Abstract:
A heat transfer label for application to an item includes a heat transferable substrate having a transparent window area, a carrier for carrying the substrate and a variable graphic component including printed indicia on the window area. The variable graphic component is printed separate from the application of the substrate to the carrier and on an opposing side of at least a portion of the substrate from the carrier. The variable graphic component is printed prior to application of the heat transfer label to the item.

Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA  
       [0001]     The present application is a continuation in part of U.S. patent application Ser. No. 10/742,297, filed Dec. 19, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     The present invention relates to indicia-containing labels. More particularly, the present invention relates to heat transfer labels containing variable data, which labels are applied to articles to provide unique markings, methods of making the labels and methods of using the labels.  
         [0003]     Indicia and/or graphics-containing labels are in widespread use in most every industry. For example, labels are used in the garment industry to mark articles of clothing to identify the manufacturer, the size of the garment, to provide laundry instructions, composition of the fabric, manufacturing location information and the like. In such a marking, there is both fixed and variable data. The fixed data can include the manufacturer, manufacturing location and laundry instructions whereas the size of the garment and the composition of the fabric can be variable data.  
         [0004]     Another market that uses labels is the durable goods market. In this market, labels may be used on, for example, hand held power tools. Such labels may include both fixed data, e.g., manufacturer&#39;s name and manufacturing location, and variable data, e.g., model number, serial number, and power (voltage and ampere) requirements.  
         [0005]     One drawback to the use of individually printed labels (that is, labels with variable data) is that large inventories of completely finished pre-printed labels are needed at the manufacturing or packaging location. While this approach provides desirable information on an item-attached label, the large label inventory that is needed, in conjunction with the space necessary for storing such an inventory, makes this approach undesirable.  
         [0006]     In addition, when such individualized or customized labels are used, they are maintained in large quantities in inventory. This increases the likelihood of label obsolescence. That is, there may well be a large quantity of completely finished labels in inventory when a product is changed or discontinued.  
         [0007]     Accordingly, there is a need for a variable data heat transfer label that provides the flexibility to locally print variable, e.g., changeable data, immediately prior to applying the label to the item. Desirably, such a label includes some manner of fixed data and a transparent window in which the variable data is printed and through which the data is viewed when the label is affixed to an object or item.  
       SUMMARY OF THE INVENTION  
       [0008]     A heat transfer label for application to an item includes a heat transferable substrate having a transparent window area. The substrate is carried on a carrier. The window area can be completely or partially transparent.  
         [0009]     A variable graphic component including printed indicia is printed on the window area. The variable graphic component is printed separate from and subsequent to the application of the substrate to the carrier, but prior to application of the heat transfer label to the item.  
         [0010]     Such a variable data heat transfer label provides the flexibility to locally print variable or changeable data immediately prior to applying the label to the item. A present label includes some manner of fixed data and a window area in which the variable data is printed, and through which the variable data is viewed after application to the item.  
         [0011]     A method for marking an item includes providing a carrier web, applying a heat transferable substrate having a transparent window area to the carrier web to form an elongated coated web, printing a variable graphic component on the window area, printed separate from the step of applying the substrate to the web to form an elongated strip of heat transferable labels, transversely slitting the elongated strip of labels to provide item applicable labels and transferring the item applicable labels to the item.  
         [0012]     These and other features and advantages of the present invention will be readily apparent from the following detailed description, in conjunction with the claims.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]     The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein:  
         [0014]      FIG. 1  is a schematic illustration of a master web having three rows of printed variable data heat transfer labels embodying the principles of the present invention, in which the labels are shown in one row having fixed graphics on top of the transparent window, in a second row having fixed graphics immediately adjacent to the window, and in a third row having no fixed graphics;  
         [0015]      FIG. 2A  illustrates a web having a single row of labels with both fixed graphics and variable data printed on top of the transparent windows;  
         [0016]      FIG. 2B  illustrates a web similar to that of  FIG. 2A , except that the labels have only variable data printed on top of the transparent windows;  
         [0017]      FIG. 3  shows an exemplary apparatus for printing variable data onto the labels;  
         [0018]      FIG. 4  is a cross-sectional view of the label on the carrier web prior to application to an object;  
         [0019]      FIG. 5A  is a cross-sectional view of the label applied to an object in which the fixed and variable graphics are printed on top of the transparent window prior to application to the object;  
         [0020]      FIG. 5B  is a cross-sectional view of the label applied to an object in which the fixed graphics are printed adjacent to the transparent window and the variable graphics are printed on top of the transparent window prior to application to the object;  
         [0021]      FIG. 5C  is a cross-sectional view of the label applied to an object in which variable graphics are printed on top of the transparent window prior to application to the object;  
         [0022]      FIG. 5D  is a cross-sectional view of the label applied to an object in which fixed graphics are disposed below the transparent window and variable graphics are printed on or over the window area;  
         [0023]      FIGS. 5E and 5F  are plan views of an alternate embodiment of the label in which the window areas are formed as panes or islands of material on the carrier web; and  
         [0024]      FIG. 6  is an illustration of an exemplary overall process for making and using (preparing for application and applying) the variable data labels of  FIGS. 4 and 5 A. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]     While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated.  
         [0026]     It should be understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein.  
         [0027]     In the present disclosure, the terms article, item, object, and product are used interchangeably to describe something that is produced that has commercial value and is, for example, an item that is the subject of a commercial transaction.  
         [0028]     Referring now to the figures and briefly, to  FIG. 1 , there is shown one embodiment of a set of variable data heat transfer labels indicated generally at  10 , embodying the principles of the present invention. In the illustrated embodiment, a carrier web  12  has three distinct rows  14 ,  16 ,  18  of discrete labels  10  on the carrier web  12 . The discrete labels can be printed using a screen printing process; however, other processes can also be used including gravure, rotary screen, offset, or combinations of printing processes, for example, rotary screen and flexo, and the like.  
         [0029]     The present heat transfer labels  10  can be applied to an object (such as object  20  in  FIG. 5A , which can be a “soft” item such as a fabric item of clothing or a “rigid” item, such a power tool) and provide a way in which the label  10  can contain both fixed data  22  and variable data  24 . Such labels  10  allow a manufacturer to purchase rolls of heat transfer labels  10  with certain, desired fixed data  22  pre-printed and then print the appropriate labels with variable data  24  as need on-site. It will be understood that, as an example, the fixed data  22  is shown as alpha or letter characters in the figures and that the variable data  24  is shown as numeric characters in the figures.  
         [0030]     The carrier web  12  is typically a release-coated paper or plastic film. The release coating, indicated generally at  50  in  FIG. 4 , can be silicone based, or it can employ other release coatings that will be recognized by those skilled in the art. Typically, both sides of the carrier web have a release coating, and the release coatings will generally have different release characteristics. The printed side will typically have a tighter release than the non-printed side.  
         [0031]     Each label  10  is formed with a transparent window area  26  and optionally fixed graphics  22 . For purpose of the present disclosure, the term transparent means completely transparent, e.g., see-through, as well as partially transparent, e.g., translucent or capable of transmitting light to permit reading the imparted variable and/or fixed information through the window. Also for purposes of the present disclosure, the terms graphics, data and indicia are used interchangeably to indicate the fixed printing  22  of the label  10  or the variable printing  24  on the label  10 . The fixed graphics  22  can vary depending on the object  20  that is being decorated with the label  10 . For example, the labels  10  can include fixed data  22 , such as a manufacturer&#39;s name, manufacturing location, logos, trademarks and the like.  
         [0032]     If the object  20  has a rigid, e.g., plastic form, the window area  26  and fixed graphic  22  inks can be an acrylic, a vinyl, an epoxy, a polyester, a polystyrene or similar thermoplastic resin system. If the object is a fabric-based article, chemistries such as those disclosed in U.S. Pat. Nos. 4,256,795, 3,992,559 and 3,959,555 would be suitable for both the fixed graphics  22  and window area  26 , which patents are incorporated herein by reference.  
         [0033]     The entirety of the “printed” area forms the label  10 . That is, the window  26  and the fixed graphics  22  (if used) that are printed on the web  12  constitute the label  10 . In transferring the label  10  to the object  20 , the adhesive layer  56  (shown as  156  in  FIGS. 5B and 256  in  FIG. 5C ) on the label  10  softens and adheres to the object  20  by the application of heat and pressure.  
         [0034]     Generally, the term “printing” connotes the application or transfer of colored or tinted indicia through the use of inks, dyes, pigments or the like. In the present label  10 , the window  26  material is “printed” on the carrier web  12  without a pigment or tint, thus providing the characteristics of the transparent window area  26 .  
         [0035]     The fixed graphic  22  can be printed on top of or within the discrete window area  26  (as seen in row  14  in  FIG. 1 ) or immediately adjacent to the window  26  (as seen in row  16 ). Alternately still, there may be situations where there is no need for fixed graphics at all, and in those cases, only a window area  26  is printed (as seen in row  18 ). It will also be appreciated that the window area  26  can be printed over the entirety of the carrier web  12 , such that it essentially forms a continuous coating on the web  12 .  
         [0036]     In a preferred label  10 , eye marks  28  are printed near the labels  10 . These marks  28  can serve a variety of functions, such as providing a trigger for printing the variable graphic  24 , for cutting the continuous roll of labels  10  into discrete single labels  10   a,b,c  (see  FIG. 3 ) or for activating an application process, if, for example, the labels  10  are supplied to the application equipment in roll form. The eye marks  28  are not typically within the target label area in that the marks  28  are not generally transferred to the object  20 .  
         [0037]     In another embodiment of the preferred label  10 , the eye marks  28  are printed in the form of a two dimensional bar code. The two dimensional bar code can be used to trigger the variable data printing process, to verify the authenticity of the label  10 , to control the form, text, graphics, and the like of the variable data printed on the label  10 , to control the position and timing of the cutting process to produce single labels  10   a ,  10   b ,  10   c  or to optionally control the application parameters (time, temperature and pressure) used in applying that label  10  to article  20 . The two dimensional bar code can have a 2D Matrix Symbol that is commonly used in the industry, for example, as represented by DataMatrix, MaxiCode and QR Code.  
         [0038]     In another variant of the label  10 , the machine readable eye marks  28   a  ( FIG. 2A ) are printed within the transparent window area  26  using inks that are not visible under normal lighting conditions, but are readily detected under special conditions of lighting, for example, ultraviolet light, infra-red radiation, or electronic sensing, e.g., magnetic responsive inks. The machine readable eye marks may also be a component of the fixed graphics, through either graphic design parameters (such as shape, size, color contrast and the like), or the incorporation of special chemicals, including ultraviolet or infra-red active compounds, magnetic responsive inks, electrically activated luminescence, thermochromatic inks, photochromatic inks and the like.  
         [0039]     Referring to  FIG. 1 , in a preferred form, a master roll  30  is slit down to yield individual rolls  32   a,b,c  (collectively  32 ) of material that are single width, i.e., rolls  32  having one row of labels  10 . It is anticipated that rolls  32  in this single width form will be supplied to, for example, the article manufacturer.  
         [0040]     The labels  10 , as supplied, have the window area  26 , the associated eye mark  28  and the optional fixed graphics  22 . The fixed graphics  22  can be single or multiple color as desired by the article manufacturer.  
         [0041]     The variable data  24  is printed on the window area  26  prior to applying the label  10  to the object  20 . It is contemplated that the printing of variable data  24  will done at a different time and in a step separate from the printing of the fixed graphics  22  and window  26 . In fact, it is anticipated that the variable data  24  will be printed at the article manufacturer&#39;s plant or at a nearby service facility using a variable data  24  printing process. The variable data  24  printing process can be carried out using ink jet, thermal transfer ribbon, ion printing and like printing processes.  
         [0042]      FIG. 4  illustrates a cross-sectional view of one embodiment of the label  10  prior to application to an object. The carrier web  12 , which can be supplied with a pre-coated release coating (not shown), is printed with a patterned release coat  50  followed by an optional clear coat  52 . Preferably, the clear coat  52  is either a cross-linked material or a composition that has a melting point greater than about 300° F. to about 350° F. (about 150° C. to about 177° C.). The fixed graphics  22  are then printed on the clear coat layer. The fixed graphics  22  can be one or more layers or colors of inks as required to achieve the desired fixed graphics  22 . The fixed graphics  22  can be in the form of letters, numbers, pictograms, logos or other unique graphic designs. The fixed graphics  22  are then over-coated with a layer of clear cross-linked or high melt point, i.e., melting point greater than about 350° F. (177° C.) material  54 . This material layer  54  facilitates maintaining image definition during the application process. Without such an over-coat layer, the fixed graphics may become distorted during application to the article. A transparent or partially transparent adhesive layer  56  is printed over the cross-linked overcoat layer  54 . The adhesive layer  56  provides good bonding (adhesion) between the label  10  and the object  20  and typically has a melting point less than about 250° F. to about 300° F. (about 120° C. to about 150° C.). The composition of the adhesive layer  56  will depend upon the chemical nature and structure of the article and the required performance characteristics of the label on the article.  FIG. 5A , which is discussed in more detail below, illustrates that label of  FIG. 4  as applied to an object  20 .  
         [0043]     An exemplary work flow process  1010  is illustrated generally in  FIG. 6 . The exemplary work flow process represents the making and using of the label illustrated in  FIGS. 4 and 5 A. The work flow  1010  includes, as set forth above, providing a carrier web having a release coat applied thereto  1012 . Alternately, and/or with the application of the release coat, the web can have a release coat pre-applied thereto. A typical carrier web will be a multiple width label. For example, the label can be three labels wide to facilitate certain of the process steps (e.g., printing).  
         [0044]     The optional cross-linked top coat or high melt point composition can be applied to the release coat  1014 . The top coat can be applied in a continuous manner, over the entirety of the web or in discrete regions on the web. Fixed graphics are then printed on the release coat or the optional top coat  1016 . Eye marks are likewise printed along with the fixed graphics. A fixed graphic label is thus formed.  
         [0045]     Following printing of the fixed graphics, optionally, a cross-linked clear layer or high melt point composition is applied over the fixed graphics  1018 .  
         [0046]     An adhesive layer is then applied over the cross-linked clear layer (if used) or over the fixed graphics  1022 . The web is then slit to form lesser width labels  1024  (e.g., ribbons of labels), preferably single width labels, which are then fed into a printer to print the variable data or graphics  1026 . An exemplary printer is commercially available from ITW Norwood of Downers Grove, Ill. under the trademark JAGUAR®. Following printing of the variable graphics, the individual labels are slit or cut  1028  and are applied to the desired goods  1030 . Application of the labels to the goods or product can be carried out using, for example, a heat transfer press such as those commercially available from United Silicone, Inc., of Lancaster, N.Y.  
         [0047]     This printing and application arrangement provides a number of advantages. First, in that the processes that require the completed labels (fully printed with both fixed and variable graphics) may require different quantities of labels, the variable data can be printed “as-needed” onto (fixed graphics) pre-printed labels. In addition, the variable graphics printing process is considerably faster (typically) than the transfer or application process. As such, the labels  10  can be printed on one printer, such as the JAGUAR® printer, and slit and distributed to a number of applicators, e.g., United Silicone, machines (for immediate or later use) to provide a cost effective and flexible process configuration. Other process configurations include having the printer and applicator integrated as taught in U.S. Pat. Nos. 5,813,772 and 5,658,647; however, in such an arrangement, the total capital (equipment) costs are higher.  
         [0048]      FIG. 3  illustrates one exemplary apparatus  34  for printing the variable data  24  using a thermal transfer ribbon  36 . In this process, a roll  32   a  of preprinted labels having a window area  26  and optionally fixed graphics  22  is fed into a variable data print unit printer  38 . The variable graphics  24  are printed on to the window area  26  by a print head  40 . As can be seen from  FIG. 4 , the variable graphics  24  are printed onto the adhesive layer  56 , which covers (and forms part of) the window area  26 . The patterned transfer of the coating from the ribbon  36  to the window area  26  forms the variable data  24  images. The labels  10  containing the variable data  24  are then either cut into individual labels  10   a,b,c  using a cutting mechanism  42 , or are rewound onto another roll (not shown). The thermal transfer ribbon  36  may have different types of coatings. Common commercially available coatings include resin, resin-wax and wax based compositions. A preferred coating composition will depend upon the composition of the window area  26  and the performance requirements of the decorated object  20 .  
         [0049]     In an ink jet printing process (not shown), the variable information is printed on the window area  26  using liquid inks dispensed in a controlled pattern, e.g., as small ink droplets ejected from a computer controlled ink jet printing nozzle. The inks used in this process are aqueous or organic solvent based inks. Suitable organic solvents include, for example, ketones, alcohols, esters, or hydrocarbons. Preferred solvents are low boiling point compounds including ketones such as acetone and methyl ethyl ketone, alcohols such as ethanol, iso-propanol and n-propanol, esters such as ethyl acetate and n-propyl acetate, and hydrocarbons such as heptane and toluene. Other organic solvent based inks will be recognized by those skilled in the art.  
         [0050]     In another embodiment of the invention, the variable data is printed using a hot stamping apparatus  34  that uses interchangeable dies and an appropriate heat transfer ribbon  36 . This process can be used when the variable data  24  does not have to change on each successive heat transfer label  10 . The interchangeable dies can have the required specific variable data, such as size code, fabric composition, manufacturing location, SKU, bar code, and the like, and the die could be changed as required to print the required quantity of heat transfer labels  10  for each specific product. In this fashion, varying quantities of heat transfer labels  10  could be produced to meet production needs. The thermal ribbon  36  used in this process is such as that commercially available from ITW Coding Products of Kalkaska, Mich., ITW Norwood Marking Systems of Downers Grove, Ill., and ITW FoilMark of Newburyport, Mass. The specific source and grade of hot stamping ribbon  36  used in the invention will depend on the composition of the transparent window  26 , the chemical and physical nature of article  10  to which it is being applied and the end use performance requirements of article  10 . Suitable hot stamping apparatus  34  and dies are available from United Silicone of Lancaster, N.Y.  
         [0051]     The ink jet inks can also be radiation curable, such as those printed by an ink jet printer and cured by radiation, such as ultraviolet light, electron beam or infrared radiation. In a preferred process, the ink is cured after printing on the discrete window area  26  by exposing it to radiation from a suitable source. Radiation curing transforms the liquid ink into a solid form. Typically, such radiation curable inks provide good resistance to smearing.  
         [0052]     Still another process (not shown) for printing the variable data is laser marking, in which the variable data is established by removing material from the discrete window areas. In one process, the window areas are over-printed with a solid layer of colored ink during the original (fixed) printing of the label. The labels are then marked with the variable data by exposing the label to a laser capable of generating the required marks. When the graphics are to be viewed in what is referred to as a positive format, the marking involves the ablation (removal) of the colored ink in the non-image areas associated with the variable data.  
         [0053]     Conversely, when the variable data is to be viewed in a reverse format, the image is developed by laser marking or engraving the data into the colored ink printed on the discrete window areas. In this instance, the colored ink is removed (ablated) to generate the image and non-image areas are left unchanged on the window areas.  
         [0054]     Regardless of the manner in which the variable data  24  is printed, it is anticipated that a variable data  24  printing unit in a stand-alone configuration or as part of the application process will be used at the article manufacturer&#39;s facility.  
         [0055]     In the stand-alone configuration, the variable data printing unit (such as the printing apparatus  34  of  FIG. 3 ) prints the labels  10  at a location remote to the application station and labels  10  are delivered to an application machine station in either roll form or as discrete, single piece labels. This process allows the article manufacturer to have a different number of variable data printers (generally fewer) as compared to the number of application machines. This also allows the variable data printer to be located in a central location within the facility to enhance security and provide better control of label inventory, both pre-printed and printed.  
         [0056]     Alternately, the variable data printing unit can be associated with the application machine. In this configuration, a roll of pre-printed labels is mounted on the printer-application machine, the labels are transported through the variable data printing unit where the variable data is printed, and then the labels are advanced into the application section of the machine for application to the article. Such a concept is disclosed in U.S. Pat. Nos. 5,658,647 and 5,813,772. In a variation of this concept, the label could be applied to the article first and then the article with the applied label is advanced into the variable data printing unit where the variable data is printed on to the already applied label.  
         [0057]      FIGS. 5A-5D  illustrate various embodiments of labels  10 ,  110 ,  210 ,  310  as applied to objects  20 . In  FIG. 5A , the label  10  is applied to the object  20  at an exposed surface  46  of the label  10 , such that the variable graphics  24  are in contact with the object  20  and are covered by the window  26  material. That is, the variable graphics  24  are sandwiched between the window  26  and the object  20 . In this arrangement, the window  26  is formed from a composite or combination of the adhesive layer  56 , the cross-linked clear layer  54 , the split release coat  50 , and optionally (as illustrated) the top clear layer  52 . The fixed graphics  22  are applied to the optional cross-linked top coat  52  or the release coat  50 , as desired and appropriate. It will be appreciated from the drawings that the label  10  of  FIG. 4 , which is shown on the carrier web  12  in that figure is the label  10  which is shown in  FIG. 5A  as applied to an object  20 . This serves to protect the variable data  24 , while maintaining the variable data  24  visible through the window  26 .  
         [0058]     In the label  110  of  FIG. 5B , the variable graphics  124  are in contact with the object  20 , and are covered by the entirely of the window  126  material which includes the adhesive layer  156 , the cross-linked clear coat layer  154  and the split release coat  150 . The fixed graphics  122  are in contact with and between the adhesive layer  156  and the split release coat  150 . In this arrangement, the variable graphics  124  and adhesive  156  are in direct contact with the object  20 .  
         [0059]     Alternately as seen in the label  210  of  FIG. 5C , the label  210  does not contain fixed data and, consequently, only variable graphics  224  and the window  226  material are in contact with the object  20 , with the window  226  overlying and protecting the variable data  224 . In this arrangement, the window area is formed from the adhesive layer  256 , the cross-linked clear coat layer  254  and the split release coat  250 .  
         [0060]     In another embodiment of the label  310 , as seen in  FIG. 5D , the fixed graphics  322  are disposed within the window area  326 , which is formed from the adhesive layer  356 , the cross-linked clear coat layer  354 , an optional cross-linked clear layer  352  and the split release coat  350 . In this arrangement, the fixed graphics  322  are disposed between the cross-linked clear coat layer  354  and the optional cross-linked clear layer  352 , and the variable graphics are disposed on the split release coat  350 .  
         [0061]     In still another embodiment of the label  310 , as seen in  FIGS. 5E and 5F , the transparent window area  26  is not a single contiguous block area, but is formed from a group of islands or panes, hat can be discrete and “free standing” or can be connected through a series of contact points to create a chain of connected islands or panes. The exact form of the heat transfer label  10  will depend on the graphic content of the label and the desired use.  
         [0062]     It will be appreciated that the labels of  FIGS. 5B-5D  are formed, on a carrier web, in a manner similar to the label  10  illustrated in  FIG. 4 , that is, is in a reversed order from that in which the respective labels  110 ,  210 ,  310  are shown applied to their respective objects  20 .  
         [0063]     All patents referred to herein, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure.  
         [0064]     In the disclosures, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular.  
         [0065]     From the foregoing it will be observed that numerous modification and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.