Abstract:
A computer-controlled identifier tag production system. The system employs perforated plastic sheets comprising a plurality of transparent identifier tags. The sheets are designed to be fed through a conventional ink jet or laser printer to print one or more of the tags in accordance with user input. Each sheet is a single layer in thickness and is sufficiently flexible and heat-stable such that it will not deform if passed through a printer multiple times. The printed tags are used in conjunction with a plastic holder and backer plate to form an adhesive-free identifier tag assembly. The backer plate is preferably a rigid metal plate which may be embossed with indicia, such as a corporate logo. The identifier tag assembly may further include a magnet or pin fastener for temporarily affixing the backer plate to an article of clothing.

Description:
FIELD OF THE INVENTION 
     This application relates to a computer-controlled identifier tag production system. The system employs perforated plastic sheets comprising a plurality of transparent tags. The sheets are designed to be fed through a conventional ink jet or laser printer to print one or more of the tags in accordance with user input. The printed tags are then separated from the remainder of the sheet and used in conjunction with a plastic holder and backer sheet to form an adhesive-free identifier tag assembly wearable on an article of clothing. 
     BACKGROUND OF THE INVENTION 
     Temporary name tags are required for many social and business events. The most rudimentary name tags are paper labels having an adhesive backing. Attendees simply handwrite their name on a label and affix it to an article of clothing. Alternatively, sheets of adhesive labels may be fed through a desktop printer controlled by a computer processor to create computer-generated name tags having a consistent appearance. In order to avoid the use of adhesives, it is also commonplace to create computer-generated name tags on sheets of plain paper which are then cut or divided along tear lines to produce individual name tags suitable for insertion into plastic holders. Such holders are then typically affixed to an article of clothing with a pin or clip or are suspended from a strap worn around the user&#39;s neck. 
     Many businesses having staff members dealing with the public require name tags which are sufficiently durable for long-term wear and which project a more professional appearance than conventional paper labels. For many years the applicant has sold metal identifier tags customized to meet this market demand. The identifier tags may be screenprinted with the name and/or title of the staff member together with a corporate logo. Such metal identifier tags are releasably held in place on an article of clothing with a small magnet to avoid the disadvantages of adhesives or pin fasteners. While such identifier tags are very durable and project a very professional appearance, they are relatively expensive to manufacture and are not readily reusable. This poses problems for companies having a large staff turn-over. 
     In order to meet this concern, the applicant has previously developed an identifier tag production system using a pen plotter controlled by a software application. The plotter is programmed to apply ink directly to a metal identifier tag in accordance with data inputted by the user. The ink is formulated so that it is readily removable from the metal surface using suitable solvents. This permits customers to remove names, titles or other printed indicia from the metal identifier tags and reuse the tags as their staffing roster changes. However, one drawback of this system is that it requires that each customer purchase a pen plotter and custom templates for holding the identifier tags in the preferred alignment in the plotter during the printing process. 
     Another approach known in the prior art to produce custom identifier tags is to print employee indicia on a flexible plastic film which is then affixed to a more rigid backing plate. For example, U.S. Pat. No. 5,398,435 dated Mar. 21, 1995, Kanzelberger, relates to a method of making plastic plates which may be adorned with graphics to make such things as badges, name tags, desk plates, wall plaques and the like. According to the Kanzelberger method, a transparent Mylar sheet may be printed with information using a printer controlled by a microprocessor The transparent Mylar sheet is then laid on top of a separate information-carrying sheet (which may be embossed, for example, with a corporate logo). The various sheets are maintained in their preferred orientation using adhesives. For example, a double-sided pressure sensitive adhesive tape may be applied to the bottom of the Mylar sheet. The use of adhesives to hold the assembly of graphic material together restricts the capacity of the user to remove the information-carrying Mylar sheet and substitute alternative information (such as a new name or job title). 
     Kanzelberger also obtained a patent in the United States on Jul. 17, 1984 (U.S. Pat. No. 4,459,772) specifically relating to debossable plastic name tags and plaques. Embodiments of the invention are described employing transparent folders or envelopes for aligning underlying graphic displays. However, the assembly of graphic material is held together with adhesives. 
     U.S. Pat. No. 4,236,331 dated Dec. 2, 1980, Mattson, discloses a magnetic badge assembly comprising an outer panel and an inner panel, each comprising magnetic material, such as magnetic tape. Each of the panels may also include a thin metal plate. The magnetic tape and metal plate, which form the core of each panel, are enclosed in a laminated plastic film jacket comprising a pair of thermofusable plastic sheet material sections. An indicia-carrying sheet may be either attached to the outer face of the panel or laminated within the plastic jacket. The outer indicia-carrying sheet may be equipped with a pressure sensitive adhesive so that it may be removed and replaced with another sheet. However, such a sheet would be prone to fraying and would not be sufficiently durable for long-term use. In the case of the embodiment laminated within the interior of the plastic jacket, it is not intended to be removable. 
     U.S. Pat. No. 4,597,206 dated Jul. 1, 1986, Benson, discloses a snap-together badge and clip to be worn on a person&#39;s clothing as a name badge, display button or the like. Display material bearing information is sandwiched between a substantially transparent element and a backplate. Thus, the display element is removable and is maintained in the proper alignment with the other pieces of the cover assembly. However, Benson does not teach the advantages of producing the display element in an automated manner using a conventional desktop printer. 
     U.S. Pat. No. 4,183,149 dated Jan. 15, 1980, Isaac, discloses a portable transparent display device which is reusable. The Isaac display device primarily comprises two separate elements, namely a transparent cover and an insertable element, which may be flexed to insert or remove the element from a recessed space defined by the cover. An information-carrying sheet of material may be inserted into, and is aligned within, the recessed space. Isaac contemplates that the insertable element may be clear or opaque, but he does not teach the advantages of producing the insert in an automated manner using a conventional desktop printer. 
     U.S. Pat. No. 4,184,275, Thornell, similarly discloses a reusable badge which is assembled by snapping a backing plate into a transparent lens. Display material is removably placed between the lens and the backing member. 
     While some reusable identifier tags and badges are known in the prior art, they are not specifically adapted for holding transparent tag inserts created using conventional desktop printers or for maintaining such inserts in a preferred alignment without the use of adhesives. The need has therefore arisen for an identifier tag production system which overcomes the various limitations of the prior art in a cost-effective manner while still yielding durable identifier tags having a professional appearance. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, an identifier tag assembly is provided comprising (a) an optically clear holder having a cavity formed therein; (b) a backer sheet sized to fit snugly in the cavity; and (c) an identifier tag having indicia printed thereon, wherein the tag is positionable in the cavity between the holder and the backer sheet, and wherein the tag is held in alignment with the backer sheet without the use of adhesives. 
     Preferably the tag comprises a single layer of flexible plastic film. The backer sheet may consist of a rigid metal plate. The plate may bear indicia which is visible through the holder and printed tag when the holder, tag and backer sheet are assembled together. 
     An identifier tag production system is also provided comprising (a) a computer processor; (b) a storage device connected to the computer processor, the storage device storing software for controlling the processor and for storing identifier tag data inputted by a user; (c) a printer adapted to receive the identifier tag data from the computer processor and output the data to an output medium; (d) at least one sheet subdividable into a plurality of identifier tags, wherein the sheet is adapted to pass through the printer to receive the identifier tag data outputted by the printer. 
     Preferably, the sheet comprises a single layer of plastic film having perforated tear lines separating the tags. The film is sufficiently flexible and heat-stable such that it may pass through the printer multiple times without substantially deforming. 
     The invention also relates to a flexible sheet comprising a single layer of material capable of bearing printed indida, the sheet having leading and trailing ends and opposed side edges, wherein the sheet is at least partially sub-divided into a plurality of tags arranged in rows between the leading and trailing ends, wherein each of the rows is separated by a perforated tear line extending transversely across the sheet at least part-way between the side edges. 
     Preferably the sheet comprises a first portion proximate the trailing end and a second portion comprising the remainder of the sheet, wherein the tear lines extend across the entire width of the sheet in the first portion and only part-way across the sheet in the second portion, thereby defining non-perforated side margins in the second portion. 
     The sheet is used as part of a method for producing a reusable identifier tag assembly comprising (a) providing computer software operable with a computer processor, wherein the software is adapted to receive and store identifier tag data inputted by a user; (b) providing a computer printer connected to the computer processor and configured to receive the identifier tag data; (c) providing an identifier tag sheet subdividable into a plurality of identifier tags; (d) passing the sheet through the printer to print the identifier tag data on at least one of the identifier tags, thereby producing a printed tag; (e) retrieving the sheet from the printer and removing the printed tag from the remainder of the sheet; (f) providing an optically clear tag holder having a cavity formed therein and a rigid backer sheet adapted to fit snugly in the cavity; and (g) inserting the printed tag into the holder cavity together with the backer sheet to form a wearable identifier tag assembly. 
     An identifier tag production kit is disclosed comprising (a) computer software operable with a computer processor, wherein the software is adapted to receive and store identifier tag data inputted by a user; (b) a plurality of sheets subdividable into a plurality of identifier tags; and (c) a plurality of identifier tag holder assemblies, each of the assemblies comprising (i) an optically clear holder having a cavity formed therein; (ii) a rigid backer sheet adapted to fit snugly into the cavity; and (iii) a fastener for detachably coupling the backer sheet to an article of clothing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In drawings which illustrate preferred embodiments of the invention, but which should not be construed as restricting the spirit or scope of the invention in any way, 
     FIG. 1 is schematic view of the applicant&#39;s identifier tag production system comprising software running on a personal computer, a conventional desktop printer and perforated plastic identifier tag sheets adapted to be fed through the printer. 
     FIG. 2 a  is a top plan view of a blank identifier tag sheet; 
     FIG. 2 b  is a top plan view of an alternative embodiment of a blank sheet; 
     FIG. 2 c  is a top plan view of the sheet of FIG. 2 a  separated along its longitudinal centerline to form two separate subsheets. 
     FIG. 3 is a top plan view of the sheet of FIG. 2 a  partially printed with one row of identifier tags; 
     FIG. 4 is a top plan view of the sheet of FIG. 3 illustrating the row of identifier tags torn away from the remainder of the sheet; 
     FIG. 5 is an top isometric exploded view of an identifier tag assembly comprising an optically clear holder for receiving a printed identifer tag and a backer sheet; 
     FIG. 6 is a bottom isometric view of the holder of FIG. 5; 
     FIG. 7 a bottom isometric exploded view of the identifier tag assembly of FIG. 5; and 
     FIG. 8 is a top isometric view of the identifier tag assembly of FIG. 5 in its assembled configuration. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     This application relates to a customizable identifier tag production system. As shown in FIG. 1, the system utilizes a personal computer  10  running computer software programmed to control the operation of a conventional ink jet or laser printer  12 . Identifier tag sheets  14 , consisting of a single layer of transparent plastic, are fed through printer  12  to produce printed identifier tags  16  which may then be torn away from the remainder of sheet  14 . As shown best in FIG. 5, each printed tag  16  may then be inserted into a plastic holder  18  together with a rigid backer sheet  20  to form a wearable identifier tag assembly  22 . 
     FIG. 2 a  illustrates a blank identifier tag sheet  14 . Sheet  14  includes a leading end  24 , a trailing end  26  and side edges  28 . In the illustrated embodiment, tags  16  are arranged in parallel rows  30  between ends  24 ,  26  and are separated by transversely extending perforated tear lines  32 . As will be apparent to a person skilled in the art, the layout of sheet  14  may vary depending upon the size, shape and quantity of tags  16  desired. In the illustrated embodiment, sheet  14  comprises two parallel columns  34  of tags  16 . Tags  16  are centered in each column  34  to define a side margin  36  extending adjacent a side edge  28  of sheet  14  and a central webbing  38  extending adjacent to the longitudinal centerline of sheet  14 . Sheet  14  also includes margins  40  and  42  adjacent the leading and trailing ends  24  and  26  of sheet  14  respectively. 
     In an alternative embodiment of the invention illustrated in FIG. 2 b , labels  16  in adjacent columns  34  meet along the longitudinal centerline of sheet  14  and central webbing  38  is omitted. Many other possible alternative layouts for sheet  14  may be envisioned as indicated above. 
     In a further alternative embodiment (not shown) sheet  14  could comprise a single tag  16  surrounded by a perforated margin. This embodiment would be suitable, for example, for signs or desk plaques. 
     Each sheet  14  is preferably constructed from a thin single layer of transparent plastic suitable for use in either an ink jet or laser printer  12  (i.e. capable of accepting either water-based inks delivered by ink jet printers or toner delivered by laser printers). By way of example, coated polyester sheets available from Arkwright Incorporated are suitable for ink jet printers. For laser printers, MELINEX™ sheets available from Dupont Corporation are suitable. As discussed further below, it is an important feature of the invention that sheets  14  are heat-stabilized and are capable of being fed through printer  12  multiple times without significantly deforming. Accordingly, conventional plastic sheets used for overhead transparencies and the like are not suitable. 
     The perforation pattern of tear lines  32  on sheet  14  is preferably created using a custom die cutter (not shown). As shown in FIGS. 2 a  and  2   b , tear lines  32  extend transversely across the entire width of sheet  14  in the trailing half of sheet  14  (i.e. from a central portion of sheet  14  to trailing end  26 ). In the leading half of sheet  14  (i.e. from a central portion of sheet  14  to leading end  24 ) tear lines  32  do not extend into side margins  36 . As explained further below, this ensures that sheet  14  is a minimum acceptable length for use in printers  12  to avoid printer jams and sheet misalignments. 
     As shown in FIG. 2 c , sheet  14  may be torn along a central longitudinal perforation line to form two separate subsheets  15 . Each subsheet  15  may be fed through printer  12  in the same manner as a conventional envelope. 
     In use, sheets  14  are printed in a manner generally similar to conventional sheets of paper labels having adhesive backings. The applicant&#39;s system includes software running on computer  10  designed to process and store user input, such as the name and title of each individual for whom an identifier tag is required, or other similar identifying information. Preferably the software includes an initial set-up utility for configuring the system to match the features of the particular printer  12  or other output device to be used. For example, the size and position of the printer input tray, feed rollers and internal transport mechanism may vary depending upon the model in question. The set-up utility prompts the user to print test print jobs using plain paper and then make any necessary adjustments to calibrate the software to the output device specifications. 
     For example, in one embodiment, the set-up utility prompts the user to print a sample sheet of plain paper bearing calibration lines. A blank identifier tag sheet  14  is then laid over top of the plain paper to compare the position of tags  16  relative to the calibration lines. The software may then be appropriately adjusted until the position of tags  16  and the calibration lines are aligned. This ensures that any indicia  41  printed on tags  16  will not be off-center or otherwise askew. For example, if identifier tags  16  are used as part of a name tag assembly, it is critical that the name and title of the employee be precisely centered in order to convey a professional aesthetic impression. 
     After the initial set-up and input of identifier tag data or other indicia to be printed, sheets  14  are loaded into the input tray of printer  12  as shown in FIG.  1 . It is imperative that leading end  24  of sheet  14  be fed into printer  12  first. The applicant&#39;s software is configured to print tags  16  at locations on sheet  14  measured relative to leading end  24 . In order to prevent misalignments, leading end  24  should preferably be square, straight and the full width of the printer infeed. 
     Sheet  14  is printed in a conventional manner by printer  12  and is deposited into the feeder output tray (FIG.  1 ). In the illustrated example, two identifier tags  16  are printed in the row  30  closest to trailing end  26 . As shown in FIG. 4, the trailing end margin  42  together with the row  30  closest to trailing end  26  are then separated from the remainder of sheet  14  along tear lines  32 . This results in a partially-used sheet  14  which is similar in structure to the original blank sheet  14  except that it is shorter in length. The partially-used sheet of FIG. 4 may be reused on multiple occasions. Accordingly, if it is necessary to produce only a few identifier tags  16 , the user need not be concerned that he or she will waste an entire sheet  14  of tags  16 . 
     Each time sheet  14  is used, an entire row  30  of tags  16  is removed. This ensures that the new trailing end  26  of the partially-used sheet is square, straight and extends across the full width of sheet  14  to prevent conflicts with the “paper out” sensors of printer  12 . However, many printers  12  have minimum sheet length requirements due to internal distances between printer transport rollers. Accordingly, the perforation pattern of sheet  14  has been configured so that sheet  14  may not be divided along tear lines  32  into less than half its length. As discussed above, this is achieved by not extending tear lines  32  into side margins  36  in the leading half of sheet  14  (i.e. label rows  1 - 5  in the illustrated embodiment). 
     Many printers  12  also have minimum sheet width requirements. Such printers  12  only allow for a minimum sheet width to be fed (i.e. envelope width). Accordingly, the perforation pattern of sheet  14  has also been configured to ensure that it may not be subdivided into less than half its width. For example, in the illustrated embodiment, only two columns  34  are provided divided by a tear line  32  extending along the longitudinal centerline of sheet  14 . As shown in FIG. 2 c , sheet  14  may be subdivided longitudinally along the central tear line  32  into two separate subsheets  15 . Each subsheet  15  may be individually passed through printer  12  using the envelope feed. For example, if a user wishes to print only a single tag  16 , a subsheet  15  could be used to ensure that no tags  16  are wasted when the printed tag  16  is removed (as indicated above, after a tag  16  is printed, the entire row of tags  16  is removed to ensure that the trailing edge of the remainder of sheet  14  or subsheet  15  is straight). 
     In the applicant&#39;s system, identifier tags  16  are always printed from the trailing end  26  of sheet  14 , or subsheet  15 , toward the leading end  24 . Thus the leading end margin  40  is maintained to prevent printing misalignment (i.e. end  24  serves as a reference for the sheet sensors of printer  12  irrespective of whether any identifier tag rows  30  are removed in the trailing half of the sheet). This feature is the opposite of conventional printing sequences which begin at the leading end of a sheet and print toward the trailing end. 
     As shown in FIG. 4, each printed tag  16 , now bearing indicia  41 , is separated along tear lines  32  from the attached side margin  36  and central webbing  38  and is ready for use as part of an identifier tag assembly  22 . With reference to FIG. 5, printed tag  16  is sandwiched between holder  18  and backer sheet  20 . An important feature of the applicant&#39;s invention is that tag  16  is held in alignment in assembly  22  without the use of adhesives. 
     As shown best in FIGS. 6 and 7, the bottom surface of holder  18  has a cavity  42  formed therein defined by a peripheral rim  44 . The shape and size of cavity  42  preferably matches the shape and size of tag  16  and backer sheet  20 . Holder  18  also includes inwardly-projecting flexible tabs  46  located at opposite ends of holder  18 . In use, tag  16  is inserted into holder cavity  42  together with backer sheet  20  as shown in FIG.  7 . Tabs  46  engage the side edges of backer sheet  20  to securely hold assembly  22  together. FIG. 8 illustrates assembly  22  in the fully assembled configuration 
     In one embodiment of the invention, backer sheet  20  may consist of a rigid piece of coloured metal plate. This would enable name tag assembly  22  to be held in position on an article of clothing using a magnet. Alternatively, backer sheet  20  may comprise a conventional pin or equivalent fastener. 
     Since tag  16  is preferably transparent (apart from the indicia  41  printed thereon) it is not readily detectable when assembled together with backer sheet  20  and holder  18  as shown in FIG.  7 . Rather, in the assembled configuration of FIG. 8, the visual effect that is created is that indicia  41  is printed directly on backer sheet  20 . Backer sheet  20  may be screenprinted with other indicia, such as corporate logos or the like, to enhance the visual effect. As will be apparent to a person skilled in the art, backer sheet  20  may also be produced in different background colours to create different visual effects. Holder  14  may include a magnifying lens or a custom contour to also enhance the readability of the name tag assembly  22  or to vary other visual effects. 
     As will be apparent to a person skilled in the art, in alternative embodiments of the invention tags  16  may be non-transparent (e.g. translucent, opaque or bearing solid designs) to create other visual effects. 
     An important advantage of the applicant&#39;s invention is that the printed tag  16  may be easily removed from assembly  22  and replaced with another tag  16 . For example, if the name or position of an employee changes, the old tag  16  may be removed from assembly  22  and discarded and a new tag  16  bearing the correct indicia  41  may be substituted. Since no adhesives are used, the applicant&#39;s system does not result in a sticky and potentially unsightly residue on backer sheet  20 . This feature is particularly attractive to large companies using customized backer sheets  20  (for example, metal plates bearing a corporate logo) and having a large amount of staff turnover. The applicant&#39;s invention enables such customers to retain the custom backer sheets  20  and print substitute tags  16  on demand quickly and easily using conventional desktop printers  12 . 
     As will be apparent to a person skilled in the art, the applicant&#39;s invention may also be sold as a kit to the general consumer market. Such a kit could include the application software, a supply of blank sheets  14 , a supply of plastic holders  18  and a supply of backer sheets  20  and fasteners (such as magnets). The kit would also include detailed instructions explaining how to load the software and run the initial set-up operation as well as how to print custom identifier tags  16  as discussed above. 
     In an alternative embodiment of invention, sheet  14  may be printed in a non-perforated format and then cut to size using a custom hand-operated die cutter sold to customers as part of the overall system. In still another embodiment, sheets  14  may be suitable for use in output devices other than conventional printers, such as pen plotters. 
     Although this invention has been described in relation to wearable identifier tag assemblies  22 , the same principles would apply in creating wall plaques, desk plaques, badges and the like. 
     As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.