Systems and methods for decorating substrates
Systems and methods for forming and applying decorations onto substrates are disclosed. According to some aspects, a decoration may be formed on a carrier web at a decoration forming station positioned along a web path. The decorations may be transported along the web path to an application station at which the decorations are applied to substrates from the carrier web.
1 . A method for decorating a substrate, comprising:
transporting a portion of a carrier web along a web path to a decoration forming station;
forming a decoration on the portion of the carrier web at the decoration forming station, the decoration comprising one or more decoration layers and an adhesive layer formed in register with the one or more decoration layers and exposed on a surface of the decoration facing outwardly from the carrier web;
transporting the decoration along the web path from the decoration forming station to an application station after forming the decoration;
using a festoon to adjust a path length in a portion of the web path before the application station through which the carrier web travels to allow accumulation of the carrier web within the festoon; and
applying the decoration to a substrate at the application station.
2 . The method of claim 1 , further comprising activating the adhesive layer of the decoration at an activation station positioned along the web path between the decoration forming station and the application station, wherein the adhesive is tacky after being activated.
3 . The method of claim 1 , further comprising exposing the decoration to radiation and/or an air flow at one or more curing stations positioned along the web path between the decoration forming station and the application station.
4 . The method of claim 1 , further comprising cleaning the carrier web at a cleaning station positioned along the web path after the application station.
5 . The method of claim 1 , wherein applying the decoration to the substrate at the application station comprises transferring the decoration from the carrier web directly to the substrate.
6 . The method of claim 1 , wherein applying the decoration to the substrate at the application station comprises moving the substrates through the application station with a substrate transport while the carrier web is stopped.
7 . The method of claim 6 , wherein moving the substrates through the application station includes moving a substrate along the carrier web to transfer a decoration to the substrate.
8 . The method of claim 1 , wherein forming the decoration includes using one or more of protrusions and/or depressions on the carrier web to form a textured surface on at least a portion of the decoration formed on the carrier web.
9 . The method of claim 1 , wherein the step of using a festoon includes using the festoon to accumulate a portion of the web at a location between the decoration forming station and the application station.
10 . The method of claim 1 , wherein the step of transporting the decoration along the web path includes transporting the decoration from the decoration station to the festoon.