Abstract:
A label adapted for direct thermal printing on both sides thereof and having a sealable pouch is described. In one embodiment, the label comprises two substrates, each substrate being coated on an outer face with a thermally sensitive coating. The inner faces of the substrates are respectively coated with an adhesive and a release material. A configuration of die cuts and perforations on the two substrates is provided to allow the label to adhere to a surface such as a package and to form a sealable pouch with respect to said surface.

Description:
BACKGROUND OF THE INVENTION 
     Two-sided direct thermal printing and media adapted therefor are described in U.S. Pat. Nos. 6,759,366; 6,784,906; 7,589,752; and 7,777,770, the contents of which are incorporated herein by reference. In such processes, paper or other media comprising one or more substrates are coated with thermally sensitive material to enable printing thereon. The media is fed through a two-sided thermal printer which selectively heats portions of one or both sides of the media as it is fed through the printer. The thermally sensitive coating on the outside faces of the media darkens or changes color in response to said heating, thus producing text, images, or other information on the respective faces of said media. 
     SUMMARY OF THE INVENTION 
     Disclosed herein is a label adapted for direct thermal printing on both sides thereof and adapted for forming a sealable pouch capable of holding paper or other objects. In one embodiment, the label comprises two substrates, each substrate being coated on an outer face with a thermally sensitive coating. The inner faces of the substrates are respectively coated with an adhesive and a release material. A configuration of die cuts and perforations on the two substrates is provided to allow the label to adhere to a surface such as a package and to form a sealable pouch with respect to said surface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows an exploded view of one embodiment of a two-sided direct thermal label. 
         FIG. 2A  shows a perspective view of the label of  FIG. 1  partially removed from the label backing. 
         FIG. 2B  shows a perspective view of the label of  FIG. 1  completely removed from the label backing. 
         FIG. 3A  shows a plan view of the back side (underside) of the label of  FIG. 1  after it has been completely removed from the label backing. 
         FIG. 3B  shows a plan view of the front side (top side) of the label of  FIG. 1  after it has been completely removed from the label backing. 
         FIG. 4A  shows a perspective view of the label of  FIGS. 3A and 3B  after the label has been affixed to a package and with the sealable pouch remaining open. 
         FIG. 4B  shows a perspective view of the label and package of  FIG. 4A  after the pouch has been sealed. 
         FIG. 5  shows a perspective view of the label and package of  FIG. 4B  after the pouch has been partially opened. 
         FIG. 6  shows a cross-sectional detailed view of the label of  FIG. 1 . 
         FIG. 7  shows a cross-sectional detailed view of a two-sided direct thermal label in an alternate embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the figures contained herein in which like numerals indicate like elements throughout the several views,  FIG. 1  shows an exploded view of a two-sided direct thermal label  100  in a sample embodiment of the invention. Label  100  includes an upper layer  110  and a lower layer  150 . 
     Turning to  FIG. 6 , a cross-sectional detailed view of the label  100  from  FIG. 1  is shown. Upper layer  110  preferably comprises a substrate  320  which is coated with a thermally sensitive coating  326  on the outer face  109  of label  100 . Substrate  320  preferably comprises a cellulosic material, although other materials can be used such as polymers, particularly polypropylene or polyethylene, which may be in the form of films. Such substrate materials are described more fully in U.S. Pat. Nos. 6,784,906 and 6,759,366, the contents of which are incorporated herein by reference. 
     Thermally sensitive coating  326  may comprise a heat-sensitive dye or dyes that are capable of changing color or darkening when heated. Such coatings are generally known in the art and are described in U.S. Pat. Nos. 6,784,906 and 6,759,366. 
     Upper layer  110  also preferably comprises an adhesive  330  on the inner face  111  of substrate  320 . Adhesive  330  may comprise a high tack hot melt adhesive and/or a low residual tack adhesive, as known to those skilled in the art. 
     Lower layer  150  of label  100  preferably comprises a substrate  310 , a release layer  340  attached to an inner face  149  of substrate  310 , and a thermally sensitive coating  316  on the outer face  151  of substrate  310 . Release layer  340  may comprise silicon and/or some other substance suitable for disengaging substrate  310  from adhesive  330  when a pulling force is applied to pull the two substrates  310 ,  320  apart from one another. Materials suitable for release layer  340  are discussed more fully in U.S. Pat. No. 7,777,770, the contents of which are incorporated herein by reference. 
     Substrate  310  preferably comprises a cellulosic material or polymeric material similar to substrate  320 . Similarly, thermal coating  316  may comprise a heat-sensitive dye or dyes similar to thermal coating  326 . 
     Returning to  FIG. 1 , upper layer  110  comprises an outer face  109  and an inner face  111 . As described above, outer face  109  preferably has a thermally sensitive coating  326  and inner face  111  preferably has an adhesive coating  330 . 
     Upper layer  110  includes a central portion  113  and a peripheral portion  114 . Perforation lines  115  separate the central portion  113  from the peripheral portion  114 . Advantageously, peripheral portion  114  extends around the entire periphery of upper layer  110 . Peripheral portion  114  further comprises an end portion  118 . Unlike end portion  158  of lower layer  150  (described more fully below), end portion  118  of upper layer  110  is not severed from peripheral portion  114 . Rather, end portion  118  is an integral part of peripheral portion  114 . End portion  118  preferably has a shape substantially congruent to, and in vertical alignment with, end portion  158  of lower layer  150 . 
     Pull tabs  131 ,  132  are optionally included at one end of central portion  113  to facilitate the separation of central portion  113  from peripheral portion  114  as described more fully below. Upper layer  110  also optionally includes pull tabs  121 ,  122  at one end of label  100  to facilitate the separation of upper layer  110  and the central portion  153  of lower layer  150  from the peripheral portion  154  of lower layer  150  as described more fully below. Finally, upper layer  110  optionally includes pull tabs  125 ,  126  to facilitate the separation of the end portion  118  of upper layer  110  from the end portion  158  of lower layer  150  as described more fully below. 
     Upper layer  110  of label  100  is preferably adapted to be processed by a direct thermal printer to allow the printing of text, images, and/or other information on the outer face  109  of upper layer  110 . Such thermal printers are described more fully in U.S. Pat. Nos. 7,589,752 and 7,777,770, the contents of which are incorporated herein by reference. Upper layer  110  may also include pre-printed text, images, and/or other information as well as security threads or other security features known to those skilled in the art. 
     Lower layer  150  comprises an outer face  151  and an inner face  149 . As described above, outer face  151  preferably has a thermally sensitive coating  316  and inner face  149  preferably has a release layer  340 . 
     Lower layer  150  preferably includes a first die cut  157  that runs along the entire width of lower layer  150 , thus forming an end portion or strip  158  along one edge of lower layer  150 . A second die cut  155  preferably is disposed in lower layer  150  such that a peripheral portion  154  is formed in lower layer  150  around the periphery of the lower layer  150 . As shown in  FIG. 1 , the second die cut  155  meets up with the first die cut  157  at two points but does not cut into the end portion  158 . The two die cuts  155 ,  157  effectively create three contiguous regions in lower layer  150 : end portion  158 , peripheral portion  154 , and central portion  153 . The two die cuts  155 ,  157  preferably completely cut through lower layer  150 , thus ensuring that the aforementioned three contiguous regions are severed from one another. 
     Advantageously, the two die cuts  155 ,  157  in lower layer  150  trace the same outline as the perforation lines  115  in the upper layer  110 , thus ensuring that central portion  153  in the lower layer  150  is substantially congruent to—and substantially aligned with—central portion  113  in the upper layer  110 . Additionally, the peripheral portion  154  and end portion  158  together are substantially congruent to—and substantially aligned with—peripheral portion  114  of upper layer  110 . As described above, the first die cut  157  continues to the edges of lower layer  150  to completely sever end portion  158  from peripheral portion  154 . The peripheral portion  154  and end portion  158  of the lower layer  150  collectively form a label backing for label  100 , with peripheral portion  154  forming a first (partial) backing and end portion  158  forming a second (partial) backing. 
     Lower layer  150  is preferably adapted for use in a direct thermal printer to allow the printing of text, images, and/or other information on the outer face  151  of lower layer  150 . Lower layer  150  may also include pre-printed text, images, and/or other information as well as security threads or other security features known to those skilled in the art. 
       FIGS. 2A and 2B  show how peripheral portion  154  of the lower layer  150  may be peeled away from label  100  to expose the adhesive on the underside (i.e., inner face) of peripheral portion  114  ( FIG. 3A ) of the upper layer  110  of label  100 . Optional pull tabs  121 ,  122  may be used to peel away the label  100  from the peripheral portion  154  of lower layer  150 . Advantageously, the release layer  340  ( FIG. 6 ) on the inner face  149  of lower layer  150  allows for the peripheral portion  154  to be peeled away from label  100 . After removal, peripheral portion  154  of lower layer  150  may be discarded. 
       FIGS. 3A and 3B  respectively show the back and front of label  100  after it has been removed from peripheral portion  154  of lower layer  150 . As seen in  FIGS. 2B ,  3 A, and  3 B, only the peripheral portion  154  of lower layer  150  is separated from label  100 . End portion  158  of lower layer  150  remains attached to label  100 . Similarly, central portion  153 —which preferably includes text, images, and/or other information printed by the thermal printer—also remains attached to label  100 . As noted above, second die cut  155  completely severs the peripheral portion  154  of lower layer  150  from both the central portion  153  and the end portion  158  of lower layer  150 . Thus, when pull tabs  121 ,  122  of label  100  are pulled, only the peripheral portion  154  of lower layer  150  will separate from label  100 . 
       FIG. 4A  shows how label  100  is attached to a package  201  or other container to create a sealable pouch  205 . As shown in  FIG. 4A , the label  100  is first affixed to the package  201  such that the exposed adhesive on the underside (i.e., inner face) of peripheral portion  114  ( FIG. 3A ) of upper layer  110  is brought in contact with the surface of the package  201 . Advantageously, the end portion  158  ( FIG. 3A ) of lower layer  150  remains attached to the label  100  such that no adhesive is exposed to the package along the end portion  118 ,  158  ( FIG. 4A ) of label  100 . As shown towards the right of  FIG. 4A , this creates a pocket or pouch  205  along one edge of the label  100 . This pouch  205  can be used to store a piece of paper (either folded or unfolded) or any other suitable insert capable of fitting inside the pouch  205 . Such an insert could include a packing slip, a receipt, a return label, a coupon, promotional literature, or any other suitable information. Alternatively, the pouch  205  could be left empty in certain situations. 
     After inserting a paper or other object into pouch  205  (or deciding to leave pouch  205  empty), the pouch  205  can be closed by peeling the end portion  158  of lower layer  150  away from the end portion  118  of upper layer  110 . Optional pull tabs  125 ,  126  can be used to pull the two end portions  158 ,  118  apart from one another. This will expose the adhesive contained on the underside (i.e., inner face) of end portion  118  of upper layer  110 . End portion  158  of the lower layer  150  can be discarded and end portion  118  of upper layer  110  can be brought into contact with the package  201 , thus sealing the pouch  205 . 
       FIG. 5  shows how the pouch can be opened after it has been sealed. The central portions  113 ,  153  of upper layer  110  and lower layer  150 , respectively, can be removed from the peripheral portion  114  of the label  100  by tearing along perforation lines  115  ( FIG. 1 ). Optional pull tabs  131 ,  132  ( FIG. 1 ) can help facilitate the removal of the central portions  113 ,  153  from the package  201 . Once the pouch  205  is open, the contents of the pouch  205  can be removed. In addition, any text, images, or other information printed on the outer face  151  of central portion  153  of the label  100  will then be visible. 
     In some embodiments, the adhesive  330  on the inner face  111  of the central portion  113  of the upper layer  110  will be of a higher tack than the adhesive  330  on the inner face  111  of the peripheral portion  114  of the upper layer  110 . This higher tack adhesive will help to prevent central portion  113  of the upper layer  110  from peeling away from central portion  153  of the lower layer  150  when the pouch  205  is opened along perforation lines  115  as shown in  FIG. 5 . 
     In some embodiments, the release layer  340  on the inner face  149  of lower layer  150  contains release material (such as silicon) only on the peripheral portion  154  and end portion  158  of lower layer  150 . That is, the release material is omitted from the inner face  149  of central portion  153  of the lower layer  150 . This facilitates the permanent bonding of the central portion  153  of lower layer  150  to the central portion  113  of upper layer  110 . 
     In some embodiments, the shape of label  100  varies from the rectangular shape shown in  FIG. 1 . Any shape including, but not limited to, circles, ovals, squares, rhomboids, trapezoids, or other polygons may be used. Irregular shapes may also be used. Such alternate embodiments preferably comprise central portions  113 ,  153 , peripheral portions  114 ,  154 , and end portions  118 ,  158  on the upper layer  110  and lower layer  150 . In addition, the central portions  113 ,  153  in such embodiments will preferably be substantially congruent to one another, with central portion  153  located below central portion  113  and substantially aligned therewith. Likewise, the peripheral portion  154  and end portion  158  of the lower layer  150  is such embodiments will together preferably be substantially congruent to—and substantially in vertical alignment with—the peripheral portion  114  of upper layer  110 . 
     Use of Label 
     A preferred use of label  100  is for shipping labels for packages. A person or business organization who desires to mail a package  201  (a “sender”) can use a direct thermal printer to print a destination address of a recipient on the outer face  109  of upper layer  110  of label  100 . On the outer face  151  of lower layer  150  of label  100 , the sender can use the direct thermal printer to print a return address, a packing list/manifest, a receipt, a coupon, promotional literature, or any other suitable information. Such printing could occur in one or more passes through a two-sided direct thermal printer. Alternately, such printing could occur in two or more passes through a single sided direct thermal printer. Suitable printers are described in U.S. Pat. Nos. 7,589,752 and 7,777,770, the contents of which are incorporated herein by reference. In some embodiments, label  100  will have pre-printed text, images, or other information (such as the sender&#39;s logo) and the sender will not need to utilize the direct thermal printer to print such information. 
     In addition to printing information on the front (outer face  109  of upper layer  110 ) and back (outer face  151  of lower layer  150 ) of label  100 , the sender can print additional information on a separate piece of paper. Such information could include a return address, a packing list/manifest, a receipt, a coupon, promotional literature, or any other information. 
     Next, the sender would peel label  100  off of the label backing (i.e., peripheral portion  154  of lower layer  150 ) as shown in  FIGS. 2A-2B . As discussed above, optional pull tabs  121 ,  122  can be used to pull the label  100  off of its backing. 
     The sender would then affix label  100  to the front of a package  201  for shipping to the recipient as shown in  FIG. 4A . Because the end portion  158  of lower layer  150  remains attached to label  100 , an opening to pouch  205  is created. The sender then inserts the separate piece of paper described above into pouch  205 . The sender may also insert any other suitable object (such as a key, token, or other item) into pouch  205  in addition to, or in lieu of, the separate piece of paper. 
     Finally, the sender would peel the end portion  158  of lower layer  150  apart from label  100  and discard end portion  158 . Optional pull tabs  125 ,  126  can be used to peel end portion  118  away from end portion  158 . The sender would then affix end portion  118  of upper layer  110  to the side of package  201 , thus sealing pouch  205 , as shown in  FIG. 4B . The sender would then mail the package  201  to the recipient. 
     Upon receipt, the recipient could tear along perforation lines  115  to remove the central portions  113 ,  153  of label  100  from package  201 , as shown in  FIG. 5 . Optional pull tabs  131 ,  132  can help facilitate the removal of the central portions  113 ,  153  of label  100  from package  201 . 
     The central portion  113  of upper layer  110  of label  100  will preferably remain attached to the central portion  153  of lower layer  150  of label  100  when the recipient tears along perforation lines  115 . As described above, the adhesive  330  on the inner face  111  of the central portion  113  of upper layer  110  of label  100  may be of a relatively high tack to ensure that the two central portions  113 ,  153  remain attached to one another when the recipient tears along perforation lines  115 . In some embodiments, the recipient may then optionally peel the central portion  153  of lower layer  150  apart from the central portion  113  of upper layer  110 . Alternatively, in some embodiments, the release material (such as silicon) may be omitted from the inner face  149  of central portion  153  of the lower layer  150  of label  100 , thus permanently bonding central portion  153  to central portion  113 . 
     When the recipient tears along perforation lines  115 , the recipient advantageously gains access to the information printed on the outer face  151  of lower layer  150  of label  100  as shown in  FIG. 5 . The recipient also advantageously gains access to the contents of pouch  205 . 
     Alternate Embodiments 
       FIG. 7  shows an alternate embodiment of a label  300  having three thermally printable surfaces, one of which is embedded within the label  300  after it has been printed upon. Label  300  comprises an upper layer  110  and a lower layer  150 . Upper layer  110  of label  300  ( FIG. 7 ) is identical to upper layer  110  of label  100  ( FIG. 6 ). Specifically, upper layer  110  of label  300  comprises a substrate  320 , adhesive  330 , and thermally sensitive coating  326 . 
     Lower layer  150  of label  300  ( FIG. 7 ) is similar to lower layer  150  of label  100  ( FIG. 6 ) with one exception: lower layer  150  of label  300  ( FIG. 7 ) comprises an additional thermally sensitive coating  318  on the inner face  149  of substrate  310 . This additional thermally sensitive coating  318  on substrate  310  allows for text, images, or other information to be printed on both sides of lower layer  150 . The release layer  340  of lower layer  150  of label  300  preferably contains release material (such as silicon) over the entire inner face  149  of lower layer  150 , including central portion  153  of lower layer  150 . 
     When such a label  300  is affixed to a package  201  and sent to a recipient, the recipient can tear along perforation lines  115  to gain access to pouch  205  and also to the printed information on the outer face  151  of the central portion  153  of lower layer  150  of label  300 . In addition, the recipient can peel the central portion  153  of lower layer  150  away from the central portion  113  of upper layer  110  to gain access to the printed information on the inner face  149  of lower layer  150 . 
     Additional thermal imaging elements suitable for use in alternate embodiments of the present invention are described in U.S. Pat. Nos. 7,777,770 and RE38,976, the contents of which are incorporated herein by reference. 
     In some embodiments of the invention, indentations, tear strips, or other features known to those skilled in the art may be used in addition to, or in place of, one or more pull tabs  121 ,  122 ,  125 ,  126 ,  131 ,  132 . 
     In some embodiments of the invention, indentations, tear strips, or other features known to those skilled in the art may be used in addition to, or in place of, perforation lines  115  or portions of perforation lines  115 . 
     Accordingly, while the invention has been described with reference to the structures and processes disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may fall within the scope of the following claims.