Abstract:
A labeling media for electronic printers according to the present invention has labels integral with a carrier strip. The labels are defined by a die cutting process outlining the labels and cutting away portions of the carrier strip adjacent to the labels to allow for release of the labels by hand after being printed. The labels remain attached to the carrier strip at one or more tack points at various locations, which are broken by the user when releasing the labels from the carrier strip. The labels are evenly spaced throughout the length of the carrier strip and are fixed relative to reference guides formed in the carrier strip.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     (Not Applicable) 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     (Not Applicable) 
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates to labeling media, and more particularly to labeling media for use in electronic printing devices. 
     2. Description of the Related Art 
     There are a number of industrial applications requiring identifying markers for tagging components in complicated assemblies or wiring configurations, such as in aircraft electronics and manufacturing control systems. Wires may be marked very simply by writing an identifiable legend on a tape flag affixed to the wire. An alternate method includes marking the wires with a metal or plastic marker sleeve crimped or otherwise attached to the wire. An electronic printer may be used to provide clearly recognizable alphanumeric labeling. The marker sleeves may be printed on directly, or a label may be printed and inserted in or adhered to the marker sleeve. 
     Whether it is a label or a sleeve that is printed, the labeling media typically comprises a series of printable portions that are attached to a carrier transport web, also known as a carrier strip. A transport web is generally a thin, flexible supporting member with evenly spaced apertures throughout its length that engage with a drive sprocket or are detected by a photoelectric sensing device for advancing the transport web incrementally past the print head. The transport web is fed through the printer and one or more labels are marked. The labels/sleeves are then removed from the carrier and attached to objects, such as wires, needing identification. As there are many types of label applications, there are many combinations of labels and transport webs that provide labels of varying sizes, colors and formats. 
     There are a number of U.S. patents that disclose labeling media for use in electronic printing devices in which either a marker sleeve or label is printed on and used for wire identification. These patents generally fall into one of three groups, namely: (1) label markers supported by and adhered to a separate transport web, such as U.S. Pat. No. 4,920,882; (2) label marker sleeves fastened to a separate transport web with a tab-slot or other mechanical fastening arrangement, such as U.S. Pat. No. 4,032,010; and (3) label marker sleeves made of multiple webs, such as U.S. Pat. No. 4,442,939. 
     The first two groups include separate labels or sleeves which receive the ink marking and a transport web supporting the labels/sleeves. In both cases, the labels/sleeves are removably fixed to the transport web. The difference between the groups principally resides in the way in which the labels/sleeves are joined to the transport web. Labels may be adhered either to a surface of the web or adhered to an adhesive layer backing of the web with the labels disposed in openings in the web. Sleeves, such as the tubular sleeves of the &#39;010 patent, may be joined to the transport web at tab projections sized to fit within the ends of the tubular sleeves. The third group of patents stated above has an assembly of two separate transport webs sealed together along longitudinal and transverse seams. The material is weakened at these seams so that marker sleeves can be broken away from the carrier web. 
     The above labeling media are assemblies of labels physically connected to a separate transport web in some way. The union of the labels to the web or the use of multiple webs adds to the complexity of producing the labeling media. Furthermore, the multiple components and assembly represent a large percentage of the production cost of the labeling media. Accordingly, a need exists in the art for an economical labeling media for use with a printer such that assembly is simplified or not required. 
     SUMMARY OF THE INVENTION 
     The present invention provides a one-piece labeling media having labels integral with a carrier strip, which may be fed through a printer and broken free for use. The labeling media can be economically formed from a single piece of material in a single operation, thus accomplishing the general objective of providing an economical labeling media. 
     Specifically, the present invention is a labeling media for use in a printer. The labeling media includes a carrier strip for transporting the label through a printer; a label formed in the carrier strip, and having a perimeter defined by cuts through the carrier strip; and a tack point which connects the label to the carrier strip. 
     The present invention can provide labels of a variety of rectilinear or non-rectilinear configurations, such as rectangular, square, oval or circular for use in desktop printers or portable, hand-held label printers. Additionally, the labeling media can be used with a number of printer formats, including thermal transfer printers, laser printers, ink jet printers, and dot matrix printers. For use with these and other printers, the labels can have at least one surface with an ink receptor coating, thus accomplishing another objective of providing a versatile labeling media. 
     The labels remain connected to the carrier strip by any number of discrete tack points, at any location, which can be broken free from the carrier strip by any suitable means, such as by hand, to completely separate the label from the carrier strip, thus accomplishing another objective of the present invention of providing a labeling media which is easy to use. 
     Thus, the present invention provides the object and advantage of a one-piece wire labeling media for use in a printer that has labels integral to the carrier strip so that no assembly is required. Moreover, because the labels can be formed from a die cutting process, their size and shape may be varied easily. Additionally, the labeling media can be used with many standard commercial and consumer printer formats. 
     These and other objects, advantages and aspects of the invention will become apparent from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention and reference is made therefore, to the claims herein for interpreting the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a desk top label printer with which the labeling media of the present invention may be used; 
     FIG. 2 is a side plan view of the printing mechanism of the desk top label printer of FIG. 1 showing the thermal transfer ribbon and labeling media path; 
     FIG. 3 is a perspective view of a hand held label printer with which the labeling media of the present invention may be used; 
     FIG. 4 is an exploded perspective view of the printer in FIG. 3; 
     FIG. 5 is a cut-away cross-sectional view taken along line  5 — 5  of FIG. 3 showing the thermal transfer ribbon and printing mechanism of the hand held label printer of FIG. 3; 
     FIG. 6 is a cut-away front plan view of a preferred embodiment of the labeling media of the present invention for use with the desktop printer of FIG. 1; 
     FIG. 6A is an exploded view of a label end along line  6 A— 6 A of FIG. 6; 
     FIGS. 7-13 are cut-away front plan views of alternative embodiments of the labeling media of the present invention; 
     FIG. 12A is an exploded view of a label end along line  12 A— 12 A of FIG. 12; and 
     FIG. 14 is a perspective view of a label inserted into a marker sleeve attached to a wire. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIGS. 1 and 2, a thermal transfer printer  20  suitable for use with the present invention includes a housing  22  having a front control panel  24  with a display  26  and a hinged cover  28 . The hinged cover  28  provides access to a printing mechanism  30  enclosed by the housing  22 . The printing mechanism  30  urges labeling media  32  and a thermal transfer ribbon  42  past a print head  50  which transfers ink (not shown) from the thermal transfer ribbon  42  onto the labeling media  32  to produce a printed label. 
     Referring to FIG. 2, the printing mechanism  30  includes the print head  50 , a labeling media supply spindle  36 , and a ribbon supply spindle  46 . Labeling media  32  wound onto a media supply spool  34  is mounted to the media supply spindle  36  which feeds the labeling media  32  to the print head  50 . The labeling media  32  is guided toward the print head  50  by a supply spool guide  38  and media guide  40 . A thermal transfer ribbon  42  is similarly wound onto a ribbon supply spool  44  and mounted on the ribbon supply spindle  46 . Ribbon guides  48  guide the ribbon  42  toward the print head  50 . A rotatably driven drive roller  54  pulls the labeling media  32  and thermal transfer ribbon  42  from the respective spools  34 ,  44 , and urges them in close proximity to the print head  50 . 
     A stepping motor (not shown) rotatably drives the drive roller  54  and a ribbon take-up spool  60  to advance the thermal transfer ribbon  42  and labeling media  32  past the print head  50 . The drive roller  54  is rotatably mounted on shaft  56 , and urges the thermal transfer ribbon  42  and labeling media  32  in close proximity with the print head  50  while advancing the labeling media  32  and ribbon  42  past the print head  50  during the printing process. The labeling media  32  then exits the printer  20  and the ribbon  42  is wound on the ribbon take-up spool  60  which is rotatably mounted on shaft  58 . 
     The print head  50  is arranged to cooperate with the thermal transfer ribbon  42  and the labeling media  32  such that the print head  50  can print characters or symbols on the labeling media  32 . This is described in greater detail in U.S. Pat. No. 5,078,523 which is incorporated herein by reference. 
     More specifically, a lever operated cam mechanism  49  urges the print head  50  into close abutting relation with the labeling media  32  and ribbon  42  captured between a drive roller  54  and the print head  50 . Printer circuitry (not shown) energizes the stepping motor to drive the drive roller  54 , and advance the labeling media  32  and ribbon  42 . When a desired character is input by an operator or other means, the printer circuitry energizes pixels (not shown) on the print head  50  as the labeling media  32  and thermal transfer ribbon  42  advance past the print head  50 . The pixels of the print head  50  are variously energized to imprint the character on the labeling media  32 . 
     As the labeling media  32  advances past the print head  50  during printing, it passes a photoelectric sensor  52  which is electrically connected to the printer circuitry. The sensor  52  includes a transmitter  130  and a receiver  132  disposed on opposing sides of the labeling media advancing past the print head  50 . Reference guides (discussed in further detail below) formed in the labeling media are detected by the sensor to properly advance and align the labeling media  32  with the print head  50  during printing. 
     An alternate printer suitable for use with the present invention will be described below. In the following description of the alternate printer, components substantially equivalent to the table top printer are assigned the same reference number. Referring now to FIGS. 3 and 4, an alternate thermal transfer printer  62  for hand-held use includes a molded plastic housing  64  that supports a keyboard  66  on its front surface and a display  68  positioned above the keyboard  66 . A cavity  70  formed in the housing  64  above the display  68  receives a media supply spool  34  containing the labeling media  32  formed as a roll. The spool  34  is inserted into the cavity  70 . A cover  74  enclosing the spool  34  in the cavity  70  is pivotally attached to the housing  64 . 
     A thermal transfer ribbon cartridge  76 , shown in FIGS. 4 and 5, containing a thermal transfer ribbon  42  is inserted into a cavity  78  in the side of the printer housing  64 , and received by a print frame assembly (not shown). The ribbon cartridge  76  rotatably accommodates a ribbon supply spool  44  containing the ribbon  42  and a ribbon take-up spool  60  for taking up the ribbon  42  as it is used in the thermal transfer printing process. The ribbon cartridge  76  as used with this invention is fully described in copending U.S. patent application Ser. No. 09/033,341 filed on Mar. 2, 1998 and incorporated by reference herein. 
     The labeling media  32  and ribbon  42  are advanced through the printer  62  by a stepping motor (not shown) and drive roller  54 , such as described above with respect to the desk top embodiment. Also as described above, the labeling media  32  and ribbon  42  are in intimate contact with a similarly configured thermal transfer print head  50  during printing. As in the table top embodiment shown in FIGS. 1 and 2, a sensor  52  having a sensor transmitter  130  and receiver  132  controls advancement of the labeling media  32  and ribbon  42 , as will be described below. 
     For illustrative purposes only, the labeling media and printer operation will be described with reference to the printer disclosed in FIGS. 1 and 2. However, it should be understood, that the labeling media  32  and use thereof with the printer disclosed in FIGS. 3-5, is substantially similar. Referring to FIG. 6, the labeling media  32  includes labels  100  formed as an integral part of a carrier strip  98 . Forming the labels  100  as an integral part of the carrier strip  98  provides a labeling media  32  which can be formed from a single piece of material in a single operation, such as by die cutting. This feature simplifies the label manufacturing process to provide an economical labeling media. 
     Preferably, the labeling media  32  is made from material known in the art for printing, such as filled polypropylene. Advantageously, filled polypropylene can be extruded and spooled to any length required for a particular printer application. The surface of the polypropylene material is suitable for thermal transfer printing such that no coating is required, however, an ink receptor top coat can be applied to the labeling media to define a printing surface. Although filled polypropylene is preferred, the labeling media material may be any material known in the art in which labels can be defined by cutting. For example, suitable material for use with the present invention includes paper, laminate material having a release liner, and the like. 
     The labeling media  32  width may be of any suitable lateral dimension, but typical sizes include widths between 0.75 and 3.5 inches. For example, the narrower widths would be more suitable for a hand held printer, while a larger printer can accommodate a wider labeling media. Preferably, the labeling media  32  is approximately between 15-25 mils thick. This thickness range provides a suitable balance of the opposing requirements that the labeling media  32  be flexible enough to pass through a printer, such as disclosed herein, but be sufficiently robust so that labels  100  may be easily handled and inserted into label carriers  150  (see FIG. 14) during use. However, the invention is not limited to labeling media having the above dimensions. For example, labeling media thicker than described above, may be desired if flexibility of the carrier strip is not as important as stiffness of a printed label. The size, color, and labeling media material can vary depending upon the particular printing application. 
     In a preferred embodiment shown in FIG. 6 for use in a large printer, such as shown in FIGS. 1 and 2, two columns of generally rectangular labels  100  are die cut in the carrier strip  98 . Preferably, the labels  100  are uniformly spaced along the carrier strip  98  length. The carrier strip  98  transports the labels  100  through the printer  20 , and cooperates with the printer  20  to properly align each label  100  for printing. 
     Reference guides  104  evenly spaced along the length of the carrier strip  98 , cooperate with the sensor  52  (shown in FIG. 2) to properly align each label  100  with respect to the print head  50  as the printer  20  (shown in FIG. 1) consumes the labeling media  32 . The reference guides  104  provide registration locations for the sensor  52  within the printer  20  to control advancement of the labeling media  32  through the printing mechanism  30 , and ensure the labels  100  are properly aligned with the print head  50  during printing. In the preferred embodiment, the reference guides  104  are slots disposed between the columns of labels  100 . However, as disclosed below, any shape, such as notches formed in an edge of the carrier strip may be used, or even release cuts, further defined below, can be used as reference guides. 
     Referring to FIGS. 6 and 6A, each label has a leading edge  106 , trailing edge  112 , and sides  113  joining the leading and trailing edges  106 ,  112 . The leading edge  106  is defined by a cut line  108  formed during the die cutting process along the label edge which is first to encounter the print head  50  (shown in FIG.  2 ). The cut line  108  extends between the label sides  113 , and separates the label  100  from the carrier strip  98  across the leading edge  106 . As best shown in FIG. 6A, the cut line  108  is non-continuous to form tack points  110  interrupting the cut line  108  which connect the label leading edge  106  to the carrier strip  98 . 
     Side release cuts  102  formed at each label side  113  define the lateral ends of the label  100 , and facilitate separation of the label  100  from the carrier strip  98 . Each side release cut  102  extends from the label leading edge  106  to just short of the label trailing edge  112  along each side  113  of the label  100 . These side release cuts  102  are formed by removing media material adjacent the label  100 . Removing the media material adjacent the label  100  prevents distorting or wrinkling the label  100  during the die cutting process. 
     Similarly, a trailing edge release cut  103  is formed at the trailing edge  112  of the label  100  to define the label trailing edge  112 , and facilitate separation of the label  100  from the carrier strip  98  after printing. The trailing edge release cut  103  extends slightly less than the width of the labels  100  to define tack points  114  at the junction of the trailing edge  112  and each label side  113 . As in the leading edge tack points  110 , the trailing edge tack points  114  connect the label  100  to the carrier strip  98 . 
     Referring to FIGS. 2,  5  and  6 , depending upon the construction of the printing mechanism  30 , the labeling media  32  may be required to flex through relatively small radii while advancing toward the print head  50  or unwinding from the labeling media supply spool  34 . As a result, the labels  100  may bow or flex laterally with respect to the carrier strip  98  about the tack points  110 ,  114 . If the print head  50  is mounted as a floating head, it may not be possible to adequately flatten the labels  100  against the print head  50 , which may degrade print quality. In such applications, additional tack points at other locations, such as the lateral mid-points and ends, may be needed to more adequately unite the labels  100  and the carrier strip  98 . 
     In use, referring to FIGS. 2 and 6, the printing mechanism  30  indexes each label  100  past the print head  50  by the drive roller  54  rotatably driven by the stepping motor. The stepping motor, and thereby the drive roller  54 , is controlled in part by the sensor  52 , which detects the reference guides  104  formed in the carrier strip  98 . 
     The sensor  52  detects the opaqueness of the advancing labeling media  32 . As long as the sensor  52  detects the opaque media of the carrier strip  98  or labels  100 , the stepping motor is energized at a prescribed voltage and the drive roller  54  rotates a prescribed distance sufficient to position the labels  100  adjacent to and in contact with the print head  50 . When a reference guide  104  passes between the sensor transmitter  130  and receiver  132 , the motor is energized at a second prescribed level as the label  100  passes by the print head  50  and is printed. Thus, although appearing to travel continuously at a constant rate, the labeling media  32  actually advances through the printer  20  (shown in FIG. 1) in a step-wise fashion at an overall rate of approximately 3-4 inches per second. 
     Referring to FIGS. 6-13, after the printing process the labels  100  can be released from the carrier strip  98  by cutting or breaking the tack points  110 . Due to the small amount of media comprising the tack points  110 , the labels  100  may be easily broken free from the carrier strip  98  by hand. Once the labels  100  are separated from the carrier strip  98 , they may be affixed to a component of a machine or other structure requiring identification. 
     Referring to FIG. 14, when labeling wires  130 , the label  100  may be inserted into a sleeve of a transparent label carrier  150  having legs  152  defining a semi-cylindrical channel for receiving and attaching to the insulated shaft of the wire  130 . The present invention is not limited in this regard, however, as the labels may be affixed by any suitable means to wires or any other elements. 
     The labels  100  can be formed in the carrier strip  98  to provide a variety of alternate embodiments, some of which are shown in FIGS. 7-13 and are discussed below. In the alternate embodiments, the carrier strip  98  may have different widths and lengths and include labels  100  of various shapes and sizes. Although possibly having a different form, common elements, such as the carrier strip  98 , labels  100 , release cuts  102 , and reference guides  104  are designated using the same reference as in the first embodiment. 
     Referring to FIG. 7, in an alternate embodiment, a single column of labels  100  is formed in the carrier strip  98 . As in the embodiment shown in FIG. 6, each label  100  is defined by the cut line  108  and release cuts  102 ,  103  and connected to the carrier strip  98  by two tack points  110  at the leading edge  106  and two tack points  114  at the trailing edge  112 . However, in this embodiment, the reference guides  104  are notches formed along a side of the carrier strip  98 . 
     In another alternate embodiment of the present invention, shown in FIG. 8, each label  100  has a trailing edge release cut  103  which intersects with the side release cuts  102 . The intersecting release cuts  102 ,  103  free the label trailing edge  112  from the carrier strip  98 . Thus, only the two tack points  110  at the label leading edge  106  connect the label  100  to the carrier strip  98 , thus simplifying separating the label  100  from the carrier strip  98 . 
     Another embodiment shown in FIGS. 9 and 10, as applied to the embodiment of FIG. 8, includes a thin layer of an adhesive tape  118 , such as splicing tape and the like, applied to a surface of the labeling media  32  across at least a portion of each label  100  and the carrier strip  98 . This will provide a backing support for the labeling media  32  to ensure the labels  100  and the carrier strip  98  flex consistently. The adhesive tape  118  can be applied in multiple longitudinal (FIG. 9) or lateral strips, or as a single strip (FIG.  10 ), according to the lateral dimension of the labeling media  32  and the adhesive tape  118 . As an alternative to applying the adhesive tape  118 , an adhesive can be applied to the labeling media  32 , and protected by a release liner (not shown). 
     Referring now to FIG. 11, in yet another embodiment of the present invention, each label  100  is defined by the leading edge cut line  108 , and the release cuts  102 ,  103  as in the first embodiment. However, the trailing edge release cut  103  defines two triangular projections  120  forming tack points at the label trailing edge  112  inward from each label side  113 . 
     In another embodiment shown in FIGS. 12 and 12A, the labels  100  are substantially identical to the embodiment of FIG. 7, except the leading edge  106  of each label  100  is defined by a leading edge release cut  122  substantially identical to the trailing edge release cut  103  to form the tack points  110  connecting the label leading edge  106  to the carrier strip  98 . 
     Referring now to FIG. 13, the labels  100  are substantially identical to the embodiment of FIG. 11, except the label leading edge  106  is defined by a leading edge release cut  122  which extends slightly less than the width of the labels  100  to define tack points  110  at the junction of the leading edge  106  and each label side  113 , and defines a triangular projection  123  proximate the lateral midpoint of each label  100 . The triangular projection  123  tapers in a direction opposite the projections  120  formed at the label trailing edge  112 , and is a tack point which connects the label leading edge  106  to the carrier strip  98 . 
     Referring again to FIGS. 1,  2 ,  3 , and  6 , preferably, labeling media  32  having multiple columns of labels  100  are used with the desktop printer  20  and the single column embodiments are used in the hand-held printer  62 . The larger size of the desktop printer  20  permits the use of wider labeling media  32  having multiple columns of labels  100 , thus allowing multiple labels  100  to be printed on each pass by the pixel line of the print head  50 . However, the single column embodiments may be used in both the desktop  20  and hand-held printers  62 . Referring also to FIGS. 7-13, when a single column labeling media  32  is used in the desktop printer  20 , the trailing edge release cut  103  (or leading edge release cut  122  depending upon embodiment) can be used as a guide by the sensor  52  for advancing the labeling media  32  through the printer  20  and properly positioning the labels  100  next to the print head  50  during printing. 
     Various methods known in the art may be used to practice the present invention as disclosed herein. The preferred embodiment discussed above discloses labeling media for use in a thermal transfer printer. However, the labeling media of the present invention may also be used with other printer formats such as dot matrix, laser and ink-jet style printers. In particular, due to the projecting pin print head arrangement of known dot matrix printers, small, hand-held dot matrix printers could operate without securing the labels at additional tack points or adding an adhesive layer as may be needed in hand-held thermal transfer printers. 
     Additionally, it is also within the scope of the invention for the labeling media to include labels having other rectilinear or non-rectilinear configurations, such as square, oval or circular. Moreover, although the drawings illustrate embodiments with two, four, and five tack points, embodiments with one, three, or more than five tack points are also within the scope of the present invention. Similarly, the location of the tack points shown in the figures is not intended to limit the scope of the invention. Lastly, the labeling media is shown as having one column or two columns of labels, however, the invention includes labeling media having three or more of such columns and one or more columns of reference guides. 
     Thus, while the foregoing specification illustrates and describes the preferred embodiments of this invention, it is to be understood that the invention is not limited to the precise construction herein disclosed. The invention can be embodied in other specific forms without departing from the spirit or essential attributes. For example, the carrier strip can be a standard A4 or 8.5″×11″ sheet of labeling media material which is fed through a printer. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope of the invention.