CA2482176A1 - Method and apparatus for making signs - Google Patents

Abstract

An apparatus for digitally generating an image includes a printer for generating a desired image either on a final substrate or a carrier sheet with the image then being transferred from the carrier sheet onto the final substrate.
The generated image is "built up" on the carrier sheet or substrate to form a sign, thereby eliminating the need for the weeding process. According to one aspect of the present invention, the apparatus includes a printer that allows the digital application of adhesive onto an image, substantially placing an adhesive in register with the image, for subsequent application of the image with adhesive placed thereon.
According to a further aspect of the present invention, a layer of adhesive is applied over a substrate. An image is built atop of the adhesive. A consumable sheet is then brought in contact with the substrate to remove excess adhesive, which is still disposed on the substrate, such that once the consumable sheet is separated from the substrate, the image remains on the substrate with the adhesive disposed therebetween. According to another embodiment of the present invention, liquid film or structural ink is used to generate structure for the image.

Description

t.
Pp~F~IT T 206, 6 75 ~pT'T~C?I7 ~?oT'17 A.PP~,.~l~'I'US F~~ ~.~~GG~~F~ S1G~TS
~d~i0~~ The present application relates to an apparatus and method for signmaking and, more particularly, to a~ apparatus and method for additive signmaking lay digitally generating an image either on a final substrate or on a carrier sheet.
~A~I~G~.O~JhII~ ~~' '7~':~ II~~T~I~I'~'IC~1~I
TeChrllCal ~'leld ' The present invention relates to an apparatus and rn.ethod for signmaking and, more particularly, to an apparatus and n-~ethod for additive sianrnaling.

2. 'background Art ~Q~Q~~~ The signmaking industry ,was revolui~ onzzed by technology ~r~vented and implemented by Ger?oer Scientific, fnC. of South ~Tindsox, ~onnect~cut, a com'.mon assignee with the present inven~.on. Several inventions .r elating to signmakin~ are described in LT.S. Patent I'~Tos. 5f 537,135 and 4, 4.&7, 525, which disclose an apparatus far printing and CutEix~.g signs on sheet mcaterial.
Such signxnalEing apparatcrs includes a computer for storing image data and a printer which, based on th.e image data,. applies colorant onto a vinyl sheet material adhered to a i~aCking sheet. once the desired image is printed, the sheet material is then tLarisfei-red to a cutter maC°nine. The cix~~er cuts through "the vinyl sheetma'terial around the contour of the irn.age, leaving the backing sheet intact.
Syxbse~uent to the cutting operation, the unwanted vinyl ~riaterial is removed or v~Teeded from +.he sheet material. The desas-~ed image is subsequently applied. to a ~ansfel sheet anCl then to the n.nal proCLuCt.

CA 02482176 2004-09-20 p I000~] Although the above-described method and apparatus have enjoyed great success arid popularity, there are several drawbacks. First, the weeding process results in a significant amount of non-recyclable waste. Additionally, the weeding process is labor intensive and time consuming. Furthermore, the weeding process can reduce the quality of the finished sign, because when tha excess 'vinyl material is weeded, the sign image can become damaged. Additional difficulties associated with transferring the printed sheet material from the printer to th.e cutter include proper alignment between the printer and the cutter. Moreover, the cutter must be properly calibrated with respect to the printer.
X0005] ~J.S. Patent No. 5,87T,~37 to Adair entitled "Method of Fi>;ixag an ~nage to a Rigid Substrate'° discloses a $nethod of fixing an image t~ a rigid substrate coated with a thermally tad<ifiable coming. More specifically, fhe patent discloses a process wherein the image is printed onto a transfer f-ilrn, the image bearing surface of the transfer film is then joined in pressing contact with a therri~.oplastic coating which has been warmed to a softened or tacky state. Once fhe thermoplastic coating is cooled to a hard, durable state, the transfer film is removed, leaving the image securely affixed to the rigid substrate. 1-Iow~ver, the process disclosed~'in the Adair patent has limited use. The Adair method is not practical, for example, for generating a sign for a car door. More specifically, the wThole car door would have fo be coated with fine tacky material with the image then being ~ansferred onto the coated door. ~-Iowever, once the image is adhered, the image will be surrounded by additional polymer, resulting in bar:.kground haze a_xound the image.
Therefore, although the Adair patent provides an alternative to conventional signmaking, the Adair method is limited a..nd is frequently impracf~cal.
10006 . Anofher shortcoming of.conventional signmaking is that the signs are not sufficiently durable for man~F purposes.

A' 4 F., [0~~7] Although automated signmakiiig has significantly improved the time consuming process of manual signmaking, it is still desirable to further simplify and improve the signmaking process by eliminating the waste resulting from weeding and by generating a more d~zrable image.
Si_TIvTI~AR.'~' ~p';r'~I~ II~t~T~~T'I(~ht [0008 According to the present invention, an. apparatus and method for an Additive SignmakingTM Process includes a printer for genes afing a desired image either on a final substrate or a carrier sheet with the image then being transferred from the carrier sheet onto the final substrate. The generated image is "built up" on the carrier sheet or substrate to form a sign, thereby eliminating the need for the weeding process.
[0~~9~ According to one aspect of the present invention, referred to herein as an Adhesive Split TransferTM i rocess, the printer initially prints the ianage onto a carrier sheet. A layer of adhesive is then applied onto the carrier sheet with the image panted thereon. Subsequently, a substrate is joined with the carrier sheet such that the layer of adhesive and image are disposed therebetween. once the carrier sheet is removed, the image remains adhered to the substrate, completing the Adhesive Split TransferTM Process. If necessary, the image may be cured onto the substi ate for improved adherence. The Adhesive Split TransferT'~ Process simplifies the signmaking process by consolidating the printing, c~xtdng and weeding operations that are required by existing methods into a s~:gie operation. one advantage of the Additive Signrn~akirgTM Process, it general, and of the-Adhesive Split'I'ransferT'~ Process, specifically, is that the weeding process is no longer necessary, thus eliminating the waste resulting therefrom, reducing potential dazr~age to the sign, and decreasing labor costs.

(0010] According to a further aspect of the present invention, an apparatus and method for the Additive Si~an.making Process includes a printer that allows the digital appiication of adhesive onto an image, substantially placing an adhesive in register with the image, for subsequent application of the image with adhesive placed thereon. I?igital application of adhesive onto an image significantly simplifies the signmaking process. Digital application of an adhesive eliminates the need to use Boated sheet material that requires subsequent weeding.
I0~1~.] According to a further aspect of the present invention, a layer of adhesive is applied over a substrate. An image is built atop of the adhesive.
A
consumable sheet is then brought in contact with the substrate to remove excess adhesive, which is still disposed ort the substrate, such that once the consumable sheet is separated from the substrate, the image remains on the substrate with the adhesive disposed therebetween.
L00~21 According to another embodiment of the present invention, adhesive is digitally applied to be substantially in register with the image. The adhesive is ink jetted through an ink jet print head. The adhesive may include colorants.
L~0~.3~] According to another e~.bodixnent of the present invention, liquid.
film or structur al ink is used to genes ate structure for the image. The liquid fil~x~. is ink jetted through an ink jet pint head to be substantially in register with the image.
The liquid film may be clear or translucent or include colorants.
] The present inven~on introduces the concept of Additive SignmakingTM Processf wherein an image is built on 'top of a substrate without the need for weedang unnecessary ~rcater'~al. The image can be either permanently adhered to the sT.xbstrate or.be temporarily placed on a carrier sheet and subsequently transferred onto a final substrate. The image can be 'built ixp with use of a variety of apparatus' and/ or methods incl-ading, but not limited to, use'of n. ~. : F.
different colorants, multiple layers of colorants, clear coating, protective coating and/or adhesive. The present invenfiion also introduces a concept of digitally applying adhesive onto a substrate: Furthermore, the pr esent invention introduces another concept of applying adhesive over the entire substrate, building up an image atop of adhesive, and then xemoving excess adhesive. Thus, the concepts introduced by the present invention result in improved quality of the final product, as well as savings in time, labor, and materials.
[001~I The foregoing and other advantages of the present invention become more apparent in light of the following detailed description of th.e exemplaay embodiments tnereof, as illustrated in the accompanying drawings.
~I~.I~F I~~SCI~IpTI~1'3 ELF T'I~~ T~I~~TII'3~S - .
[~~1~~ FIG. ~. is a schematic representation of a signrnaking system including a computer and a printer;
~OOIfi~ FIG. 2 is an enlarged, simplified, perspective view of the printer of FIG.1;
[0~~8I FIG. 3 is a block diagram of a process for printing a sign onto a carrier sheet for subsequent transfer to the final location using fine sigx~rtaking system of FIG. 2;
~(3019~ FIG. 4 is a front view of a carrier sheet with an image printed thereon in accordance wi'-~h t_he pr ocess of FIB. ~;
~f~0?0~ F I~. ~ is a side view of fhe carrier sheet and 'the image of FAG. ~;
~0~2~~ FIG. ~ is a partially broken away, front view of the carrier sheet with the image printed thereon and adhesive, in accordance with the process of ,~
G. ~;
~~s022~ FIG '7 is a side vie~T of the, carrier sheet, flte image and the adhesive of FIG. E; ~ . - __ b f (04123] FIG. ~ is a partially broken a«ay, front view of the carrier sheet, the image, the adhesive and substrafie, in accordance with tile process of FIG. 3;
(~0~4j FIG. 9 is a side view of the carrier sheet, the image, the adhesive and the substrate of FIG. ~;
[Ofl25j FIG. ~~ is a partially broken away, front vied of the carrier sheef with excess adhesive, in accordance with the process of FIG. 3;
~0~?6j FIG. ~~ ~s a front view of the substrate with the image adhered thereto, in accordance with the process of FIG. 3;
~0027I I?IG. ~2 is a schematic representation of a printer for an Additive SignmakingTM Process, according to another embodiment of the pxesent invention;
~fl02~I PIG. ~3 is a schematic representation of a side view of a carrier sheet with an adhesive layer to be engaged by an ink foil;
~~oz~I FIG. '~4. is a schema~c representation of the side view of the carrier sheet after engagement with the inic foil of FIG. ~.3;
~0030J FIG. ~5 is a schematic representation of an apparatus for generating signs; and ~~03~] I:~IG. ~6 is a schematic representation of another embodiment of an apparatus for generating signs;
X00321 I~IG. ~7 is a schematic representation of another embodiment of an apparatus for generating signs;
~0~331 FIG. ~.~ is a schematic representation of arEObu~.er embodiment cif an apparatus for generating signs;
~OU3~I FIG. ~.g is a scherr~atic representation of another embodimerit of an apparatus for generating signs ~U~35j FIG. 20 is a schematic representation, of another embodiment of an apparatus for generating signs ' ~ w .

r., r [036] FIB. 2T is a schematic representation of another embodiment of an apparatus for generating sins;
[0037] FIB: 2'2 is a schematic representation of another embodiment of an apparatus for generating signs;
[00381 FLG 23 is a schematic representation of another embodiment of an apparatus for generating signs; and [0039] ~'I~. 2~ is a schematic representation of another embodiment of an apparatus for generating signs.
'~~'~~~[,~~ I~~~~RII''~'IC.7N ~~ '~':I'IZ~h~R~I~ ~I~~~1~II~i~N'I' [0040 Referring to ~f~. ~., an Additive Signm.al:.i.ngxM System ~0 for an Additive SignmaidngTM Proeess, according to one aspect of the present invention, includes a prod a~mr~able computer I2. for generati~°~g an image ~~
based on an input data T 6. The system ~.0 also includes a printer ~.~, which communicates witf~. the computer ~.2. The printer ~~ includes at least one developer cartridge 20 that is filled va~ith developer 22.
[~a~~.~ Referring to ~I~. ~, in an Adhesive Split TransferTM Process, according to one aspect of the present invention, a carrier sheet ~~ having a first carrier side 26 and a second carrier side Z~ is placed into the printer T.~. The printer I3 generates an image 30 having a first irr~age side 32 and a second image side 3~, as indicated by A~
in ply. 3 and best seen in PI~S. ~ and ~. The image 3~0 is transferred onto the first side 2~ of the carer sheet '~~ within the printer 'T3, as seen in Pz~S. ~, ~
and ~. In the preferred embodiment of the present invention, the imzage 30 is reverse printed or a ynirror image is printed onfo the carrier sheet ~~.
[00~2j . _ Referrixtg to ~~GS. 3s ~ and 7, once the image is printed onto the carriex sheet 2~-,- an adhesive layer 36 is applied onto the first side .~e~ of the carrier sheet ~~

L.
and the first side 32 of 'the image 30, as indicated by A4 in IaIG. 3. A
substrate 38 is subsequently joined with the carrier sheet 2~ such that the adhesive layer 36 and the image 30 are sandwiched therebetween, as indicated by A6 in FIG. 3 and shown in FIGS. H and 9. The substrate 38 and the earriei sheet 2~ with the image 30 and adhesive 36 disposed therebetween can be pressed together far tl~e film image 3a to properly adhere to the substrate 38. Then, the carrier sheet 24 is removed from the substrate 38, as indicated by A8 in FIG. 3 and shown in FIG. 9. The adhesive 3& that was in direct contact with the carrier sheet 24 adheres to the carrier sheet and is removed from the substrate 38, as shown ill ~'IG. ~Q. 'tNith the removal of the carrier sheet 2~ and excess adhesive 36 from the substrate 38, the film image 30 remains properly adhered to the substrate 38, completf~.g the Adhesive Split Transfer pr ocess, as shown in ~G. ~~. f3ptionally, the substrate 38 a~-td image 30 may be additionally cured. for improved adherence of the film image onto the substrate.
~larious curing processes can be used, including but not limited to, ultraviolet I~ght ~eatment, infrared heating, RF h.eating and / or conventional heating.
~00~-3] The adhesive 36 can be any type of adhesive, as long as the adhesive has preference for the carrier sheet 2~ over the substrate 38. Several different techniques can be used to apply the adhesive. ~3ne approach is to use liquid adhesives applied with a wire wrapped drawdown bar. Cane type of the ~rir~e wrapped drawdown bar is ananufactured by Paul N. Gardner, Ine. of Pompano Beach, Florida. To obtain fihe appropriate coverage with the adhesive, the adhesives can be thinned to r educe the surface tension of the adhesive. Fxamples of such liquid adhesives are Covinax 386T'" manufactured by Franklin International, Inc. of Columbus, ahio and ScotchGrip 422~rM manufactured by 3~ Corporation of St.
Paul, ~'~innesota. In tlae preferred embodiment,, the liquid adhesives were thinned with deionized water and dish soap accoraing to the following composition: 50 ml of . 8 i i' adhesive, 50 ml of water, and 5 mI of Joy~'f dish soap. joy~''~ dish soap is fabricated by Proctor & Gamble of Cincinnati, Ohio. However, numerous ofi~ler=Iiquid adhesives can be used, as long as the adhesive has preference for the carrier sheet.
~a~44] Other types of adhesive that can be used are pressure sensitive adhesive films. These films are from a class known as adhesive transfer films, that include adhesive only, rather than adhesive and some other supporting filrn.
The mast commonly used adhesive films are manufactured by Xyron, Inc. of Scottsdale, Arizona and are applied with the Xyron H50TM laminator, also manufaciured by X~~ron, Inc.
[0045] in the Adhesive Split Transfer Process, there are four {4) important bonds:
[046] I. The bond between the image a~-~d the ca~wrier sheet ("lxnage / Carrier"), [0047] 2. The bond between tl~e irn.age and the adhesive ("image/ Ad-hesive");
[OQ4~I 3. The bond between the adhesive and the earner sheet {"Adhesive / Gaxrier"); and ~~0~9] The bond betS,veen the adhesive and the substrate ("Adhesive / Substrate").
[0050] The .Adhesive Split 'Transfer process will occur when the following set of relationships between the bond strengths exists:
~0~5I] 2. The lnzage / Adhesive bond is stronger than the lm.age / Oarri.er bond;
(t~~5~] 2. T,he Adhesive / Substrate bond is stronger than the hnage / harrier bond; and [Ot~53] 3. The Adhesive / Carrier bond is stronger than the . , Adhesive/Substrate bond.

CA 02482176 2004-09-20 ,.~
f i~ f (4Q5~I Any combination of adhesive, carrier, and substrate that satisfies aII
three (3) of these relationships may be used for the ~.dhesive Split Transfer Process.
The toner used to generate the image must also satisfy the above-identified relationships.
~0055I Therefore; the substrate can be fabricated from any material that allows the substrate, in the non-image area, to release adhesive to the carrier sheet and,.in the image area, allows adhesive to bond the film to the substrate. The carrier sheet can be fabricated from any material that will not permanently bond to the image and is preferred over various substrates by the adhesive in the non-image area. ~
the preferred embodiment, Gerber 220' vinyl and Gerber 22~~' vinyl were used as the carrier sheet. Gerber 220~vinyl and Gerber 225'M vinyl are products of Gerber Scientific, Inc. of South i~~lindsor, Connecticut.
~0~56~ The developer can be any type of toner used in standard printers.
Plowever, in one embodiment of the present invention, the developer is either a powder paint or a dual component developer comprising ferrite carrier beads and powder paint or powder toner, as discussed in greater detail below. In the preferred embodiment, the dual component developer comprises ~0-99% (eighty to ninety nine percent) ferrite carrier beads and ~-2~% (one to twenty percent) powder paint or powder toner. Piowever, in the most preferred embodiment, the developer comprises 90-95% ferrite carrier beads and 5-10 o powder paint or powder toner.
t3se of the toner tlhat includes powder paint or powder toner results in the generation of a durable film image. Powder Paint comprises resin and pigment is selected to be outdoor durable and ~..Tt1 stable.
~flG57~ The l~dditive SignmalingTM Process, in general, and the ~.~.hesive Split TransferTM Process, in particular, of the present invention simplifies the sigrux~~king process by consolidating the printing, cut~"ng and weeding operations required~by ~r conventional methods into a single operation. One advantage of the present invention is that the weeding process is no longer necessary, thus, eliminatir~:g the waste resulting therefrom, potential damage to the sign during the weeding process, and labor costs therefor. Another advantage is that -.Then powder paint or powder toner is used, the image generated is d~zrable, with the powder paint generated image, the image could withstand outside elements for prolonged period of time. A
further advantage of the Additive S bsmmaking Process and of the Adhesive split Transfer Process is that there are no limitations on where the signs can be applied.
For example, these processes overcome the drawbacks of the LT.S. Patent No.
5,8X,837, as discussed in the Background of the Invention section of the present invention.
E0058~ Referring to ~'~~. '~'~, according to another aspect of the present invention, an Additive SignmakingT~ System 1'~~ for generating a film image ~'~ 4 includes a printer ~~F. The film image'~.~~ is essentially "built up" onto a substrate ~.?0, according fo the present invention. The substrate ~z0 has a first substrate side ~.~ and a second substrate side ~.2~. The printer ~~8 includes a housing X26 with an input opening X28 for intaking the substrate '~.'~0 arid an output opening ~31~ (not shown in PIE. ~) formed therein for allowing egress of the substrate X20.
[0059 This process results in "building up" of the final film image comprising multiple layers. The types of layers anal order of application of the layers could vary depending on particular requirements of the final film image product., The thickness of ead2 layer can also vary from product to product.
~0060I According to a further aspect'of the presentinvent~on, the adhesive is aigitally applied to eitr~er the first surface of the carrier sheet or the first image side of the film image. .Adhesive is applied to areas where the film image has been or will be created. Oigital application of tie adhesive may be achieved through several a1I

k techniques including electrophotography of a heat and/.or pressure activated powdered adhesive, ink jetting of a liquid adhesive, or thermal transfer of a dry film.
adhesive. The digitally applied adhesives may be heat sensitive, pressure sensitive, or T~TV sensitive. One such type is Hot Melt powder adhesive manufachzred by I~'nion, Inc., R.idgefield, New Jersey. A protective film can be applied to cover the adhesive and is removed just prior to the application of .the film image to the final substrate. Application of the protective film is needed when the adhesive is disposed atop of tlh.e image. In the situations v~Then the image is disposed.
atop of the adhesive, the adhesive and ti~.e film image anay then be lifted from the carrier sheet with transfer tape and applied to the final substrate, as is tyTpical in traditional signm~akin.g.
~OOdI] According to an additional aspect of the present invention, as discussed in greater detail belowr the adhesive may contain colorant and has a dual purpose of arc adhesive and a colorant. 'The colorant can be either pigment or dye.
I00~2~ Additionally, as will be discussed in greater detail below, although some systems include means for digital app3.ication of adhesive, in accordance with the teachings of tile present invention, some systems xnay include internal or external means for applying adhesive, wherein the adhesive means may be adapted to apply adhesive either digitally to be in register with the izx~age or globally over the entire substrate.
~(3~f3~ I~.eferring to ~'l~~< ~~-~~, in accordance with anof~~er eznbodirnent of the present invention, the f~aditive SignanakingT'~ Process can be i~nx~aemented by building up an image 7?9, ~'?3, 9'?~ on a carrier sheet ~~~, s~~, ~~~ with an adhesive layer v3g, ~~~, g.3a disposed tlzerebefiween such that the adhesive layer has been either pre-applied to the carrier sheet or applied uniformly onto the carrier sheet and excess adhesive ?3~, E~~, g~~. is subsequently removed from the earner sheet.
Thus, ~2 an adhesive layer 73~, 83Q~, 930 is initially applied onto a carrier or release sheet ~2~, 824, 924. A colorant 728, 828, 928 is subsequently applied onto the adhesive layer 73Q, 830, 93Q to build an image 729, 829, 929 on top of the adhesive Layer.
The image adheres to the carrier sheet by means of the adhesive Layer, naw sandwiched therebetween. The portions of tl~e carrier sheet without tile image still have exposed adhesive portion or excess adhesive 73'x, 83~, 98L A consumable sheet 833, 933 is then brought into contact with the carrier sheet and into direct contact with the excess adhesive 731, 83~, 93I and with the image. The excess adhesive adheres to the consumable sheet 839, 939. 'tN~hen the consumable sheet is removed, the adhesive splits along the borders or the perimeter of the image, rernaving the unwanted portions of excess adhesive and leaving the previously printed image backed by the remaining adhesive on the carrier sheet.
~6Uc~4~ Referring to .~I~S. ~3 and ~4, in one embodiment, a thermal printer'~~8 is used to generate an image. In the preferred embodiment, a MAXX~ system has been used. The MA3~C~ system is a signmaking apparatus manufactured by Berber Scientific Products, inc. of South i~Tindsor, Connecticut, an assignee of the present invention. The MAXA~ system is described;in ~J.S. ~'atent Nos. ~, 2~-3,x.20 and 6,322,265, with their disclosures being incorporated herein by reference.
However, other thermal printers can be used. As is well known in the art, a thermal printer or signmaking apparatus includes a thermal printhead that comes into contact with an ink foil to generate an image on a substrate.
Ia~~S~ Deferring to ~~~. ~3, in a thermal system '7~8, an iruc foil 72~ comes into contact witk~ an adhesivE layer 73~ disposed on a carrier sheet ~2~. The ink foil as~2Q
comprises a foil '226 with resin X28 disposed thereon. !~s is known in the art, resin or colorant 72.8 is subsequently separated frorrr the foil to generate an image 729: In the . , preferred embodiment of the present invention, the release or carrier sheet ~2~ is °
~3 coated with the adhesive Layer 730 and is placed into the thermal printer with the adhesive layer '730 facing the ink foil 720. In this embodiment, the inle foil 720 also serves as a consumable sheet.
IO~66j In operation, referring to ~I~. ~:~, as the thermal system 71~
selectively energizes printing elements 732 of a thermal printhead 734 that come into contact with the carrier sheet 724 ~nrith the foil 720 and the adhesive layer 730 disposed therebetween to generate an image, the resin 723 that is disposed substantially below the energized printing elements 732 is transferred from the foil 720 onto the carrier sheet 724, atop of the adhesive layer 730, thereby printing the image 729 onto the adhesive Layer 730 of the carrier sheet 72~. Excess adhesive 73~. or portions of the adhesive layer 730 that do not have resin 723 disposed atop thereof, adhere to the resin reanaining on the foil 720 and are, thereby, removed fror.~. the ca~-~rier sheet 72~
and roiled onto the takeup roll (not shown) with the used foil. Thus, wherW.e printing of the image 729 is completed, tt~.e carrier sheet 72~ is free of exposed or excess adhesive 73~ except in the area of the image, and includes the image disposed thereon with she adhesive layer sandwiched between the carrier sheet and the irrrage. Subsequently, the image can be transferred ~nrith transfer tape onto its Final location. Optionally, the carrier sheet with. the adhesive Layer and the image can be cured.
~00~7~ The adhesive Layer 730 can be either pre-applied onto the carrier sheet or applied internally with~n the system. 7:~3 by an adhesive application means 7~g.
~f30~3~ The release or ca~~-ier sheet 72~, adhesive 730, and foil 720 ca.n be a variety of products. However, the carrier sheet must allow the release of adhesive with the adhesive having a preference for the foil over the carrier substrate and with resin having a preference for the adhesive over ~-~he foil when the foil is in contact with the energized printing element. In the preferred embodiment, polymer coated . f: . . .
paper, such as the backside of the carrier used with Gerber t,~uantum 4000 vinyl, a product of Gerber Scientific, Inc. of South Windsor, Connecticut, was used.
One type of adhesive is Covinax 386~'~, manufactured by Franklin International, ~nc. of Columbus, Ohio. Any t~.>pe of ink foil can be used.
~Q0691 Referring to FfG. ~5, in another embodiment of tile present invention, an ink jet system 8~8 is used to apply ink or colorant 828 to form an image 829 over the pressure sensitive adhesive film 83a. The ink jet system 8~8 is adapted to either receive a carrier sheet 824 with adhesive 830 applied or to apply adhesive 830 to the carrier sheet 824 by adhesive application means 8~9. The ink jet system 8T8 also includes at least one ink jet print head 834 to dispense ink 828 to form the image 82J
atop the carrier sheet with the adhesive Payer 83a disposed therebetween. The inkjet system 818 may further include a curing station 835 far curing ink onto tlla adhesive layer and onto the carrier sheet 824. I-~.Iternatively, the image 829 can be cured Qutside of the system 8~8. The curing station 835 can provide any type of curing, including U''l ccxre lamp, infrared, laser, thermal and/or others. The ink jet system 818 also includes means for removing excess adhesive 83~. In the preferred embodiment of the present invention, the means for removing excess adhesive includes a consumable sheet 839 that contacts the carrier sheet with the image and excess adhesive thereon such that upon separation of the consumable sheet and the carrier sheet, the excess adhesive 83~ remains on the consumable sheet 839 and the carrier sheet 824 or subs~ate has the i~rtage disposed thereon with the adhesive 83~
disposed therebetwPen.
~d~370~ In one embodiment, the means for rernaving excess adhesive 837 is a consumable sheet, such as.foil, rolled on a supply roll 84~ v,~ith the fail being dispensed from the supply roll and taken up by a take~up roll 843. A,pressure roller 8~~ is disposed between the supply roll and the t~.ke up roll. The pressure roller acts IS

i on the back side of the foil to apply a substantially uniform pressure which promotes the desired adhesive bonding between the foil 839,and the exposed, unwanted adhesive 832. The take up roller acts to peel and store the foil and the excess adhesive. After the foil and unwanted adhesive have been removed, the release or carrier sheet 824 is free of the excess adhesive except where the adhesive resides underneath the printed image.
~0t~7I] In an alternate embodiment, the means for removing excess adhesive 837 is disposed outside the system ST.B.
[00~2~ The non-contact nature of ink jet printing is desirable because it simplifies the problems associated with handling the adhesive coated carrier sheet.
l~ cure inks are desirable because they are 100% solids (during the UV cure process, 100.% of the liquid ink is converted to solid polymer) and will form.
a film over tlhe adhesive when printed. Traditional water-based or solvent-based inks will not form, a solid film upon drying and, therefore, may not provide sufficient structure for blocking of the adhesive. Phase e~~ange inks where the colorant is disbursed in wax are also X00% solid and. will form a film over the adhesive.
nor sign making applicafions, the ~'~ cure inks are generally preferred over phase change inks because they provide a more durable image.
I06731 .According to another aspect of the,present invention, the irr~age can be generated when liquid film or structural ink is used. The liciuid film is used to generate a sturdy, durable and transferrable image. The liquid film or structural ink, as refe~--red to.in the present application, is an irk ~ettabie, liquid polymer ~.at can be cured into a film wit~r. many of the same properties found in the cast and calendared vinyl films that are well known in the sign. making and specialty graphics industry.
[(3~~~~ The liquid film, in accordance with the present invention, provides the structure fof° the image and sut~sequenfiy, the sign;. may provide a base upon which ~6 images are generated; and / or may be used to generate the image itself, as will be discussed in greater detail below. TI~e liquid film may include a combination of the following properties and/or characteristics: reflective, translucent, metallic, photoluminescant, glossy, matte and/or frosted.
[QQ75] One type of ink that was used to generate a sign froze liquid film was from Sericol Imaging, operating thraugh its parent company, Sericol International, based in Broadstairs, IJK. The sign was generated by printing six (6) layers of Sericol ~Jvijet ink with a Xaar XJ~26 manufactured by Xaar PIrC of Cambridge, UK, drop on demand printhead at 360 I;7Pl. The ink was cured with an Integration Technology VZero 085 W lamp. The images were printed onto Xyron Low Tack Permanent adhesive (P / IdTAT202-50). The Xyron cartridge that contained tha adhesive-also contained the adhesive removal film that was used. The total thickness of one sign generated was approximately 3.5 n~i.Is. The adhesive was approximately ~-2 mils thick and the film that was printed onto the adhesive was 1-2 mils thick.
However, other materials and equipment can be used and thicker or thinner adhesives may be used and thicker or thinner films rrtay be generated.
[fl~76~ Referring back to ~< ~5 anal according t~ a fuz-fher embodiment of the present invention, the adhesive 830 includes white colorant therein with at least one ink jet print head 83~ dispensing structural ink, which. xriay be process color, spot color, or combination. thereof. The white adhesive 830 provides a background for the image 82g.
[Q;D7~~ l~ccording to a further embvdirtent of the present invention, the adhesive transfer film 830 includes at least one spot color for the final image H~~9.
The at least one print head 83~, in t his embodiment, dispen ses clear structural ink to provide stx~cture for the resulting sign, as seen i~ ~I~. ~.5.
t7 B

,r X0078] Referring Ff G.16 and according to yet another embodiment of the present invention, the adhesive transfer film 830 is white. The at least ane ink jet print Izead 834 includes colorants) which maybe spot colors, process colors or both.
At leasf one additional ink jet print head 834 dispenses clear stiructural ink 8~5 atop of the ink colors to provide a protective layer-and structure for the image ~2~.
~0(179~ Still referring to F~~. ~.6, in accordance tNi.th a further embodin~.ent of the present invention, an ink jet system 8I8 includes at least one ink jet printhead 834 dispensing at least one colorant 828 onto an adhesive layer 83~ disposed atop of a carrier sheet 824. The at Least one colorant 828 defines an image 8'?~ that is reversed printed. The system 818 further includes an ink jet printhead 8a~ for dispensing liquid film 855 atop of the image 829. ~n the preferred embodiment of the present invention, the liquid film is white to provide background for the image 829. This embodiment is particularly suited for signs that are placed on the inside of a glass to be seen outside, such as a store window.
~0080~ Referring to F'I~. ~7, according to a further embodiment of the present invention, the adhesive fransfer film 83a is disposed atop a carrier sheet 824. The ink jet print head 854 dispenses white structural ink 85S onto the adhesive layer 830. At least one ink jet print head 834 dispenses ink jet colors 82&, which may be spot process or both, atop of the structural ink layer 855 to form a sign.
[0081 For embodiments depicted in ~~5. T3-'~7, the adhesive application means ~~9, 8~.9 is optional. The carrier sheet 724, 82~: can have adhesive 73~, 83~
ei~.her pre-applied prior to entering ~.he system 7~8, 8~8 or the adhesive applacatio~.
means 7~.3, 8~.~ may be incorporated intc system. X18, ~~:~8 to apply adhesive globa~Ty to the carrier sheet X24, 82~. Furthermore, the curing system 835 can be either included in tthe system 8~8 or disposed outside of the system. Similarly, the means.

~;, r for removing excess adhesive 837 may be either internal to the system 8'18 or external.
~Q0821 Referring to pI~.18, in a further embodiment of the present invention, an electrophotographie. system 9~8 includes means for electophotographically generating an image 9~8, means for fusing 935, and means for removing excess adhesive 937. The system 918 may or may not include means for applying adhesive 919, as discussed above. The means for electophotographically generating an image 933 can have various cor..figurations, some of which are described above anti shown in ~I~S-:13-~~ of the parent application, IBS Patent Application No.IO/360,4~8. Thus, the means for electrophotographically generating an irrtage 9z8 builds a single or multiple color powder image on a photoconductor roller or belt or a final.
transfer roller or belt 95~. The image is then electrastatically transferred onto the adhesive layer 930 disposed atop of the carrier or release sheet 92~. The imaged pov.Tder toner or powder paint 92~ is subsequently fused info a film image g29 disposed atop of the carrier sheet v~ith the means for fusing 935. The carr3:zer sheet 924 with the fused image 929 and excess adhesive 931 still disposed thereon is brought into contact with the consumable sheet 939 of the means for removing excess adhesive 937.
In the embodiment shown, the means far removing excess adhesive 937 is substantially analogous to the means 837 'shown in I~I~.15 and described above.
~00~3~ The powder paint or powder toner materials 92~ used for imaging in the electrophotographic systems described in the above-referenced parent application, form a solid film that can b~ either used as a sign on the carrier sheet or subsequently transferred onto a final substrate.
~005~I For the embodiments describing _rernoval of excess adhesive, It is not necessary to remove the consurnable sheet X39, 93g in the printer.1-i.ather, it may be desirable to.Ieave he consumable sheet atop the carrier sheet and the excess adhesive as a protective layer to be removed at the time of application to the final substrate.
(0085 For mufti-color printing wherein multiple foils or colorants are used sequentially, in the preferred embodiment, it m.ay be preferable to initially print over the entire image area with clear-abrasion guard, white ink or similar transparent ink to remove an appropriate amount of adhesive from the carrier sheet while leaving adhesive on the entire image area. Then, various colors or half-tone colors can be printed, as necessary. For example, in some instances there will be a physical. limit on the smallest amount of adhesive that can be reliably removed by the above-described technique. In those situations, as a first imaging step, a backing material can be applied initially upon which subsequent colors will be.printed. process valor half-tone printing tech=niques, which- are employed to generate picture images provide the clearest example of f'nis situation. The small dots of cyan, I~tagenta, Yellow; and Black color fihat are used to generate half-tone images are generally too small to have the adhesive split around them. To arcun~vent this problerr~, a backing layer of, usually but not necessarily, white, translucent or clear, is applied over the entire image area. By printing a clear coating over the entire image area, the adhesive is only required to split along the perimeter of the image .area rather than along the perimeter of each individual dot used to generate the r~alf-tone image. This technique can also be used to simplify more basic mufti-color printing when multiple colors are serially applied to generate a mufti-color image, such as in thermal 'tra_n.sfer printing, inkjet printing or electrophotagraphic printing.
~ a backing gayer is first printed over all areas that are~to receive any color, the unwanted adhesive may be removed at t~ne begirLning of the sign making process.
X11 subsequent printing steps occur in the absence ,of any exposed adhesive, which simplifies ~natersal handling in the printer.
2fl L
(OU86I Referring to Fig, ~.9, according to another embodiment of the present invention, an ink jet system 1Ø8 includes an adhesive application means I~19, at least one ink jet print head ~D34, and a curing station I035. The adhesive application means 1029, in the preferred embodiment of the present invention, is an ink je't adhesive head for selectively dispensing adhesive I030 onto a carrier sheet 1024.
The ink jet system 'LD~8 may also include an internal processor ~.D~2 or be controlled remotely through an external computer 12, as shown in Fag. ~. The ink jet adhesive head 1D19 digitally applies adhesive AD30 onto the carrier sheet '024 to be substantially in register with the image. C~n.ce the adhesive is applied, the ink jet head ~ 034 applies ink or colorant X028 onto the adhesive It330 to form an image ~ D~3.
The curing station ~.(~35 provides any type of curing, including W curing Lamp, infrared laser, thermal and! or others. In the preferred embodiment, as discussed above, the ink jet system ~.D~.B uses T.J'~~T cured inks. Although other types of adhesives can be used; the preferred adhesive as discussed above, is adhesive number I3-82-4; fabricated by ~ Tec'h, LL,~ of New Hartford, Connecticut.
(DO8~'~ 'The advantage of this embodiment of the present invention is that the system 1D~S generates a sign with the Ieast number of steps and eliminates the need for both weeding and removing excess adhesive. Thus, the system ~O~S of the present invention generates a sign with appropriate amount of adhesive and colorant. As discussed above, adhesive may also serve as colorant. For example, the adhesive may include dire or pigrrs.ent to provide color for the sign.
Addictonally, adhesive can be either white to provide background for process colors or ' - transparent.
(0088 According to one aspect of the present invention, the ink 205 is structural ink that provides structure to the image ~.Q~9 .and the resulting sigz~., as disclosed above. Fore specifically, the at least one the ink jet head ~D34 dispenses Z~

r liquid film or strucfiural ink. Such-structural liquid, once dispensed and cured, forms a structural film, sufficiently sturdy and durable to be handled and transferred as a sign. The structural liquid can be process color,. spot color, or both.
The structural ink can also be generally clear or ~r~rhite and used either as a background for color or protective film.
[00391 Thus, referring 'to fag. ~9, the ink jet head ~03~ can dispense a standard ink or structural ink, which can be either process color, spot color or both.
[0090] Referring to pig. 20, in another embodiment of the present invention, an adhesive ~.~.34~ is dispensed from an ink jet adhesive head ~~~g onto a carrier sheet ~~24. An. ink jet print head ~~3~ dispenses ink jet printed base liquid film X155 to form a clear or white Layer atop of ~e adhesive layer ~~.30 and to provide struct~,rre fo the resulting sign.. Subsequently, at least one ink jet print head ~.I3~
dispenses at least one ink or colorant ~'~2~ onto the liquid film layer ~~39 to provide color to the resultant sign. The printed color may be either process colors, spot colors, or both.
The layers ~.~.30, ~~39 and ~1~.9 are subsequently cured to form a durable sign.
IOOg~~ Refea-ring to ~'l,g. 2~., in a further embodiment of the present invention, an ink jet printer 5.13 includes an ink jet adhesive: head ~2I9 for dispensing ink jet printed adhesive 130 to form an adhesive layer on a cal-rier sheet ~Z~~. The ink jet printed adhesive in this embodiment of the present invention includes white colorant and is, therefore, white. The ink jet printing system 12.3 further includes at least one ink jet print head ~.~34 for dispensing at least one colorant. The colorants) may be process colors, spot colors, or both. The system ~.2~.8 further includes an inlc jet head ~23~: fo~ dispensing liquid film X233. The liquid fila-n is dispensed atop of tL~.e colorant layer X223 a~.o.d is clear to provide a protective layer to the resulting sign.
A curing mechanism 1235 cures the layers ~23~, 229, ~~39 for rendering a strong and durable sign.
~~

~009~1 Referring to Fig. 22, according to. a further embodiment of the present invention, an ink jet system 23I~ includes at least one izzk jet print head ~33~ that dispenses at least one ink jet printed colors ~.3?8, which may be process colors, spot colors, or both to form an image layer x.329 on a carrier sheet ~.3~4. The ink jet system '~31s further includes an ink jet liquid film head 1354 that dispenses liquid film 1355 to be placed atop of image layer x.329. In this embodiment of the present invention, the liquid film. is either clear or white and provides structur a to the resultant sign. The ink jet sysiem ~3~~ further includes an ink jet adhesive head ~.3~.9 that digitally dispenses ink jet printed adhesive ~'33~ atop of the image layer X329 and the protecfiive layer ~3v5. The ink jet printed color layer I329, the protective layer x.355, and the adhesive layer x.330 are then cured by the curing means X335 fo form a sign.
[~0~3~ Referring to Fgg. 23~, according to another embodiment of the present invention, an ink jet system ~~~~ includes ar~ inkjet liquid film head'~~5~, dispensing substantially clear liquid film '~~55 onto a carrier sheet ~.~2~.
'I'he ink jet system ~.~~~ also includes at least one ink jet head ~.~3~ including at least one colorant ~.~, which ~.r~ay be process colors, spot color or c~rnbination ther eof to be digitally placed atop of the liquid film layer ~~55. °~"he ink jet system ~~3~. further includes an adhesive ink jet head 1~~9 dispensing adhesive ~~3Q to be placed substantially in register vVith the liquid film layer ~.~55 and at least one colorai~.t Layer The layers ~~55, ~.~.~~ and ~~3~ are subsequently cured by the curing means :~~35. This embodin~e_~-a of.the present invention may need an adhesive protection layer be placed atop of the adhesive layer ~~3~ far subsequent transfer onto a final subSti ate.
~OE~94] Referring to Fig. ~~, in accordance with.a further embodiment of the present invention, an ink jet system ~5~~ includes a least one ink jet head ~53~~ to dispense at least one structural ink or liquid film ~.5~8 that includes.
colorants, which rn.ay be either process colors, spot colors or combination thereof, as well as white or clear, onto a carrier sheet 2524. Thus, the layer 3.528 may include colors for the final signas well as structural ink to provide structure thereto. The ink jet system '518 further includes an ink jet adhesive head 159 that digitally dispenses ink jet printed adhesive X530 atop of the image layer ~.5~9. In this embodiment of the present invention, an adhesive protection layer may be included to protect adhesive until the sign is applied fo the final substrate.
[005] According to a further embodiment of the present invention, the image 1.t~29, X129, X229, ~.32g, ~.~25, T529 can be reversed printed wifh either adhesive, sfruetur al ink or conventional ink including white colorant to provide background for the image. Thus, the resulting sign can be applied to inside of glass to be seen from the outside.
~0096~ The present invention infroduces the concept of the Additive Signmaking Process, as opposed to other known processes of signmaking, such as weeding. The Additive Signmaking Process includes building an image or film onto a substrate. The built up film or image either can be permaneritly adhered to tl~e substrate or subsequently transferred onto a final substrate. 'phe building up of the image or film can involve either a single layer of de~reloper or multiple layers, including, but not limited to, different colors of developers, clear coating film.
and / ar adhesive. The Additive Signmaking Process has great advantages over the weeding signrnaking process. The Additive Siaruna3cing ?rocess eliminates the need for weeding excess material from the sign, thus elimir~ating waste from the weeding and minimizing potential damage to the actual sign. Use of powder paint and powder toner in signmaking has tremendous advantages. Use, of powder paint and powder toner in signznaking yields durable signs capable of being used outdoors.

rt<:
[Q097] Although powder paint is well known in some indusfiries, such as automotive, use of pawder paint in the signmaking industry has not been k'I'IOW11.
Similarly, although powder toner has been used in office laser printers and copiers for regular printing operations, powder toner in durable signmaking has not been used.
~0098I While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art, that various modifications to this invention rnay be made withocxt departing from. the spirit and scope of the present invention. por example, although the printer 118 was described as having a preferred configuration, many other configurations are within the scope of the present invention.
Additionally, although the preferred embodiment describes an electrophotographic printer, other types.of printers, such as thermal, ink jet, and/ or Iaser, can be used to generate an image and/ or durable ' 3m~ image to be used in the Additive Signmakxng Process and/or Adhesive Split ~'ransfer process.

Claims (117)

1. An apparatus for generating a sign, said apparatus comprising:
at least one ink jet print head for printing at least one colorant to generate an image; and an adhesive ink jet head for applying adhesive.

2. The apparatus according to claim 1 wherein said apparatus comprises a plurality of ink jet print heads, each said ink jet print head having a different colorant.

3. The apparatus according to claim 2 wherein said plurality of ink jet print heads dispenses spot colors and process colors.

4. The apparatus according to claim 1 wherein said at least one ink jet print head dispenses process colors.

5. The apparatus according to claim 1 wherein said at least one ink jet print head dispenses spot colors.

6. The apparatus according to claim 1 wherein said at least one colorant dispensed from said at least one ink jet print head is liquid film.

7. The apparatus according to claim 6 wherein said liquid film provides structure to said sign.

8. The apparatus according to claim 1 wherein said adhesive is applied selectively to be substantially in register with said image.

9. The apparatus according to claim 1 wherein said adhesive is applied digitally to be substantially in register with said image.

10. The apparatus according to claim 1 wherein said adhesive is applied uniformly and wherein excessive adhesive is subsequently removed.

11. The apparatus according to claim 1 wherein said adhesive includes colorant.

12. The apparatus according to claim 1 wherein said adhesive is clear.

13. The apparatus according to claim 1 wherein said adhesive is translucent.

14. The apparatus according to claim 1 wherein said adhesive is white.

15. The apparatus according to claim 2 further comprising:
a curing station to cure said image and said adhesive.

16. The apparatus according to claim 15 wherein said curing station provides UV
curing to said adhesive and said image.

17. The apparatus according to claim 1 wherein said colorant is UV cured ink.

18. The apparatus according to claim 1 wherein said adhesive applied onto a carrier sheet with said image being applied onto said adhesive.

19. The apparatus according to claim 18 wherein said image includes liquid film.

20. The apparatus according to claim 18 wherein a clear layer is applied atop of said image.

21. The apparatus according to claim 20 wherein said clear layer includes liquid film to provide structure to said image.

22. The apparatus according to claim 1 wherein said at least one colorant is applied onto a carrier sheet to form an image, said at least one colorant including liquid film, and said adhesive being applied onto said image.

23. The apparatus according to claim 1 further comprising:
a liquid film ink jet head for applying liquid film.

24. The apparatus according to claim 23 wherein said liquid film is applied selectively to be substantially in register with said image.

25. The apparatus according to claim 23 wherein said liquid film is applied digitally to be substantially in register with said image.

26. The apparatus according to claim 23 wherein said liquid film includes colorant.

27. The apparatus according to claim 23 wherein said liquid film provides structure to said sign.

28. The apparatus according to claim 23 wherein said liquid film is clear.

29. The apparatus according to claim 23 wherein said liquid film is translucent.

30. The apparatus according to claim 23 wherein said liquid film is white.

31. The apparatus according to claim 23 wherein said liquid film provides structure and protection to said sign.

32. The apparatus according to claim 23 wherein said liquid film ink jet print head includes process colors.

33. The apparatus according to claim 23 wherein said liquid film ink jet print head includes spot colors.

34. The apparatus according to claim 23 wherein said liquid film ink jet print head includes spot colors and process colors.

35. The apparatus according to claim 23 wherein said adhesive includes colorant.

36. The apparatus according to claim 35 wherein said adhesive is white to provide background to said image.

37. The apparatus according to claim 23 wherein said adhesive applied onto a carrier sheet, said liquid film applied over said adhesive with said image being applied onto said liquid film.

38. The apparatus according to claim 23 wherein said at least one colorant is applied onto a carrier sheet to form an image, said liquid film applied over said image with said adhesive being applied onto said liquid film.

39. The apparatus according to claim 23 wherein a protective layer is applied onto said adhesive.

40. The apparatus according to claim 23 wherein said liquid film is applied onto a carrier sheet, said at least one colorant is applied onto said liquid film to form an image with said adhesive being applied onto said image.

41. An adhesive comprising:
a liquid adhesive for being digitally applied through an ink jet mechanism onto a carrier sheet for subsequent use of adhering a printed sign onto a final substrate.

42. A method for generating a sign comprising the steps of:
providing a carrier sheet;
providing an adhesive layer on top of said carrier sheet; and generating an image by placing at least one image layer on top of said adhesive layer to form a sign.

43. The method according to claim 42 wherein said adhesive layer is generated digitally.

44. The method according to claim 43 wherein said adhesive layer is generated digitally to be substantially in register with said image.

45. The method according to claim 42 wherein said adhesive layer is generated selectively to be substantially in register with said image.

46. The method according to claim 42 wherein said adhesive is applied through an ink jet mechanism.

47. The method according to claim 42 wherein said adhesive layer is white.

48. The method according to claim 42 wherein said adhesive layer is clear.

49. The method according to claim 42 wherein said adhesive layer is translucent.

50. The method according to claim. 42 wherein said adhesive layer includes colorant.

51. The method according to claim 42 wherein said image is generated by at least one ink jet printhead.

52. The method according to claim 42 wherein said image is generated by a plurality of ink jet printheads.

53. The method according to claim 52 wherein said plurality of ink jet printheads dispenses a combination of process and spot colors.

54. The method according to claim 42 wherein at least one ink jet printhead includes process colors.

55. The method according to claim 42 wherein. at least one ink jet printhead includes spot colors.

56. The method according to claim 42 wherein said image is generated by ink jetting of liquid film.

57. The method according to claim 56 wherein said liquid film provides structure to said sign.

58. The method according to claim 42 further comprising the step of:
curing said image.

59. The method according to claim 58 wherein said step of curing comprises UV
curing.

60. The method according to claim 58 wherein said step of curing comprises thermal curing.

61. The method according to claim 58 wherein sand step of curing comprises laser curing.

62. The method according to claim 42 wherein said adhesive layer is placed uniformly onto said carrier sheet.

63. The method according to claim 62 wherein excess adhesive is removed from said adhesive layer once at least one said image layers has been generated.

64. The method according to claim 42 further comprising a step of:
generating another layer atop of said of said adhesive layer of clear liquid film to provide structure to said image.

65. The method according to claim 42 further comprising a step of:
generating at least one layer of liquid film to provide structure to said image.

66. The method according to claim 65 wherein said at least one layer of liquid film is placed atop of said adhesive layer.

67. The method according to claim 65 wherein said at least one layer of liquid film is generated to be substantially in register with said image.

68. The method according to claim 65 wherein said at least one layer of liquid film is generated by ink jetting said liquid film through an adhesive ink jet print head.

69. A method for generating a sign comprising the steps of:
providing a carrier sheet;
generating an image by placing at least one image layer on top of said carrier to form a sign; and generating an adhesive layer.

70. The method according to claim 69 further comprising a step of:
placing a protective layer atop of said adhesive layer.

71. The method according to claim 69 further comprising a step of:
generating at least one layer of liquid film to provide structure to said image.

72. The method according to claim 71 wherein said at least one layer of liquid film is placed atop of said image layer.

73. The method according to claim 71 wherein said at least one layer of liquid film is placed atop of said carrier sheet.

74. The method according to claim 71 wherein said at least one layer of liquid film is generated to be substantially in register with said image.

75. An apparatus for generating an image comprising:
means for applying at least one colorant onto a substrate coated with an adhesive layer to generate an image atop of said adhesive layer.

76. The apparatus according to claim 75 wherein said means for applying at least one colorant is at least one ink jet print head.

77. The apparatus according to claim 75 wherein said at least one colorant comprises liquid film.

78. The apparatus according to claim 75 wherein said adhesive includes colorant.

79. The apparatus according to claim 75 wherein said adhesive includes white colorant.

80. The apparatus according to claim 75 further comprising:
means for curing said image.

81. The apparatus according to claim 75 further comprising:
means for fusing said image.

82. The apparatus according to claim 81 wherein said means for fusing is a non contact fuser.

83. The apparatus according to claim 75 wherein sand means for applying at least one colorant is an ink jet system.

84. The apparatus according to claim 75 further comprising:
an ink jet print head dispensing clear liquid film to provide structure to said image.

85. The apparatus according to claim 75 further comprising:
means for removing excess adhesive from said substrate to result in said image being disposed atop of said substrate with said adhesive layer being disposed therebetween.

86. The apparatus according to claim 85 wherein said means for removing said excess adhesive is a system bringing a consumable sheet into contact with said substrate to remove said excess adhesive upon separation of said consumable sheet with said substrate leaving. said image disposed atop of said substrate with said adhesive layer sandwiched therebetween.

87. The apparatus according to claim 86 wherein said means for removing said excess adhesive comprises:
a supply roll for dispensing said consumable sheet; and a take up roll for taking up said consumable sheet with said excess adhesive disposed thereon.

88. The apparatus according to claim 87 further comprising:
a pressure roller disposed between said supply roll and said take up roll and substantially adjacent to said consumable sheet to apply pressure thereto to promote bonding between said consumable sheet and said excess adhesive.

89. The apparatus according to claim 86 wherein said consumable sheet material is foil.

90. The apparatus according to claim 86 wherein said consumable sheet functions as a protective sheet and is removed from said carrier sheet at a later time.

91. The apparatus according to claim 85 further comprising:
means for printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter to allow subsequent printing over some portion of said image background perimeter with at least one color to generate a multi-color image.

92. The apparatus according to claim 85 further comprising:
means for printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter to allow subsequent printing over some portion of said image background perimeter with at least one half-tone color to generate a half-tone image.

93. A method for generating an image comprising the steps of:
providing a substrate with an adhesive layer; and generating an image onto said substrate with said adhesive layer such that said image is disposed atop of said adhesive layer.

94. The method according to claim 93 wherein said image comprises liquid film.

95. The method according to claim 93 further comprising a step of:
applying a protective layer atop of said image.

96. The method according to claim 95 wherein said protective layer comprises clear liquid film to provide structure to said image.

97. The method according to claim 93 further comprises the step of:
removing excess adhesive from said substrate such that said image remains on said substrate with said adhesive layer sandwiched therebetween.

98. The method according to Claim 97 wherein said excess adhesive is removed with a consumable sheet.

99. The method according to Claim 98 wherein said excess adhesive adheres to said ink foil.

100. The method according to Claim 93 wherein said image is generated on an ink jet printer.

101. The method according to Claim 100 wherein UV cure ink is generated to print said image.

102. The method according to claim 93 wherein said step of generated further comprises the steps of:

printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter; and printing over some portion of said image background perimeter with at least one color to generate a multi-color image.

103. The method according to claim 93 wherein said step of generated further comprises the steps of:

printing with predetermined background color over an entire image to remove excess adhesives to define an image background perimeter; and printing over some portion of said image background perimeter with at least one half-tone color to genes ate a half-tone image.

104. An apparatus for generating a sign, said apparatus comprising:

means for printing at least one colorant to generate an image for a sign; and means for applying adhesive for subsequent application of said sign.

105. An apparatus for generating an image, said apparatus comprising:

at least one ink jet print head for generating an image, said at least one ink jet print head having liquid film disposed therein to provide structure to said image.

106. An apparatus comprising:

an adhesive ink jet head for digitally dispensing adhesive such that said adhesive is placed selectively.

107. An apparatus for generating a sign, said apparatus comprising:

at least one ink jet print head for printing at least one colorant to generate an image for a sign; and an adhesive ink jet head for digitally applying adhesive for subsequent application of said sign.

108. A method of generating a sign comprising the steps of:

providing a carrier sheet;
generating an adhesive layer on top of said carrier sheet; and generating an image by playing at least one image layer on top of said adhesive layer to form a sign.

109. A method of generating a sign comprising the steps of:

providing a carrier sheet;
providing an adhesive layer on top of said carrier sheet; and generating an image by placing at least one image layer on top of said adhesive layer to form a sign;
wherein said adhesive is selectively placed to be substantially in register with said image.

110. A method of applying adhesive, said method comprising the steps of:

generating an adhesive layer by ink jetting adhesive through an ink jet mechanism.

111. A method of generating a sign comprising the steps of:

generating an image by applying at least one liquid film layer substantially in register with an image, said liquid film layer providing structure to said image.

112. The apparatus according to claim 18 wherein a clear layer is applied atop of said adhesive.

113. The method according to claim 69 wherein said adhesive layer is generated to be substantially in register with said image.

114. The apparatus according to claim 84 wherein said liquid film is clear.

115. The apparatus according to claim 84 wherein said liquid film is white.

116. The method according to claim 96 wherein said liquid film is applied by an ink jet head.

117. The method according to claim 98 wherein said consumable sheet is ink foil.