Patent Grant
6916130
This invention is directed to a method for continuously printing, activating and issuing an activated time dependent label or badge.
Time dependent self-expiring visitor labels and badges are well known and presently manufactured and sold by TEMTEC Division of Brady Worldwide, Inc., see for example U.S. Pat. No. 4,903,254. Generally, these labels comprise two parts: a) a front part wherein the rear surface is coated with a pressure sensitive adhesive and the front surface is white, and b) a back part having migrating ink printed on one surface thereof. Printed on the white front face of the front part are the security design and other data, such as the visitor's name, date, time of entry, etc. When the pressure sensitive adhesive on the front part is contacted with the migrating ink printed on the back, the label or badge is activated. After a predetermined period of time the dye bleeds through to the white front part.
This VCP (visually changing paper) technology produces images and colors that appear after a predetermined period of time after activation. The process is primarily physical and chemical in nature and does not employ reactive chemistry, although it may. In known methods and devices, in order to initiate the timing function, a physical assembly must take place that puts the migrating dye materials (on the Back Part) in contact with an active dye absorber layer (the Front Part). Typically this is accomplished with a pressure sensitive adhesive Front Part label applied to the Back Part that is printed with migrating ink The adhesive of the Front Part label contacts the migrating ink dye and initiates the dye diffusion process.
The variable data, e.g., name of the visitor or attendee is usually added to the front part prior to or after activation. When the variable data is written by hand with a pen or marker, it can be done prior to or after activation. However, when a printer is used to add the variable data it is generally always performed before the label is activated because after activation the label is too thick and/or has misaligned substrates making the label difficult or impossible to pass through a printer.
Typically the printer used for applying the variable information to the front part of the label is a dot matrix printer, direct thermal printer, or thermal transfer printer. Once the front part of the label has been printed with the variable data it is removed from the printer and adhesively attached to the surface of the back part that has the migrating ink printed thereon. This activates the self-expiration process of the time dependent label. Typically within a day, the white surface or a portion of the white surface on the front of the label turns red to show its expiration.
There are numerous patents issued that cover the aforedescribed type self-expiring badges, labels and passes. Examples of these products and the technology used by these products are described in the following Haas patents and application, e.g., U.S. Pat. Nos. 5,364,132; 5,446,705; 5,602,804; 5,699,326; 5,715,215; 5,719,828; 5,785,354; 5,822,280; 5,873,606; 5,930,206; 5,957,458; 6,295,252; 6,452,873; and 2002/0105183. The entire disclosures of all of these patents and application are incorporated herein by reference. The products described in these patents have become widely accepted as a means for controlling and improving visitor security and as temporary badges. However, all of these products contemplate the use of a printer prior to activation followed by manual activation, i.e., the front part is manually placed on the back part to activate the time process.
This manual assembly and activation after the printing process in order to issue the self-expiring badges or labels creates certain difficulties. Some of these difficulties are: misalignment of the front part when it is attached to the back part, the length of time required to peel the release liner from the front part and attaching the front part to the back part, the litter caused by the release liners, and the most serious problem, the issuer of the badge failing, by accident or intent, to assemble the two parts. Without proper assembly, the visitor receives a badge with a front part that is continuously valid because it has not been activated to expire.
Other U.S. Patents of interest or relevance are the following:
U.S. Pat. No. 6,524,000 to Roth describes time-temperature indicators activated with direct thermal printing.
U.S. Pat. No. 6,384,854 to lbs et al. discloses a printer controller, e.g., a microprocessor, which is used to control the printing process. Substrates can comprise an identification card blank for receiving thermal printing. The ribbon can comprise a thermal resin.
U.S. Pat. No. 2002/0191066 to Bouchard et al.
U.S. Pat. No. 6,433,807 to Francis et al.
U.S. Pat. No. 5,956,067 to Isono et al.
U.S. Pat. No. 5,633,836 to Langer et al.
U.S. Pat. No. 4,916,112 to Henzel et al.
It is an object of this invention to provide a method for using a computer and thermal transfer printer for printing, activating and issuing an activated time dependent label or badge without manual activation.
It is another object of this invention to provide a method of issuing a fully assembled, activated self-expiring label that is fully printed on the face of the front part, eliminates most, if not all of the problems described above.
It is a further object of this invention to provide a method of issuing a fully assembled, activated self-expiring label that is fully printed on the face of the front part and wherein there is no misalignment of a front and a back part, and can be rapidly assembled, eliminating the time required to peel the front part from its release liner and attaching it to the back part, and avoids litter and prevents the issuance of labels or badges that are not activated.
It is yet another object of this invention to provide a method and apparatus for producing an issued and activated time dependent label or badge that is produced completely within a thermal transfer printer and is a computer controlled process.
The aforedescribed objects of this invention are accomplished by the method of this invention for continuously producing a plurality of printed and activated time dependent labels or badges. In one embodiment, the method comprises. providing a web having a plurality of inked substrates thereon. Each substrate has a migrating ink pattern printed on a surface of the substrate. A transfer printer is provided that has a first ribbon means for applying a timing layer through which the migrating ink bleeds after a predetermined period of time. A second ribbon means is provided for printing variable data. The web of inked substrates is continuously fed through the printer, each inked substrate passing sequentially under the first ribbon means and then the second ribbon means. The first ribbon means is activated to apply the timing layer to a portion of the printed surface of each inked substrate thereunder to produce a coated substrate. The second ribbon means is activated to print the variable data information on each coated substrate thereunder, thus continuously producing a plurality of activated time dependent labels having variable data information printed thereon.
In another embodiment for producing a plurality of printed and activated time dependent labels, the web having the plurality of inked substrates thereon is continuously fed through a transfer printer having a single ribbon means. The single ribbon means includes a first ribbon portion for applying a timing layer through which the migrating ink bleeds after a predetermined period of time, and a second ribbon portion for printing variable data. The web is continuously fed through the printer, wherein the first and second ribbon portions pass sequentially over each inked substrate. The first ribbon portion is activated to apply the timing layer to a portion of the printed surface of the inked substrate thereunder, to produce a coated substrate, and then the second ribbon portion is activated to print the coated substrate with the variable data information, thus continuously producing a plurality of activated time dependent labels having variable data information printed thereon.
In another embodiment of this invention, a web is provided that has a plurality of inked substrates having a migrating ink pattern printed on a surface of the substrate. A transfer printer is provided having a ribbon means for applying a timing layer through which the migrating ink bleeds after a predetermined period of time, and for printing variable data. The web of inked substrates is continuously fed through the printer, wherein the ribbon passes over each inked substrate. The ribbon is activated to simultaneously apply the timing layer to a portion of the printed surface of the inked substrate thereunder to produce a coated substrate and to print the coated substrate with the variable data information. Thus, a plurality of activated time dependent labels having variable data information printed thereon is continuously produced. Optionally, the coated substrate is reverse printed with variable data.
Other important objects and features of the invention will be apparent from the following Detailed Description of the Invention taken in connection with the accompanying drawings in which:
The color changing time processes and chemistry used to produce the labels and badges herein are substantially similar to that described in the Haas patents and application previously mentioned, i.e., U.S. Pat. Nos. 5,364,132; 5,446,705; 5,602,804; 5,699,326; 5,715,215; 5,719,828; 5,785,354; 5,822,280; 5,873,606; 5,930,206; 5,957,458; 6,295,252; 6,452,873; and 2002/0105183. The entire disclosures of all of these patents and application are incorporated herein by reference. Generally, the migrating ink dye printed on the label slowly bleeds into the white coating on the label and after a predetermined period of time, e.g., one day, the white front of the label turns red, showing expiration.
A primary feature of this invention is to provide a method for continuously producing a plurality of activated and printed (issued) time dependent labels or badges with a computer controlled thermal transfer printer. For the sake of brevity herein, such labels or badges will be referred to herein as “labels.” Broadly, the assembly comprises transferring the various coatings in the VCP construction from different ribbons, from sequential panels or portions within one ribbon, or from one ribbon onto a substrate. By the use of the term “substrate” it is meant, for example, a paper label, or badge. The substrate is printed, coated or overlaid with a migrating ink pattern which is subsequently coated with a white timing layer through which the migrating ink bleeds followed by printing the variable data information thereon. Optionally a clear enhancement layer overlays the timing layer.
The apparatus and method of this invention can produce a time dependent label (VCP product) from a plurality of thermal ribbon coatings in one pass through a printer controlled by a computer.
The printer may be a conventional thermal transfer printer with one or more print heads. Such printers, card printers, processors and systems are well known in the art and sold by numerous companies, e.g., Tharo Systems, Inc., Zebra Technologies International, LLC (Eltron) and Fargo Electronics, Inc. (Fargo).
Referring to
Optionally, although not shown in the Figures, a single thermal transfer print head similar to that depicted in
The chemical composition of the white timing layer 56 that is applied to the printed label 12 is highly dependent on the particular dyes used in the migrating ink that is printed or coated on the substrate. For example, employing hydrophobic dyes for printing will require a white timing layer 56 to be made of hydrophobic like materials such as urethane or polyolefin. Employing hydrophilic dyes for printing will require that the white timing layer 56 be ionic in nature such as vinyl or polyester. Thus, the timing for the dye migration will be a function of the particular timing layer materials, its thickness, the type and amount of other additives such as whiting agent (example: TiO2), plasticizers and fillers added.
Additionally, it is possible to add low molecular weight organics to the substrate or inks that are printed thereon that diffuse into the timing layer and alter the timing characteristics of the dye migrating through the timing layer. The timing characteristics for these time dependent labels must all be formulated for the specific temperatures and conditions of use.
A property of thin printed layers or coatings like the timing layer 56 herein is their inability to hide non-uniform backgrounds. For example, black and white printing on a white substrate produces sharp contrast differences. Thin white coatings as the timing layer do not always have the ability to hide these contrasts and the images printed in migrating ink show through the white timing layer to coating. Thus, the white timing layer is not opaque, but is translucent.
The inventors have solved this problem by printing the migrating ink onto a substrate which is not white, but dark in color so that the contrast between the migrating ink and background is low.
When the white timing layer is placed over this low contrast background, the image printed in migrating ink does not show through the timing layer. This technique permits the use of a very thin translucent timing layer that can provide after the predetermined period of time has expired, a relatively sudden color change from solid white to red.
Another advantage of having a dark or black substrate is that the variable data can be printed on the white timing layer by reverse printing. Reverse printing yields a white background with the black background showing the data. This eliminates the need for a second ribbon to print the variable data.
Referring to the printer 15 in more detail and to
Referring to
This process produces an activated label 14 which has an opaque white face and appears similar, if not identical, to a white paper label. This provides a white substrate media for printing the variable data 64 such as the persons name, etc.
Preferably the ribbon 52 comprises a film carrier material 102 which is a polyester film of about 0.25 to 0.5 mil thickness. On top of this film carrier material 102 is a low friction slip layer 101, which permits the ribbon 52 to easily slide over the print head. The timing layer 103 on the lower side of the ribbon 52 is pressed in intimate contact with the preprinted substrate. As the ribbon 52 is pressed onto the substrate, the timing layer 103 adheres by any of several means to the substrate and is stripped from the film carrier material 102 as both the ribbon 52 (now 101 and 102) is transported through the printer.
Again referring to
Typically when the substrate label is printed with the migrating ink prior to entering the first printing station 12 (FIG. 2), the printed pattern will not be solid or continuous, but the pattern will be dots with portions of the natural substrate exposed between the dots. This is important in order to assure a strong bond between the timing layer 56 and the substrate material 12. Since the migrating dye 54 is typically printed onto the label substrate 12 by means of a printing press, the print could interfere with the bonding of between the timing layer 56 and the substrate.
In the preferred embodiments of this invention, it is desirable to produce a time dependent label 40 having a multiple layer construction. In particular it is preferred that the face of the white timing layer 103 be overlaid with a clear enhancement layer to permit the migrating dye to concentrate in front of the white timing layer. Without this clear enhancement layer, the dye remains intermixed with the whitening agent such as titanium dioxide and therefore, does not become a dark color, like dark red. By concentrating the colored dye in a clear media one obtains a dark, intense color to clearly show that the ID label has expired.
It is also possible to have multiple print heads for applying different timing layers. For example, if we have two print heads, there can be one for producing a one-day expiration portion for a label and another for producing a one-week expiration portion for such label. Thus, the time dependent label may show authenticity and expiration by having the one-day portion turn red to show it was issued a day ago, yet still remain valid for the remainder of the week, with the second one week timing portion expiring thereafter.
In the type of thermal transfer printer that may be used in this invention, it is common to have more than one color print head so that the operator can print pictures and graphics onto the labels. Thus, whereas print head 22 is shown as a single unit, print head 22 could be replaced by a plurality of print heads to enable the printing of multi-color graphics and images. These are all printed on the white timing layer 56 in order to make a more secure and aesthetically pleasing label.
Optionally, it is possible to produce an authenticity device, such as a gold hologram, foil printed on the substrate as a graphic image or simply a metallic design, either being printed on top of a short term timing material, which produces a unique color to appear throughout the metallic design. This authenticity device is designed so that it could only be produced with this type of a printer construction.
Other additional benefits of the method of this invention can be the employment of a segmented heated print head wherein only portions of the preprinted substrate are coated and not the entire substrate. For example, the printing device may be used for printing different size labels, such 2″×3″ or 3″×3″ and only a portion of the larger label is coated, leaving the uncoated portion visible. Likewise, an operator could also print only an isolated area, such as a 1″×1″ square on a label in order to reduce the label cost.
The materials used in the ribbons are known in the art. The materials commonly used are polymers, waxes, additives, tackifiers, fillers and pigment. Other layers could be incorporated into the ribbon such as release layers that allow easy release of the other layers in the ribbon. There can be a release layer between the enhancement layer and the ribbon. The release layer could be composed of low melting point polymers, waxes, silicone based resins, Teflon type materials, etc. that are well known in the art.
In one embodiment of this invention, the label substrate has a pressure sensitive adhesive which contains a migrating dye on its outside or top surface. The timing layer from the ribbon can be applied to the preprinted substrate by mere pressure of the first print head (no heat). The label substrate would be self-wound so that the adhesive is exposed as soon as it comes off the feed roll. The primary benefit of a pressure sensitive adhesive attachment is that no heat is applied to any of the elements.
In another embodiment, the timing layer employs a co-adhesive coating that reacts with a co-adhesive coating on the preprinted substrate to cause them to adhere to each other. In this case, neither co-adhesive has tack so that it does not have to be protected from contact with other objects by a release liner. Simply pressing the two co-adhesives coatings together will cause them to form a firm adhesion bond. This assembly also eliminates the need for heat to attach the timing layer to the preprinted substrate.
In yet another embodiment, the timing layer is coated onto the preprinted substrate by employing a heat transfer method which either employs a heat activated adhesive or actually causes the timing layer to melt and coat the substrate so that in the heated, liquid state, it flows onto the substrate coats and bonds thereto. The heat activated coating also offers the ability to control the portion of the preprinted label that is covered by the timing layer. For example, if only half the heating elements are activated, then the coating will only be half as wide as a full coating. This offers the benefit of being able to “spot apply” the timing layer coating onto the preprinted substrate.
A preferred embodiment of a three layer thermal transfer ribbon is similar to that depicted in FIG. 8. In this embodiment, the ribbon comprises a 0.25 mil polyester film (Toray Plastics America, Inc.; Toray Industries, Inc.) Ribbon Film that contains a slip layer Back Coat on one side. On the opposite of the Ribbon Film is a coated (2 lbs/ream) black thermal ink layer, Black Ink, followed by a Release Layer (0.1 lbs/ream), and the third layer is a White Timing Layer (5 lbs/ream). The White Timing Layer transfers to the printed substrate 12 by pressure from the print head and is released from the film after the head lifts. The black thermal layer, Black Ink and the Release Layer are released from the Ribbon Film by heat from the print head. An additional layer (not shown) may be used between the Black Ink layer and the Ribbon Film. Such release layers are well known in the art.
The following is a description of the preferred elements of this preferred ribbon:
Still referring to
The purpose of the black/dark migrating and non-migrating ink is two fold. One is to provide the dark contrast of the reverse printed timing layer in order for the variable data to be seen as normal print. The other purpose is that the ink also serves as a pressure sensitive adhesive containing the migrating component(s). The function of the pressure sensitive adhesive is that the white timing layer adheres to the inked substrate and transfers or separates from the ribbon after the print head. This substrate is provided in roll form and wound upon itself. The backside of the substrate may have coated on it a release coating containing such polymers as polysiloxane, commonly used in liner paper or other release materials. After the substrate is unwound in the printer, the adhesive must not permanently stick to any surface, treated rollers would be needed in the printer. This inked substrate material is similar in a way to linerless label media used in thermal transfer printers whereas the backside of the substrate has pressure sensitive adhesive exposed and is self wound. In this case, the adhesive is faced up/out instead of face down/in. The adhesive properties only need to be strong enough to remove the white timing layer from the ribbon. A weak adhesive would be sufficient and remain easy to handle.
In another embodiment, depicted in
The preferred materials used are:
In another similar embodiment, an additional layer can be added to the previous example. A two layer ribbon can be used. A clear enhancement layer can be used between the white timing layer and the polyester film. The clear layer will transfer with the white timing layer. The function of this layer is to allow the dye to migrate through the white timing layer and concentrate in the clear layer. The result is a more intense final color since the majority of the colorant resides in front of the white pigment. It enhances the final color. The layer also may help or assist in releasing the white layer from the film and act as a release layer.
The preferred materials used are the same as the previous example except it includes the following materials for the clear enhancement layer.
Typical Operation
With two print head printers, there is a first ribbon for applying the timing layer to the preprinted substrate to activate the label and a second ribbon to apply the variable data to the face of the activated label. The preprinted substrate enters the printer from a roll on one side and is ejected from the printer from the other side of the printer. After installing the two ribbons and the roll of preprinted substrate into the printer, the computer is activated to control the feed and print head parameters as well as the variable data to be printed.
The preprinted substrate advances to the first print head, then the timing layer is placed in contact with the preprinted substrate, and the two are driven under the print head simultaneously. This applies the timing layer to the face of the preprinted substrate and initiates or activates the time expiration process. The first print head is lifted so that the timing layer ribbon releases its contact with the substrate. The substrate label with timing layer attached thereto then advances to the second print head where the imaging ribbon is placed into contact with the substrate. As the substrate passes under the print head, the variable data pattern is energized so that the variable data is applied on top of the timing layer. When all the variable data is printed, the second print head lifts off the label substrate. Then the finished label is ejected from the printer and issued to the person(s).
Although this invention contemplates a multiple head printer and a single head printer, a multiple head printer is preferred. For example, the two print head printer described may be more advantageous than a single print head unit, because the web having the labels thereon advances simultaneously through both the first and second print heads and is printed simultaneously by both heads. In a single print head unit, the ribbon for the single print head has two or more panels on it and the web of labels must reverse after each panel is printed and realigned with the print head for applying the next layer (print or timing label) for a second pass under the print head. The reversing and reprinting requires a more complicated drive mechanism as well as more precise sensor marks on the label in order to position it exactly. Further, a two print head printer generally has a greater throughput per unit of time than a single print head printer. Additionally, a multiple panel ribbons cannot employ a mechanism called a “ribbon saver” because each of the two panels must be completely used for printing of a single label. Thus, with ribbon savers on the ribbons of the two head printer, one could extend the use of the ribbon substantiality by printing smaller time spots on each label instead of a full label. With a single head printer, the ribbon will have two panels and the transport mechanism will move the label under the print head with the first panel, timing layer, being transferred onto the substrate. Then the print head is raised to separate the ribbon from the substrate and the substrate label is returned to its beginning position. Then the second printing pass is performed. Thereafter, the label is ejected from the printer with the entire construction of the self-expiring label complete.
The time dependent labels produced by the method of this invention have many advantages when compared to the prior art methods of printing and activating such labels:
Minimizes any misalignment of the parts of the label, i.e., front and back parts.
Eliminates the time required for peeling the front part from its release liner and attaching it to the back part for activation.
Eliminates litter from the release liner pulled from the front part.
The issuer cannot fail to activate the label because the activation is performed inside the thermal transfer printer.
Preprinted security designs can be provided on the Substrate insuring authenticity control.
More rapid issuance of labels.
Computer data can be downloaded in order to print thousands of labels for shipping, security, authorization, admission that are complete and activated to self-expire, providing a time indicator label that is much more versatile than ID labels only.
Lower cost per label.
No activation by user.
No label is issued that is not activated.
Only one label material is required as the primary component of the label.
Time indicators can be applied to product labels such as food. products, pharmaceuticals, etc.
There are many other possible uses for the labels, badges and the like produced by this invention, for example:
Security ID labels, self-expiring parking tags, package and shipping labels, wrist bands, tickets, self-expiring passes for tours, emergency rooms, hospitals, museums, and other locations with open doors or many doors, backstage passes, race track passes, baseball dugout passes which are issued specifically for one-day control in addition to the admission ticket, security labels for screened luggage, purses, bags at airports to show the aircraft control people that the particular items were inspected, unmanned but video controlled entrances for visitors where the self- expiring visitor label issued electronically from a kiosk printer.
While various changes may be made in the detailed construction and processes of this invention, it will be understood that such changes will be within the spirit and scope of the present invention.
Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit and scope thereof. What is desired to be protected by Letters Patent is set forth in the appended claims.
This application claims the priority of Provisional Patent Application Ser. No. 60/423,803, filed Nov. 6, 2002, the entire disclosure of which is incorporated herein by reference.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4903254 | Haas | Feb 1990 | A |
| 4916112 | Henzel | Apr 1990 | A |
| 5364132 | Haas | Nov 1994 | A |
| 5446705 | Haas | Aug 1995 | A |
| 5602804 | Haas | Feb 1997 | A |
| 5633836 | Langer | May 1997 | A |
| 5699326 | Haas | Dec 1997 | A |
| 5715215 | Haas | Feb 1998 | A |
| 5719828 | Haas | Feb 1998 | A |
| 5785354 | Haas | Jul 1998 | A |
| 5822280 | Haas | Oct 1998 | A |
| 5873606 | Haas | Feb 1999 | A |
| 5930206 | Haas | Jul 1999 | A |
| 5956067 | Isono et al. | Sep 1999 | A |
| 5957458 | Haas | Sep 1999 | A |
| 6295252 | Holt | Sep 2001 | B1 |
| 6384854 | Ibs | May 2002 | B1 |
| 6433807 | Francis | Aug 2002 | B1 |
| 6452873 | Holt | Sep 2002 | B1 |
| 6493015 | Bhatt et al. | Dec 2002 | B2 |
| 6517239 | Roth | Feb 2003 | B1 |
| 6524000 | Roth | Feb 2003 | B1 |
| 6663945 | Miyano | Dec 2003 | B2 |
| 6752430 | Holt et al. | Jun 2004 | B2 |
| 20020105183 | Holt | Aug 2002 | A1 |
| 20020191066 | Bouchard | Dec 2002 | A1 |
| Number | Date | Country |
|---|---|---|
| PCT WO 03077227 | Sep 2003 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 60423803 | Nov 2002 | US |
