Printed Foamed Film Packaging

Abstract

A method of constructing a package having printed indicia of acceptable quality includes providing at least one layer of foamed thin film and printing the indicia on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink. The layer of foamed thin film comprises a bio-based content of between about 10% and about 100%, a caliper of between 10 and 250 microns, and between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition, wherein a first surface of the at least one layer of foamed thin film is the printed surface of the package.

What is claimed is: 
     
         1 . A method of constructing a package having printed indicia of acceptable quality present on a printed surface, the method comprising:
 a. providing at least one layer of foamed thin film, wherein the layer of foamed thin film comprises:
 i. a bio-based content of between about 10% and about 100%; 
 ii. a caliper of between 10 and 250 microns; and 
 iii. between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition, wherein a first surface of the at least one layer of foamed thin film is the printed surface of the package; and 
   b. printing the indicia on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink;
 wherein the printer surface comprises a plurality of raised dots, the raised dots having top surfaces configured to contact the printed surface to imprint the indicia on the printed surface, and wherein the raised dots have a dot percentage of no greater than approximately 70%. 
   
     
     
         2 . The method of  claim 1 , wherein the raised dots have a dot percentage of between about 50% to about 60%. 
     
     
         3 . The method of  claim 1 , wherein the raised dots have a dot percentage of approximately 70%. 
     
     
         4 . The method of  claim 1 , wherein the ink is selected to have approximately a 20 second increased viscosity as compared to ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition. 
     
     
         5 . The method of  claim 1 , wherein the ink is selected as having an intensity that is approximately 30%-50% greater than an intensity of an ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition. 
     
     
         6 . The method of  claim 1  wherein the printed surface is contacted with the inked printer surface with a pressure that is greater than a printer pressure that would be used to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition. 
     
     
         7 . A method of constructing a package having printed indicia of acceptable quality present on a printed surface, the method comprising:
 a. providing at least one layer of foamed thin film wherein the layer of foamed thin film comprises:
 i. a bio-based content of between about 10% and about 100%; 
 ii. a caliper of between 10 and 250 microns; and 
 iii. between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition, wherein a first surface of the at least one layer of foamed thin film is the printed surface of the package; and 
   b. printing the indicia on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink;   wherein the printer surface comprises a half tone rotogravure print cylinder configured to contact the printed surface to imprint the indicia on the printed surface, the print cylinder having a dot percentage of no greater than approximately 70%.   
     
     
         8 . The method of  claim 7 , wherein the print cylinder has a dot percentage of between about 50% to about 60%. 
     
     
         9 . The method of  claim 7 , wherein the print cylinder has a dot percentage of approximately 70%. 
     
     
         10 . The method of  claim 7 , wherein the ink is selected to have approximately a 20 second increased viscosity as compared to ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition. 
     
     
         11 . The method of  claim 7 , wherein the ink is selected as having an intensity that is approximately 30%-50% greater than an intensity of an ink that would be selected to print substantially the same indicia on a print surface of a non-foamed thin film of substantially the same caliper and composition. 
     
     
         12 . A package comprising:
 a. at least one layer of foamed thin film, wherein the layer of foamed thin film comprises:
 i. a bio-based content of between about 10% and about 100%; 
 ii. a caliper of between 10 and 250 microns; and 
 iii. between 5% to 50% density reduction as compared to a non-foamed thin film of substantially the same caliper and composition, wherein a first surface of the at least one layer of foamed thin film is the printed surface of the package; and 
   b. printed indicia of acceptable quality that is printed on a printed surface of the package, wherein a first surface of the at least one layer of foamed thin film is the printed surface of the package.   
     
     
         13 . The package of  claim 12 , comprising a foamed thin film co-extrusion that has a layer comprising a foamed thin film that includes the printed surface. 
     
     
         14 . The package of  claim 12 , comprising a foamed thin film laminate that has a layer comprising a foamed thin film that includes the printed surface. 
     
     
         15 . The package of  claim 12 , wherein the indicia is imprinted on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink and wherein the printer surface comprises a plurality of raised dots, the raised dots having top surfaces configured to contact the printed surface to imprint the indicia on the printed surface, and wherein the raised dots have a dot percentage of no greater than approximately 70%. 
     
     
         16 . The package of  claim 15 , wherein the raised dots have a dot percentage of between about 50% to about 60%. 
     
     
         17 . The package of  claim 15 , wherein the raised dots have a dot percentage of approximately 70%. 
     
     
         18 . The package of  claim 12 , wherein the indicia is imprinted on the printed surface by applying ink to a printer surface and contacting the printed surface with the inked printer surface to coat the printed surface with ink and wherein the printer surface comprises a halftone rotogravure print cylinder configured to contact the printed surface to imprint the indicia on the printed surface, and wherein the print cylinder has a dot percentage of no greater than approximately 70%. 
     
     
         19 . The package of  claim 18 , wherein the print cylinder has a dot percentage of between about 50% to about 60%. 
     
     
         20 . The package of  claim 18 , wherein the print cylinder has a dot percentage of approximately 70%.