Roll-fed tape/film system for application of adhesive to various media in inkjet printing devices

Conventional media receives print imaging and an adhesive during a printing operation thereby converting such conventional media into a label, i.e., media having print imaging and an adhesive for application to a contact or display surface. Print imaging is applied in conventional fashion. Adhesive is applied as taken from a reel-form stock including in various embodiments and configurations protective backing sheets and the like supporting application of adhesive to media to produce as output labels on arbitrarily selected media. As a result, users produce labels from arbitrary media and need not limit selection to commercially available label-making media.

BACKGROUND OF THE INVENTION

The present invention relates generally printing methods and apparatus, and particularly to printing methods and apparatus producing printed label media bearing an adhesive for application to a contact or display surface.

While most printing operations involve application of print imaging, e.g., graphics and text, to simple sheet-form media, some printing operations involve production of labels. Generally, a label bears print imaging as applied in a printing operation and also includes an adhesive on at least one side of the resulting printed media. Labels are often used for addressing, e.g., an address is printed on the label and the adhesive portion of the label allows one to adhere the label to a package for introduction into the postal or other delivery system. Other examples of printing operations producing labels include production of bar code indicia and informational or identification tag labeling such as for application to articles, e.g., a variety of items such as desk drawers, boxes, packages, and the like, wherein content of a given article or the character of the article itself may be indicated by label attached by adhesive thereto.

One popular method of producing labels is by label sheets. A sheet-form media including a waxy back sheet and an array of adhesive labels attached thereto feeds through a printing device. The printing device applies print imaging to one or more of the labels. Once ejected from the printing device, individual labels may be peeled from the waxy back sheet and applied to a contact or display surface as desired. Typically, the labels have on a front side print imaging as applied by the printing device and on the back side an adhesive adhering the label to a contact or display surface. A variety of other label-making methods and apparatus have evolved. These label-making printing operations share, however, a common characteristic of a label having incorporated therewith an adhesive on at least one surface prior to application of print imaging. Thus, specialized label media as so configured, i.e., with an adhesive surface integral therewith, feed into a printing device.

In some cases, specialized printing devices have been proposed for production of special-form labels. For example, U.S. Pat. No. 4,927,278 issued May 22, 1990 and entitled Tape Cassette And Tape Printer For Use Therewith shows a specialized tape printer which joins together an image receiving tape and an adhesive tape following application of imaging by ink ribbon to the image receiving tape. The ink ribbon, image receiving tape, and adhesive tape are held in a cassette which mounts to a tape printer. The image is applied to the image receiving tape and the adhesive is then applied thereover. After printing, the tape is fed out together with the adhesive tape applied to the printing surface of the image receiving tape. Unfortunately, this printer severely restricts the available media which may be used in production of labels. More particularly, this is a dedicated, specialized type of media. The user has no opportunity to select an arbitrary media for production of labels.

As a result, media suitable for production of labels is limited. In other words, media supporting label-making printing operations is special media typically having the above-noted characteristic of a waxy back sheet protecting an adhesive integrally formed with the label media and allowing passage thereof through a printing device. Such label-making media is generally more expensive than conventional printing media. Users wishing to produce labels must select from a limited set of commercially available label-making media. Users do not have opportunity to produce labels from arbitrarily selected media, i.e., cannot select for label-making purposes any media suitable for printing, but must select only media specifically manufactured for label-making printing operations.

It would be desirable, therefore, to allow users to produce labels from arbitrary media, i.e., from any selected media suitable for application of print imaging thereon.

SUMMARY OF THE INVENTION

In accordance with the present invention, a method of producing a label includes the steps of selecting a media, the media having a first side and a second side, feeding the media into a printing device, applying print imaging to a selected one of the first and second sides, and applying adhesive to a selected one of the first and second sides. As a result, conventional media, i.e., not originally intended for use as a label, converts under the present invention into an adhesive bearing label including print imaging thereon.

The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation of the invention, together with further advantages and objects thereof, may best be understood by reference to the following description taken with the accompanying drawings wherein like reference characters refer to like elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention contemplates, for example, an inkjet printing device allowing application of an adhesive to arbitrary media thereby converting arbitrary media to an adhesive-bearing printed output capable serving as a label, i.e., capable of adhering to a selected contact or display surface. This expands the range of available label-making media well beyond commercially available media dedicated specifically to label-making; and thereby expands greatly the opportunity to select media for particular uses according to a desired label-making printing operation without limitation to media specifically designed for label-making operations. This enables small business and personal printing operations to create self-adhering documents usable in a wide range of applications. Examples include posting flyers, posting notes, creating greeting cards, securing photos into scrapbooks, creating personalized self-adhesive notes, creating name tags, and the like. By allowing the user to add an adhesive during the printing process the user enjoys flexibility in media choice, sizes, and shapes well beyond that presently available in the limited set of media designed specifically for label-making operations.

FIG. 1illustrates schematically and in side view a two-sided adhesive tape10proposed for use under one embodiment of the present invention. InFIG. 1, tape10comes in reel-form on a spool12. Spool12is placed into a spool holder (not shown inFIG. 1) located in a printer. The spool holder has a central axis concentric width that of spool12as shown inFIG. 2. Tape10is illustrated inFIG. 1with its distal end10aseparated to show the various components thereof. Tape10includes a substrate14bearing on an upper surface thereof an adhesive coating14aand on a lower surface an adhesive coating14b.In other words, substrate14is a double-sided adhesive tape. A backing sheet16lies against lower adhesive coating14b.When wrapped around spool12, upper adhesive coating14alies against the lower-facing surface16aof backing sheet16. The upper surface16bof backing sheet16lies in contact with the lower adhesive coating14b.As provided on spool12, therefore, tape10enjoys protection against inadvertent contact with adhesive coatings14aand14bby virtue of backing sheet16therebetween. Backing sheet16includes a leader16cextending beyond the distal end of substrate14. Leader16cwraps about the exterior of tape10as provided on spool12to protect adhesive coating14aagainst inadvertent contact prior to use of tape10, i.e., as packaged for distribution and prior to use. As may be appreciated, backing sheet16is a waxy material adapted for light adhesion to coatings14aand14b,but easily separated therefrom without degrading the adhesive function of coatings14aand14b.As deployed from spool12, backing sheet16remains in contact with the lower adhesive coating14bof tape14. The upper adhesive coating14a,however, is exposed upon deployment of tape10from spool12.

FIG. 2illustrates schematically a printer22making use of tape10during a label-making printing operation. InFIG. 2, sheet-form media20moves through printer22. A pick roller24collects individual media20from, for example, an input tray (not shown) and delivers media20to feed rollers26. An inkjet print head28lies along a feed path established by feed rollers26and applies print imaging to an upper surface20aof media20. An adhesive station30carries spool12and deploys therefrom tape10. More particularly, station30deploys tape10from spool12in the media transport direction32. Upper adhesive coating14ais exposed to the lower surface20bof media20. As media20, at its lower surface20b,comes into contact with upper adhesive coating14a,tape10adheres to media20at lower surface20bthereof. Media20velocity must be such that any print imaging on media20has opportunity to dry sufficiently to avoid smudging by contact prior to reaching roller29. A pinch drive roller29bears against the upper surface20aof media20and captures therebelow tape16to better adhere tape16to media20, i.e., to insure full, even contact between the adhesive coating14aand lower surface20bof media20. It is suggested that spool12be upwardly biased to keep coating14ain contact with media20as the supply of tape10diminishes and, therefore, the diameter of material carried on spool12diminishes. For example, spool12may be supported at the distal end of a lever arm pivotally mounted at its proximal end. Spring biasing upward towards media20maintains roll10in contact with the lower-facing surface20bof media20and thereby completes in combination with roller29coupling therebetween. Biasing may be intermittently actuated to achieve selective application of adhesive14aas a function of a driver-based user input or the mechanical sensing of a leading or trailing edge of media20. In other words, spool12may be controllably brought out of position for contact with media20and thereby disable application of adhesive14athereto. Application of adhesive14ais enabled, therefore, by returning spool12to its media engaging position with biasing applied to fully engage media20. As media20continues in the feed path direction32, it pulls tape10from spool12. Adhesive coating14athereby adheres to the lower surface20bof media20.

Eventually, media20moves past station30and its trailing edge20chalts, as under suitable control circuitry and programming, at a cutter34. A user of printer22grasps media20and tears away tape10at cutter34. In other words, the user severs or tears away a distal segment of tape10at station30, the segment being that portion of tape10adhering to lower surface20bof media20. In the alternative, an automated cutter may be employed which moves across the combined structure of media20and tape16to automatically sever at an appropriate point tape10. The resulting product is a sheet-form media20having on its upper surface20aselected print imaging and on its lower surface20ba segment of tape10. As may be appreciated, the backing sheet16remains in place and protects lower adhesive coating14bagainst inadvertent contact with other media20or other surfaces. In other words, a set of such media20can be stacked one on top of another with the backing sheets16in place therebetween to prevent undesired adhesion. Once a suitable contact or display surface is selected for placement of media20, backing sheet16is pulled from the resulting label, i.e., from media20as bearing a segment of tape10thereon, thereby exposing lower adhesive coating14bfor adhering to the selected contact surface.

Thus, a user of printer22has the option of selecting an arbitrary media20capable of feeding through printer22, and mounting a segment of tape10on its lower side20b.The user thereby converts conventional media20into a label with print imaging on one side and an adhesive coating on the other.

FIG. 3illustrates first alternative tape10′ including predefined or precut sections. InFIG. 3, tape10′ is illustrated with its distal end10a′ separated to show components thereof Tape10′ includes a substrate14and backing sheet16similar to that of tape10. In other words, substrate14is a double-sided adhesive having an upper adhesive coating14aand a lower adhesive coating14b.Backing sheet16includes a lower-facing surface16aand an upper-facing surface16b.Tape10′ differs from tape10, however, in use of lateral perforations10bdistributed along the length of tape10. Perforations10bare cut through both substrate14and backing sheet16whereby a user tears tape10along a selected perforation10bto separate a segment of tape10′ from the remaining tape10′ on spool12. Thus, use of tape10′ eliminates need for a cutter34in printer22. More particularly, the user tears tape10′ at a selected perforation10bas desired when removing media20from printer22. Thus, printer22operates as described above transporting media20through printer22and capturing a segment of tape10′ against the lower surface20bof media20. When print imaging is complete, the user tears the distal segment of tape10′ from printer20along with media20as attached thereto during the printing operation.

FIG. 4Aillustrates in side view the layers of a third alternative tape100. InFIG. 4, a segment of tape100is illustrated in side view and in exaggerated proportion with slight separation between layers to better illustrate the various components thereof. It will be understood, however, that tape100is provided in reel-form on a spool12as discussed above in relation to tape10and tape10′. Tape100includes four separate layers. The upper layer, as viewed inFIG. 4A, is an adhesive film114. Film114includes an upper-facing surface114aand a lower-facing surface114b.A backing sheet116engages at its upper-facing surface116athe lower-facing surface114bof adhesive film114. A second adhesive film118, including an upper-facing surface118aand a lower-facing surface118b,lies just below backing sheet116with its upper-facing surface118aengaging the lower-facing surface116bof sheet116. Finally, a carrier120lies as the lower-most layer as viewed inFIG. 4Awith its upper-facing surface120acontacting the lower-facing surface118bof adhesive film118. The lower-facing surface120bof carrier120engages the upper-facing surface114aof adhesive film114when tape100is wrapped about a spool12.

Tape100as illustrated inFIG. 4Amay be varied according to particular implementations of the presented invention. More particularly, tape100may be provided with predefined segments similar to tape10′, but complete cuts102to enable automated separation of tape100. More particularly,FIG. 4Billustrates use of adjacent precut sections104andFIG. 4Cillustrates use of nonadjacent precut sections104. InFIGS. 4B and 4C, adhesive film114and backing sheet116are precut to define distinct sections thereof. Adhesive film118and carrier120, however, are continuous and thereby support continuous printing operations as described more fully hereafter. With reference specifically toFIG. 4B, tape100′ includes a series of lateral cuts102distributed along its length and extending through adhesive film114and backing sheet116. Cuts102are complete, i.e., not perforations. During a printing operation, cuts102define a series of segments104, each including the combined layers114and116. Because cuts102are complete, sections104when coupled to media remain attached thereto. A given segment of tape100′, i.e., comprising one or more sections104, naturally adheres to a media without requiring use of a cutter and without requiring user intervention, i.e., user tearing away a portion of tape100for each media printed.

FIG. 4Cillustrates tape100″ having nonadjacent sections104. In this embodiment of tape100, cuts102are in essence much wider and defined open space between segments104. Greater separation between sections104facilitates better deployment of sections104onto media as described herein. For example, sections104will be less likely to hang together and therefore better separate from one another as necessary upon application to media20.

As described more fully hereafter, tape100′ or100″, collectively referenced as tape100, moves from a first spool12b(FIG. 5) to a second spool12a(FIG. 5) during a label-making printing operation. As tape100wraps around the second spool, however, adhesive film114and backing116split away from adhesive film118and carrier120. The upper-facing surface114aof adhesive film114contacts and adheres to a media sheet and carries therewith the backing sheet116. More particularly, those sections104contacting media remain adhered to media and are carried away thereby. Some sections104may not engage media, i.e., corresponding to gaps between media moving along the feed path of printer122, are simply carried away by adhesive films118and carrier120. Adhesive film118and carrier120, as well as unused sections104, collect about the second spool. Thus, the function of adhesive film114is to adhere to a media sheet as contiguous sections104, thereby converting a conventional media sheet into a label, and also to carry the protective backing sheet116. Once a contact or display surface is selected, backing sheet116is removed and the media attached thereto by means of adhesive film114. The function of adhesive film118, however, is to carry the combined adhesive film114and backing sheet116on the carrier120.

FIG. 5illustrates schematically a printer122making use of tape100to convert a conventional media124into a label. InFIG. 5, media124passes adhesive station130. Adhesive station130includes a first spool12aand second spool12b.Tape100originates on spool12band deploys therefrom onto spool12aand onto media124. More particularly, as media124passes spool12a,the upper-facing surface114aof adhesive film114is exposed and contacts the lower-facing surface124bof media124. A pinch roller129presses against the upper-facing surface124aof media124and established good adhesion between the upper-facing surface114aof film114and the lower-facing surface124bof media124. As with printer22, it is suggested that spool12abe biased upward and against pinch roller129to maintain good contact between adhesive surface114aand media surface124b.Media124then carries with it both adhesive film114and backing sheet116as contiguous sections104. In other words, tape100splits at adhesive station130with a first portion, i.e., adhesive film114and backing sheet116, being carried away in sections104on media124and a second portion, i.e., adhesive film118, carrier120and unused sections104, being taken up on spool12a.

Printer122further includes a print head128and feed rollers126according to conventional printing methods and structures. Print head128applies print imaging to the upper-facing surface124aof media124. Feed rollers126propel media124suitably through printer122. The resulting output of printer122is an arbitrary media124, i.e., a media not originally designed for use as a label, converted into an adhesive label, i.e., a media having both selected print imaging as applied in a printing process by printer122and an adhesive film114.

FIG. 6illustrates a third alternative tape200. InFIG. 6, tape200includes two components, an adhesive film214and a carrier220. Tape200is similar to tape10in that film214includes an upper-facing adhesive214aand a lower-facing adhesive214b.Carrier220includes an upper-facing surface220bcontacting lower-facing surface214bof film214and has a lower-facing surface220a.A leader220cextends beyond the end of film214. Thus, tape200may be provided on a spool12with leader220cwrapped about the exterior outward-facing surface214aas provided prior to use. Generally, in use tape200automatically adheres to a selected media during a print imaging process. In this case, however, the resulting output includes a selected media including print imaging on one side and the adhesive film214on the other side. Thus, use of tape200under one aspect of the present invention contemplates output not including the carrier220. In other words, when output from printer122′ (FIG. 7), adhesive surface214bis exposed and ready for use, i.e., ready for adhesion to a selected contact or display surface.

FIG. 7illustrates schematically mechanical features of a printing device making use of the tape200ofFIG. 6. InFIG. 7, printer122′ is similar to printer122ofFIG. 5but includes also a cutter230. Generally, tape200originates at spool12bat adhesive station130. As media124passes station130, tape200engages at surface214athe lower-facing surface124bof media124. Upwardly biasing spool12aof station130maintains good contact between adhesive surface114aand media surface124b.As such, media124carries away film214, but carrier220collects on spool12a.Thus, as printer122aejects media124therefrom, media124carries thereon film214with adhesive surface214bexposed and ready for adhesion to a selected contact or display surface.

Selecting the relative degree of adhesion provided by film214allows stacking of media124including film214attached thereto. More particularly, the degree of adhesion between adhesive surface214aand lower-facing surface124bof media124should be very strong. The degree of adhesion between adhesive surface214band media124, specifically, upward-facing surface124athereof, should be less. In other words, by establishing a relatively smaller degree of adhesion between surface214band surface124a,a stack of media124including film214may be organized and separated without separating individual media124from the associated film214. In this manner, media124may stack in the output tray of printer122′ without user intervention. As such, resulting output, i.e., adhesive-bearing labels, may be used as “sticky notes” or other such non-permanent labeling applications. Otherwise, i.e., with relatively stronger adhesion available at surface214b,user intervention may be employed as each media124ejects from printer122′. In either case, cutter230severs film214at the trailing edge of media124upon ejection from printer122′.

It is understood that while the embodiments illustrated herein are shown in side view without illustrating the width of a particular media or adhesive film attached thereto during a printing process, a given implementation may include adhesive having width corresponding to or less than a given media width. Furthermore, the length dimension of adhesive film may be equal to or less than the corresponding length dimension of media attached thereto. Thus, a user may use adhesive film of various widths under the present invention. Sensors within the various printers described herein may be employed to locate the leading and rear edges of media20as media20passes therethrough. Spools12aand12bcan be driven to control and locate adhesive to prevent application of adhesive film beyond the edges of media20. Furthermore, sections104as described herein may be of sufficiently small dimension in the feed direction so as to minimize any registration issues which may arise, i.e., registration of the leading or trailing edges of adhesive film relative to the leading or trailing edges of media. Thus, controllably biasing a spool bearing adhesive as described herein in combination with media edge detection will support segmented adhesive registration relative to media edges.

Thus, improvements in label making methods and apparatus have been shown and described. The present invention permits use of conventional media to produce labels. In other words, media not originally intended for use as labels may be used as labels under the present invention. In this regard, a user has opportunity to select media from a range of given media sizes, i.e., media sizes which may be fed through the printer adapted in accordance the present invention. Users may apply conventional sheet-form media such as standard paper sizes or standard card stock sizes such as are often selectable as media for print imaging, but heretofore not selectable as label-making media. As a result, a user has a broader spectrum of choices available for label media under the present invention.

It will be appreciated that the present invention is not restricted to the particular embodiment that has been described and illustrated, and that variations may be made therein without departing from the scope of the invention as found in the appended claims and equivalents thereof.