 100 during curing. FIGS. 5-5A displays an example using a white base substrate 100. Such example shows the increased contrast created when a color is omitted from a print design and then printed onto a white base substrate 100. FIGS. 6-6A displays an example where the color of the base substrate 100 has been selected to match the omitted color of the pixels, displaying less contrast compared to FIGS. 5-5A.

[0052] As a non-limiting example, a color may be selected to be omitted that matches the color of a base substrate 100. In such an example, a color to be omitted may be selected based on the color of a base substrate 100 rather than selecting the color of a base substrate 100 to match a color being omitted. In other examples, a color to be omitted may be pre-selected with the color of a base substrate 100 later selected to match the pre-selected, omitted color. In examples where a base substrate 100 and the color being omitted from a print design match, the void percentage of a printed layer 200 may be increased compared to examples where the base substrate 100 and color omitted do not match, such as with a white base substrate 100 and a brown omitted color. [0053] As a non-limiting example, when the color of a base substrate 100 is selected to be nonwhite, the printing design will need to be calibrated to have a white balance calibration. This requires color adjustments in the rest of the print area. In such an example, a non-white substrate 100 will cause a color shift in the print. A white balance calibration applied to the design counteracts the shift caused by the non-white substrate 100 to provide a proper result in the printed image. As a non-limiting example, if a substrate 100 is a brown fdm, then the print depth of color is modified to account for the color shift caused by the brown film.

[0054] Voids 230 may additionally be created using other selection methods outside of removing one or more selected colors. Voids 230 may be created by indiscriminately selecting pixel locations throughout a print design to be omitted during printing. As a non-limiting example, patterns of voids 230 may be created using a grid and then overlaid onto a print design to determine which pixels to omit. In such an example, voids 230 may affect a variety of colors included in a print design. In other instances, the voids 230 can be incorporated into the design of the image. That is, the voids 230 can be strategically placed within the image in order to form a pattern of the image. As non-limiting examples, voids 230 may be strategically designed to create patterns including zig-zag, wavy-line, spline (i.e., to create a wood grain), and vein (i.e., to create a stone effect) patterns. In additional examples, machine learning methods may be applied to select pixels to be omitted while still achieving a desirable level of or absence of contrast or distortion in a final product. In such examples, outputs of a machine learning algorithm can be scored based on desired contrast and image quality to train a model for selecting pixels to be omitted as voids 230 in the future. In such examples, machine learning may allow for a model to be trained that is capable of creating a minimal amount of voids 230 to ensure proper adhesion of additional layers. In such examples, minimal void 230 creation may be desired for darker images where a maximal amount of ink may be desired. Machine learning methods include known training methods, such as neural networks, clustering, reinforcement learning, and any learning method capable of being trained on outputs of product quality to intelligently calibrate void 230 creation. Machine learning also includes deep learning.

[0055] In additional, non-limiting examples, voids 230 may be created by randomly or semirandomly choosing pixels to be omitted using a computer software. Distributions of pixel omission may be designed to be uniform or non-uniform as implemented by the software.

[0056] Voids 230 may additionally be disposed around the edges of a print design. In such an example, edges of a print design may include increased concentrations of voids relative to void concentrations on the interior of a print design. Such enhanced void concentration along the edges of a print design may enhance binding of an additional layer where the additional layer is allowed to substantially interact with the base substrate 100 along the edges. Such interaction creates a stronger bond between the additional layer and the printed substrate to prevent delamination.

[0057] In all examples, voids 230 may be introduced as to have a given percentage of the printed layer 200. In an aspect, the surface area of the printed layer 200 attributable to voids 230 can make up twenty (20) percent to fifty (50) percent of the printed layer 200 over the substrate. For example, if a pixel count of 306 dpi (dots per inch) is used there can be a possibility of 14,517 dots per cm². Using the range between 20 to 50 percent, a count of voids per area (that is, missing dots/pixels) would range from about 2,903 (20%) to 7,258 for 50% for the 306dpi. If the resolution or dpi changes then these numbers of missing dots/pixels would change as well based upon the percentage chosen for the voids 230. In addition, the size and the shape of the voids 230 can vary based upon the number and concentration of adjacent missing dots/pixels. In an aspect, the size and shape of the voids 230 can be generated randomly, or can be selected based upon input parameters, or a mixture of both.

[0058] After a printed layer 200 including selected voids 230 is printed onto a base substrate 100, the printed layer 200 is at least partially cured. As a non-limiting example, a printed layer 200 can be fully cured after being applied to a base substrate 100 and before coupling an additional layer to the printed substrate. In additional, non-limiting examples, a printed layer 200 can be partially cured before an additional layer is coupled to the printed substrate. Then, the product including a printed substrate and an additional layer coupled thereto can be cured together. This will complete the curing of the partially cured printed layer 200 and also adhere the additional layer to the printed substrate via the curing process. [0059] As described herein, curing can occur through any method known in the art. Curing methods include but are not limited to UV-curing, heat curing, drying, and the like. As a nonlimiting example, UV-curing methods may use any appropriate UV source including but not limited to LED, mercury, or galium lamps. UV-curing methods may apply energy at wave lengths of about 300 nm up to about 500 nm. In further examples, energy may be applied from about 315 nm up to about 485 nm, about 330 nm up to about 470 nm, about 345 nm up to about 455 nm, about 360 nm up to about 440 nm, about 375 nm up to about 425 nm, and about 390 nm up to about 410 nm. The introduction of voids 230 into a printed layer 200 may create difficulties before and during curing. Such difficulties may include the migration of a substance deposited during printing, including but not limited to ink, into voids 230 before curing can occur. Such migration would decrease the impact of voids 230 on allowing a base substrate 100 and an additional layer to bind.

[0060] The present disclosure relates to methods of preventing migration of a substance deposited during printing, including but not limited to ink. Migration is prevented from the time of deposit, including but not limited to when ink is initially dropped onto a base substrate 100, until the end of a curing process that cures the substance. Migration prevention may include methods of partially curing or increasing the cross-linking of a deposited substance to prevent the deposited substance from flowing freely across a base substrate 100. As a non-limiting example, a base substrate 100 with a low dyne level may also prevent migration where an ink may tend to hold a round, droplet shape instead of migrating across the base substrate 100. In additional, nonlimiting examples, base substrates 100 with higher dyne levels may allow deposited substances to more freely flow across the base substrate 100 laterally. Methods of preventing migration further include methods of applying surface treatments to a base substrate 100 before depositing a substance to be cured. Surface treatments applied to a base substrate 100 prevent substances deposited on the base substrate 100, including but not limited to inks, dyes, paints, soluble pigments, and the like, from migrating on the surface before the deposited substance is cured. This prevents a deposited substance from potentially migrating into intentionally created selective voids 230, as described herein. Migration of deposited substances pre-curing may also be achieved by using “pinning” lamps during the printing process.

[0061] As described above, the present disclosure relates to selectively introducing voids 230 into a printed layer 200 deposited onto a first surface 110, a second surface 120, or both surfaces 110, 120 of a base substrate 100. Voids 230 overcome obstacles associated with coupling additional layers 300 to a printed substrate by allowing the additional layer 300 to directly interact with the base substrate 100 instead of the printed layer 200 because the additional layer and printed layer 200 may not effectively bind. Similar to the printed layer 200, the additional layer 300 includes a first surface 310 and a second surface 320, as shown in FIG. 7. In an aspect, the voids 230 will receive filling portions 330 (from the second surface 320 as shown in FIG. 7) of the additional layer 300.

[0062] In non-limiting examples, filling portions 330 may be present when an additional layer 300 is applied as a curable liquid. In such aspect, the curable liquid will be received by voids 230 and come into contact with a base substrate 100. The additional layer 300 can then be cured to couple the additional layer 300 to the printed substrate where the cured layer 300 is in direct contact with the base substrate 100 where voids 230 are located. In additional aspects where the additional layer 300 is a solid layer, the additional layer 300 may first be disposed above a surface 210, 220 of the printed layer 200. The additional layer 300 may then be coupled to the printed substrate by processes including heat lamination. As a non-limiting example, heat lamination may cause an additional layer 300, such as a polymeric film, to at least partially melt and enter voids 230. This creates filling portions 330 received in voids 230 coupling the additional layer to the printed substrate where the additional layer 300 is now in contact with the base substrate 100 where voids 230 are present.

[0063] Additional layers 300 include but are not limited to wear films that prevent unwanted wear on a finished product. Wear films may be thermoplastic wear films. Wear films include but are not limited to polymers. Polymers include but are not limited to PET, PVC, PP, PE, and any other polymers capable of preventing wear on a finished product. Additional layers may be solid when applied to a printed substrate or liquid.

[0064] In the example of applying a solid, additional layer 300, the layer may be applied to the printed substrate by using heat lamination. The presence of voids 230, as described herein, allows the additional layer to more substantially contact the base substrate 100 during heat lamination, more strongly bonding the additional layer to the printed substrate.

[0065] In the example of applying a liquid, additional layer, the layer may be applied by depositing the liquid onto the printed substrate and then curing the additional, liquid layer by curing methods disclosed herein. When deposited, a liquid additional layer will migrate into the voids 230 in the printed layer 200 to allow the liquid to come into contact with the base substrate 100. The liquid layer is then cured to solidify its contact with the base substrate 100. As a nonlimiting example, a liquid layer may include various materials capable of being deposited and cured into a wear layer. Such materials include but are not limited to polyurethane reactive (PUR). In the example of PUR, PUR may be utilized for three purposes, as described herein. In the first example, PUR may be used as an additional, wear layer 300, as described above. In such example, it may be advantageous to further coat the liquid-poured PUR layer 300 with a UV- cured scratch coat. PUR can then be cured by moisture and cross-linking or by application of energy, such as by a UV-curing process. In the second example, PUR may be used as an adhesion promoter, as described herein, to promote adhesion between a printed layer 200 and a base substrate 100. In such an example, the printed layer and the PUR adhesion promoter may be cured before an additional layer 300, as described above, may be applied and coupled to a printed substrate. In the third example, PUR may be used as an adhesive applied to a printed substrate before coupling an additional layer 300, such as a polymeric film, to the printed substrate, as described further below.

[0066] Additional materials capable of being used as additional layers 300 include solutions and films of polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), ultraviolet-cured (UV-cured) polyurethane, any combinations thereof, and the like.

[0067] In an additional, non-limiting example, adhesives may also be used when coupling an additional layer to a printed substrate. Adhesives may be used when using voids 230 alone to couple an additional layer 300 to a printed substrate is insufficient, such as where an additional layer 300 may de-couple from a printed substrate. In such examples, an adhesive may be applied to the printed substrate where the adhesive will migrate into voids 230 of the printed layer 200. An additional layer 300 can then be placed on top of the layer of adhesive and coupled to the printed substrate. As a non-limiting example, PUR, modified silanes and solutions thereof, modified terminated polymers and solutions thereof, and the like may be used as adhesives. In examples using an adhesive, the adhesive may be cured, according to curing methods described herein, once the additional layer has been placed on top of the adhesive layer. The curing process will thus bind the additional layer to the printed substrate. [0068] In some examples, the present disclosure relates to the use of one or more adhesion promoters for promoting the adhesion of a deposited substance in a print layer 200 to a base substrate 100. In such examples, a deposited substance may not readily adhere to or wet the base substrate 100 upon which it is deposited. As a non-limiting example, a UV-curable ink may not readily adhere or stick to or wet a polymeric fdm, including but not limited to a PET, film onto which it is deposited. In such examples, an adhesion promoter can first be deposited onto the base substrate 100 before depositing the substance of the printed layer 200, including but not limited to ink. Adhesion promoters include but are not limited to primers, solvent-based primers, paint primers, acrylic-based primers, and the like. Adhesion promoters may also reference mechanical surface treatments that increase surface tension on a base substrate 100 before a print layer 200 is deposited. Such treatment-based adhesion promoters include corona surface treatments, plasma surface treatments, ozone surface treatments, and the like. In examples where an adhesion promoter is applied as a liquid, solution, or the like, such as with an acrylic-based primer, the adhesion promoter may be chosen to include a color of a pixel to be omitted. Such a selection is similar to selecting a base substrate 100 to match the color of an omitted pixel, as described herein. Selecting an adhesion promoter to match the color of an omitted pixel may decrease unwanted contrast and otherwise improve image quality of a printed substrate.

[0069] In examples using an adhesion promoter, such as when needed to make a printed layer 200 adhere to a base substrate 100, the printed layer 200 is then deposited on top of the layer of the layer of adhesion promoter. As such, when additional layers 300, as described above, are coupled to the printed substrate, the additional layer 300 will come into contact with the adhesion promoter layer, not the base substrate 100, through voids 230 of the printed layer 200. Adhesion promoters also increase the bonding strength of an additional layer 300 to a printed substrate where the adhesion promoter and material of the additional layer 300 are compatible for bonding. In such examples, the adhesion promoter may both promote adhesion of the deposited print layer 200 to the base substrate 100 and serve as an adhesive to bind the additional layer 300 to the printed substrate. As a non-limiting example, a layer of an acrylic-based primer may be deposited onto a base substrate 100 of a PET film that is then printed using a UV-cured ink. After curing, an additional layer, such as a thermoplastic wear film or other additional layers discussed herein, may then be coupled to the printed substrate through heat lamination. The additional layer and the acrylic-based primer will come into contact through voids 230 of the printed layer 200 and effectively bind during heat lamination.

[0070] It is to be understood that any combinations of devices, embodiments, aspects, and examples of the above disclosure are within the scope of the present disclosure. Any number of base substrates 100, including but not limited to one, two, three, four, or more, of any material, including but not limited to PET, PVC, PP, PE, and any other polymers can be used with or without any number of layers of adhesives, adhesion promoters, and/or deposited print layers 200, including but not limited to inks, UV-cured inks, electron-beam cured (e-beam cured) inks, aqueous inks, non-aqueous inks, dyes, paints, soluble pigments, and the like, applied to a first surface 110, a second surface 120, or both surfaces 110, 120 of a base substrate 100 to create a printed substrate. Printed substrates may be coupled with any additional layer disclosed herein by any method of coupling disclosed herein. It is to be understood that any number of further layers may also be applied to the outer surface of embodiments disclosed herein. As a non-limiting example, an additional layer coupled to a printed substrate may further be coupled, on its exposed surface, to a scratch coat for flooring products.

[0071] The present disclosure relates to an example of a product or a decorative article including a base substrate 100, including a first surface 110 and a second surface 120, with a printed layer 200, including a first surface 210 and a second surface 220, deposited onto the base substrate 100 as a UV-curable ink and at least partially cured to form a printed substrate. The printed layer 200 includes selectively deposited voids 230 that extend completely through the printed layer 200 from a first surface 210 to a second surface 220. Such voids 230 can be selectively deposited using any method disclosed herein. The printed substrate further includes an additional layer coupled thereto. In such an example, a product or decorative article may include a base substrate 100, a printed layer 200 deposited onto and cured onto a surface 120 of the base substrate 100 where the first surface 210 of the printed layer 200 abuts the surface 120, and an additional layer coupled to the remaining surface 220 of the printed layer 200 where the printed layer has been at least partially cured before addition of the additional layer. Materials to be used for a base substrate 100, a printed layer 200, and an additional layer are disclosed herein and can be used in any combination.

[0072] The present disclosure additionally relates to a non-transitory computer readable medium or software to selectively create voids 230 in a printed layer 200, according to methods described herein. Such computer readable medium or software may select a color, set a threshold value associated with RGB values of the selected color, and delete pixels having RGB values that fall within said threshold value of the RGB value of selected color. An image can then be generated to be printed (e.g., a print design), created by the computer readable medium or software to, with deleted pixel values where a raster file is created of said image. As a non-limiting example, vector files may be used in a computer readable medium or software. In such examples, Raster Imaging Processor (RIP) software may be used to give complete control over files to be printed. Such control allows accurate and precise scaling, color correction, rotation, dot size and opacity choosing, and the like required for selectively creating voids 230 in print designs, as discussed herein. In such examples, RIP files control printer actions to selectively create voids 230 from a computer via a vector file. As a non-limiting example, rasters refer to pixel-based high resolution images for making high detailed images and photos according to the present disclosure.

[0073] The present disclosure relates to an example of a method for creating a product or decorative article including a base substrate 100, a printed layer 200, and an additional layer coupled thereto. In such an example, a base substrate 100 is provided. A raster file may then be created according to methods disclosed herein to create a print design selectively omitting certain pixels based on methods disclosed herein. Such raster file may then be used to print the design onto the base substrate 100, creating a printed layer 200. Optional steps, including the use of a pinning lamp, may be used to immobilize the deposited print layer 200 before curing. A printed layer 200 may then be at least partially cured. An additional layer may then be disposed adjacent an exposed surface 210 or 220 of the at least partially cured printed layer 200 and coupled thereto by a curing process or any method disclosed herein.

[0074] Although several aspects have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects will come to mind to which this disclosure pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the disclosure is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of any claims that can recite the disclosed subject matter.

[0075] It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and subcombinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.

EXAMPLES

Example 1.

[0076] Images with selected levels of removed pixels are printed onto a base substrate. The printed substrate is then heat laminated and tested for pull force. Adhesion values using the standard print method with no print ink open area, as shown in FIGS. 1-1 A, result in 3 force pounds of pull strength. Additional printed substrates are created with voids introduced, as shown in FIGS. 5-6A. Adhesion values with of printed substrates with 3% of pixels removed during printing result in 5 force pounds of pull strength. Adhesion values with of printed substrates with 10% of pixels removed during printing result in 8 force pounds of pull strength.

Claims

1. A product comprising a printed substrate, the printed substrate comprising: a. a base substrate, wherein the base substrate includes a first surface and a second surface, wherein the second surface opposes the first surface; and b. a printed layer deposited onto a surface of the base substrate and cured, wherein the printed layer comprises a plurality of voids, wherein the plurality of voids is selectively configured to provide enhanced coupling abilities.

2. The product of claim 1, wherein the base substrate includes a material, and wherein the material is selected from polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), paper, cellulosic materials, wood-based materials, high-density fiberboard (HDF), medium-density fiberboard (MDF), low- density fiberboard (LDF), coated fiberboard, melamine-formaldehyde-coated fiberboard, urea-formaldehyde-coated fiberboard, metals, leathers, cloth-based materials, ceramics, and glass.

3. The product of claim 1, wherein the printed layer includes a material, and wherein the material is selected from inks, UV-cured inks, electron-beam cured (e-beam cured) inks, aqueous inks, non-aqueous inks, powdered inks, PET-powdered inks, dyes, paints, and soluble pigments.

4. The product of claim 1, wherein the printed layer includes a percentage of voids relative to a printed material over the area of the base substrate, and wherein the percentage ranges from about 20 percent to 50 percent per cm².

5. The product of claim 1, wherein the product further comprises one or more additional layers, wherein the one or more additional layers are coupled to the printed substrate, and wherein the plurality of voids in the printed layer enhances the coupling.

6. The product of claim 5, wherein the one or more additional layers comprise a material, wherein the material is selected from polyethylene terephthalate (PET), polyvinyl chlorine (PVC), polypropylene (PP), polyethylene (PE), and polyurethane reactive (PUR), and ultraviolet-cured (UV-cured) polyurethane.

7. The product of claim 5, wherein the product further comprises an adhesive, wherein the adhesive is deposited on top of the printed layer and beneath the additional layer.

8. The product of claim 1, wherein the product further comprises an adhesion promoter, and wherein the adhesion promoter is disposed between a surface of the base substrate and the printed layer.

9. A method of creating a product, the method comprising: a. providing a base substrate, wherein the base substrate comprises a first surface and a second surface, and wherein the first surface opposes the second surface; b. selectively depositing a substance above a surface of the base substrate, wherein the substance is selectively deposited to include a plurality of voids; and c. curing the substance selectively deposited above the surface of the base substrate.

10. The method of claim 9, wherein the substance is selectively deposited by choosing a color from a design comprising multiple colors and depositing all remaining colors of the substance included in the design, excluding the chosen color, above the surface of the base substrate.

11. The method of claim 9, wherein the substance is selectively deposited to reduce the amount of deposited substances around an edge of the base substrate.

12. The method of claim 9, wherein an adhesion promoter is deposited between the base substrate and the substance deposited above the surface of the substrate.

13. The method of claim 9 further comprising a step of coupling an additional layer to the product.

14. The method of claim 13, wherein the additional layer is placed above the cured layer of the deposited substance and coupled to the base substrate and the deposited substance through heat lamination, and wherein the additional layer contacts the base substrate by extending through the voids in the selectively deposited substance.

15. The method of claim 13, wherein the additional layer is deposited as a liquid above the base substrate and the deposited substance and then cured to couple the additional layer to the base substrate and the deposited substance.

16. The method of claim 13, wherein an adhesive is first deposited above the base substrate and the deposited substance, wherein an additional layer is then placed above the adhesive, and wherein the adhesive is then cured to couple the additional layer to the base substrate and the deposited substance.

17. The method of claim 9, wherein the deposited substance is prevented from migrating into the plurality of voids between depositing and curing the substance, and wherein migration is prevented by applying a surface treatment to the base substrate before depositing the deposited substance.

18. The method of claim 9, wherein the deposited substance is prevented from migrating into the plurality of voids between depositing and curing the substance, and wherein migration is prevented by exposing the base substrate and the deposited substance to a pinning lamp.

19. A computer-implemented method for creating a printed substrate configured to provide enhanced adhesion of an additional layer to the printed substrate, the computer- implemented method comprising: a. providing a user interface allowing for inputs of various parameters, wherein the parameters to be input are selected from a color, a red-green-blue (RGB) threshold value associated with the color, a void percentage, and a pattern; b. creating a print design according to the inputs provided, wherein the print design is capable of being produced using machine learning; c. creating a set of instructions to be provided to a device configured to print designs onto a base substrate to create the printed substrate, wherein the instructions are created by using the print design; and d. causing the device to utilize the print design from the set of instructions to create the printed substrate.