Abstract:
A printable identification medium, namely wristbands, labels, tags, or sheets including combinations thereof comprises a polymeric substrate bonded to a printed media layer. The printable media layer includes a core layer with an image receiving layer on one side and an adhesive layer on an opposite side. The media layer is constructed such that the identification medium and printed indicia is durable against abrasions, water, soap, hand sanitizers and other solvents in the environment. The core layer may be constructed of polymeric compounds, synthetic paper compounds, or cellulose paper. The image receiving layer is optimized to receive printable identification information thereon from a standard printer.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Form based wristbands, labels and/or tags for identification have been known in the prior art. Such identification forms have heretofore been made using standard paper label media as the top layer that receives identification information. The ability of these standard paper label media to resist fluids has been found to be inadequate for many applications. For example, in hospitals or settings involving exposure to fluids. Such inadequacy has previously been addressed by providing a lamination layer in addition to the printable media layer wherein the lamination layer is foldable over the media layer to protect the same from fluids. The addition of this lamination layer creates manufacturing and design issues such as increased cost, increased complexity, and increased user difficulty in properly aligning or sealing the lamination layer of the printable media layer. 
         [0002]    Accordingly, there is a need for a durable wristband that along with an array of labels and/or tags can be printed on a standard printer without the need for a foldable lamination layer. In addition to being durable, the media layer should be solvent resistant and involve low cost, ease of manufacture, and ease of use. The present invention fulfills these needs and provides other related advantages. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention is directed to a printable identification medium. The identification medium preferably comprises at least one of a wristband, a label, a tag, or a sheet including a combination of a wristband, a label or a tag. In any of these forms the printable identification medium is configured for passing through a standard printer, i.e., laser printer, inkjet printer, thermal printer, electro-photography printer, or standard office printer. 
         [0004]    The medium includes a polymeric substrate preferably made from polyethylene terephthalate (PET). A printable media layer is disposed adjacent to the polymeric substrate. The printable media layer preferably includes a core layer, an image receiving layer on a first side of the core layer, and an adhesive layer on an opposite second side of the core layer for bonding the printable media layer to the polymeric substrate. A release layer is preferably disposed between a portion of the adhesive layer and the polymeric substrate as discussed below. 
         [0005]    The media layer preferably includes a wristband region, a label region, a tag region, or a combination thereof. Die cuts through both the printable media layer and polymeric substrate define a wristband within the wristband region. Die cuts through the printable media layer and polymeric substrate define a tag within the tag region. Die cuts through only the printable media layer define a label in the label region. An interior die cut within the defined wristband defines an attachment portion, wherein the interior die cut is only through the substrate. An interior die cut within the defined tag defines a tag attachment portion, wherein the interior die cut is only through the substrate. 
         [0006]    In the label region, the core layer preferably comprises cellulose paper or synthetic paper. In the wristband and/or tag regions, the core layer preferably comprises a polymer. The image receiving layer preferably comprises urethane, polyethylene, polyethylene terephthalate (PET), vinyl, polyolefin, low-density polyethylene (LDPE), or high-density polyethylene (HDPE), each having a filler. 
         [0007]    Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The accompanying drawings illustrate the invention. In such drawings: 
           [0009]      FIG. 1  illustrates a layout of a printable form including a wristband portion and a plurality of label groups; 
           [0010]      FIG. 2  illustrates a cross-section of the printable form along line  2 - 2  of  FIG. 1 ; 
           [0011]      FIG. 3  illustrates a partial cross-section of a liner layer of the present invention; 
           [0012]      FIG. 4  illustrates a partial cross-section of an alternate embodiment of a liner layer of the present invention; 
           [0013]      FIG. 5  illustrates a partial cross-section of a media layer of the present invention; 
           [0014]      FIG. 6  illustrates a partial cross-section of a media layer of an alternate embodiment of the present invention; 
           [0015]      FIG. 7  illustrates a partial cross-section of another alternate embodiment of a media layer of the present invention; 
           [0016]      FIG. 8  illustrates a configuration of a wristband of the present invention; 
           [0017]      FIG. 9  illustrates a cross-section of the wristband along line  9 - 9  of  FIG. 8 ; 
           [0018]      FIG. 10  illustrates a cross-section of the wristband along line  10 - 10  of  FIG. 8 ; 
           [0019]      FIG. 11  illustrates a cross-section of the wristband along line  10 - 10  of  FIG. 8  after removal of the closure portion; 
           [0020]      FIG. 12  illustrates an alternate embodiment configuration of a wristband of the present invention; 
           [0021]      FIG. 13  illustrates a cross-section of the wristband of along line  13 - 13  of  FIG. 12 ; 
           [0022]      FIG. 14  illustrates a cross-section of the wristband along line  14 - 14  of  FIG. 12 ; 
           [0023]      FIG. 15  illustrates a cross-section of the wristband along line  14 - 14  of  FIG. 12  after removal of the closure portion; and 
           [0024]      FIG. 16  illustrates a layout of an alternate embodiment of the printable form including a wristband region, a tag region and a label region. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    As shown in the exemplary drawings, for purposes of illustration, the present invention is concerned with form-based identification wristbands, labels and/or tags generally referred to by reference numeral  20 . Different embodiments of the inventive form-based identification wristbands, labels and/or tags  20  will be described below. Throughout the description of each embodiment, the same reference numerals will be used to refer to similar components. In some cases where an inventive form  20  is depicted in cross-section, the thickness of the layers will be exaggerated for clarity. However, a person having ordinary skill in the art will understand that the depicted layers are much thinner than illustrated. 
         [0026]      FIG. 1  illustrates the layout of a first preferred embodiment of a form  20  of the present invention having an array of labels and a wristband. The form  20  includes a wristband portion or region  22  having a wristband  23  and a plurality of label groups or regions  24 , each label group  24  including multiple labels  26 . Some of the label groups  24  may include colored tags  27  as illustrated. The colored tags  27  may also be included in the wristband portion  22  or omitted entirely. In an alternate embodiment described below ( FIG. 16 ), a separate tag region  25  may be included. The form  20  is configured to pass through a standard printer. 
         [0027]      FIG. 2  is a cross-section of a portion of the form  20  taken along line  2 - 2  of  FIG. 1 . This cross-section illustrates the various layers of the form  20 . As illustrated, the form  20  consists primarily of a liner layer or polymeric substrate  28  and a printable media layer  30 . The liner layer  28  is preferably made from a synthetic polymer material. The media layer  30  includes a core layer  32 , an image receiving layer  34  on an upper surface thereof and an adhesive layer  36  on a lower surface thereof. It is at this adhesive layer  36  that the media layer  30  is joined to the liner layer  28 . 
         [0028]    In a label group or region  24 , a series of discontinuous or continuous die cuts  38  through only the media layer  30  define each of the labels  26 . A release layer  40  underlies the adhesive layer  36  under each of the labels  26 . The release layer  40  allows each label  26  including the underlying portion of the adhesive layer  36  to be removed from the liner layer  28 . The release layer  40  is preferably silicon but may be any other material commonly used for a release layer. 
         [0029]    In a tag region  25 , a series of continuous or discontinuous die cuts  29  through both the media layer  30  and the liner layer  28  define an outline of the tags  27 . The cuts  29  are configured to enable the tag  27  to remain reliably attached to the form  20  during printing and handling but to be easily removed after printing in a manner such that media layer  30  and liner layer  28  remain permanently bonded together over most of the tag  27 . A release layer  50  underlies a portion of the adhesive layer  36  on each tag  27  such that a portion of the underlying liner layer  28  is removable to expose the adhesive layer  36 . In this way the tag  27  may be adhered or secured to an object either directly or by forming a loop with the tag  27 . 
         [0030]    In a wristband region  22 , a continuous or discontinuous die cut  42  through both the media layer  30  and the liner layer  28  defines an outline of the wristband  23 . The cut  42  is configured to enable the wristband  23  to remain reliably attached to form  20  during printing and handling but to be easily removed after printing. Over most of the area of the wristband portion  22 , the adhesive layer  36  is in direct contact with the liner layer  28  such that it is effectively permanently bonded to the media layer  30  over most of the area of the wristband  23 . 
         [0031]    The wristband  23  preferably includes a closure portion  44  at one end of the wristband. The closure portion is defined by a continuous cut  46  through only the liner layer  28 . The closure portion  44  is a U-shaped feature defining a void in the liner layer  28  that approximates the shape of the strap  48  on the opposite end of the wristband  23 . Another release layer  50  (similar to that for tags described above) underlies this closure portion  44  such that the corresponding portion of the liner layer  28  can be separated from the adhesive layer  36 . The release layer  50  is preferably silicon or any other commonly used material. Once the portion of the liner layer  28  corresponding to the closure portion  44  is removed, the strap may be inserted therein to effect an adhesive closure of the wristband  23 . 
         [0032]    The media layer  30  is preferably made from a synthetic material such as synthetic paper or polymer. In one embodiment, the media layer  30  for the label group  24  and/or tag region  25  may be the same as the media layer  30  for the wristband portion  22 . In another embodiment, the media layer  30  for the labels  26  and/or tags  27  may be different from the media layer  30  for the wristband portion  22 . The media layer  30  within the label group  24  and/or tag region  25  may be synthetic paper, polymer, cellulose paper, or an overcoated paper. A non-synthetic media layer  30  used in these regions  24 ,  25  will decrease the overall manufacturing cost of the form  20 . 
         [0033]    In a particularly preferred embodiment, the liner layer  28  includes a polyethylene terephthalate (PET) core layer  54  that is treated on both sides. As depicted in  FIG. 3 , a lower surface of the PET core layer  54  receives a slip coating  56  that optimizes the liner layer  28  for feeding through a printer. The slip coating  56  allows the pick roller in printers to advance one form  20  at a time out of a plurality of forms, i.e., singulation, and improves handle-ability of the form  20 . The upper surface of the PET core layer  54  receives a surface treatment or skin layer  58  that promotes adhesion of printing inks and handling of printed information. An example of a slip coating  56  is a very thin layer of polytetrafluoroethylene (PTFE). Examples of a surface treatment  58  include a mineral filled urethane layer, as well as water based co-polymers of acrylic, polyester, polyurethane, polyvinyl acetate and polyvinylidene chloride. The adhesive layer  36 , release layer  40  and/or release layer  50  are adhered directly to the surface treatment or skin layer  58 . 
         [0034]    In another preferred embodiment as illustrated in  FIG. 4 , the liner layer  28  may include a core or base layer  54  and upper and lower skin layers  58 ,  56 . The core or base layer  54  may have mineral fillers such as mica dispersed throughout. The core  54  and skin layers  58 ,  56  are polymeric films that may be formed by coextrusion to form a multilayer film or liner layer  28 . Such coextruded multilayer films are known in the industry wherein each layer is selected for particular functions such as barrier protection. The core layer  54  provides the bulk of the chemical resistance and mechanical properties of the liner layer  28 . The upper skin layer  58  provides a surface optimized to receive a release layer  40 ,  50 , thus preventing the release layer  40 ,  50  from being absorbed by the core layer  54 . The lower skin layer  56 , while providing barrier protection, must also provide a function similar to the slip coating  56  described above. 
         [0035]    The core layer  54  is preferably made from a polyester such as PET. However, the core layer  54  may also be made from polyolefins such as polyethylene (PE), high density polyethylene (HDPE), low density polyethylene (LDPE), or vinyl. The core layer  54  may also include fillers such as mica described above, or silica, paper pulp, ground polymer, wollastonite, glass fibers, talc, graphite platelets, graphite fibers, boron fibers, sapphire fibers, steel fibers, or polymeric or polyester fibers such as Kevlar®. The fill may be about 50% by weight of the core layer  54 . Typical thickness of the core layer  54  would be in the range of 50-125 microns or 2-5 mil. 
         [0036]    The upper skin layer  58  is preferably formed from polypropylene or another material having good holdout properties of plastics for preventing the release layer  40 ,  50  from being absorbed into the core layer  54 . The thickness of the skin layers  58 ,  56  would preferably be in the range of about 2-10 microns. An alternative or addition to the skin layers  58 ,  56  would be a surface treatment designed to achieve similar results. 
         [0037]    As illustrated in  FIG. 5 , in a preferred embodiment the media layer  30  preferably includes a polymer core  32  coated with the adhesive layer  36  on one surface and an image receiving layer  34  optimized for printing on the opposing surface. An image receiving layer  34  preferably comprises a urethane, polyethylene, polyethylene terephthalate (PET), vinyl, polyolefin, low-density polyethylene (LDPE), or high-density polyethylene (HDPE). Regardless of which polymer is used to create the image receiving layer  34 , each would include a filler such as those described above for the core layer  54 . The filler improves the printability of the layer. 
         [0038]    In an alternate embodiment for the media layer  30 , as shown in  FIG. 6 , a core layer  60  is sandwiched between an upper skin layer  62  and a lower skin layer  64 . The adhesive layer  36  underlies the lower skin layer  64 . The image receiving layer  34  overlies the upper skin layer  62 . 
         [0039]    The skin layers  62 ,  64  are preferably made from polyethylene vinyl acetate or plasticized polyvinylchloride (PVC). Alternatively, as discussed above, the skin layers  62 ,  64  may comprise a surface treatment. The lower skin layer  64  should be optimized for anchoring the adhesive layer  36 . The image receiving layer  34  optimizes the upper surface of the media layer  30  for printing with a laser or ink-jet printer. In addition to the materials described above, the image receiving layer  34  may be a thin UV-cured urethane coating that contains a mineral filler. Laser printed images bond to an image receiving layer  60  having this type of construction very effectively. A media layer  30  so constructed provides a very durable multilayer structure. 
         [0040]    As illustrated in  FIG. 7 , the media layer  30  may also include tie layers  66  between the core layer  60  and the upper and lower skin layers  62 ,  64 . The tie layers  66  enhance the adhesion of the skin layers  62 ,  64  to the core layer  60  and are extremely thin, in the range of 0-5 microns. Corona discharge or other surface treatments such as plasma ashing can also be used to enhance the adhesion of the various layers or of printed material. 
         [0041]      FIG. 8  illustrates a configuration of a preferred embodiment of the wristband  23 . The wristband  23  includes a strap portion  48 , a printable area  70  and a closure portion  44  as described above. The strap portion  48  includes a plurality of apertures  72  and the closure portion  44  includes a single aperture  74 . One of the apertures  72  on the strap portion  48  may be aligned with the single aperture  74  on the closure portion  44 . Alternatively, the closure portion  44  may be removed from the liner layer  28  as described above exposing the adhesive layer  36  such that the strap portion  48  may be adhered thereto. 
         [0042]      FIG. 9  illustrates a cross-section of wristband  23  along line  9 - 9  of  FIG. 8 . From this image, the liner layer  28  and media layer  30  are shown. The liner layer  28  is illustrated as having core layer  54 . While the slip coating  56  and surface treatment  58  are not shown in this figure, they may be included as needed. The media layer  30  is shown as having core layer  32 , adhesive layer  36  and image receiving layer  34 . 
         [0043]    According to  FIGS. 8 and 9 , media layer  30  is permanently bonded to liner layer  28  over most of the area of wristband  23 . Referring back to  FIG. 1 , the wristband  23  is removed from form  20  by separating the wristband  23  from wristband portion  22  along outline or cut line  42 . As the wristband is removed, the liner layer  28  remains bonded to media layer  30 . Because liner layer  28  and media layer  30  are both polymeric layers, and because they are permanently bonded together over most of the area inside outline  44 , the wristband  23  has a high durability to physical use, water, hand sanitizers, alcohols, and other environmental factors encountered by a patient or patron during sustained use of wristband  23 . 
         [0044]      FIG. 10  illustrates a cross-section of the wristband  23  through line  10 - 10  in  FIG. 8 . In addition to showing the same layers shown in  FIG. 9 ,  FIG. 10  illustrates the construction of the closure portion  44  with the addition of the release layer  50 .  FIG. 10  shows the wristband prior to removal of the closure portion  44 . Therefore closure portion  44  is configured to be removed by virtue of release layer  50  that allows adhesive  36  (and hence media layer  30 ) to be easily peeled and separated from liner  28  over the area of closure portion  44 . Closure portion  44  is also easily removed because it is partially bounded by a die cut  46 . In the illustrated embodiment die cut  46  is a U-shaped die cut. 
         [0045]      FIG. 11  illustrates the same cross-section as  FIG. 10  after the removal of the closure portion  44 . One can see that removal of the closure portion  44  removes a corresponding portion  44  of the liner layer  28 , thereby exposing the adhesive layer  36  from beneath so that the strap portion  48  may be inserted therein and adhered thereto. 
         [0046]      FIG. 12  illustrates a wristband  23  having a configuration similar to that of  FIG. 8 . However, the layered construction of the wristband  23  shown in  FIG. 12  includes additional layers as shown in  FIGS. 13-15 .  FIG. 13  shows a cross-section of the wristband  23  in  FIG. 12  along line  13 - 13 . This cross-section is similar to that cross-section shown in  FIG. 9 . However, the cross-section in FIG.  13  illustrates the slip coating  56  and skin layer  58  of the liner layer  28  described above. 
         [0047]      FIG. 13  also illustrates the upper skin layer  62 , lower skin layer  64  and image receiving layer  34  of the media layer  30 , also described above. Again, the adhesive layer  36  bonds the media layer  30  to the liner layer  28 . 
         [0048]      FIGS. 14 and 15  illustrate a cross-section of the wristband  23  from  FIG. 12  along line  14 - 14 .  FIG. 14  illustrates the cross-section prior to removal of the closure portion  44  whereas  FIG. 15  illustrates the cross-section after removal of the closure portion  44 . Again, these figures are similar to the cross-section shown in  FIGS. 10 and 11 , except they illustrate the addition of the slip coating  56  and skin layer  48  in the liner layer  28  as well as the upper skin layer  62 , lower skin layer  64  and image receiving layer  34  in the media layer  30 . Except for the addition of these layers, the closure portion  44  functions as described above in  FIGS. 10 and 11 . 
         [0049]      FIG. 16  illustrates an alternate embodiment of the sheet  20  of the present invention. In this embodiment, the wristband region  22  and label region  24  are positioned on opposite edges of the sheet  20 . The tab region  25  is positioned between the wristband region  22  and the label region  24 . The construction of the liner layer  28  and media layer  30  in the sheet  20  and the various regions  22 ,  24 ,  25  are as described above. In this alternate embodiment, the media layer  30  for the wristband region  22  and the tag region  25  is generally of similar polymeric construction, whereas the media layer  30  in the label region  24  may more closely approximate synthetic paper or cellulose construction. 
         [0050]    Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention.