GB2419110A

GB2419110A - An authentication article encapsulated in a curable coating on a substrate

Info

Publication number: GB2419110A
Application number: GB0422882A
Authority: GB
Inventors: Nicholas John Murray; Lee Nicholas Murray
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-10-14
Filing date: 2004-10-14
Publication date: 2006-04-19
Also published as: GB0422882D0

Abstract

A method of encapsulating an article within a coating of a substrate comprises: providing a substrate; applying a first receiving layer of a curable coating on the substrate; introducing one or more articles to be encapsulated; applying a second layer of a curable coating to the substrate over the receiving layer; and curing the coating, so that the article is encapsulated within the coating. The coating may be cured using ultra violet radiation. The article may be an authentication means comprising a RFID providing biometrics information to provide a tamper proof passport or identity card with laser printed text. Barcodes and magnetic information strips may be included. The substrate may also be a vehicle registration plate. Also, a method of forming a durable image comprises: providing a substrate which may be polyethylene terephthalate; depositing an image by ink jet printing on the substrate; spraying a curable water soluble lacquer coating over the image; and curing the coating. Printed organic light emitting polymers or diodes and other flat screen display devices may be disposed between layers of curable lacquer.

Description

241911 0 DE S CRTPTl ON

METHOD OF PRODUCING AN IMAGE

TECHNICAL FIELD

The present invention relates to a method for producing a durable image, particularly but not exclusively a durable photo-realistic image comprising a gloss and/or a textured anti-scratch finish

BACKGROUND

Durable images can form, or be included in a number of articles for security purposes For example, durable images may be formed or included in articles such as signs, pictures, placards, posters, holographics, bar codes, visible legal identifiers, RF1D (radio-frequency identification) enabled license plates/windscreen tags, contactless biometrics enabled passports and visas, REID enabled citizen identity/entitlement cards, REID enabled card driving licenses/medical passports/immigration benefit and work entitlement cards that have been made interoperable for the secure exchange of personal information and data held by governments and police central databases internationally in the fight against terrorism and identity theft Recent advances in security technology have resulted in cards being produced that are interoperable such - 2 that the exchange of secure information is by means of using active and passive contactless biometrics enabled microchips using programmable, or read only wireless RFID enabled electronic microchips which may additionally be quantum encrypted These microchips can be utilised in a number of applications, such as wireless RFID enabled microchips embedded in biometrics enabled passports, biometrics enabled bank cards, secure citizen identity and entitlement cards and RFID enabled identity documents In addition to security cards and chips, images disposed on pictures, plates and stickers may also be used for means of security, for example in organic polymer flat screen displays used for advertising and vehicle identification The use of wireless RFID enabled electronic microchips embedded in vehicle license plates (which may be either active or passive), allows for the chips to be read and interrogated by static and/or mobile readers and cameras for the prevention of vehicle cloning and vehicle identity fraud Electrophoretic (e-ink) active display license plates, wireless RFID enabled vehicle registration plates and scratch resistant displays can also be used for security purposes.

Typically, such an article includes a laminate optically transparent protective cover surface and a substrate, reflective material or polymeric sheet receptive to digital and 3 laser toner printing, carrying the required image (which may also include visible legal identifiers) The image is generally produced by a conventional colour printing technique The image-carrying sheet may be laminated to the optically transparent cover surface using (an optically clear UV curable adhesive or radiation curable lacquer) on a carrier film or transferred by roller transfer or continuous transparent web. If necessary, a protective backing surface may also be adhered to the sheet on the opposite side to the optically transparent cover surface Such an image- carrying article is disclosed, for instance, in EP-A-0638019 A rigid peer- off backing material may be provided to a flexible reflective substrate to add rigidity during printing by digital laser printer and then removed after printing through a laser printer. One problem with the use of conventional printing paper in the production of an image carrying article is that it may discolour, become scratched and/or degrade, particularly when used in adverse weather conditions In applications where a high quality colour image is required for outdoor applications (such as printable arrays of organic light omitting polymer and organic light emitting diodes for producing thin flat screen displays), the image- carrying electronic electrophoretic ink paper substrates and reflective substrates must be protected against ingress of water. For such applications it is known to encapsulate the image-carrying substrate or laminate, for instance by means of a plastic pouch which is heat-sealed around all sides of the laminate sheet, or by laminating a clear plastics material over the printed substrate which may also comprise a visible legal identifier Producing a durable high quality image using lamination techniques can be expensive and inconvenient This is partly due to the cost of the optically transparent protective cover surface and adhesive materials used, which is generally significantly greater than the cost of the image-carrying sheet itself In addition, it is generally necessary to use a lamination machine to apply the transparent protective cover Heavy commercial rollers for wide format print laminating are extremely costly (often costing in excess of 1 O,000) A third factor is the cost of printing the image itself, high quality colour printing and the silver halide film and print processing of conventional photographic techniques are not only expensive, but also time consuming Conventional photographic techniques also require the use of wet and often toxic and hazardous chemicals which require particular methods of waste disposal The production of such images and products can be relatively expensive, particularly when only a small number of prints are required.

It is an object of the present invention to provide a method for producing a durable image which overcomes or at least minimises the problems associated with existing print-lamination techniques. In particular, it is an object of this invention to provide a method for producing an image which is secure and tamper proof (and/or tamper evident, so as to protect against frauds and in particular, identity- theft and fraud it is preferred that the method for producing the image is provided with contactless biometrics enabled electronic microchips and wireless RFID enabled electronic microchips, along with a visible legal identifier between layers, which may be scratch resistant, long lasting and weather resistant A further object of this invention is to provide a method for producing high-quality, photo-realistic durable images and printing high resolution digital camera and digital data files from computer software without the use of toxic chemicals whilst retaining image quality. As used herein, a photo-realistic image means an image having a visual appearance comparable to a conventional silver halide print produced by wet bath and photographic chemistry and a digital camera image displayed on a thin flat organic light emitting polymer or organic light emitting diode display screen. A photo realistic image may be a digital image from a digital camera printed by inkjet or laser, or biometrics images held in an image recordable chip embedded in the structure of a tamper proof biometrics enabled polycarbonate passport or RFID enabled programmable bank card, laser printed legal identifier, debit and visa cards, pages in a biometrics enabled passport comprising embedded organic printed polymer conductive circuitry and active and passive RFID wireless enabled electronic micro chips adjacent to an antenna protected by a scratch resistant radiation curable laminate - 6 Whilst a a photorealistic image would not usually be included in a legal identifier (a legal identifier being generally a laser printed or etched legal identifier digitally printed on a clear film introduced between the layers of a license plate or pages of a passport), it may additionally contain a photorealistic image.

A further object of this invention is to provide an inexpensive alternative or equivalent to a conventionally laminated and textured photographic print which may include a high gloss finish with the whole or part area antenna layers tuned to wireless RFID and/or cell phone frequencies and/or signals. The wide variety of transfer coated surfaces may have applications in passports, visas and identification and authentication documents, Smart cards, citizen entitlement cards, immigration cards, benefits and work entitlement cards, European medical passports, DNA medical benefits cards, TDSC (image displaying swipe cards) and RFID enabled card driving licenses The transfer coated surfaces may be embedded between coating layers and films for producing clear lacquer identity devices and micro electronic flexible structures forming printable organic light emitting polymer, organic light emitting diode flat screen displays, tamper proof electrophoretic vehicle active display license plates and third license RFID enabled windscreen license tags. - 7

SUMMARY

The present invention is directed to, in one embodiment, a method of encapsulating an article, which may be a printed organics polymer device, plastic printed circuitry, printed polymer microchip or battery within a coating of a substrate. The method involves the steps of providing a substrate, applying a receiving layer of a printable and curable coating on the substrate, introducing an article to be encapsulated, applying a further layer of a curable coating to the substrate over the receiving layer and curing the coating in an air free environment, the article thereby being encapsulated within the coating which is preferably resistant to abrasion In biometrics enabled passports the cold UV cured lacquer layers and components that are laminated between two films of laser printed polycarbonate and hot laminated on either side of the structure using hot melt adhesive to bond the UV cured layers between the polycarbonate outer layers. The adhesive may be degradable to provide evidence of tampering.

In another embodiment, the invention is directed to a method of forming a vehicle registration plate incorporating an encapsulated authentication means such as passive or active display panels displaying registration marques, having a visible vehicle legal identifier layer and a matched pair of wireless REID enabled electronic microchips that can be read at any speed and record excessive vehicle speeds travelling over the national speed limit for motorways A REID enabled device in accordance with the present invention may also be used for remotely crediting expired road tax fund and interrogating the true identity and authentication, a vehicle and the validity of mot and insurance, a visible VIN number (which is usually a minimum of 6 or 8 digits), visible year and month of vehicle first registration, display by conventional digital print on reflective or a non-reflective substrate or e-ink embedded devices including holographics, a barcode identifier and/or an electronic microchip alternative to bar codes. A number plate may be pressed form a metal material (such as used in USA) or alternatively, it may be manufactured from a plastics material (such as used in the UK). The method involves the steps of providing the text of the registration plate on a substrate, applying a receiving layer of a curable coating on to the substrate, introducing an authentication means to be encapsulated, applying a further layer of a curable coating to the substrate over the receiving layer and curing the coating, the authentication means thereby being encapsulated within the coating The receiving layer over a substrate may be a transparent layer coating or a reflective material made receptive to digital laser toner printing by laser printer and computer software for depositing the government legislated text in a legally required format For number plates, conventional reflective may not always be printable without the addition of a laser print transparent toner receptive coating applied over a reflective before the 9 - registration and vehicle identification details are printed The print reflective transparent coating on a reflective may optionally comprise whole or part areas of metallic oxide particles and a water mark or legal printed identifiers across the face of a registration plate such that the layers are encapsulated within the layer In another embodiment, the invention is directed to a method of forming a matching pair of wireless RFID enabled vehicle registration plates that operate together with an interoperable wireless RFID enabled third license identifier sticker displayed inside a vehicle windscreen using destructible tamper evident adhesive, each device incorporating visible display panels for displaying a registration marque and vehicle identifiers adjacent to wireless RFID enabled electronic micro-chips programmed with driver information, MOT and Road Tax and Insurance expiry dates, together with visible laser toner printed information and a laser etched legal identifier film layer, holographics, and printed VIN numbers comprising minimum eight digit bar- codes for visually identifying chassis numbers with month and year of first registration, displayed by conventional print or embedded E-ink devices, that can be interrogated and/or programmed by computers, mobile and static cameras, and remote RFID biometrics enabled scanning and reading devices including display-centric hand held mobile imaging devices Active and passive electronic ink OLED display panels can be formed on or embedded in biometrics enabled passports and in viewing (idsc) image display swipe cards comprising a biometrics image programmed into a biometrics enabled electronic microchip on a secure document or embedded in a passport a smart visa and smart biometrics and/or REID enabled identity card.

In yet another embodiment, the invention is directed to a method of forming a durable image comprising the steps of providing a substrate, depositing an image on the print receptive substrate, applying a curable coating over the image and curing the coating In another embodiment, the invention is directed to an apparatus for forming a durable image on a substrate. The apparatus includes means for depositing an image on a substrate, means for embedding devices between the substrate and the coating, means for applying a curable coating over the image and means to cure the coating The apparatus for digitally printing and transfer coating and UV curing may provide for a continuous process using a compact in-line apparatus that uses less space than individual pieces of equipment. This will be of particular use in a home or office where there is little space.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more clearly understood, embodiments thereof will now be described by way of example and with reference to the accompanying drawings in which FIG I is a plan view of a durable image; FIG. 2 is a cross-sectional view of the image of FIG. 1, taken along the line A-A of FIG. 1; FIG 3 is a schematic view of an embodiment of apparatus according to the invention, FIG 4 is a schematic view of another embodiment of apparatus according to the invention.

FIG 5 is a perspective view of an apparatus in accordance with the present invention, showing the processing of a digital image to an article containing the image thereon, FIG. 6 is a schematic diagram of an additional apparatus in accordance with the present invention, and FIG 7 shows a schematic diagram of an identification card produced in accordance 12 with the present invention With reference to Fig 5, there is provided an apparatus 28 for reading a digital image and placing it onto a suitable card such as an identity card, the device and associated devices are as follows Computer/Tmage Display Processor (30), CD/DVD/Mini- DVD Player (32), Digital Camera Memory Card Reader/Processor (40),USB Data Memory Storage Device (45), Digital Camera Direct Image Firewire Source (52), Functional Operation Display Screen (62), Function Operatinig Wheel (42), Push Button Controls (44), Electric Power Supply (49), Digital Camera Plug-In Reader Device (60), USB Data Memory Player (58), CD/DVD (56), Mini-DVD (54), Digital Camera Memory Cards (50), DVD and Player (34), External Speaker (48), External Antenna for Image Capture Using Wireless RFID/Bluetooth/Centrino, Broadband Images/Cellphone Images/and Images using (IP) Internet Protocol (46), System Housing (47), Plug-ln Digital Camera Memory Card (38), CD/DVD/Mini DVD Player Feed Tray (36).

With reference to Fig 6, there is provided an apparatus for reading cards and additionally has a visual display unit 70 for viewing cards, an antennae 72 for communication purposes and a slot 74 for receiving a card 76. - 13

With reference to Fig 7, there is provided a "biometric" card 80 having a magnetic strip 84, and electronic chip 86 and an image 88 disposed on the card containing secure data for identification purposes The card may also comprise an antennae (not shown) for communication purposes A VDU is also provided 82, on which details of the card can be viewed when the card is either in close proximity or inserted into a base station 90 connected to the VDU and optionally a database.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

According to a first aspect of the present invention there is provided a method of forming a durable image comprising the steps of providing a substrate, depositing an image on the substrate, applying a curable coating over the image, and curing the coating In a preferred embodiment, the durable image is a photo-realistic durable image with the feel and appearance of an optically bright gloss or textured photograph.

The substrate may form a rigid platform on which the image is formed and may be capable of independent existence in the absence of any further supporting base The substrate may be absorbent or not absorbent to the image-forming material, i e 14 ink or toner The substrate should be thermally and dimensionally stable under the conditions used in the image deposition process, which may involve passage of the substrate through a photocopier or digital laser printer. The temperature of a copier fuser roller, for example, is normally at least 150 degree C, and typically in the range of 160 to 190.degree C Although the substrate is exposed to the heat of the roller for only a short time during the image production it can become degraded, twisted and buckled, or even melt In general, the substrate should be capable of withstanding a temperature ofatleastl50.degree C end preferably atleastl90.degree C without substantial instantaneous degradation, structural change, dimensional change, or colour change Most preferably the substrate should be such that it is thermally and dimensionally stable when exposed to a temperature of 200.degree C for at least 0.5 seconds The substrate may include a thermoplastics polymeric material, and may be formed from any suitable film-forming polymeric material. Such materials include homopolymers or copolymers of a 1 -olefin (including ethylene, propylene and but- I ene), polyamides, polycarbonates, PVC, PVA, polyacrylates, celluloses and polyesters Preferably the substrate and coating carrier include a polyester, particularly a synthetic-linear polyester.

The synthetic linear polyesters useful as the substrate may be obtained by condensing one or more dicarboxylic acids or their lower alkyl (up to 6 carbon atoms) diesters, eg terephthalic acid, isophthalic acid, phthalic acid, 2,5-, 2,6-, or 2,7- naphthalenedicarboxilic acid, succinic acid, sebacic acid, adipic acid, azelaic acid, 4,4 sup.7-diphenyldicarboxylic acid, hexahydro-terephthalic acid or 1,2- bis-p- carboxyphenoxyethane (optionally with a monocarboxylic acid, such as a pivalic acid) with one or more glycols, particularly an aliphatic or cycloaliphatic glycol, eg ethylene glycol, 1,3-propanediol, 1,4-butanediol, neopenthyl glycol and 1,4- cyclohexanedimethanol An aliphatic glycol is preferred.

In a preferred embodiment, the polyester is polyethylene terephthalate (PET) or a copolyester thereof with other co-monomeric units, as set out above The substrate may also include a polyarytether or analogue thereof, particularly a polyaryletherketone, polyarylethersulphone, polyaryletheretherketone, polyaryletherethersulphone, or a copolymer or thioanalogue thereof. Examples of these polymers are disclosed in EP-A001879, EP-A-0184458 and U.S Pat. No. 4,008,203 Blends of such polymers may also be employed.

The substrate may include one or more discrete layers of the above filmforming materials. For instance, the substrate may include one, two, three, four or five or more layers The polymeric materials of the respective layers may be the same or different.

In a preferred embodiment the film may include a multilayer substrate comprising two or three, preferably two, different types of layer Typical multilayer structures may be of the AB, ABA, ABC, ABABA, or ABCBA type Where the substrate includes more than one layer, preferably at least one of the layers includes polyethylene terephthalate Formation of the substrate may be effected by conventional techniques well known in the art Conventionally, formation of the substrate is effected by extrusion, in accordance with the procedure described below In general terms the process includes the steps of extruding a layer of molten polymer, quenching the extrudate and orienting the quenched extrudate in at least one direction The substrate may be uni-axially oriented, but is preferably bi-axially oriented by drawing in two mutually perpendicular directions in the plane of the film to achieve a satisfactory combination of mechanical and physical properties Orientation may be effected by any process known in the art for producing an oriented film, for example a tubular or flat film process In a tubular process, simultaneous biaxial orientation may be effected by extruding a thermoplastics polyester tube which is subsequently quenched, reheated and then expanded by internal gas pressure to induce transverse orientation, and withdrawn at a rate which will induce the longitudinal orientation In a preferred flat film process, the substrate-forming polyester is extruded through a slot die and rapidly quenched upon a chilled casting drum to ensure that the polyester is quenched to the amorphous state. Orientation is then effected by stretching the quenched extrudate in at least one direction at a temperature above the glass transition temperature of the polyester. Sequential orientation may be effected by stretching a flat, quenched extrudate firstly in one direction, usually the longitudinal direction, i e.

the forward direction through the film stretching machine, and then in the transverse direction Forward stretching of the extrudate is conveniently effected over a set of rotating rollers or between two pairs of nip rollers, transverse stretching then being effected in a strenter apparatus. Stretching is effected to an extent determined by the nature of the polyester, for example polyethylene terephthalate is usually stretched so that the dimension of the oriented film is from 2 to 5, more preferably 2 5 to 4 5 times its original dimension in the or each direction of stretching. Typically, stretching is effected at temperatures in the range of 70 to 125 degree C. Greater draw ratios (for example up to about 8 times) may be used if orientation in only one direction is - 18 required It is not necessary to stretch equally in the machine and transverse directions although this is preferred as balanced properties are desired A stretched film may be, and preferably is, dimensionally stabilized by heat-setting under dimensional restraint at a temperature above the glass transition temperature of the polyester but below the melting temperature thereof, to induce crystallization of the polyester. In applications where the film shrinkage is not of significant concern, the film may be heat set at relatively low temperature or not at all On the other hand, as the temperature at which the film is heat set is increased, the tear resistance of the film may change. Thus, the actual heat set temperature and time will vary depending on the composition of the film and its intended application but should not be selected so as to substantially degrade the tear resistant properties of the film Within these constraints, a heat set temperature of about 135 to 250.degree. C. is generally desirable, as described in GB-A-838708 Where the substrate includes more than one layer, preparation of the substrate is conveniently effected by coextrusion, either by simultaneous coextrusion of the respective film-forming layers through the independent orifices of a multi-orifice die, and thereafter uniting the still molten layers, or preferably by single-channel coextrusion in which molten streams of the respective polymers are first united within a channel leading to a die manifold, and thereafter extruded together from the die orifice under conditions of streamline flow without intermixing thereby to produce a multilayer polymeric film, which may be oriented and heat- set as hereinbefore described. Formation of a multilayer substrate may also be effected by conventional lamination techniques, for example by laminating together a preformed first layer and a preformed second layer, or by casting, for example, the first layer onto a preformed second layer The substrate may conveniently contain any of the additives conventionally employed in the manufacture of polymeric films. Thus agents such as cross-linked agents, dyes, pigments, voiding agents, lubricants, anti-oxidants, radical scavengers, UV absorbers, thermal stabilizers, anti-blocking agents, surface active agents, slip aids, optical brighteners, gloss improvers, prodedradents, viscosity modifiers and dispersion stabilizers may be incorporated in the substrate layer as appropriate. In particular the substrate may include a particulate filler. The particulate filler may, for example, be a particulate inorganic filler or an incompatible resin or a mixture of two or more such fillers.

By an "incompatible resin" is meant a resin which either does not melt, or which is substantially immiscible with the polymer, at the highest temperature encountered during extrusion and fabrication of the film The presence of an incompatible resin usually results in a voided layer, by which is meant that the layer includes a cellular structure containing at least a proportion of discrete, closed cells Suitable incompatible resins include polyamides and olefin polymers, particularly a homo- or copolymer of a mono-alpha-olefin containing up to 6 carbon atoms in its molecule Preferred materials include a low or high density olefin homopolymer, particularly polyethylene, polypropylene or poly-4methylpentene-1, an olefin copolymer, particularly an ethylene-propylene copolymer, or a mixture of two or more thereof.

Random, block or graft copolymers may be employed.

Particulate inorganic fillers include conventional inorganic fillers, and particularly metal or metalloid oxides, such as alumina, silica (especially precipitated or diatomaceous silca and silica gels) and titamia, calcified china clay and alkaline metal salts, such as carbonates and sulphates of calcium and barium The particulate inorganic fillers may be of the voiding or non-voiding type Suitable particulate inorganic filler may be homogeneous and consist essentially of a single filler material or compound, such as a titanium dioxide or barium sulphate alone. Alternatively, at least a proportion of the filler may be heterogenous, the primary filler material being associated with an additional modifying component. For example, the primary filler particle may be treated with a surface modifier, such as a pigment, soap, surfactant coupling agent or other modifier to promote or alter the degree to which the filler is compatible with the substrate layer polymer Preferred particulate inorganic fillers include titanium dioxide and silica Titanium dioxide particulates may be of anatase or futile crystal form The titanium dioxide particles preferably include a major portion of futile, more preferably at least 60% by weight, particularly at least 80%, and especially approximately 100% by weight of futile The particles can be prepared by standard procedures, such as the chloride process or the sulphate process The titanium dioxide particles may be coated, preferably with inorganic oxides such as aluminium, silicon, zinc, magnesium or mixtures thereof Preferably the coating additionally includes organic compound(s) such as fatty acids and preferably alkanols, suitably having from 8 to 30, preferably from 12 to 24 carbon atoms. Polydiorganosiloxanes or polyorganohygonsiloxanes, such as polymidethysiloxane orpolymethylhydrogensiloxane are suitable organic compounds. The coating is suitably applied to the titanium dioxide particle in aqueous suspension. The inorganic oxides are precipitated in aqueous suspension from watersoluble compounds such as sodium aluminate, aluminium sulphate, aluminium hydroxide, aluminium nitrate, silicic acid, or sodium silicate. The coating layer on the titanium dioxide particles is preferably in the range from 1 to 12% of organic oxides, - 22 and preferably in the range from 0.5 to 3% of organic compound, by weight based upon the weight of titanium dioxide The inorganic filler should be finely-divided, and the volume distributed median particle diameter (equivalent spherical diameter corresponding to 50% of the volume of all the particles, read on the culmative distribution curve relating volume % to the diameter of the particles--often referred to as the "D(v,O 5)" value) thereof is preferably in the range from 0 01 to 5 microns, more preferably 0.05 to 1 5 microns, and particularly 0 15 to 1.2 microns.

The size distribution of the inorganic filler particles is also an important parameter, for example the presence of excessively large particles can result in the film exhibiting unsightly "speckle", i.e where the presence of individual filler particles in the film can be discerned with the naked eye It is preferred that none of the inorganic filler particles incorporated into the substrate layer should have an actual particle size exceeding 30 microns. Particles exceeding such a size may be removed by sieving processes which are known in the art However, sieving operations are not always totally successful in eliminating all particles greater than the chosen size In practice, therefore, the size of 99.9% by the number of the inorganic filler particles should not exceed 30 microns, preferably should not exceed 20 microns, and more preferably should not exceed 15 microns. Preferably at least 90%, more preferably at least 95% by volume of the inorganic filler particles are within the range of volume distributed median particle diameter ±.0 8 microns, and particular ± 0 5 microns Particle size of the filler particles may be measured by electron microscope, courter counter, sedimentation analysis and static or dynamic light scattering Techniques based on laser light diffraction are preferred The median particle size may be determined by plotting a cumulative distribution curve representing the percentage of particle volume below chosen particle sizes and measuring the 50 sup th percentile The substrate may be opaque, translucent or transparent.

In the preferred embodiment, the substrate layer is opaque and highly filled, preferably exhibiting a Transmission Optical Density (TOD) Sakura Densitometer, type PDA 65, (transmission mode) in the range from 0.1 to 2 0, more preferably 0.2 to 1 5, more preferably from 0 25 to 1.25, more preferably from 0 35 to 0.75 and particularly 0.45 to 0 65 The substrate layer is conveniently rendered opaque by incorporation into the polymer blend of an effective amount of an opacifying agent. Such opacifying agents include incompatible resin filler, a particulate inorganic filler or a mixture of two or more such fillers, as hereinbefore described. The amount of filler present in an opaque substrate layer is preferably in the range from 1% to 30%, more preferably 3% to 20%, particularly 4% to 15% and especially 5% to 10% by weight, based on the weight of the substrate layer polymer An opaque substrate may be white or pigmented, and is preferably white The surface of an opaque substrate layer preferably exhibits a whiteness index, measured as herein described, in the range from to 120, more preferably 80 to 110, particularly 90 to 105, and especially 95 to 100 units In an alternative embodiment the substrate layer of the present invention is optically clear, preferably having a % of scattered visible light (haze) of <10%, preferably <6%, more preferably <3 5% and particularly <2%, measured according to the standard ASTM D1003. In this embodiment, filler is typically present in only small amounts, generally not exceeding 0.5% and preferably less than 0.2% by weight ofthe substrate The thickness of the substrate is preferably between about 20 and 200 microns, more preferably between about 50 and 150 microns, still more preferably between about 90 to 120 microns. Typically, the substrate is about 100 microns thick.

Further examples of substrates suitable for use in the present invention are described in EP-A-0408197 and WO-A-97/37849, the disclosures of which are incorporated herein by reference Preferably, the substrate is treated or coated to improve the adhesion of the image- forming substance hereto The identity of the image-forming substance will, of course, depend on the method used to form the image and includes the toners and inks used in equivalent electrostatic copying and printing methods, and the other image-forming processes mentioned herein In one embodiment the substrate, particularly a PET polyester substrate, is coated with a primer layer such as those disclosed in EP-A-0408197, EP-A-0429179, EP-A- 0576179 or WO-A-97/37849, the disclosures of which are incorporated herein by reference. Preferably, the primer layer includes an acrylic and/or methacrylic polymeric resin and optionally includes a cross- linking agent. Cellulosic materials may also be used Suitable polymers for the primer layer include at least one monomer derived from an ester of acrylic acid, especially an alkyl ester where the alkyl group contains up to ten carbon atoms (including methyl, ethyl, n-propyl, isopropyl, n- butyl, isobutyl, terbutyl, hexyl, 2-ethylhexyl, heptyl and n-octyl). Polymers derived from an alkyl acrylate, for example ethyl acrylate and methyl methacrylate are preferred. Polymers comprising - 26 ethyl acrylate and methyl methacrylate are particularly preferred The acrylate monomer is preferably in a proportion in the range 30 to 65 mole %, and the methacrylate monomer is preferably present in a proportion in the range of 20 to 60 mole %.

Other monomers which are suitable for use in the preparation of the polymeric resin of the primer layer, which may be copolymerised as optional addition monomers together with esters of acrylic acid and/or methacrylic acid, and derivatives thereof, include acrylonitrile, methacrylonitrile, halo-substituted acrylonitrile, halo-substituted methacrylonitrile, acrylamide, methacrylamide, N-methynol acrylamide, ethanol acrylaminide, N-propanol acrylamide, N-methacrylaminide, -ethanol methacrylaminide, -methyl acrylaminide, N-tertitiary butyl acrylamide, hydroxythyl methacrylate, glycidyl acrylate, glycidyl methacrylate, dimethylamino ethyl methacrylte, itaconic acid, itaconic anhydride and halfester ofitaconic acid Other optional monomers of the primer layer polymer include vinyl esters such as vinyl acetate, vinyl chloracetate, vinyl benzoate, vinyl pyridine, vinyl chloride, vinylidene chloride, maleic acid, maleic anhydride, styrene and derivatives of styrene such as chloro styrene, hydroxy styrene and akrylated styrenes, wherein the alkyl group contains from one to ten carbon atoms.

A preferred primer layer polymer includes 35 to 60 mole % ethyl acrylate, 30 to 55 mole % of methyl methacrylate and 2 to 20 mole % of methacrylamide The molecular weight of the primer layer polymer can vary over a wide range but is preferably within the range 40,000 to 300,000, and more preferably within the range 50,000 to 200,000 The primer layer composition may also contain a cross- linking agent which improves adhesion of the primer layer to the substrate Additionally, the cross-linking agent should preferably be capable of internal cross-linking in order to provide protection against solvent penetration A cross-linking agent can also provide extra rigidity to the coated-substrate which improves the dimensional stability during the image-deposition process.

Suitable cross-linking agents may include epoxy resins, alkyd resins, amine derivatives such as hexamethoxymethyl melamine, and/or condensation products of an amine, e g melamine, diazine, urea, cyclicethylene urea, cyclic propyelene urea, thioureau, cyclic ethylene thiourea, alkyl melamines, and melamines, benzo guanamines, alkyl guanamines and aryl guanamines, with an aldenhyde, e g. formaldehyde A useful condensation product is that of melamine with formaldehyde The condensation product may optionally be alkoxylated The cross-linking agent is preferably used in amounts of up to 25% by weight based on the weight of the polymer in the coating composition A catalyst is also preferably employed to facilitate the cross-linking action of the cross-linking agent Preferred catalysts for cross-linking melamine formaldehyde include ammonium chloride, ammonium nitrate, ammonium thiocyanate, ammonium dihydrogen phosphate, ammonium sulphate, diammonium hydrogen sulphate, pare toluene sulphonic acid, maleic acid stabilized by reaction with a base, and morpholiniumpara toluene sulphonate The polymer of the primer layer composition is generally water-insoluble The coating composition including the water-insoluble polymer may nevertheless by applied to the substrate as an aqueous dispersion or alternatively as a solution in an organic solvent Any suitable conventional coating technique such as dip coating, bead coating, reverse roller coating or slot coating may be used The coating medium may be applied to an already oriented film substrate However, application of the coating medium is preferably effected before or during the stretching operation In particular, it is preferred that the primer layer medium should be applied to the film substrate between the two stages (longitudinal and transverse) of the biaxial stretching operation Such a sequence of stretching and coating is especially preferred for the production of a coated linear polyester film substrate, such as a coated polyethylene terephthalate film, which is preferably firstly stretched in the longitudinal direction over a series of rotating rollers, coated, then stretched transversely in a stenter oven, preferably followed by heat-setting.

A primer layer composition applied to the substrate is preferably applied as an aqueous dispersion The temperatures applied to the coated film during the subsequent stretching and/or heat-setting are effective in drying the aqueous medium, or the solvent in the case of solvent applied compositions, and also, if required, in coalescing and forming the coating into a continuous and uniform layer. The cross-linking of the cross-linkable primer lay compositions is also achieved at such stretching, and preferably at such heat setting temperatures In order to produce a continuous coating, the primer layer is preferably applied to the polymeric film at a coat weight within the range O I to 1 0 mgdm. sup. -2, especially 0 2 to 2 0 mgdm sup -2, as known in the art. A discontinuous layer can be produced, for instance on the reverse side of the substrate, by applying a coat weight of less than 0 1 mdgm sup.-2, which may improve the slip properties of the film Modification of the surface of the primer layer, e.g. by flame treatment, ion bombardment, electron beam treatment, ultra-violet light treatment or preferably by 30 corona discharge, may further improve the adhesion of subsequently applied coatings or toner powders The preferred treatment by corona discharge may be effected in air at atmospheric pressure with conventional equipment using a high frequency, high voltage generator, preferably having a power output of from 1 to 20 KW at a potential of 1 to 100 KV.

Discharge is conveniently accomplished by passing the film over a dielectric support roller at the discharge station at a linear speed preferably of 1.0 to 500 m per minute.

The discharge electrodes may be positioned O I to 10,0 mm from the moving film surface Prior to deposition of the primer layer onto the substrate, the exposed surface of the substrate may be subjected to a chemical or physical surface-modifying treatment to improve the bond between the substrate and the subsequently applied primer layer A preferred treatment, because of its simplicity and effectiveness, is to subject the exposed surface of the substrate to a high voltage electrical stress accompanied by a corona discharge Alternatively, the substrate may be pretreated with an agent known in the art to have a solvent or swelling action on the substrate polymer Examples of such agents, which are particularly suitable for the treatment of a polyester substrate, include a halogenated phenol dissolved in an organic solvent, e g a solution of p- chloro-m- cresol, 2,4-dichlorophenol, 2,4,5- or 2,4,6-trichlorophenol or 4- chlororesorcinol in acetone or methanol.

The ratio of the thickness of the substrate and the primer layer may vary within a wide range, although the thickness of the primer layer preferably should not be less than 0.004% nor greater than 10% of that of the substrate. In practice, the thickness of the primer layer is desirably at least 0.01 microns and preferably should not greatly exceed about I O microns The primer layer may conveniently contain any of the additives conveniently employed in the manufacture of the polymeric films, as described above. The primer layer preferably includes a particulate filler, such as a silica, preferably in an amount of not exceeding 50% by weight of the polymeric material and the particle size thereof should not exceed 0.5 microns, and is preferably less than 0 3 microns, and is especially in the range from 0.005 to 0 2 microns The primer layer preferably contains to 15% by weight, and particularly 10% of filler(s). The use of a filler in the primer layer is of particular benefit since it increases the surface roughness of the film, thereby improving the feeding characteristics of the film in photocopiers and printers. This is of particular use when the image-deposition process is effected by using a high-speed electrostatic copying machine A primer layer may be provided on one or each surface of the substrate, and an image may thus be generated on one or each side of the substrate Image deposition may be effected directly onto the primer layer. However, it is preferred that the substrate includes an additional receiving layer applied on top of the primer layer. Image deposition is preferably then effected onto the receiving layer. The composition of the receiving layer will vary depending on the image deposition method used. A receiving layer preferably has a thickness of about 5 to about 15 microns, and may be applied on each side of the substrate For instance, a receiving layer for an electrostatically applied image may contain conductive particles in order to improve the conductivity required to obtain optimum image quality in colour and monochrome photocopiers and laser printers, as is well known in the art The resistivity of such a receiving layer is preferably in the range I to Gohms per square. The type and concentration of conductive particle in the receiving layer may vary as appropriate to the print application being used The receiving layer may include a mixture of polymeric antistatic resins and adhesion promoters Receiving layers suitable for electrostatic methods of image deposition are described, for example, in U.S Pat No. 5,663,030 and the prior art referenced therein, the disclosures of which are incorporated herein by reference Receiving layers suitable for receiving an image applied by an inkjet method are well- known in the art and include, for instance, layers such as those described in EP-A- 0696516 and U.S. Pat No. 588,635, the disclosure of which is incorporated herein by reference If desired, an anti-static coating medium may be applied. Suitable antistatic coatings are described, for instance, in EP- A-0027699 and U.S. Pat. No 5,453,326 and U S. Pat No. 5,882,800, the disclosures of which are included herein by reference. The static friction of the substrate can be reduced by applying a wax, for example a natural wax, such as a canuba wax, or a synthetic wax, to one or both surfaces of the substrate, the wax coating on that surface carrying the receiving layer being applied over that layer. These precautions facilitate the feeding of single sheets from a stack of sheets in a high speed copying machine A preferred polyethylene substrate is commercially available as Melinex Film from DuPont Preferred grades for use in the present invention include Melinex 542, - 34 Melinex 506 and Melinex 347 film The substrate could also be formed from materials other than plastics materials, for example paper, cardboard, wood, metal, MDF, rubber, glass, leather, reflective and magnetic materials. The substrate may be absorbent The substrate could also include a printed circuit, plastic circuit, micro component, semi conductor or pharmaceutical Image Deposition The image, which may of course be a colour image, is preferably deposited on the substrate in a manner such that a photo- realistic image is produced Preferred methods include electrostatic deposition by photocopier or laser printer and inkjet application by an inkjet printer Thermal transfer, dye-sublimination, gravure fine printing, web off-set, lithographic printing, screen printing, dye transfer pictography and hot foil stamping may also be used A toner printing process wherein the various pigments (including black, cyan, magenta, yellow, red, blue, green and white pigment(s)) and colourant(s) are deposited may also be used Preferably the image is deposited by an electrostatic process, and preferably by an electrostatic copying process In one embodiment, the image is formed by a conventional electrostatic copying technique using a thermally fusible (thermoplastics) toner powder Available toner powders include those based on styrene-acrylate copolymers, and blends thereof.

Electrostatic copying machines are well-known and generally available Any conventional and commercially available laser or inkjet printer or photocopier can be I. used in the process of the present invention including those marketed by Canon, 0 p Id ^ ^ ( - ^ Eastman Kodak, Xerox, Ricoh, Minolta, Epson, Hewlett Packard, Oce Machines of this nature generally operate by initially depositing a uniform positive electrostatic charge from a corona discharge electrode onto a drum having a photoconductive surface, e g a selenum coated drum, maintained in a dark environment. The charged surface is then exposed to a light image of the original document or representation to be copied, whereby the charge is dissipated and flows to earth from those areas of the drum struck by light The discharge is not affected in the dark areas masked by the original document or representation The image is then formed by passing negatively charged coloured thermoplastic toner powder over the light-exposed drum so that the powder is electrostatically attracted to the residual charged areas of the drum surface The thus formed toner powder image may be transferred to the film substrate by placing the substrate over the toner image and positively charging the substrate by corona discharge so that the toner powder is attracted to the substrate by the residual negative 36 charge on the toner powder Finally, the substrate may be heated and/or chemically treated to fuse the toner powder and bond it to the substrate as an image layer In conventional electrostatic copying processes, thermal bonding of fusible toner powder to a film substrate is generally effected at relatively high fusion temperatures, for example at about 160degree C., and is commonly achieved by infra-red heating However, somewhat lower temperatures, in the region of 120 degree. C., applied by heated rollers or ultra-violet lamps may also be used.

A stabilizer or fuser used to fix the toner powder to the substrate is typically a silicone material such as a silicone oil, which remains on the surface of the image However, this silicone-containing material may inhibit adhesion of the subsequently-applied optically clear/or colour pigmented UV curable transfer coating to the surface of the imagecarrying substance in the method of the present invention Thus, in one embodiment of the present invention, the silicone-containing stabilizer is removed from the image-carrying substrate, for example by gentle washing and/or wiping with a cleaning liquid or solution. The cleaning liquid or solution may be applied to a damp cloth and used to wipe away the adhesion-inhibiting stabilizer from the surface of the image-carrying substrate Alternatively, the image-carrying substrate can be immersed in a bath of the cleaning liquid or solution. In a further embodiment, the solution may be applied as a wash process inside a coating machine, or by means of detergent-impregnated wipes A spray or roller brush may also be used, for instance a hand held spray with a hand- pump trigger action Thus, a fine spray of the solution can be applied onto the surface of the image-carrying substrate and the liquid wiped away and the surface thoroughly dried using a clean, soft, lint-free cloth.

Any aqueous or non-aqueous liquid or solution capable of removing the adhesion- inhibiting stabilizer from the surface of the image-carrying substrate can be used, provided that the image is not disturbed and that the substrate is not discoloured or degraded It is preferred to use an aqueous soap or detergent solution Suitable liquids are those that do not scratch or damage the surface of the image, are smear-free and stain-free, are non-toxic, and do not give offunpleasant or hazardous vapours or fumes. Conveniently, commercial liquid detergents such as Fairy Liquid or Palmolive may be used, for instance as an aqueous solution of a few drops of the detergent in a litre of water The washing process, where necessary, is generally carried out below about degree C, and conveniently at ambient temperature However, any temperature that will not affect the substrate or image may be used Not all the image-deposition processes which may be used in the method of the present invention utilise silicone- based stabilisers and consequently the step of removing any adhesion- inhibiting stabiliser is not always necessary For example, in an inkjet process, the deposited liquid ink dries in air and requires no application of a stabilizing material The preferred image deposition methods according to the present invention produce a "relief' image on the substrate In other words, an image is formed by regions of image-forming toner or ink which forms contours on the surface of the substrate, i e.

the toner or ink adheres to the surface of the substrate rather than being absorbed into the substrate, as occurs for instance with paper substrates. It is believed that it is the "relief" image produced by the preferred electrostatic deposition methods according to the present invention which results in the photorealism of the images produced by the present invention However, it is not intended that the scope or the invention be limited by this theory.

The image could be formed by a water based and/or curable ink, particularly a UV curable ink. 39

The Curable Coating The technology and use of curable coatings and radiation-curable coatings in particular is well-established and many such coatings are commercially available (see The International Radiation Curing Yearbook and Directory (1998, DMG Business Media Ltd UK) which provides a useful review of the art (pages 2 to 20), the disclosure of which is incorporated herein by reference).

One suitable curable coating for use in the present invention includes an acrylate resin and is preferably solvent free. Examples include epoxy acrylates, polyether acrylates, polyester acrylates, urethane acrylates, silione acrylates and amine-functional and polyether acrylates Preferably the coating is cured by radiation, preferably exposure to ultraviolet (UV) radiation Cold curing of the coating is advantageous in that distortion and curling of the substrate, and damage to the deposited image is minimized. A radiation-cured coating includes one or more photoinitiators which may use one or both of intermolecular and intramolecular mechanisms Other types of radiation curable coating include carionic, thiolene, unsaturated polyester or maleate/vinyl ether type curable resins 40 In one embodiment the coating is an optically clear UV curable transfer coating, and may be tinted if desired, and is preferably a viscous gel transfer coating which may contain one or more additives such as an optical brightener to enhance its optical clarity over the photo-realistic image However, the curable coating may be applied onto the image-carrying substrate by any other suitable means including electronic delivery, thermal transfer, screening, spraying, roll-to-roll, transparent continuous web transfer, roller-on-roller, lithographic and gravure printing application. The means may comprise an in-line desktop or industrial printing and transfer coating and curing apparatus for rolls and sheeted materials In one embodiment, an electronic spray head, similar to those used in inkjet printers is used In a further embodiment the coating is applied using disposable sachets or refillable cartridges, optionally mounted on a coating levelling device such as a levelling blade For an acrylate resin the dry thickness of the applied coating is preferably between about 1.5 and 50 microns, more preferably between 10 and 30 microns and still more preferably between about l O and 25 microns Typically the coating is about 20 microns thick. A polyurethane coating may also be used. The dry thickness of such a coating is preferably between 1 and 20 microns In one embodiment, the coating is - 41 suffciently thin so that it is able to follow the contours of the relief effect created by varying depths of toner on the substrate, thereby resulting in the coating having a contoured surface In an alternative embodiment, the coating is sufficiently thick that peaks and troughs in the image layer are not expressed in the surface of the lacquer layer and a smooth gloss finish is provided Examples of suitable lacquers include IN7LZ441, IN7UC746, CND755D and OPTISET (RTM) (Akzo Nobel Industrial Coatings Ltd. UK) OPTISET is a UV curable lacquer suitable for use in a home or office environment, allowing a user to coat and texturise very short print or material runs that would ordinarily be uneconomical for use by industry. Further examples of suitable lacquers include the radiation curable lacquers commercially available as Crodamer UVE series, UPV series, UVU series, UVS series and a UVA series (Croda Resins Ltd. UK) and the radiation curable cationic epoxide resins and associated materials available as Cycacure (Union Carbide<Corporation, Connecticut, USA; as described, for example, in Cyracure Cycloaliphtic Epoxides Cationic UV Cure (1995), the disclosure of which regarding specific formulations is incorporated herein by reference).

A preferred transfer coating of the present invention includes a viscous or thickened UV curable transfer coating comprising optical brighteners, hardeners, and anti - 42 scratch additives One such coating is an optically clear Akzo Nobel Optiset coating supported on a transparent polyester carrier film having thereon at least one side a smooth gloss surface, or an embossed or textured surface. The UV coating remains attached to the carrier film until after the coating has cured, that is to say the coating is exposed to UV light and curing takes place through the carrier film. After the transfer coating has cured the carrier film may be peeled from the coated image to reveal the replicated texture on the cured coating which may be, for example, a canvass texture on a photo- realistic image of the present invention Another suitable coating is a UV curable polyurethane transfer coating (that may be water soluble) which can be used as an anchor coating to encapsulate printing and materials when a second coating is applied over the first coating on a substrate which may be plain or printed or laser printed reflective which may be rigid or flexible A curable transfer coating may be applied onto the image-carrying substrate by any suitable means. However, the preferred method is by passing the imaged layer and the coated carrier layer jointly between a pair of heated rollers under pressure. For example, the preferred AkzoNobel optically clear UV curable transfer coating is a hot melt coating which may be applied to sheets and rolls of transparent gloss Melinex polyester film at a temperature of 60 to 120 degree. C, more preferably 80.degree C - 43 The carrier film is preferably about 100 microns in thickness Once the coating has cooled the transparent layers can be applied to the image-carrying substrate by laminating the transparent film and the optically clear coating using heat and pressure onto the substrate over the image. The carrier layer remains attached to the UV transfer coating and the layers are exposed to a UV light source to cure the coating The carrier layer does not inhibit UV curing through the film Preferably a micro-wave generated light source is used to power cold curing UV lamps Subsequently the carrier layer is removed from the cured coating to reveal a smooth gloss or a textured finish The effect is created by use of a wide variety of smooth and textured carrier layers which, when cured, are replicated into the cured coating For example, a highly polished gloss carrier film will produce a gloss finish, whilst a canvas carrier will be replicated in fine detail. A transfer coating on a transparent carrier film may be printed and the image transferred onto a plain or printed sheet substrate. A second coating may also be applied and cured so as to provide protection to the image and resistance to abrasion.

The carrier film may be coated with a release agent, which may include silicone, to facilitate release of the cured coating Alternatively the coatings itself may be provided with silicon or other release additive mixed into the curable coating chemistry to effect a release from the carrier film after the lacquer is cured An important advantage of the present invention is versatility and ease of use For example, a single mix of optically clear UV curable transfer lacquer can be used to produce many kinds of surfaces and finishes. In a further example a high- gloss, semigloss, opaque, matt, water-mark, canvas, silk, sand-stone, fabric, woodgrain, slate, parchment, brick, anti-reflective, anti-glare, embossed stamp or any other suitably transferable surface or texture is replicated into the coating by the carrier film for example textured carriers can be used to apply decorative textures onto flooring and metal-cladding sheets and signs Additionally using a carrier with a lenticular surface texture means that 3D lenticular lenses can be formed in an optically clear UV curable transfer coating applied over lenticular printed images used in small medium and large format advertising, 3D birthday cards, citizen identity and entitlement cards, secure documents, biometrics enabled passports and travel visas, biometrics enabled card driving licenses, 3D and lenticular printed self adhesive vinyl sheet, reflective material, and low cost lenticular images printed onto cans metal boxes, bottles, and all kinds of REID enabled active labels and packaging. The substrate of choice may comprise or be independently provided with an ink or toner receptive printable layer which can be printed and provided with clear coatings and printed images onto plain and printed sheet materials and roll to roll materials A W curable water soluble transfer coating is preferably environmentally friendly, safe to use, non yellowing, resistant to chemicals and cured through a transparent carrier film layer or transparent continuous web film carrier in an air-free curing environment therefore eliminating ozone emissions and odour which are produced using conventional UV curing methods In a further example, the curing speed of the transfer coating is increased and the hardness of the coating is improved making it ideal for producing a wide range of quality hard wearing clear decorative protective finishes and surfaces over most inks and toners, digital and computer generated images, print receptive film and paper, card, plastics, polycarbonate, metal, composites, softwood, hardwood, fiber boarddecorative paper furniture foils, reflective, and non reflective metal and plastic license plates including all kinds of computer generated digital laser and inkjet printing and generally for transfer coating digital print depositions on metal and plastic and reflective vehicle license plates with protective scratch and abrasion resistant coatings on, embedded wireless REID enabled micro devices and contactless biometrics enabled documents passports travel visas, bankers drafts, REID enabled driving licenses medical passports and citizen identity and entitlement cards The fluid which is a 100% solids water soluble polyurethane is applied to a transparent polyester carrier film where the water is removed from the - 46 lacquer by exposing the lacquer and carrier film to hot air or infrared drying lamps The lacquer becomes dry to the touch and repositionable over a digital image or plain or printed substrate. A lacquer on a carrier film can be reverse printed with a digital image, the ink may be UV curable, the reverse printed lacquer and carrier film are hot laminated together over a print receptive lacquer layer on a substrate whereby the UV curable ink is encapsulated between the lacquer layers, the lacquer and ink are cured together through the carrier film and the film is peeled away to reveal a high gloss tamper proof surface on the hardened W ink and coatings Fast line curing speeds can reduce manufacturing costs In one embodiment, micro layers of transfer lacquer are applied to a substrate the first of which is an anchor layer and then additional layers may be applied over one another forming a multi-laminar structure. Each transfer coating layer is supported on a clear film. The carrier film has to be removed after each coating layer is bonded by heat and by pressure to a substrate or a previous layer which has already been deposited Additional layers may be bonded to a first or second bonded coating which may comprise a variety of electronic microcomponents such as, for example, active or passive chips, transparent printed barcodes, semiconductors and/or micro- circuits and/or microchips and/or micro-batteries which can be formed by inkjet and organic polymer printed on or set within the lacquer layers Once the multiple layers are fused together as a structure they are exposed to UV light to effect curing Preferably, the structure is subjected to cold UV curing to prevent curling, except in industrial applications where other forms of radiation curing may effect curing in a variety of photo-initiators.

In another embodiment, multiple layers of lacquer must be cured with the uppermost carrier film still attached. The layers are fused by heat and pressure and the carrier film on each layer of lacquer is removed and then the final structure cured through the carrier film on the uppermost or final coating until all layers are cured through the remaining film which is finally peeled away to reveal a hardened surface The transparent polyester carrier film does not inhibit curing, The film is peeled away after the lacquer is cured The lacquer is preferably cured by cold UV curing lamps to prevent curling of the substrate but in other applications a different method of curing may be used. One multi layer coating structure uses a film and lacquer containing no release agent in either the film or the coatings so that films and lacquer fuse together in alternating materials that cure together as a flexible structure. The films can be printed with for example with UV curable inks and organic polymers inks using pulsed or jetted delivery from an inkjet printer to produce embedded printed organic polymer devices, inkjet printed semiconductors and micro and nano electronic devices and - 48 printed microchips, and organic printed polymer circuitry. Again the last film remains until the structure is cured forming for example an array of printed organic light emitting polymers (OLEPs) or organic light emitting POLYMER devices (PLEDs) or screen printable polymer light emitting diodes for producing scratch resistant flexible thin flat screen displays In one embodiment, multiple layer coatings are fused and then cured together to form either a rigid or flexible structure of fused layers of hardened lacquer After fusing a first layer coating to a substrate the carrier film is removed to enable a second layer coating to be fused onto the first layer. The second layer of carrier film is also removed after fusing and so on through the layers so that no films remain between the layers of lacquer except by design but for organic light emitting displays and biometrics enabled screens in passports. Subsequently the multiple fused coatings are cured as one through the uppermost carrier film which remains attached to the top layer of coating until after UV curing has taken place through the structure of the polyester carrier film which creates an air free environment and does not inhibit curing The Lacquer mixture may optionally contain a release additive for improving the release action between the cured lacquer and the removal of the carrier film which optionally has a smooth or textured or print receptive surface on either the film or coating surfaces that replicates onto the lacquer during curing In some applications the process may benefit from anchor layers and print receptive coatings being printed or etched onto substrates or a surface of a transfer lacquer or 2 sides of film to improve bonding between the layers and enable digital and inkjet printing to take place on a thin coating of lacquer or on a first or second side of the carrier film before printing or attaching devices that become embedded between the layers of film and lacquer which form a tamper proof adhesive between the layers In a further example a clear coating is provided over a reflective license plate material for making it receptive to ink and toner deposited by inkjet and Xerographic laser printers for printing a registration identifying marque on a reflective. The reflective material is preferably white or yellow although other colours may be used, the back of the reflective material may be provided with a rigid peel off backing paper to add rigidity during printing through a digital laser printer or imaging device In one embodiment, typically for use in industry, the UV curable transfer coating used is a thick hot melted optically clear coating, that is to say a viscous coating which requires heat to activate and improve its flow and adhesion Such a transfer coating is 50 a thickened "Solar" W Toner-Protection Transfer Coating CND755D manufactured by Akzo Nobel Industrial Coatings Ltd. Hollins Road, Darwen, Lancashire, BB5 OBG.

The UV transfer coating is a hot melt coating which can be applied onto a wide range of smooth and/or textured surface carrier films by any continuous transparent web or hot melt coating method In a further example a safe to use non solvent environmentally friendly optically clear non yellowing hard wearing scratch resistant UV curable transfer lacquer comprising 100% solids water soluble polyurethane coating produced as a result of a joint development project between NJ Murray and Akzo Nobel Industrial Coatings Ltd 1997-2004, is used UV curable film and web transfer lacquers can comprise a release additive that enables the hardened lacquer to separate easily from a transparent carrier layer after curing, such a lacquer is coated onto an optically clear polyester carrier film or a transparent reel to reel web used in laminating transfer lacquer to a printed or non printed flat substrate of the present invention. After lamination is effected the lacquer is cured through the structure of the transparent carrier layer which may be a sheet or roll-to-roll polyester film or a transparent continuous web suitable for transferring radiation curable lacquers to surfaces and effecting curing by exposure to a radiation source provided through the carrier layer In general, the coatings are optically clear and provide layer protection and abrasion resistance over printed organic light emitting polymers and printed organic polymer drivers and circuitry, inkjet printed polymer microchips and printed polymer semiconductors used in the imaging and micro polymer construction/printed micro and nano electronics devices area Wetting and levelling of the transfer coating can be adjusted by modifying the flow characteristics of the coating with flow modifiers, such as surfactants, silicones and fluorinated alkyl esters, as is well known in the art. Brief exposure to a UV radiation can reduce the surface tension on a substrate and in a filmic carrier layer, thereby allowing a heated mixture to wet out and be coated evenly across the transparent filmic carrier layer. However, this action is not always deemed necessary The coating may include optical brighteners, surface hardeners, anti sink and antiscratch additives.

The coating may contain functional and/or decorative materials for example photochromic and/or thermochromic materials. Such a coating containing functional or decorative material provides a method of transferring such functional or decorative materials from being provided in the coating on a carrier to being provided on a desired substrate.

A transfer coating of the present invention is preferably solvent free, environmentally friendly, safe to use and may include optical brighteners, release agents, surface hardeners, anti sink and anti-scratch additives, embedded micro chips and active and reactive particles. In a further example, hard wearing anti slip surfaces and decorative finishes are provided on flooring in hospitals and on boat decks Anti-fouling coatings can also be formed and may be cured in a clean uncontaminated air free environment onto plastics, metal and composite on boat hulls and jet ski's. Aircraft panels, snow ski's, water ski's and surfboards can also benefit from the transfer of hard surface high gloss coatings for increasing speed and reducing friction and drag in the air in water and in snow, such coatings may contain decorative particles and digitally printed artwork Ultra Violet coating formulations cure instantly on exposure to UV light or radiation curing source making them ideal for use with most printed and non-printed paper and board substrates and for protecting surfaces digital images on films, plastics, new metal, digitally printed reflective materials and fiberous boards otherwise uncoatable porous materials and surfaces The application can be a fast line transfer comprising an inline printing lamination coating and W curing process which saves space and cures more economically according to an increased speed The coating may contain functional and/or decorative materials and micro electronic chips and devices for example photochromic and/or thermochromic materials and digitally printed images OLEP's, OLEP's printable conductive inks, electrophoretic- ink (e-ink), electronic paper and laser etched legal identifiers The transfer of such organic light emitting polymers and polymer light emitting diodes from a coating to a substrate allows the method to be used for the transfer of fine line print, printed organic polymers, organic light emitting polymers, conductive inks, transparent conductive inks, UV curable inks, laser etched and/or digitally printed visible legal identifiers, printed transparent conductive barcodes on smart passports, security documents, bank drafts, currency notes, the embedding of interoperable contactless biometrics enabled microchips in smart biometrics enabled passports, smart visas, smart biometrics and RFID enabled identification and authentication citizen entitlement cards, DNA strip European passports, smart medical entitlement cards, european medical passports, biometrics enabled work permits and foreigner residence, length of stay cards, RFID card driving licenses made interoperable with wireless RFID enabled microchips embedded in vehicle license plates, RFID third license windscreen stickers in association with vehicle identification and authentication active RFID tags and embedded microchips Photo-realistic images text and graphics comprising solid inks7 toners, polymers, pigments, particles, primers, and paints from a coatings to a substrate, such lines and images being applied to the coating by any suitable means Furthermore this method is suitable for applications in the can printing and RFID active label and packaging print industries, on identity cards, organic polymer circuitry and displays, and for multi-layer security applications including producing micro and nano-electronics, and also is suitable for transferring printed organic polymers and organic light emitting polymers and organic light emitting diodes and polymer printed devices from a coating to a substrate to form low powered flexible scratch resistant optically clear light emitting thin, flat screen displays or other organic printed circuits or transparent plastic printed polymer-microcircuits and nanocircuits and nano devices, printed organic polymer microchips and semiconductors This method allows conductive ink polymer and plastic printed circuits formed by nano-dot inkjet pixel depositions to be placed over whole and part areas of a circuit board provided as a substrate Also to provide whole and part area shielding or antenna layers between single and multiple layer micro electronic boards and printed layer RFID enabled circuits.

The transfer of such organic light emitting polymers from a coating to a substrate allows a variety of rigid or flexible scratch resistant low voltage thin flat screen displays and scratch resistant roll up flexible displays to be included with micro and nano printed polymer electronics semiconductors drivers and printed polymer microchips and polymer electronic devices and optionally, a power source to be embedded within the cured layers to be formed Additionally the transparent carrier for the transfer coating can be bent around shapes or hot formed by vacuum moulding or other suitable moulding technique before being UV cured The carrier layer can then be removed leaving an organic light emitting polymer display unit adapted to conform to the shape of the mould which may for example be a display integrate with an automotive panel, a vehicle dash board, a head up display on a car windscreen or a video light emitting polymer display screen moulded into the casing of a television or a stereo unit or a moulded polymer screen comprising an active wireless RF1D signal and Bluetooth enabled frame In a further embodiment the W curable transfer coating of the present invention is pigmented and/or coloured, and then coated onto a layer thickness of carrier film which may also be used to adjust and control the curing times and surface hardness of the coating. A film may be coated or processed to make it receptive to depositions of jetted or pulsed ink, or polymer inks, or laser toner from a digital laser printer or CLC colour laser copier. Alternatively a clay coated transfer carrier may be digitally printed by colour copier or laser toner printer and the image transferred to a substrate or a fabric of the present invention by means of hot roller or vacuum thermal transfer and then coated and cured using scratch resistant transfer lacquer which may be applied to any flat surface or sheet.

Transfer Coatings and direct printing including decorative and protective coatings on Metal, Plastic, Leather, Wood, Card, Fabric, Cardboard, ,^ Fibre-Board, Cladding, Lexan, Aluminium, Softwood, Hardwood, Carbon Fibre, Vinyl, Glass, Marble, Ceramics, Fein Paper, low grade Paper, Archival Prints and Documents, Paintings, ceramics, parchment, linen, canvass, Furniture wood veneers, Polycarbonate, Polymeric Film, Smart card material, Passport Pages, Dry Surface Polyurethane Transfer Lacquer, Reflective materials, circuit boards, printed and non- printed sheet and roll substrates such as wipe clean protective and decorative wallpaper, hot foil stamping and decorative printed paper foil on furniture and plain and printed substrates, sheet and roll materials including bendable organic light emitting diode electronic paper, MDF and wood for doors floors and worktops.

It is well known to coat newly manufactured steel(s) and corrosion sensitive metal(s), with organic, or metallic, or high-performance plastisol coatings and finishes For example, Corus UK Limited are known to protectively coat steel products, examples & - Q1i' ,\ of these are Colorcoat Celestia, Colorcoat Pvf2 and Colorcoat HPS200 Furthermore, impression rollers are used to texture some products but the process is expensive and limited in its application.

Advantageously, the present invention provides means to transfer a hard wearing scratch resistant non yellowing plain or decorative topcoat onto metal hardwood softwood plastics glass fibre composites in an air free environment, by means of continuous web film transfer, or by roller to roller transfer onto plain or printed flat sheet substrates, by means of in-line printing transfer coating and UV curing The optically clear UV transfer coating of the present invention may be applied to new steel and aluminium products as a scratch resistant hard wearing protective sealer layer or a top coat provided with a high level gloss or textured surface which may be transferred in whole or part area and decorative print depositions for protecting mild steel and aluminium sheet used in the automotive architectural aircraft and boat building industries, alternatively a wide variety of colours pigments metallic particles and anti fouling agents and components may be added to produce a durable UV coating which, may be further enhanced with UV When the transfer coating digital images' new steel and aluminium and other sheet materials through the polyester carrier layer or a transparent continuous layer TRANSPARENT transfer coating web an oxygen free curing environment is created and the usual odours and ozone emissions associated with conventional UV or ED curing are prevented, the curing time is faster, and coating hardness is improved In-line speed coating reduces manufacturing costs and equipment takes up less space.

Alternatively, the scratch resistant UV curable transfer coating of the present invention may be applied to plastics, leather, wood, card and/or paper MDF, composites, films, OLED OLEP PLED layers, Polycarbonate, Glass, micro electronics boards and polymer printed circuitry, and plain or digitally printed or foil stamped substrates and decorative papers and foils used in automotive components, furniture, doors, worktops, and panels, and scratch resistant digitally reflective and non reflective license plates and signs, and scratch resistant flexible active electrophoretic display electronic ink (E-ink) signs, electronically tagged and tamper evident protected license plates and wireless REID enabled third license windscreen labels and identification and authentication devices on vehicles.

The durable image of the present invention may be provided with an additional backing layer either for protection or for a particular enduse, for example, a releasable card backing for adding rigidity to flexible reflective layer license plate material during printing through a digital laser printer, after use the card is peeled away and other uses as described herein below For example a metal (including any magnetic and rubberised magnetic material) reflective sheet, glass, plastic, cardboard, or paper, film, polymeric, woodblock backing layer may be provided, for instance, to enhance the strength of the image-carrying substrate or to provide certain applications and products flexible and durable. Adhesion to the backing layer may be effected using a double sided film such as Steratape, or Hunt Europe/Seal USA Printmount PMI or PM9. Many other types of adhesive, such as acrylic, or rubber-based adhesive, as known in the art can also be used The adhesive may be applied as a coating from a solvent-based system, or by any other convenient means. In some cases it is possible to obtain a backing layer with the adhesive already adhered thereto and ready for use once a protective overlay is removed The composition of the Digital or computer and software generated image which is to be applied to the substrate may be derived from a conventional photograph In this case, the image of the photograph may be reproduced on the substrate using a conventional electrostatic copying device as described herein. Alternatively the image from a conventional photograph, negative or colour transparency, digital camera, CD, DVD may be digitally scanned and stored, the reproduction of the image may then be achieved using a computer and a laser printer, inkjet printer or other suitable printer Images from the internet using (IP) internet protocol can be download to a usb data storage device so that images can be stored and printed at a later time.

One aspect of the present invention is the reproduction of images taken on digital cameras and the printing thereof, and of photo-realistic images displayed on scratch resistant flat screen displays, particularly on OLEP and OLED thin flat screen displays for use in the home, in display and poster advertising, or in industry In fact any image output from a computer, including images scanned into or generated by a computer, and whether or not enhanced or otherwise modified by computer, can be applied to a substrate in the process of the present invention. Two dimensional 2D prints can be made from CAD design drawings generated using a computer and the appropriate software and three dimensional 3D display images and 3D animations can be produced on computers and software for example using 3D Max, Combustion, Real Flow, Soft Image, Mayer, Lightwave, Dreamscape for providing images to be displayed on thin flat screen displays of the present invention. Flat screen display images could also include digital photo-realistic images from digital cameras, ultrasound images used in hospitals and industry or full colour X-ray images and images received using wireless RFID, laser transmission, cellphone signals and images, Bluetooth and RF wireless signals, microwave, fibre optics, micro-waves, GPS, and satellite signals, and images received on the internet using high speed multi functional broadband and (ip) internet protocol The method of the invention can be used to produce a wide variety of image- containing products in any size The size of the products can range between nano and micro-sized products up to super-wide formats, such as those used in printing for advertising on billboards etc. Examples include printed self adhesive vinyl and labels, wireless REID enabled active packaging labels, books, book bindings, print protection and print texturing, workshop manuals, manuscripts, coated gloss and/or textures digital photograph albums and OLEPs digital image display albums olep and oled wall hanging digital camera flat screen photorealistic image displays and 3d animations, contactless biometrics enabled passports and biometrics enabled (IDSC) Image Display Swipe Cards, gloss and textured photo display for advertising, textured photos and photo-enlargements, coated textured inkjet posters, textured metallic photo wall plaques, floor and wall coverings including textured floor tiles and RF1D enabled active flat screen display tiles, all weather GPS and wireless REID enabled flexible maps and point-of-sale photo displays, textured plastic and metal signage including estate agent's boards, metal mounted signs, magnetic signs for external and internal application, illuminated signs, anti-glare car registration plates, anti-glare reflective road signs, external markings, currency notes digitally printed with transparent conductive inks and conductive transparent bar codes and legal identifiers, tamper proof and tamper evident quantum encrypted contactless biometrics and wireless RFID enabled smart cards and internationally interoperable biometrics enabled passports travel visas citizen identification cards, immigration -medical and state benefit entitlement cards and documents, and programmable read only biometrics enabled Internationally interoperable visa cards and card driving licenses, and biometrics enabled DNA stripe medical ID passport cards, smart IDSC Image Display Swipe Cards and bank cards, citizenidentification and entitlement cards, immigration and medical eligibility and employment entitlement cards, biometrics enabled photo-certificates and legal-drafts, biometrics enabled securing devices and government identity passes optionally comprising in their embodiment wireless RFID electronic programmable electronic microchips and contactless biometrics enabled electronic microchips and devices embedded in and between tamper proof and tamper evident pages of polycarbonate page passports and visa documents comprising wireless RFID recognition and identification and authentication chips, in internationally interoperable driving licenses, wireless RFID enabled vehicle license plates and windscreen mounted RFID enabled 3rd license vehicle identity and authentication identifiers and other documents Passport pages may contain a digital photograph or an active biometrics enabled OLEP or OLED flat screen display. Specific examples of the above include intelligent active and passive wireless RFID enabled re-programmable electronic microchips using quantum encrypted pin number access in smart cards and driving licenses, frequent traveller airline issued passports, European medical entitlement passport cards, immigration benefit and work entitlement cards, and European and/or United States citizen Homeland Security entitlement cards each comprising means for storing a DNA signature stripe and immunisation records, RFID and Biometrics interoperable between the United Kingdom and mainland Europe and other countries requiring information access such as, for example a biometrics iris image, eye colour, facial features, ear shape, DNA stripe, left and right hand finger and thumb prints, gender, hair colour, age, passport proof comprising quantum encrypted date place and country of birth and country of permanent residence and/or other information including identification and authentication and laser printed water marks legal identifiers and holographics, micro- text, magnetic swipe strips, active swipe chips and wireless RFID enabled biometrics enabled chips and micro and nano electronic memory devices provided on a substrate and/or embedded between one or more optically clear abrasion resistant secure layers of UV curable lacquer on cards and document pages comprising a conductive wireless RFID enabling antenna means Other examples include biometrics enabled technologies embedded in cards and documents, made interoperable between other countries able to share and compare information embedded in RFID and Biometrics enabled card driving licenses, citizen identity and entitlement cards, medical passports and read only DNA medical records cards, wireless RFID electronically chipped and tagged vehicle license plates and RFID enabled third license vehicle identification and authentication windscreen stickers comprising embedded read only digitally printed visual identifiers and RFID micro- electronic retrievable programmed and quantum encrypted digital information and data and biometrics images Internationally interoperable between Biometrics enabled passports - citizen identity cards - driving licenses - medical passports - vehicle and driver wireless RFID authentication and identifying devices. Combined read only interoperable information may be RFID and Biometrics enabled held on electronic microchips embedded in the cover or pages of laser printed structures of a passport The products may further comprise digitally printed bar codes and transparent conductive ink bar codes digitally printed on currency notes and bankdrafts, and on antiques, artworks and valuables magnetic strips, active and passive and programmable and read or view only electronic microchips and memory storing cards and devices disposed between adjacent layers of transfer lacquer In one embodiment, the cured product is a thin multiple layered electronic device 65 comprising active and/or passive chips and/or other micro-electronic components which may be organic polymer printed circuitry and polymer devices which are disposed between adjacent layers of a substantially rigid or flexible structure.

Conventional micro-devices may also be embedded and/or encapsulated in the layers In one example, the following are produced. multiple layer REID enabled smart-chip and pin access identity and entitlement cards using cellphone signals and frequencies and contactless wireless signals, contactless smart chip and pin biometrics enabled passports and wireless RF1D programmable card driving licenses and read only citizen identification and entitlement cards, active chip and pin travel tickets, security quantum encrypted documents, European and United States medical entitlement passports and card containing read only patient medical history and DNA signature strip and the like.

The authentication means may comprise one or more contactless biometrics enabled electronic microchips, RF and/or REID microchips and micro and/or nano digitally printed conductive polymer circuitry and printed chip devices, holographic images, and laser etched legal identifiers on transparent polymeric film layers, active and passive identity microchips, digitally printed authentication bar codes, magnetic strips, DNA strips, scan and view biometrics enabled electronic information microchips and recordeable devices and components, embedded micro and nano programmable components, and transparent polymers conductive printed circuits and digitally printed polymer microchips semiconductors and drivers, and transparent polymer printed circuits and transparent antenna layers, including transparent ink and toner print receptive coatings on reflective material used for vehicle license identifiers on number plates, such coating may contain a watermark, printed visible (YIN) vehicle and chassis identifier numbers printed as bar codes year and month of first registration active and passive read only wireless RFID enabled microchips, holographics, programmable wireless RFID enabled electronic microchips provided with Internationally interoperable information for enabling Government authorities including Government - Home Office Police - Homeland Security - Driver and Vehicle Licensing Authority - Passport Services - Immigration Services, Ministry of Transport - Customs and Excise - Post Office regulated MOT stations and registered suppliers to top up credit on insurance and road fund licenses and taxes and for Government and police to investigate a vehicle during a state of emergency and threat to Homeland Security using active and passive wireless RFID enabled electronic microchips and biometrics identification devices and conductive inks and devices that can be read by remote cameras and scanners and hand held scanners and readers for investigating read only information and/or viewing Biometrics enabled images on a hand held scanner comprising an OLEP or OLED flat screen display or other suitable viewing screen The antenna layer can be single or multiple transfer coatings of the present invention, such coatings may be made receptive to digital printing by laser printer or inkjet printer to provide a visible registration number and printed vehicle identification and post code across the width and length of the plate and the coated antenna and covering layers may be positioned and UV cured in whole and part areas over digitally printed text and REID enabled identifiers that are provided with an optically clear hard wearing scratch resistant gloss finish In other embodiments, conductive inks and polymer transparent bar codes and barcode microchips may digitally be printed on or transferred to bank currency notes, personal cheques, bankers drafts, security bonds, shares documents, passports, visas, will's, mortgage documents, contracts, identification and authentication immigration and entitlement cards, airline frequent traveler passports and travel documents, antiques, artworks, and paintings and valuable documents to help prevent forgery, cloning and theft of personal identity and acts of terrorism In a further embodiment, printed arrays of organic light emitting polymers can be fused together with micro electronic circuitry and drivers using printed organic semiconductors and microchips so that the whole device can be printed and embedded together between ultra thin layers one over another to form flexible scratch resistant ultra thin low powered organic light emitting polymer displays provided with anti- reflective and an anti-glare scratch resistant surface providing wide angle viewing and eliminating the need for a rigid support layer, such as a sheet of glass Printable organic polymer light emitting diodes may also be used.

OLEPs also known as PLEDs organic Polymer Light Emitting Devices and OLEDs Organic Light Emitting Diodes known as Electronic paper comprising E-ink electrophoretic backplane paper and ink can be embedded in layers of flexible transfer lacquer fused together by heat and pressure to form micro thin coating structures that may optionally contain wireless RF and RFID devices, active and passive contactless RFID enabled electronic micro-chips, conductive printed plastic circuits, polymer printed semiconductors microchips and circuits, quantum encrypted contactless Biometrics enabled electronic microchips, active and passive read only information chips, remote wireless RFID enabled micro readers, miniaturised RFID scanners, microwave readers and senders, and RF1D, wireless cellphone signals and image receiving and sending devices, including electronic micro-chips using active Bluetooth and cellphone signals and digital wireless RFID identification and authentication signal technologies and (IP) interactive Internet Protocol using Broadband, metal oxide printed antenna, active and passive electronic micro chips and programmable memory devices made read only for protecting Homeland Security and civil liberties, and micro and nano printed organic semiconductors drivers circuits polymer printed microchips and batteries and UV curable inkjet inks laser etched legal identifiers and devices disposed between the layers.

The present invention enables a variety of sprayed, jetted, controlled pulse deposition and digital laser printed inks and toners, particularly cold UV curable UV inks, organic light emitting polymers, to be printed and cold UV cured in whole and part area depositions, such that the curable inks and/or organic light emitting polymers can be themselves be cured or cured between the transfer coatings of the present invention to form robust scratch resistant protective coatings, comprising inkjet printed microchips semiconductors driver circuits and polymer printed batteries and devices and components having micro and nano proportions.

The products and methods of the present invention can be for use in micro electronics engineering and pharmaceutical and medical applications and display advertising industries and for example, for producing robust flexible scratch resistant low cost OLEP, organic light emitting polymer, and OLED organic light emitting diodes arrays with improved resolution screens for use with digital cameras, hand held computers, cellphones, and for viewing enlarged digital images such wall mounted electronic OLEP and/or OLED pictures to display a digital camera image, such displays can be of reduced size and included in a wide variety of digitally printed REID smart identification and identity-control-cards, biometrics-enabledpassports Such screens may be made abrasion resistant, flexible and/or larger in size than presently known screens for displaying ID computer generated animations and graphics and significantly enlarged photo realistic images produced on a digital camera or from silver halide film images Such images may be free standing or displayed on the wall or used in advertising on a moving vehicle. In a further example, active and passive REID labels for packaging, polymer printed electronic microchips for replacing barcodes, and polymer drivers and circuits each comprising robust hard wearing scratch resistant finishes on all kinds of substrates and surfaces produced by in-line desk-top digital print and transfer coating apparatus, and by fast track in-line industrial printing and transfer coating and curing apparatus for producing protective hard wearing clear coatings and/or decorative images and textures on softwood, hardwood, plastics, MDF, fibre board, mild-steel card, aluminium, windowglass, low grade and Fein printing papers and materials printed and coated in sheet and/or roll to roll materials which may comprise primed, printed or plain un-printed surface.

Furthermore the products and methods may be used for manufacturing thin, flexible, scratch resistant, low powered displays, and flexible roll up computers and hand held computers produced in layers comprising polymer printed circuits and devices integrated with an organic light emissive polymers OLEP or OLED flexible scratch resistant screen such a computer and display can be rolled up and stored when not in use.

Such fold up screens can be a GPS active map It is considered that the exposed surface of a transfer lacquer of the present invention could itself be made receptive to depositions of digital print and printed polymers delivered by inkjet printer-using UV curable ink jettable inks The lacquer on a transparent carrier film is printed onto the exposed face of the processed ink receptive lacquer. The image is printed in reverse image so that when the carrier is bonded to an anchor coating on a substrate the UK curable ink and UV curable coating are cured together as one and when the carrier film is removed the transferred image appears the correct way round and the digital inkjet image and/or printed polymer circuitry is provided with a smooth or textured tamper proof scratch resistant finish. A variety of components and devices may be embedded between rigid or flexible transparent layers of the invention before curing.

In another embodiment durable images of the present invention are in the form of self adhesive stickers and REID enabled labels produced by applying onto one side of the substrate a double-sided permanent adhesive film which can be destructable and tamper evident adhesive film having a protective release layer on the side of the double-sided adhesive film remote from the substrate of the durable image Such labels might comprise active and passive electronic REID enabled micro chips for use in active labelling and for example a third license plate sticker bonded by tamper evident adhesive to the inside of a vehicle windscreen, and for producing light and temperature sensitive packaging labels on chilled foods and goods, such labels may include digitally printed photo-chromic and thermochromic inks encapsulated between an adhesive film or a paper layer and protected by abrasion resistant tamper proof lacquer In another embodiment, the durable images are in the form of a photograph album A photo-realistic image produced from a digital photograph using the method of the present invention may consist of one or many individual images on a single sheet, which may carry images on one or both sides thereof A number of such sheets can be bound together to form a photograph album in which the images are an integral part of each page, unlike conventional albums in which paper photographs are individually mounted on a stiff card substrate or page. A photo-realistic image in a digital photographic album may be produced by providing an organic light emitting polymer or organic light emitting diode thin flat screen image display on a page comprising a surface of OLEPs or PLEDs light emissive arrays operating by cellphone frequencies and Bluetooth wireless RFID technologies to transmit a signal from a contactless reader to form a digital image or 3D animation formed on a display page, or a framed RFID enabled picture on a wall, and an RFID enabled advertising display or thin active advertising poster A digital memory chip reader and display enabling device and microelectronic circuitry can be provided on, for example, a wall picture whereby a digital camera memory chip is plugged into the reader on an OLEPs or PLEDs display screen and a digital photograph can be displayed as a picture on a wall The method may be used in all kinds of advertising using a variety of stored images retrievable from CD DVD mini DVD memory cards hard drives and USB data storage devices In a further example an enlarged OLEP or OLED flat screen rigid display of the present invention can comprise a built in digital camera memory card reader with circuitry for displaying one or more digital camera images on the display screen In the case of medium and large format illuminated signs the substrate may be a white, transparent or translucent Melinex (trade mark) film material, such that a digital ink- jet image is illuminated when a light is positioned behind the substrate. Reflective signs can be produced by depositing the image on a transparent substrate and providing a backing layer of reflective material Suitable reflective material for use as the reflective backing layer include Macmark and Maclite 1010 (produced by Mactac), 3M Scotchlite Reflective sheeting (produced by 3M) and Cibalite (produced by CibaGeigy). And Nikkolite Reflective (produced by Nippon Carbide) photorealistic reflective signs can be produced by inkjet printing with transparent UV curable inks onto a print receptive reflective backing which is provided with optically clear transfer lacquer coating over the image on a reflective layer, together the inks and scratch resistant coating are UV cured so that all colours reflect with the exception of solid inks.

In another embodiment, UK and European vehicle registration plates can be produced quickly and inexpensively by digitally or thermally or laser toner printing a visible registration with visible legal identifiers and customer personalisation onto a reflective layer provided with a printable transparent surface receptive to digital printing using dry toner or inks. According to 2000/2004 UK/European legislation requirements post codes referencing the plate assemblers address must be displayed In the present invention interoperable matched information tamper evident externally fitted vehicle registration plates and a third REID enabled windscreen license plate are provided with laser etched legal identifiers and digitally printed visible text with dual wireless REID enabled electronic microchips in plates that display the year and month of first registration and chassis numbers on a Scotchlite (trade mark) reflective provided with water marks and/or legal identifiers and a coated surface receptive to printing by digital laser printer using inks or toner or the transfer of inks and coatings from a carrier film. Other reflective materials such as Nikkolite produced by Nippon Carbide, Cibalite produced by Ciba-Geigy and Callon 1 I reflective which meets US Federal specifications may be used The reflective sizes and formats substrates suitable registration identifying numbers as laid out by British and European and United States legislation (incorporated into this document by reference) preferably using a digital laser printer to provide ink or toner on a print receptive transfer coating from a carrier film onto a reflective made suitable for printing ( suitable laser printers are marketed under brand names OKI Citzen Panasonic Epson Hewlett Packard and thermal printers using the trade name Merlin with a Jepson & Company number plate software package The reflective is then laminated onto a rigid substrate, for example a BSI approved high impact acrylic plastic (PET) or aluminium sheet The reflective and the substrate are cold bonded together using an all weather double sided mounting adhesive Subsequently the reflective is coated with a transparent layer of clear ink jet and laser print receptive lacquer and a layer containing a watermark and legal printed identifiers The coating comprises metalic oxide particles to provide an antenna layer coated with a UV curable transfer coating which is rolled onto the printed reflective by jointly passing the UV curable transfer coating and reflective coating through a pair of heated rollers The curable transfer coating may include a scratch resistant gloss or - 76 matt anti-glare surface which can be interpreted by roadside and speed cameras and readers and airborne police cameras and satellite readers and scanners Holograms, bar codes, identification chips, light sensitive particles and other devices can be introduced into the transfer coating before curing takes place Instant curing of the transfer coating is achieved when the coated reflective layers are passed in front of a UV light source Roadside cameras and REID scanners satellites police helicopters may be capable of reading or detecting the printed registration and/or RFID programmable and/or read only chips and devices contained between layers of lacquer or embedded between the substrate and the reflective, or between the reflective and adjacent layers of lacquer adjacent between the print receptive transfer coating and the reflective and/or between the printed and coated reflective and the acrylic over laminate sheet bond with destructable adhesives to stop fraud layers, in example of such registration plates is an electronically tagged license plate It is new to laminate an identificable ink receptive clear but digital laser printed legally identifiable lacquer or digitally printed legal identifiers on clear film onto a reflective to then print the ink receptive reflective with a registration number and visible year and month of registration identifier suppliers name and post code, and VIN vehicle identifying numbers which may be visible or in the form of bar codes and then laminate the printed reflective to the back of an acrylic transparent sheet using a permanent or a destructivable adhesive to bond the layers together, the transparent print receptive coating is UV cured to the reflective which may contain RFID chips between the lay Means between coated layers and between reflective and acrylic front Products produced according to the invention may further contain a hologram, conductive ink printed visible legal identifier bar code, RFTD microchip, or other means of authentication or identification, which may be encapsulated between the substrate and the UV curable transfer coating or within either the substrate or UV transfer coating. Authentication or identification means could also be provided by other electronic circuitry or devices such as printed plastic circuit or organic light emitting polymer circuits or displays or DNA signatures and identifiers embedded within the material layers of a UK style vehicle license plate comprising RFID identification made Internationally interoperable between UK European and United States Governments and police central data base for exchanging and matching confidential information concerning identity, authentication of a vehicle, biometrics enabled card driving license holders ID, biometric identity and data of a citizen, overseas visitor air or sea traveller or immigrant in conjunction with information programmed into duel wireless RFID enabled electronic microchips embedded in match information chips on plates mounted on the front and rear and windscreen of a vehicle.

In another embodiment heavy depositions of dot toner may be increased in height by the application of a UV curable transfer coating therefore producing an easy low cost Braille printing method for the blind In other embodiments, fine line lenticular digital print and photorealistic inkjet images can be transferred and disposed between adjacent layers of lacquer for web transfer coating for applications in the sheet metal and canning printing industries and for multi-layer security applications including micro- and nano- electronics and active tagging on labels as described above.

The present invention also provides organic light emitting polymer flat screen displays (OLEPs) and organic (PLEDs), organic polymer printed circuits and smart security cards via the transfer of printed organic polymers and/or organic light emitting polymers onto All manner of substrates described herein, including plain and printed substrates that have applications in all kinds of industry and particularly in the printing of organic polymer circuity and nano devices In the first instance the claim is for a white coated toner receptive film which is digitally printed by thermal transfer from a colour laser copier, any silicon is removed from the print which is transfer coated and then UV cured preferably with a cold UV lamp curing source in the blue or visible 79 - band or suitable W curing device These embodiments may be realized through the use of digital applications and printing with inkjet print heads.

The method of the present invention conveys numerous advantages in relation to existing lamination techniques using conventional transparent film and adhesive to protect and cover an image-carrying substrate For instance, the curable transfer coating may be applied to give a thickness which is much less than that of a conventional transparent film and adhesive and the optical clarity and brightness of the curable coating allows for the production of robust high-quality images The use of a UV curable transfer coating also provides a durable, scratch-resistant weatherable long-lasting image.

A multi layer structure of transfer lacquers and embedded micro components can be further embedded between the tamper proof pages of a contactless biometrics enabled polycarbonate passport which may optionally comprise an OLEPs biometric enabled display screen.

An important advantage of the present invention is its ease of use, enabling the rapid production of durable, photo-realistic digital and biometric and micro electronics images using conventional printing equipment Using the method of the present - 80 invention, a wide variety of image-carrying products can be quickly and economically manufactured in large or small numbers The method of the present invention may also be used to transfer compounds or compositions such as, for example, solid inks, toners, pigments, particles, primers, jettable organic polymers in ink jet inks, and UV curable inks, laser printing and paints by any controlling means known to the skilled person and described as laser printing thermal image transfer printing, hot foiling, web offset printing digital printing, silk screen printing, lithographic printing, and gravure fine printing, digital imaging, digital application for the delivery of printed CD DVD mini DVD and USB date stage devices (IP) Internet protocol using Broadband, digital camera memory chip images and finishes, ie Any process that uses, for example, computers, scanners, hard drives, digital memory, digital camera memory chips and memory readers image processors, digital software and other computer aided devices to paint, apply, transfer digital images, hot stamping foils, organic polymer printed devices, and circuits, and organic light emitting polymer thin flat screen displays and printed polymer arrays and micro and nano size devices or deposit toners, inks, dyes, pigments, paints, primers polymers to a surface. The present invention may relate to any means which causes to be deposited or delivered onto a surface or substrate a composition or compound by means of a computer In one preferred embodiment, the transfer coating comprises a 100% solids water soluble polyurethane lJV curable transfer lacquer supported on transparent gloss or textured release carrier film The finish of the carrier film dictates the surface finish of the UV cured coating The carrier film is preferably manufactured from polyester. However, in the production of contactless biometrics enabled passports the polycarbonate pages may be used to embed the multiple lacquer layers and biometrics components between indestructable polycarbonate heat sealed with hot melt adhesives of lacquer structure The jetted ink may comprise organic light emitting polymers (OLEP) or (OLED) The OLEPs or OLED may be deposited on thin UV curable abrasion resistant lacquer coatings which optionally comprise micro and/or nano components and components.

The transfer coatings of the present invention can be deposited onto avariety of surfaces and substrates and can be formed as a single layer protective coating on, for example, digital images such as inkjet or laser toner prints and colour laser copies or a multiple layered structure The coatings are preferably optically clear and abrasion resistant - 82 If necessary, the surface of a transfer coating or polymeric carrier film with a clear toner receptive coating may be treated chemically or etched or provided with an adhesion promoting lacquer such that the subsequent coatings, toner, holographic images, active and/or passive electronic devices, RF1D devices, transparent printed polymer circuits, contactless biometrics enable micro chips, printed and non-printed antenna and/or micro components are more readily received and retained on, under or between layers of transfer lacquer In a method of forming a passport incorporating an encapsulated authentication means may also be provided in accordance with the present invention and comprising the steps of providing laser printed text and/or one or more digitally printed image of the passport on a substrate, applying a first receiving layer of a curable coating on to the substrate; introducing an authentication means to be encapsulated; applying a second layer of a curable coating to the substrate over the receiving layer, and curing the coating, the authentication means thereby being encapsulated within the coating Alternatively, the hot laminating laser printed polycarbonate film on both sides of the UV cured coating layers described herein to encapsulate the structure which is embedded between durable polycarbonate without inhibiting wireless REID and biometrics image and data scanning In further embodiments, digital images patterns circuits and text, particularly photorealistic images can be transferred onto plastics glass sheet metal, drinks cans, labels and packaging. Digital decorative images 3D animations with hard textures may be transfer coated onto vinyl flooring and hard wearing surfaces such as kitchen work tops or ceramic tiles and glass before curing.

In another embodiment, a low powered, thin organic light emitting polymer (OLEP) or (OLED) flat screen surrounded by a frame comprising a compact digital camera card reader, integrated into the frame so that digital memory cards from a digital camera and video camera or USB data storage device can be scanned or read by such card readers, enabling digital camera images to be viewed on a screen on a wall An OLEP screen and card reader can be powered by means of rechargeable batteries, incorporated into the frame or by any other source of low power electricity Images from digital cameras, desktop digital readers, cellphones, and computers can be transmitted to OLEP and OLED screens by means of REID and Bluetooth wireless technology and changed by a remote hand controller, OLEP display screens may be rigid or flexible although other flat screens may be used without deterring from the invention - 84 OLEP flat screen displays can also be provided with an antenna surrounding a frame and a contactless image receiving device powered by rechargeable batteries integrated into the frame for receiving and devices for displaying digital camera and animated full colour 3D images and repeat playing 2D and 3D computer generated animations which may be stored and transmitted over short distance by means of Bluetooth and RFID/cellphone wireless technology and broadband Digital reader/scanners can be positioned in a room or an office such that several images can be display throughtout a building at one time.

According to a second aspect of the present invention there is provided apparatus for forming a durable image on a substrate comprising means for depositing an image on a substrate, means for applying a curable coating over the image and means to cure the coating The apparatus may include means for feeding the substrate either as individual sheets or as a roll of substrate material Where a roll of substrate material is used the apparatus may include a suitable cutting means to convert the roll into individual sheets, either before or after imaging Such an arrangement allows the size of the resultant image sheet to be selected by the user The apparatus preferably includes means, preferably a computer, for controlling the image-deposition means The apparatus may be adapted for connection to a digital camera, video camera, USB data storing device, reader, scanner or other source of digital images and 2D and 3D graphics and animations The means for depositing an image may include an electrostatic image deposition means, and inkjet image deposition means or any other suitable means Where an electrostatic image-deposition system is used, which may involve application of a toner stabilizer as described herein, the apparatus preferably further includes a means for removing toner stabilizer from the image-carrying substrate following deposition of the image Such means may include the application of a detergent or other cleaning solution, as hereinbefore described The apparatus may include a motorized roller brush The apparatus optionally further includes a means for drying the image-carrying substrate following the removal of toner stabilizer, for example a hot air blower The apparatus may include means for removing contaminating dust particles from the surface of the substrate prior to coating Such means may include a pair of particle transfer rollers having a surface of low-tack adhesive rubber through which the image- carrying substrate is passed The contaminated rubber of the rollers is then contacted with a means, for instance a pressure-sensitive adhesive film, for removing the contaminating particles therefrom This application may be useful for providing a clean surface for transferring printed organic polymer electronics and circuitry onto a rigid or flexible substrate The substrate may include a thermoplastic polymeric material The curable coating may be a transfer coating and may be UV curable The means for applying a UV curable transfer coating preferably includes an apparatus comprising a pair of adjustable nip rollers of which at least one roller is heated. A heated vacuum press may also be suitable.

The means to cure the coating is preferably a UV source, and may be powered by a microwave energy or other electric power source The curing of delicate objects can benefit from curing by means of cold curing lamps The foregoing and other objects, features and advantages of the disclosure will be apparent from the following more particular description of preferred embodiments of the disclosure, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure The principles and features of this disclosure may be employed in varied and numerous embodiments without departing from the scope of the disclosure Referring to FIGS I and 2 a sheet of coated polyester film 1 carries an image, formed by a toner 2 deposited on its surface The toner 2 forms a relief pattern as it does not substantially penetrate the polyester film 1 The thickness of toner 2 varies, according to the density at which it has been applied. A layer of cured, optically-clear transfer coating 3 covers both the film I and toner 2 According to a further aspect of the present invention, there is provided a display device capable of displaying an image, said device comprising a plurality of organic light emitting polymers enclosed on printed pages disposed between two adjacent layers of a multi-layered structure, said multi-layered structure comprising a layer of a curable lacquer on a page substrate onto which the OLEPs or OLEDs arrays and circuitry are deposited and provided with an optically clear abrasion resistant finish, there may be more than one coatings added to the front of the substrate, depending on the purpose, there may be several layers embedding image controlling devices and circuitry with an antenna and a power source and other micro display components. - 88

According to a further aspect of the present invention, there is provided a display device capable of displaying an image formed by the steps of: providing a substrate, depositing a plurality of organic light emitting polymers capable of displaying an image and applying a curable coating over the image, and further curing the coating. - 89

According to a further aspect of the present invention, there is provided a method of forming a biometrics passport incorporating an encapsulated authentication means, comprising the steps of providing the text and/or image of the passport on a substrate and or in a contactless biometrics enabled electronic microchips which may by single or dual purpose Internationally interoperable wireless RFID enabled electronic microchips, applying a first receiving layer of a curable transferrable coating from a transparent film carrier layer on to the substrate, introducing an authentication means to be encapsulated, applying a second layer of a curable coating to the substrate over the receiving layer, and curing the coating, the authentication means thereby being encapsulated within the coating. The above may be encapsulated between the pages or hard cover of a biometrics passport used in Finland, Denmark and Lithuania and other countries which use laser printed polycarbonate sheets laminated together with a hot melt adhesive. The present invention could be doubly protected when hot laminated between laser printed pages of tamper proof adheisive and polycarbonate, the pages may also contain a contactless OLEPs flat read only - screen display adjacent to a contactless biometrics enabled electronic microchip.

The present disclosure will be further illustrated by the following examples, which are intended to be illustrative in nature and are not to be considered as limiting the scope Do

of the disclosure

The laser printed polycarbonate may comprise a visible tamper proof legal identifiers hot melt adhesive layer UV cured multi layer structure of the present invention comprising with a printed organic polymer circuits, semiconductors, wireless REID enabled electronic active and passive micro chips, contactless biometrics enabled microchips, micro identification devices, micro battery power source, an independent biometric chip image reader and a an image view contactless OLEPs display to show 3D front and side views of passport or ID card holder Polycarbonate laser printed layers bonded on either side of a device structure using tamper proof adhesive to embed the structure and components together

Example 1

An opaque sheet of coated biaxially oriented polyethylene terephthalate Melinex 506 film is placed on a Canon colour photocopier or digital laser printer and an image xerographcally deposited thereon. The film is then washed in a warm aqueous solution of detergent, and dried with a soft lint-free cloth. A hot-melt UV-curable, optically clear transfer coating comprising an acrylate resin is applied to a transparent 100 micron Melinex polyester carrier film using a conventional Meyer/K1-bar, as known in the art, to effect drawdown of the lacquer across the surface of the film. The transparent carrier and the UV curable transfer coating are together laminated onto the printed surface of the image-carrying layer using heat and pressure from a pair of heated rollers, thereby covering the image UV light powered by microwave energy or other suitable UV curing energy is then directed onto the UV curable transfer coating causing it to cure through the transparent carrier film The cured layer has a dry thickness of about 20 microns. The carrier film may then be peeled away from the cured coating to reveal a replicated gloss and/or a textured finish (which replicates the texture of the carrier film) on the cured coating In the production of micro and nano size devices and printed organic polymer circuitry using conductive inks and organic polymers, the structures and layers can be precisely located one over another in depositions of less the 10 pixels printed by an ink jet, lithographic or gravure printer In this application a dry thickness of transfer coating may be micron thickness coating on a carrier film used to transfer printed nano devices on a carrier layer to produce active and passive conductive ink circuits and semi conductors and devices in layers and structures built up by depositions of pixels in precise register ultra thin transfer coatings may be deposited in whole and part areas and as shielding layers.

Example 2

A process using a printable reflective layer imaged with black digits in the form of a vehicle registration plate A printed 3M Scotchlite reflective is laminated onto a rigid perfect fit backing substrate using double-sided mounting adhesive A hot-melt UV curable coating supported on a transparent polyester transfer film is positioned across the imagecarrying layer thereby covering the image. The image carrying reflective layer and the coated carrier layer are bonded together using heat and pressure from a pair of heated rollers UV light is then directed onto the coating, causing it to cure Further protection may be provided by laminating a conventional UK BSI approved optically clear acrylic protective facing sheet over the printed and chipped tamper proof layers embedded between the reflective and the clear acrylic

Example 3

A process using an inkjet image printed onto a Melinex translucent backing material and protectively coated with an anti-scratch UV curable transfer coating. A transparent carrier layer carrying the UV curable transfer coating are together bonded onto the image-carrying layer using heat and pressure UV light is directed onto the lacquer which cures through the transparent film. When the coating is cured the carrier layer is peeled away from the hardened coating to reveal a high gloss or a matt surface finish dependent on the type of carrier which was used The resultant inkjet coated image can be illuminated from behind to produce a backlit illuminated sign or display It should be noted however that water based ink images are normally laminated with an optically clear film and adhesive because an ink image may dissolve on contact with liquid. It may be necessary to remove mechanical corruption such as moisture trapped between the coating and the inkjet image of the present invention For this purpose a high voltage corona discharge may be used to ensure a strong bond is achieved between the image-carrying layer and the cured UV coating

Example 4 f-

A 50 micron DuPont Teijin transparent polyester film coated with a DuPont Teijin in- line release layer (reference DTF8) was further coated with an Akzo Nobel aqueous based solvent free 100 percent solids UV curable polyurethane transfer coating having a finished thickness of 4 9 microns The film and polyurethane layer was exposed to infrared light to evaporate the moisture from the polyurethane coating until the coating became dry to the touch and repositionable over an image The transfer coating and supporting film were then hot laminated onto a photo- realistic inkjet or toner printed image on a paper substrate using heat and pressure from a heated roller laminator at a temperature of about 85 degree. C and a pressure - 94 of about 125 psi. As a result the transparent carrier film and transfer coating were bonded to the imaged substrate The laminated carrier and print layers were subsequently exposed to UV light to cure the polyurethane transfer coating FIG 3 shows apparatus for forming a durable image The apparatus includes a surface 4 for supporting a substrate 5, means 6 for depositing an image on a substrate and means 7 for depositing a curable coating on a substrate The means for depositing an image 6 may include a conventional photocopier or laser printer, such as an inkjet printer.

The means for depositing a curable coating includes a removable light tight cartridge 8 housing a roller supporting a roll of carrier film 9 coated with a hot melt UV curable coating The cartridge 8 is arranged to allow the carrier film to pass between two heated pinch rollers 10 to a guide roller 11 and then on to a take up roller 12. In the path between the pinch rollers 10 and guide roller there is disposed a UV source 13, for example a medium pressure Mercury lamp, and a source 14 of cooling air, such as - 95 a motor driven fan.

In use a substrate 5 to be coated travels through the apparatus over surface 4 in the direction of arrows 15 The substrate 5 first passes through the means for depositing an image 6 which deposits an image on the substrate 5 The imaged substrate 5 then passes between the heated pinch rollers 10 which urge the substrate in contact with the coated carrier film 9 whilst heating the carrier film 9 and substrate 5 sufficiently to melt the coating so that the coating adheres to the substrate 5 The substrate 5 and carrier film 9 combination then passes beneath the UV light source which causes the coating to cure, and then beneath the cooling air source 14 The carrier film 9 is then taken up by the take up roller 12 and the substrate 5 passes out of the apparatus causing the carrier film 9 to peel off the substrate 5 leaving the coating on the substrate 5, over the image.

FIG. 4 shows a different embodiment of apparatus for forming a durable image The apparatus includes a surface 16 for supporting a substrate 17 A track 18 supporting a number of inkjet print heads 19 extends laterally across the surface 16, followed by an infrared or hot air source 20 and a UV source 21 which also extends laterally across the surface 16.

One or more of the inkjet print heads 19 are arranged to deposit an aqueous ink or an organic polymer ink for depositing OLEPs and PLEDs in arrays for producing thin flat screen display provided with abrasion resistant finishes and anti reflective anti glare surfaces onto a substrate 17 on the surface 16 and one or more of the heads is arranged to deposit an aqueous curable coating onto a substrate 17 on the surface, over a digital ink jet printable or polymer image on the substrate The infrared or hot air source 20 is arranged to direct infrared radiation or hot air towards a substrate on the surface 16 and the UV source is arranged to direct ultra violet radiation towards the substrate 17 In use a substrate is periodically advanced along the surface 16 in the direction of arrows 22 When the substrate is static the inkjet heads travel along the track 18, across the substrate and deposits ink on the substrate, where required, to form an image, and a curable coating over the entire width of the substrate and any image thereon As the substrate advances it first passes under the infrared hot air source 20 where the ink and/or coating is dried and then under the UV source which causes the coating to cure Digital Bar Codes may also be employed in connection with the present invention so as to provide a method of reading electronic tags The above embodiments are described by way of example only Many variations are possible without departing from the invention - 98

Claims

I A method of encapsulating an article within a coating of a substrate comprising the steps of providing a substrate, applying a first receiving layer of a curable coating on the substrate, introducing an article to be encapsulated, applying a second layer of a curable coating to the substrate over the receiving layer, and curing the coating, wherein the article is encapsulated within the coating 2. The method of claim I, wherein one or more additional layers of curable coating are applied over the second layer of curable coating 3 The method of claim 1, wherein a plurality of articles is introduced 4 The method of claim 2, wherein an article is introduced into one or more of the additional layers of curable coating The method of claim 1, wherein the coating is cured using ultra violet radiation 6 The method of claim 1, wherein the layers of curable coating are applied by transferring them from a carrier - 99 7 The method of claim 6, wherein the article is introduced to the second coating layer before the second coating layer is transferred from the carrier to the substrate 8. The method of claim 6, wherein the coating is heated to facilitate bonding to the substrate 9 The method of claim 6, wherein the layers of coating are cured before the final layer of coating to be applied is transferred from its carrier.

10. The method of claim 1, wherein the article is an authentication means.

11 The method of claim 1, wherein the authentic means comprises wireless RFID enabled and contactless biometrics information.

12 The method of claim 1, wherein the article is a tamper proof biometrics enabled passport and an RFID enabled identity card comprising scratch resistant surfaces to protect printed and electronic bar codes, RFID antenna, and magnetic information strips and DNA strips 13. The method of claim 1, wherein the substrate is a vehicle registration plate.

14. The method of claim 1, wherein the substrate includes a smart card The method of claim 1, wherein the substrate includes a bank note 16 The method of claim 1, wherein the substrate includes a document 17 The method of claim 16, wherein the document is a passport or active chip Travel Visa 18 The method of claim 17, wherein the passport and visa comprises means for carrying biometrics information.

19 A method of forming a passport incorporating an encapsulated authentication means, comprising the steps of: providing laser printed text and/or one or more digitally printed image of the passport on a substrate; applying a first receiving layer of a curable coating on to the substrate, introducing an authentication means to be encapsulated, applying a second layer of a curable coating to the substrate over the receiving layer, and curing the coating, the authentication means thereby being encapsulated within the coating - 101 The method of claim 19, wherein the authentication means comprises a contactless, REID, Bluetooth devices and broadband internet protocols carrying biometric information 21 A method of forming a vehicle registration plate incorporating encapsulated dual authentication means, comprising the steps of providing the text of the registration plate on a; applying a first receiving layer of a curable coating on to the substrate; introducing an authentication means to be encapsulated, applying a second layer of a curable coating to the substrate over the receiving layer, and curing the coating, the authentication means thereby being encapsulated within the coating 22 The method of claim 21, wherein the text of the registration plate is printed onto a material which is then laminated to the substrate 23. A method of forming a durable image comprising the steps of providing a substrate, depositing an image on the substrate; applying a curable coating over the image; and curing the coating 24 The method of claim 23, wherein the substrate is not absorbent to the image - 102 forming material 25. The method of claim 23, wherein the substrate is absorbent to the image forming material 26. The method of claim 23, wherein the substrate includes a plastics material 27. The method of claim 26, wherein the substrate is formed from polyethylene terephthalate 28 The method of claim 23, wherein at least part of the substrate is coated with a primer and/or receiving layer.

29 The method of claim 23, wherein the image is deposited on the substrate using an electrostatic process 30. The method of claim 29, comprising the step of cleaning the substrate after deposition of the image but before applying the coating 31 The method of claim 23, wherein the image is deposited on the substrate using an inkjet printer 32. The method of claim 23, wherein the coating is applied by transferring it from a carrier 33 The method of claim 32, wherein the coating is heated to facilitate bonding to the image bearing substrate.

34. The method of claim 32, wherein the carrier is textured in order to give the coating a texture 3 5 The method of claim 34, wherein the carrier is textured in such a manner that the coating has a lenticular surface 36 The method of claim 23, wherein the coating is sprayed over the image.

37 The method of claim 23, wherein the coating is polyurethane water soluble W curable transfer lacquer 38 The method of claim 23, including the step of drying the coating after application, but before curing.

39 The method of claim 23, wherein the coating is cured using ultra violet radiation The method of claim 23, wherein the durable image includes a photo-realistic Image.

4 l. An image carrying article comprising an image formed by the steps of providing a substrate, depositing an image on the substrate; applying a curable coating over the image, curing the coating and optionally comprising a printable coating and toner receptive layer applied over a substrate and applying a curable coating over the image.

42 The image carrying article of claim 4 l, wherein the article comprises an identity card.

43. The image carrying article of claim 4 l, wherein the article comprises a passport or a contactless biometrics enabled passport or secure quantum encrypted documents and wireless REID enabled smart cards 44 An apparatus for forming a durable image on a substrate comprising means for depositing an image on a substrate; means for applying a curable coating over the image, and means to cure the coating 45. The apparatus of claim 44, wherein the means for depositing an image includes an electrostatic image deposition means 46 The apparatus of claim 45 comprising means for cleaning the substrate after image deposition.

47 The apparatus of claim 44, wherein the means for depositing an image includes an inkjet image deposition means.

48. The apparatus of claim 44, wherein the means for applying a curable coating includes means for applying a film transfer coating or a roller to roller transfer or continues transparent web coating 49 The apparatus of claim 48, wherein the means for applying a transfer coating includes a pair of nip rollers at least one of which is heated or by means of a heated vacuum press for transferring printed-organic polymer circuitry/digital images/and micro devices onto a substrate The apparatus of claim 44, wherein the means for applying a coating includes an inkjet type means 51 The apparatus of claim 44, wherein the means to cure the coating includes a source of ultra violet radiation 52 A display device capable of displaying an image, said device comprising a plurality of printed organic light emitting polymers or organic light emitting diodes and other flat screen display devices disposed between two adjacent layers of a multi-layered structure, said multi-layered structure comprising at least two layers of a curable lacquer 53 A display device capable of displaying an image formed by the steps of providing a substrate; depositing a plurality of printed organic light emitting polymers organic (LEP=s) and organic (PLED=s)