Combined Lithographic/flexographic printing apparatus and process

Abstract

A combined lithographic/flexographic printing process having a plurality of successive printing stations for printing color images on a substrate in a continuous in-line process. One of the stations prints a first color image using the flexographic process and at least one of the successive printing stations prints a second color image over the first color image using an offset lithographic process in the continuous in-line process.

1. Apparatus for a combined lithographic/flexographic printing process comprising:
 a substrate;  
 a plurality of successive printing stations for printing color images on the substrate in a continuous in-line process;  
 one of said stations comprising a flexographic printing station for printing a liquid vehicle image on said substrate with a slurry containing an encapsulated essence using the flexographic process;  
 at least one of said successive printing stations being a lithographic printing station; and  
 an overcoating applied over the liquid vehicle image on the printed substrate at at least one of said successive lithographic printing stations using the lithographic process in said continuous in-line process.  
 
     
     
       2. Apparatus as in  claim 1  wherein said overcoating is an aqueous overcoating. 
     
     
       3. Apparatus as in  claim 1  wherein said overcoating is an ultraviolet ink overcoating. 
     
     
       4. Apparatus as in  claim 1  wherein:
 said substrate is a paper sheet; and  
 said apparatus includes a sheet feeder.  
 
     
     
       5. Apparatus as in  claim 1  wherein:
 said substrate is a web; and  
 said apparatus includes a web feeder.  
 
     
     
       6. Apparatus for a combined lithographic/flexographic printing process comprising:
 a plurality of successive printing stations for printing color images on a substrate in a continuous in-line process;  
 one of said printing stations comprising a first offset flexographic printing station for printing an aqueous-based vehicle image using the flexographic process to form a metallic coating on said substrate;  
 a suspended metallic material being included in said aqueous-based vehicle image; and  
 a dryer disposed downstream of said first flexographic printing station in the direction of movement of said substrate with respect to said printing stations for treating said aqueous- based vehicle image; and    
 at least one of the successive printing stations comprising an offset lithographic printing station downstream of said dryer for printing a color image over the aqueous-based vehicle image using the offset lithographic process in said continuous in-line process.  
 
     
     
       7. Apparatus as in  claim 6  wherein said suspended material includes uniform-sized metal particles to form said metallic coating. 
     
     
       8. Apparatus as in  claim 6  wherein said suspended material includes nonuniform-sized metal particles to form said metallic coating. 
     
     
       9. Apparatus as in  claim 6  further including:
 said flexographic printing station including a plate cylinder having a flexographic plate thereon, a blanket cylinder, and an impression cylinder;  
 a flexographic plate image transferred from said plate cylinder to said blanket cylinder, said image being formed of said metallic coating, said impression cylinder in ink- transfer relationship with said blanket cylinder,  said blanket cylinder transferring said metallic coating to said impression cylinder  substrate for printing said flexographic plate image on said substrate; and  
 an anilox roller associated with said flexographic plate for supplying said aqueous-based vehicle containing said suspended metallic material to said flexographic plate.  
 
     
     
       10. Apparatus for creating a combined lithographic/flexographic printing process comprising:
 a plurality of successive printing stations for printing color images on a substrate in a continuous in-line process;  
 one of said stations comprising a first flexographic printing station for printing a first color image using the flexographic process; and  
 one of said stations downstream of the first flexographic printing station comprising a second flexographic printing station for printing or coating the substrate using the flexographic process;  
 at least one of the successive printing stations comprising an offset lithographic printing station for printing a second color image over the first color image using the offset lithographic process in said continuous in-line process.  
 
     
     
       11. Apparatus as in  claim 10  further including:
 said first flexographic printing station including a plate cylinder, a blanket cylinder, and an impression cylinder;  
 a flexographic plate on said plate cylinder;  
 an anilox roller associated with said flexographic plate for supplying a first color to said flexographic plate to form said first color image; and  
 said blanket cylinder receiving said first color image from said plate cylinder and transferring said first color image to said impression cylinder for printing on  said substrate.  
 
     
     
       12. Apparatus for creating a combined lithographic/flexographic printing process comprising:
 a substrate;  
 a plurality of successive printing stations for printing color images on the substrate in a continuous in-line process;  
 at least two successive ones of said printing stations being flexography stations and comprising: 
 (1) a supply of liquid coating;  
 (2) a plate cylinder associated with a blanket cylinder, said plate cylinder having a flexographic plate thereon;  
 (3) an anilox roller associated with said liquid supply coating and said plate cylinder for delivering said liquid coating to said flexographic plate to form an image for transfer to said blanket cylinder;  
 (4) an impression cylinder for receiving said liquid coating image transferred from said blanket cylinder and printing said image on said substrate, said at least two flexography stations printing the same liquid coating image in sequence and in superimposed relationship; and  
 
 at least one offset lithographic printing station for receiving said substrate and printing over said liquid coating image.  
 
     
     
       13. Apparatus as in  claim 12  wherein said liquid coating image printed on said substrate is a white color ink. 
     
     
       14. Apparatus as in  claim 12  further including an air dryer associated with each of said impression cylinders on said flexography stations, said air dryer having sufficient air velocity for drying said liquid coating before the substrate is transferred to the successive printing station in said continuous in-line process. 
     
     
       15. Apparatus for a combined lithographic/flexographic printing process comprising:
 a plurality of successive printing stations for printing color images on a substrate in a continuous in-line process, said printing stations including both lithographic and flexographic printing stations;  
 one of said printing stations comprising a first flexographic printing station;  
   one of said printing stations comprising a first lithographic printing station;    
 a blanket cylinder at at least a first one of  said first flexographic printing stations ;  
 an impression cylinder associated with said first flexographic printing station;  
 flexographic ink-providing means at said at least  first one of said  flexographic printing stations  for applying a flexographic ink to said blanket cylinder to form an image;  
 a substrate for receiving said flexographic ink image transferred from said blanket cylinder; and  
 at least one subsequenta second lithographic printing station in said in-line process for receiving said image printed substrate and printing an additional colored ink image on said substrate on top of said flexographic ink image using offset lithography.; and  
   a second flexographic printing station.    
 
     
     
       16. Apparatus as in  claim 15  further comprising:
 a plate cylinder at said at least first one of said  first flexographic stations ;  
 a flexographic plate on said plate cylinder for receiving and transferring said flexographic ink to said blanket cylinder; and  
 said flexographic ink-providing means including a flexographic ink supply and an anilox roller associated with said flexographic ink supply for transferring said flexographic ink to said flexographic plate.  
 
     
     
       17. Apparatus for a combined lithographic/flexographic printing process for printing a multicolored image comprising:
 a plurality of successive printing stations for printing color on a substrate in a continuous in-line process, said printing stations including both lithographic and flexographic printing stations;  
 at least  one of said flexographic printing stations being a first flexographic printing station having: 
 (1) a plate cylinder and a blanket cylinder, said plate cylinder including a flexographic plate having an image thereon for transferring a flexographic color ink image to said blanket cylinder;    (2) an etched anilox roller for applying a flexographic color ink to said flexographic plate on said plate cylinder;    (3) an impression cylinder in ink-transfer relationship with said blanket cylinder for transferring said flexographic color ink image from said blanket cylinder to said substrate; and    
 at least one of said succeeding printing stations being a lithographic printing station using offset lithography for printing additional colored ink images on top of said flexographic ink image. ; and  
   one of said flexographic printing stations being a second flexographic printing station.    
 
     
     
       18. Apparatus as in  claim 17  wherein said additional colored ink images are formed with lithographic inks. 
     
     
       19. Apparatus as in  claim 17  wherein said colored ink images are formed with waterless inks. 
     
     
       20. Apparatus as in  claim 17  further including an air dryer adjacent to said impression cylinder for drying the flexographic ink image transferred to said substrate before said additional colored ink images are printed thereon. 
     
     
       21. Apparatus as in  claim 17  further including halftone printing plates for printing said additional colored ink images. 
     
     
       22. Apparatus as in  claim 17  wherein said flexographic ink image and said colored ink images are printed as solid colors and/or with halftone printing plates in sequence and in registry in said successive printing stations to produce said multicolored image on said substrate. 
     
     
       23. Apparatus as in  claim 17  wherein said printing apparatus includes a sheet-fed press. 
     
     
       24. Apparatus as in  claim 17  wherein at least one of  said first flexographic printing stations  station prints said flexographic color ink image with liquid vehicle slurry containing an encapsulated essence. 
     
     
       25. Apparatus as in  claim 17  wherein at least one of  said first flexographic printing stations  station prints said flexographic color ink image with a water-based liquid vehicle containing suspended particles. 
     
     
       26. Apparatus as in  claim 25  wherein said suspended particles are uniform in size. 
     
     
       27. Apparatus as in  claim 25  wherein said suspended particles are nonuniform in size. 
     
     
       28. Apparatus as in  claim 25  wherein said suspended particles are metallic particles. 
     
     
       29. A method of combining lithography and flexographic printing in a continuous in-line process comprising the steps of:
 providing a plurality of successive lithographic/flexographic printing stations for printing colored ink images on a substrate;  
 printing a flexographic ink image on said substrate at  at least one of said  at a first flexographic stations  printing station;  
 transferring said printed substrate to at least one subsequent lithographic printing station in said continuous in-line process; and  
 printing colored ink images on top of said flexographic ink image at at least one of  said subsequent lithographic printing stations  station with an offset lithographic process; and  
   printing a coating on said substrate over said ink images at a second flexographic printing station .  
 
     
     
       30. A method as in  claim 29  further comprising the step of drying said flexographic ink image on said substrate with an air dryer prior to printing said colored ink images thereon. 
     
     
       31. A method as in  claim 29  further including the step of printing a coating on top of said colored ink images at one of said plurality of subsequent printing stations. 
     
     
       32. A method as in  claim 29  wherein said colored inks forming said colored  ink images are with waterless colored inks. 
     
     
       33. A method as in  claim 29  wherein said colored inks forming said  colored ink images are printed with colored ink in a solvent-based liquid vehicle. 
     
     
       34. A method as in  claim 29  further including the steps of:
 printing a slurry on said substrate at any of said printing stations in said continuous in-line process;  
 using an encapsulated essence in said slurry; and  
 printing an overcoating  said coating over said slurry at a subsequent printing station in said in-line process  to protect said essence.  
 
     
     
       35. A method as in  claim 34  further including  wherein the step of printing said coating comprises printing an aqueous-based coating over said slurry. 
     
     
       36. A method as in  claim 34  further including  wherein the step of printing said coating comprises printing an ultraviolet coating over said slurry. 
     
     
       37. A method of combining offset lithography and flexographic printing in a continuous in-line process comprising the steps of:
 providing a substrate;  
 applying a flexographic ink to a blanket cylinder in a pattern with a coating head at a first flexographic printing station;  
 transferring said pattern of flexographic ink from said blanket cylinder to the substrate; and  
 transferring said substrate to a second flexographic printing station;  
   applying a pattern of flexographic ink to the substrate using the second flexographic printing station; and    
 printing a waterless ink pattern over at least one of said flexographic ink pattern  patterns on said substrate at  using at least one subsequent offset lithographic printing station in said continuous in-line process.  
 
     
     
       38. A method of combining lithography and flexographic printing in a continuous in-line process comprising the steps of:
 printing an aqueous-based vehicle image having suspended particles therein on a substrate at a first flexographic printing station;  
 transferring said image printed substrate to at least one additional  a subsequent printing station in said continuous in-line process; and  
 printing additional colored ink images on said printed substrate over said aqueous-based vehicle image in an offset lithographic process at said at least one additional  subsequent printing station in said in-line process; and  
   printing a coating over said colored ink images on said substrate using a flexographic process .  
 
     
     
       39. A method of combining lithography and flexographic printing in a continuous in-line process comprising the steps of:
 (1) providing a plurality of successive printing stations for printing liquid vehicle images on a substrate in said in-line continuous process;  
 (2) utilizing an anilox roller to transfer a liquid ink as said liquid vehicle to a flexographic plate image at at least one of said printing stations;  
 (3) printing said liquid ink from said flexographic plate image to a substrate;  
 (4) transferring said printed substrate with said liquid ink image to a subsequent printing station in said in-line printing process;  
 (5) repeating steps (2)-(4) at subsequent printing stations in said in-line process to achieve a desired opacity ink image on said substrate; and  
 (6) printing an ink pattern over said flexographic ink image using an offset lithographic process.  
 
     
     
       40. A method as in  claim 39  further including the step of additionally printing colored ink images over said liquid ink image on said substrate at subsequent ones of said printing stations in said in-line process. 
     
     
       41. A method as in  claim 40  wherein said liquid ink is an opaque white color. 
     
     
       42. Apparatus for a combined lithographic/flexographic printing process comprising:
   a plurality of successive printing stations for depositing a series of images on a substrate in a continuous in - line process, said printing stations including, both lithographic and two flexographic printing stations;        a blanket cylinder at a first one of said flexographic printing stations;        a plate cylinder at said first one of said flexographic stations; and        a flexographic plate on said plate cylinder for receiving and transferring flexographic ink to said blanket cylinder;        a flexographic ink supply and an anilox roller associated with said flexographic ink supply for transferring flexographic ink to said flexographic plate and then to said blanket cylinder to form an image on one side of a substrate;        a substrate for receiving said flexographic ink image transferred from said blanket cylinder; and        at least one subsequent lithographic printing station in said in - line process for receiving said image printed substrate and printing an additional colored ink image on said substrate on top of said flexographic ink image.     
     
     
       43. A method of combining lithography and flexographic printing in a continuous in- line process comprising the steps of:    (   1   )  providing a plurality of successive printing stations for depositing a series of images on a substrate in said in - line continuous process;      (   2   )  utilizing an anilox roller to transfer a liquid ink as one of said series of images to a flexographic plate image at least one of said printing stations;      (   3   )  printing said liquid ink from said flexographic plate image to one side of said substrate;      (   4   )  transferring said printed substrate with said liquid ink image to a subsequent printing station in said inline printing process;      (   5   )  repeating steps  (   2   )-(   4   )  at subsequent printing stations in said in - line process to achieve a desired opacity ink image on the one side of said substrate; and      (   6   )  printing an ink pattern on said substrate using an offset lithographic process.      
     
     
       44. A method as in  claim 43  further including the step additionally printing ink images over said liquid ink image on said substrate at subsequent ones of said printing stations in said in- line process of.   
     
     
       45. A method as in  claim 44  wherein said liquid ink is an opaque white color. 
     
     
       46. Apparatus for a combined lithographic/flexographic printing process comprising:
   a plurality of successive printing stations for printing color images on a substrate in a continuous in - line process, the successive printing stations including:        a first flexographic printing station for printing an image on the first side of the substrate using the flexographic process;        a first lithographic printing station, subsequent in the continuous in - line process to the first lithographic printing station, for printing an image on the substrate using the lithographic process;        a second flexographic printing station, subsequent in the continuous in - line process to the first lithographic printing station, for printing an image on the substrate using the flexographic process; and        a second lithographic printing station, subsequent in the continuous in - line process to the second flexographic printing station, for printing an image on the first side of the substrate using the lithographic process.     
     
     
       47. Apparatus for a combined lithographic/flexographic printing process comprising:
   a plurality of successive printing stations for printing color images on a substrate in a continuous in - line process, the successive printing stations including:        a first flexographic printing station;        a first dryer, subsequent in the continuous in - line process to the first flexographic printing station;        a first lithographic printing station, subsequent in the continuous in - line process to the first dryer;        a second dryer, subsequent in the continuous in - line process to the first lithographic printing station;        a second flexographic printing station, subsequent in the continuous in - line process to the second dryer; and        a third dryer, subsequent in the continuous in - line process to the second flexographic printing station.     
     
     
       48. A method for a combined lithographic/flexographic printing process, the method comprising the steps of:
   providing a substrate having a first side and a second side;        printing an image on the first side of the substrate using a first lithographic printing station;        transferring the substrate from the first lithographic printing station to a first flexographic printing station;        printing an image on the first side of the substrate using the first flexographic printing station;        transferring the substrate from the first flexographic printing station to a second lithographic printing station;        printing an image on the first side of the substrate using the second lithographic printing station;        transferring the substrate from the second lithographic printing station to a second flexographic printing station;        printing an image on the first side of the substrate using the second flexographic printing station.     
     
     
       49. A method for a combined lithographic/flexographic printing process, the method comprising the steps of:
   providing a substrate;        printing an image on the substrate using a first lithographic printing station;        transferring the substrate from the first lithographic printing station to a first flexographic printing station;        printing an image on the substrate using the first flexographic printing station; transferring the substrate from the first flexographic printing station to a first dryer;        drying the substrate in the first dryer;        transferring the substrate from the first dryer to a second lithographic printing station;        printing an image on the first side of the substrate using the second lithographic printing station;        transferring the substrate from the second lithographic printing station to a second dryer;        drying the substrate in the second dryer;        transferring the substrate from the second dryer to a second flexographic printing station;        printing an image on the substrate using the second flexographic printing station;        transferring the substrate from the second flexographic printing station to a third dryer; and        drying the substrate in the third dryer.     
     
     
       50. Apparatus for providing a combined lithographic/flexographic printing process comprising:
   a plurality of successive printing stations for printing color images on a substrate in a continuous in - line process, the successive printing stations comprising:        a first flexographic printing station for printing an image on said substrate using the flexographic process;        a first lithographic printing station, subsequent in the continuous in - line process to the first flexographic printing station, for printing an image on the substrate using the lithographic process; and        a dryer disposed between said printing stations for drying the image printed by said first flexographic printing station.     
     
     
       51. The apparatus of  claim 50  including:
   at least one further lithographic printing station, subsequent in the continuous in - line process to the first lithographic printing station, for printing images on said substrate using the lithographic process.     
     
     
       52. The apparatus of  claim 51  including:
   a dryer disposed between said first lithographic printing station and said further lithographic printing station for drying images printed on said substrate.     
     
     
       53. The apparatus of  claim 52  including:
   a second flexographic printing station, subsequent in the continuous in - line process to said further lithographic printing station for at least one of printing an image on said substrate and applying a coating on said substrate using the flexographic process.     
     
     
       54. Apparatus for a combined lithographic/flexographic printing process, comprising:
   a plurality of successive printing stations for printing color images on a substrate in a continuous in - line process;        one of said stations comprising a flexographic printing station capable of printing a liquid vehicle image on said substrate with a slurry containing an encapsulated essence using the flexographic process;        at least one of said successive printing stations being a lithographic printing station for using the lithographic process in said continuous in - line process; and        means enabling the application of an overcoating over the liquid vehicle image on the printed substrate.     
     
     
       55. Apparatus for creating a combined lithographic/flexographic printing process comprising:
   a plurality of successive printing stations for printing images on a substrate in a continuous in - line process;        one of said stations comprising a flexographic printing unit for printing a first image using the flexographic process; and        at least one successive printing station comprising a lithographic printing unit for printing an image over said first image using the lithographic process in said continuous in - line process.