Abstract:
A printing apparatus for generating an image which includes a housing, a ribbon supply holder, a tape supply holder, an input device, a thermal printing head and a tape attachment device. The ribbon supply holder is operatively coupled to the housing to hold a supply of ink ribbon. The ink ribbon includes a film layer with an ink layer disposed thereon, and a receptor layer for receiving ink from the film layer. The tape supply holder is operatively coupled to the housing to hold a supply of tape, and the tape includes an adhesive layer. The input device is operatively coupled to the housing to enter data used to generate the image by the printing apparatus. The thermal printing head is operatively coupled to the housing to print the entered data on the ink ribbon. The tape attachment device attaches the tape to the film layer of the ink ribbon. Preferably, the thermal printing head generates the image by leaving a portion of the ink layer, representing the image corresponding to the data, on the film layer such that a negative of the image is transferred to the receptor layer, and the tape attachment device attaches the adhesive layer of the tape to the film layer to sandwich the remaining portion of the ink layer between the film layer and the adhesive layer. An ink jet printhead may be used instead of a thermal printhead.

Description:
This application claims benefit of Provisional application Ser. No. 60/062,463 filed Oct. 15, 1997. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to thermal and ink jet image printing apparatuses, cartridges and labels and, in particular embodiments, to a reverse image printing apparatus to provide improved images with greater durability. 
     BACKGROUND OF THE INVENTION 
     Traditionally, thermal printing is used to produce labels that can be applied to objects such as containers, books, computer disks, equipment or the like. Typical thermal image label printers are manufactured by Brother of Japan and Kroy, Inc. of Scottsdale, Ariz. 
     Generally, thermal image printers provide input capabilities, power and a housing designed to accept a label cartridge containing the material used to form the label. The label cartridge generally includes one or more spools of material that are combined and fed over a thermal printing head to generate an image on a label. 
     In conventional systems, the label is formed from three basic components: a plastic or wax ink coated on a plastic ribbon film, a paper or plastic ink receiving layer, and an adhesive backing layer. 
     In operation, the plastic ribbon with the ink and receiving layer are passed over the heating element of the thermal printing head, which melts the ink on the plastic ribbon so that it adheres to the receiving layer. The heating element is selectively heated, based on the input to the printing apparatus, to print letters, symbols or the like, on the receiving layer, while leaving ink on the plastic film that is not needed to form the image. After the plastic ribbon and receiving layer are passed over the heating element, the plastic ribbon is removed from the receiving layer to expose the image produced on the receiving layer. If the adhesive backing has not already been applied to the back of the receiving layer, opposite the side that received the ink, the adhesive layer is applied to the receiving layer and the final label is outputted from the cartridge and the printer. Once outputted, the label may be applied to an object for identification. 
     Labels produced by this method of printing have several drawbacks. First, since the ink is melted onto the receiving layer, the image tends to blur around the edges, with the amount of blurring being dependent on the type of ink and the type of receiving layer. Second, the image produced on the receiving layer is exposed and can be affected by light, weather or rubbing so that the image on the label is ultimately unusable and must be replaced. 
     To overcome these drawbacks, better inks and receiving layers have been produced to provide sharper images. However, these procedures increase costs. In addition, laminating a clear layer over the image on the receiving layer to cover and protect the image has been done. However, this step requires extra material and extra steps to produce the laminated product, which increases the cost of the label. Also, application of the clear layer may further blur the image, with the amount of blurring being dependent on the manner in which the clear layer is applied to the receiving layer. 
     Ink jet printers have also be used to generate labels. However, labels generated by inkjet printers suffer from many of the same drawbacks that thermal image labels suffered from. For example, the image is exposed and can be affected by light weather and rubbing so that the image on the label is ultimately unusable and must be replaced. Also, many ink jet inks are water based and subject to smearing and deterioration when exposed to moisture. 
     SUMMARY OF THE DISCLOSURE 
     It is an object of an embodiment of the present invention to provide an improved image printing apparatus, which obviates for practical purposes the above- mentioned limitations. 
     According to an embodiment of the invention, a printing apparatus for generating an image includes a housing; a ribbon supply holder, a tape supply holder, an input device, a thermal printing head and a tape attachment device. The ribbon supply holder is operatively coupled to the housing to hold a supply of ink ribbon. The ink ribbon includes a film layer with an ink layer disposed thereon and a receptor layer for receiving ink from the film layer. The tape supply holder is operatively coupled to the housing to hold a supply of tape, and the tape includes an adhesive layer. The input device is operatively coupled to the housing to enter data used to generate the image by the printing apparatus. The thermal printing head is operatively coupled to the housing to print the entered data on the ink ribbon. The tape attachment device attaches the tape to the film layer of the ink ribbon. In preferred embodiments, the thermal printing head generates the image by leaving a portion of the ink layer, representing the image corresponding to the data, on the film layer such that a negative of the image is transferred to the receptor layer, and the tape attachment device attaches the adhesive layer of the tape to the film layer to sandwich the remaining portion of the ink layer between the film layer and the adhesive layer. Other embodiments of the present invention include a cutter that is operatively coupled to the housing to cut the tape and the ribbon. 
     In additional embodiments, the printing apparatus further includes a cartridge casing for holding the ribbon supply holder, the tape supply holder and the thermal printer head. Also, the housing is adapted to receive the cartridge casing. 
     In another embodiment of the present invention, a cartridge for use in a printing apparatus for generating an image with a thermal printing head includes a housing, a ribbon supply holder, a tape supply holder, a tape attachment device and a drive mechanism. The ribbon supply holder is operatively coupled to the housing to hold a supply of ink ribbon. The ink ribbon includes a film layer with an ink layer disposed thereon, and a receptor layer for receiving ink from the film layer. Then a tape supply holder is operatively coupled to the housing to hold a supply of tape, and the tape includes an adhesive layer. The tape attachment device attaches the tape to the film layer of the ink ribbon. The drive mechanism is operative to feed the ink ribbon and the tape through the cartridge to generate the image. The cartridge is formed so that when the thermal printing head generates the image, it leaves a portion of the ink layer, representing the image corresponding to the data on the film layer such that a negative of the image is transferred to the receptor layer, and the tape attachment device attaches the adhesive layer of the tape to the film layer to sandwich the remaining portion of the ink layer between the film layer and the adhesive layer. 
     In further embodiments, the cartridge further includes a receptor layer stripping mechanism that strips the receptor layer from the ink ribbon after the thermal print head prints the image representing the data. In addition, the tape attachment device attaches the tape to the ink layer after stripping the receptor layer. In additional embodiments, the tape further includes a base film layer attached to the adhesive layer, a second adhesive layer attached to the base film layer and a release liner layer attached to the second adhesive layer to produce a label that has a protected second adhesive layer to facilitate application of the label to a surface. Also, the release liner layer can be peeled of the second adhesive layer to attach the second adhesive layer to the surface. 
     Yet another embodiment of the present invention is directed to a label formed with a printing apparatus for generating an image with a thermal printing head that includes an ink ribbon and a tape having an adhesive layer. The ink ribbon includes a film layer with an ink layer disposed thereon, and a temporary removable receptor layer for receiving ink from the film layer prior to removal of the receptor layer. When the thermal printing head generates the image, it leaves a portion of the ink layer, representing the image corresponding to the data, on the film layer such that a negative of the image is transferred to the receptor layer prior to removal of the receptor layer, and the adhesive layer of the tape is attached to the film layer to sandwich the remaining portion of the ink layer between the film layer and the adhesive layer. 
     In further embodiments of the present invention, the tape further includes a base film layer attached to the adhesive layer, a second adhesive layer attached to the base film layer and a release liner layer attached to the second adhesive layer so that the label produced has a protected second adhesive layer to facilitate application of the label to a surface. Also, the release liner layer can be peeled off the second adhesive layer to attach the second adhesive layer to the surface. 
     Still another embodiment of the present invention is directed to a method of producing labels. The steps include: a) receiving data to be printed on the labels; b) advancing an ink ribbon through a thermal printing mechanism (where the ink ribbon includes an ink layer, a film layer covering the ink layer and a receptor layer); c) creating an image representing the data on the ink layer by creating a negative of the image on the receptor layer; and d) attaching a tape layer to the ink ribbon. 
     In further embodiments, the method includes the steps of: a) stripping the receptor layer from the ink ribbon after creating the image on the ink layer; and b) cutting a portion of the ink ribbon having the created image. 
     In an additional embodiment, a printing apparatus for generating an image includes a housing, a transparent film holder, a base film holder, and input device, a printing head and a base film attachment device. The transparent film holder is operatively coupled to the housing that holds a supply of transparent film. The base film holder is operatively coupled to the housing that holds a supply of base film, and the base film includes an adhesive layer. The input device is operatively coupled to the housing and enters data used to generate the image by the printing apparatus. The printing head is also operatively coupled to the housing and prints the entered data on the transparent film. The base film attachment device attaches the base film to the transparent film. In preferred embodiments, the printing head generates the image, representing the image corresponding to the data, on the transparent film so that a reverse of the image is formed on the transparent film. Then the base film attachment device attaches the adhesive layer of the base film to the transparent film to sandwich the image between the transparent film and the adhesive layer of the base film. 
     A label formed in accordance with the above-described printing apparatus for generating an image includes a transparent film, and a base film including an adhesive layer. When a printing head generates the image, representing the image corresponding to the data, on the transparent film a reverse of the image is transferred to the transparent film, and the adhesive layer of the base film is attached to the transparent film to sandwich the image between transparent film and the adhesive layer to form the label. 
     Other features and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, various features of embodiments of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A detailed description of the embodiments of the invention will be made with reference to the accompanying drawings, wherein like numerals designate corresponding parts in the several figures. 
     FIG. 1 is a block diagram of an apparatus in accordance with a first embodiment of the present invention; 
     FIGS. 2-2 d  are schematic views of a cartridge for use with the apparatus of FIG. 1; 
     FIG. 3 is a detailed cross-sectional view of an ink ribbon used in the cartridge of FIG. 2; 
     FIG. 4 is a detailed cross-sectional view of a tape used in the cartridge of FIG. 2; 
     FIG. 5 is a detailed cross-sectional view of the ink ribbon of FIG. 3 as an image is produced; 
     FIG. 6 is a detailed cross-sectional view of the tape being applied to the remaining ink ribbon after an image is produced to form the label; 
     FIG. 7 is a detailed cross-sectional view of a portion of the tape being removed from the label prior to application to a surface; 
     FIGS. 8-8 d  are schematic views of another cartridge embodiment for use with the apparatus of FIG. 1; and 
     FIGS. 9-9 d  are schematic views of another cartridge embodiment for use with the apparatus of FIG.  1 . 
     FIGS. 10 a  and  10   b  are schematic views of a reverse image printer in accordance with a second embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in the drawings for purposes of illustration, the invention is embodied in a reverse image thermal printer, cartridge and label. In preferred embodiments of the present invention, the reverse image printer produces labels from a cartridge to provide durable labels having well defined images. However, it will be recognized that further embodiments of the invention may be used to produce other attachable images such as pictures, decals, transfers or the like. In alternative embodiments, the printer is an ink jet printer that produces the reverse images for the labels or other types of printers capable of producing a reverse image; rather, than a thermal printer. 
     In preferred embodiments of the present invention, the images are formed with alphanumeric characters. However, in alternative embodiments, the image may be a bar code, picture or a combination of various images. 
     Reverse image printing used in accordance with a first embodiment of the present invention provides many advantages by utilizing the used portion of the ribbon (the film layer that is normally discarded) to produce a label or the like. In this process, the negative (or unwanted portion ) of an image is printed onto a receptor layer and the receptor layer is then discarded. This leaves the positive (or wanted portion) of the image on the film layer of the ribbon. The film layer is then laminated onto a tape backing and cut to the desired length to produce a finished label or the like. The label, or the like, that is produced in this manner tends to be very scratch and chemical resistant due to the fact that the printing is protected and sandwiched between the film layer and the tape backing. 
     The use of the film layer as part of the label to protect the image offers several advantages. For example, since the printed image is under a layer of film, the image is protected from abrasion, UV rays and chemicals. The use of a thin film layer also provides for the use of an conductive ink used to form a bar code. Typically, conductive bar codes must be covered by a non-conductive film. Thus, the non-conductive film layer provides a protective layer over the bar code and also provides the correct gap between the bar code and the inductive reader in a single manufacturing step. 
     In addition, images produced by reverse image printing tend to have better edge definition than conventional thermal transfer printing since the ribbon layer does not have to bond with the label stock to form the image. Also, reverse image printing eliminates the need to match the ink ribbon and label stock to produce a good image. Since sharper images are produced, the label does not require the use of more expensive resin ribbon to produce a durable image. A much less expensive alternative, such as wax ribbon, or the like, can be used. Also, since sharp images are easier to produce, heat control is less critical to produce a sharp image, which allows the software and hardware used to form the labels in a simpler and less expensive manner. 
     FIG. 1 illustrates a reverse image thermal printer  10  in accordance with an embodiment of the present invention. The printer  10  is formed from a housing  12  and a cartridge  14 . The housing  12  is adapted to use a replaceable cartridge  14  that contains the materials or supply used to produce an image on a label, or the like. The housing includes a keyboard  16 , a data port  18 , a processor  20 , a ROM  22 , a RAM  24  and a driver  26 . The keyboard  16  is used to input various commands and alphanumeric characters to be formed on the label or the like. Alternatively, or in addition to, a data port  18  may be provided to download image information and commands to the printer  10  from a laptop, personal computer or the like (not shown). The information from the keyboard  16  and/or data port  18  is supplied to a processor  20 , which controls the printer  10  to produce labels from the materials or supply in the cartridge  14 . Generally, programs for the printer  10  are stored in a ROM  22 , and image data and/or variables are temporarily stored in a RAM  24 , and are accessed by the processor  20  as needed. The processor  20  provides information to the cartridge  14  to produce the image on the label, and may also receive various information representing feedback and/or status of the cartridge  14 . In addition, the processor  20  controls the driver  26  to operate the cartridge  14  and feed the materials or supply through the cartridge  14  to produce the labels. In alternative embodiments, various changes may be made to the printer  10  to provide additional capabilities, such as using a single custom chip, rather than a separate processor  20 , ROM  22  and RAM  24 . Also, the driver  26  may be formed as a part of the cartridge  14 , rather than as a part of the printer  10 . 
     FIGS. 2-2 d  are schematics of a cartridge  14  for use with the housing  12  of the printer  10  shown in FIG.  1 . The cartridge has a main body  30  that holds the materials, such as the ink ribbon  100  and the tape  130 , and also mates with the driver  26  of the printer  10  to produce finished labels  160 . The main body includes a partition  32  forming a dump box  34  for holding a discarded receptor layer  120  after the image has been formed on the film layer  110 . Coupled to the main body  30  is an ink ribbon roll  36  on a post (or roller)  37  that supplies the ink ribbon  100  to a thermal printing head  38 . The ink ribbon  100  is passed over the thermal printing head  38  between a platen roller  40  on a post (or roller)  41  to produce the image by heating the ink layer  115  to melt portions of the ink layer  1   15  onto a receptor layer  120  to form a negative image  115 ′ of the image left behind on the film layer  110 . The receptor layer  120  is then removed from the film layer  110  and ink layer  115  by being fed around the platen roller  40  and between a pinch roller  42  on a post (or roller)  43  so that it is directed into the dump box  34  for disposal. In preferred embodiments of the present invention, the image is produced at a resolution of 200 dots per inch. However, in alternative embodiments, other resolutions may be used, with the resolution being dependent on the application to which the label will be put. 
     The main body  30  also holds a tape roll  44  on a post (or roller)  45  that supplies the tape  130  to complete formation of the finished label  160 . The film layer  110 , the remaining ink layer  115  forming the image and the tape are fed between two additional pinch rollers  46  and  48  on corresponding posts (or rollers)  47  and  49  to press and secure the tape  130  to the film layer  110  and the remaining ink layer  115  to form the label, or the like. Finally, the main body includes a cutter  50  having blades  52  that cut the label at a desired length to form the finished label  160 . 
     In preferred embodiments, the main body  30 , the platen roller  40 , and pinch rollers  42 ,  46  and  48  are made out of plastic. However, in alterative embodiments, other suitable materials may be used, such as metal, composites or the like. The remaining components are formed from suitable materials commonly used in thermal printing cartridges. In preferred embodiments, the cartridge  14  is disposable with a single use ink ribbon roll  36  and tape roll  44 . However, in alternative embodiments, the cartridge  14  may be reused or recycled, and the end user may be able to replace the ink ribbon roll  36  and the tape roll  44 , when needed. 
     Formation of a finished label  160  will now be described with reference to FIGS. 2-7. As shown in FIG. 3, the ink ribbon  100  is formed by a film layer  110  and a receptor layer  120  with an ink layer sandwiched between them. Generally, the film layer  110  is formed from plastic and the receptor layer  120  is formed from either paper or plastic. Preferably, wax inks are used to form the ink layer  115  to produce the sharpest images. However, in alternative embodiments, other inks such as resin, conductive inks, or the like, may be used. As shown in FIG. 4, the tape  130  is formed by an adhesive layer  135  disposed on a backing  140  to attach the tape  130  to the film layer  110  and the remaining ink layer  115  forming the image after the receptor layer  120  has been removed. The backing  140  is generally made from plastic. However, paper or other suitable materials may be used. On the opposite side of the adhesive  135  is another layer of adhesive  145  disposed on the back of the backing  140 , which is used to hold a release liner  150  and ultimately to secure the label  160  to a surface. In preferred embodiments, the adhesive  135  is a permanent adhesive and the adhesive  145  is either a permanent adhesive or a removable adhesive. However, in alternative embodiments, different adhesives may be used, with the type being dependent on the type of label and surface to which the label will be applied. In alternative embodiments, different configurations of the ink ribbon  100  and the tape  130  may be formed with the configuration being selected based on the type of label and surface to which the label will be applied. 
     As shown in FIG. 5, the ink ribbon  100  is passed between the thermal printing head  38  and the platen  40 . Pixels on the thermal printing head  38  heat up to melt the ink layer  115  away from the film layer  110  so that it is transferred onto the receptor layer  120 . The receptor layer  120  with the negative image  115 ′ is then removed and discarded, as shown in FIGS. 2 and 2 b.  The remaining ink layer  115  on the film layer  110  is the final image, and the film layer  110  then serves as a transparent protective cover to protect the image. 
     As shown in FIG. 6, the tape  130  is applied to the remaining ink layer  115  and the film layer  110  by being passed through a pair of pinch rollers  46  and  48 . The tape  130  is constructed from an adhesive layer  135  coated on a backing  140  and then another adhesive layer  145  for a release liner  150  to be peeled off easily. After the unwanted portions of the ink layer  115  are transferred onto the receptor layer  120  to be discarded, the remaining image on film layer  110  travels past the platen  40  and is joined with the tape  130 . At this point, the printing process is completed and the label  160  is discharged from the cartridge  14 . The cutter  50  at the exit of the cartridge  14  cuts off the label  160  so that it is finished and ready for use. 
     As shown in FIG. 7, to use the label  160 , the user peels off the release liner  150  by simply pinching the edge of the release liner and peeling it from the adhesive  145  on the backing  140 . This exposes the adhesive  145  on the backing  140  so that it will serve as an adhesive to attach the label  160  onto a desired surface in a normal manner. 
     FIGS. 8-8 d  show another embodiment of a cartridge  214  for use with the printing apparatus shown in FIG.  1 . Instead of a dump box  34 , used to collect the discarded receptor layer  120  and negative image  115 ′, the cartridge  214  uses a take up reel  216  on a post (or roller)  216 . This type of mechanism tends to minimize jamming as discarded materials collect in the dump box  34  of the cartridge  14 . 
     FIGS. 9-9 d  show another embodiment of a cartridge  314  for use with the printing apparatus shown in FIG.  1 . This cartridge also uses a take up reel  216 . However, in this embodiment, the film layer  110  with the ink layer is on a separate roll  316  on a post (or roller)  318 , and a separate receptor roll  320  on a post (or roller)  322  to supply the film layer  110 , ink layer  115  and receptor layer  120  to the thermal printing head  38 . Advantages of this design are that there is versatility in selecting various receptor, film and ink layer combinations, and manufacture may be simplified by virtue of the various materials that may be used to produce the labels. 
     FIGS. 10 a  and  10   b  are schematic views of a reverse image printer  200  in accordance with a second embodiment of the present invention. The reverse image printer  200  includes an ink jet print head  202  and ink jet ink supply  204 . The label material may be included in a cartridge  206  that includes a transparent film roll  208  and a base film roll  210 . The inkjet head  202  produces a reverse image  212  on a transparent film  214 , which is then applied to a base film  216  that includes a peel off film  218  secured to the base film  216  by an adhesive  220  to form a label  222 . The base film  216  is secured to the transparent film  214  having the reverse image  212  by an adhesive on the base film  216 . the base film  216  and the transparent film  214  are pressed together by two pinch rollers  224  and  226 . 
     As shown in FIG. 10 b,  the base film  216  is formed by an adhesive layer  215  disposed on the base film  216  to attach the base film  216  to the transparent film  214  and the reverse image  212 . The base film  216  is generally made from plastic. However, paper or other suitable materials may be used. On the opposite side of the adhesive  215  is another layer of adhesive  220  disposed on the back of the base film  216 , which is used to hold a peel-off film  218  and ultimately to secure the label  222  to a surface. In preferred embodiments, the adhesive  215  is a permanent adhesive and the adhesive  220  is either a permanent adhesive or a removable adhesive. However, in alternative embodiments, different adhesives may be used, with the type being dependent on the type of label and surface to which the label will be applied. In alternative embodiments, different configurations of the label  22  using the tranparent film  214  and the base film  216  may be formed with the configuration being selected based on the type of label and surface to which the label will be applied. 
     In preferred embodiments of the present invention, the image  212  is produced at a resolution of 300 dots per inch. However, in alternative embodiments, other resolutions may be used, with the resolution being dependent on the application to which the label will be put. 
     Reverse image printing in accordance with this second embodiment of the present invention is similar to the reverse thermal imaging described above, and provides many same advantages to produce labels or the like. However, in this process, a reverse image is directly printed onto a transparent film and there is no discarded receptor layer. The transparent film is then laminated onto a tape backing and cut to the desired length to produce a finished label or the like. The label, or the like, that is produced in this manner tends to be very scratch and chemical resistant due to the fact that the printing is protected and sandwiched between the film layer and the tape backing. 
     The use of the transparent film as part of the label to protect the image offers several advantages. For example, since the printed image is under a layer of transparent film, the image is protected from abrasion, UV rays and chemicals. As described above, the use of a thin transparent film also provides for the use of an conductive ink used to form a bar code. Typically, conductive bar codes must be covered by a non-conductive film. Thus, the non-conductive transparent film provides a protective layer over the bar code and also provides the correct gap between the bar code and the inductive reader in a single manufacturing step. 
     The use of ink jet printing provides several advantages over thermal printing. The printing process may be faster, since ink jets tend to operate at higher speeds. Also, the use of an ink supply, rather than a transfer ribbon, would facilitate the production of color labels. Further, the use of an ink supply may minimize the waste of unused ink transferred from a ribbon. In addition, the ink may be manufactured to include adhesive properties, which could increase the durability of the produced label or the like. 
     While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. 
     The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.