Patent Description:
Adhesive signs are often used in retail applications to provide product information, such as prices and reference numbers of items offered for sale. These are adhered on or adjacent to store shelves that display the items. One process used to manufacture adhesive signage for store shelving includes applying an adhesive tape to a paper or other substrate. The product information is then printed on the resulting multi-layer assembly, and it is cut to the desired size for the signs. The adhesive tape includes a carrier layer with a pressure sensitive adhesive (PSA) on one side and a permanent adhesive on the other. The PSA layer is protected with a release liner. Problems can occur in printing the multi-layer assembly, including deposit of the adhesive on the printer components, such as print heads, slitters and diecutters, and feed problems due to uneven deformation of the multi-layer assembly. The adhesive tape used in the process is applied to the entire paper surface and adds considerable cost to the signs. Additionally, at a store, the removal of the tape release liner can be time consuming, particularly when large numbers of signs are to be positioned throughout the store.

There remains a need for an adhesive sign and method of manufacture which address these problems.

The following references are mentioned:
UV-curable inks with adhesive properties are described, for example, in <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

Printing of signage is described, for example, in <CIT>; <CIT>; and <CIT>.

US patent application <CIT> discloses a tampering indicating article with patterned adhesives. The article has a first substrate, an adhesive layer disposed on the first substrate. The adhesive layer has a first and second adhesive region having a first and second adhesive region, respectively. The first adhesive region forms indicia.

European patent application <CIT> relates to methods, systems and compositions for forming high resolution, pressure sensitive adhesive patterns or films on a range of substrates. The compositions comprise a curable, fluid composition which, when cured, forms a pressure sensitive adhesive.

<CIT> discloses an inkjet printing method including the steps a) inject printing on a substrate a UV curable colourless primer including monofunctional monomers; b) at least partially UV curing said primer; and c) inkjet printing one or more UV curable colour inkjet inks on the at least partially cured primer.

<CIT> further discloses methods of printing articles using a photocurable adhesive promoter and varnish composition jetted onto a media substrate.

European application <CIT> relates to inkjet recording methods including: discharging first UV curable ink of a radical polymerization type which contains a radical photopolymerization initiator and a radical polymerization compound in which transmittance at a wavelength of <NUM> is less than or equal to <NUM>%, onto a recording medium; and UV curing the first UV curable ink with a UV LED in which peak intensity of the irradiated UV light is equal to or more than <NUM> mW/cm<NUM>.

In accordance with one aspect of the exemplary embodiment, is an adhesive sign according to claim <NUM> including a transparent substrate layer having opposed first and second surfaces. An adhesive layer having an inner surface and an outer surface is disposed on the second surface of the substrate layer, the adhesive layer defining an exposed region of the outer surface for attachment to an associated structure. The adhesive layer is derived from a photo-curable composition suitable for inkjet printing wherein the viscosity of the uncured photo-curable adhesive composition is from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting. An ink layer is disposed on the second surface of the substrate layer. The ink layer includes an image. The ink layer is derived from a photo-curable composition suitable for inkjet printing, the image being visible through the transparent substrate, wherein the viscosity of the uncured photo-curable ink composition is from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting.

In accordance with another aspect of the exemplary embodiment, there is provided a method of forming an adhesive sign according to claim <NUM>, including providing a transparent substrate layer. A first composition is inkjet printed on the substrate layer. The first composition includes at least one of a photo-curable monomer and a photo-curable oligomer. The first composition is an uncured adhesive composition and has a first viscosity of from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting. A second composition is inkjet printed to form an image on the substrate layer. The second composition includes a colorant and at least one of a photo-curable monomer and a photo-curable oligomer. The second composition is an uncured ink composition having a having a viscosity of from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting, wherein the image is visible through the transparent substrate. The first composition and the second composition are applied to the same side of the substrate, and photo-cured on the substrate, whereby the first composition defines an exposed adhesive surface which has a second viscosity higher than the first viscosity.

Also disclosed herein is an inkjet printing apparatus which includes a transport system which transports a substrate material along a paper path from a media feeder to a curing station. A first inkjet printhead, intermediate the media feeder and the curing station, deposits an adhesive-forming composition onto the substrate material. A second inkjet printhead, intermediate the media feeder and the curing station, which deposits at least one ink composition onto the substrate material. The curing station cures the adhesive-forming composition to form an adhesive layer on the substrate material with an adhesive exposed surface region and cures the at least one ink composition to form an ink layer on the substrate material, which defines an image. The apparatus optionally includes at least one of a slitter, downstream of the curing station, which cuts the cured substrate material to form substrate sheets of a selected size, each sheet having an adhesive layer and an ink layer thereon, and a stacker, downstream of the curing station, which stacks the cured and optionally cut substrate material with the adhesive layer and the ink layer thereon to form a stack.

Also disclosed herein is an adhesive sign includes a transparent substrate having a first surface and a second surface, the first and second surfaces being spaced by a thickness of up to <NUM>. A photo-cured adhesive layer is disposed on the second surface, the adhesive layer defining an exposed region for attachment to an associated structure. The substrate and adhesive layer, in combination, define a transparent window through the adhesive sign. A photo-cured ink layer is disposed on the second surface, the ink layer including an image.

With reference to <FIG>, one embodiment of an adhesive printed sign (or label) <NUM> is shown. The illustrated sign consists of a substrate layer <NUM>, an adhesive layer <NUM> and a printed layer or coating <NUM>, although additional layers may be included in some embodiments.

The substrate layer <NUM> may be formed from a flexible transparent printable medium, such as plastic, which defines opposed first and second substantially planar surfaces <NUM>, <NUM>, each having a length l<NUM>. The surfaces <NUM>, <NUM> are spaced by a thickness t<NUM>, which is the smallest dimension of the substrate layer. The thickness t<NUM> may be, for example, from <NUM> to <NUM>, such as up to <NUM>. The length l<NUM> may be any suitable length for a sign, such as from <NUM>-<NUM>.

The adhesive layer <NUM> is be formed from a photo-curable adhesive, such as a UV-curable primer, of the type conventionally used for adhering UV-curable inks to a substrate. However, in the exemplary embodiment, the adhesive layer <NUM> does not primarily serve that function. The adhesive layer <NUM> is disposed on the second surface <NUM> of the substrate layer <NUM> and defines an exposed region on its outer surface <NUM>, which is adhesive. Being exposed allows the adhesive printed sign <NUM> to be adhered to a surface of a structure, such as a display unit, by the adhesive layer <NUM>. An inner surface <NUM> of the adhesive layer is adhered directly to the second surface of the substrate layer <NUM>. The adhesive layer <NUM>, or at least the outer surface <NUM> thereof, has a length l<NUM> which is no greater than l<NUM>, e.g., less than l<NUM>, such that the adhesive layer covers only a portion of the substrate layer, e.g., as a strip. In other embodiments, the adhesive layer may be partially, but not wholly, covered by the printed layer <NUM>. In all embodiments, at least a portion of the adhesive layer remains exposed after forming the printed layer. The length l<NUM> of the exposed portion of the adhesive layer may be, for example, from <NUM>-<NUM>. While the illustrated adhesive layer <NUM> is shown as extending from a first end <NUM> of the substrate layer, in other embodiments, the adhesive layer <NUM> may be offset from the first end. The adhesive layer has a thickness t<NUM> which may be, for example, at least <NUM> microns (µm), such as up to <NUM>, or up to <NUM>. The thickness of the adhesive layer may be adjusted to suit the smoothness of the substrate, with higher thicknesses suited to more uneven substrate surfaces.

The printed layer <NUM>, which may include one or more ink layers, is disposed on the second surface <NUM> of the substrate layer <NUM>. The printed layer <NUM> includes one or more photo-cured inks, such as cured UV-curable inks, which, in combination, define an image. The printed layer <NUM> has a thickness t<NUM> and a length l<NUM> which is less than l<NUM>, e.g., no more than l<NUM> - l<NUM>, to leave a transparent window <NUM> which provides visibility through the sign <NUM>. The thickness t<NUM> may be, for example, from <NUM>-<NUM> microns, such as up to <NUM> microns. The length l<NUM> may be, for example, from <NUM>-<NUM>. While the illustrated printed layer <NUM> is shown as extending from a second end <NUM> of the substrate layer, in other embodiments, the printed layer <NUM> may be offset from the second end.

In use, the first surface <NUM> of the sign <NUM> is outermost, with the printed layer <NUM> being visible through the substrate layer <NUM> and with the adhesive layer <NUM> attaching the sign to a display structure <NUM>, such as a store shelf or display bar, as illustrated in <FIG>.

With reference to <FIG>, another embodiment of an adhesive printed sign <NUM> is shown. The sign can be similarly configured to that of <FIG>, except as noted. Similar elements are accorded the same numerals. In this embodiment, the substrate layer <NUM> may be formed from a flexible, transparent or opaque printable medium, such as plastic, paper, or card. The adhesive layer <NUM> is disposed on the second surface <NUM> of the substrate layer <NUM>, as in the embodiment of <FIG>, while the printed layer <NUM> is disposed on the opposed first surface <NUM> and extends partially or fully between the ends <NUM>, <NUM> of the substrate <NUM>, i.e., l<NUM> ≤ l<NUM>.

With reference to <FIG>, a stack <NUM> is assembled from multiple adhesive printed signs <NUM> (or <NUM>). In the stack, the adhesive layer <NUM> of each sign is removably and adhesively attached to the sign below it, e.g., directly to the substrate layer <NUM>, except for the bottom sign, which may be supported on a release liner <NUM>. The signs can be peeled, in turn, from the stack <NUM>, and attached to a display structure <NUM>, as illustrated in <FIG>. In the illustrated embodiment, a text image or other image <NUM> on the display structure <NUM> is visible through the adhesive layer <NUM> and transparent substrate <NUM>, via the window <NUM>. The printed layer <NUM>, which includes a printed image <NUM> (such as text, a photographic image, and/or graphics) is visible through the transparent substrate <NUM>.

The material of the substrate layer <NUM> can be paper, card, or a synthetic polymer, which is transparent. Example polymers include C<NUM>-C<NUM> polyalkylene polymers, such as polyethylene and polypropylene, polyethylene terephthalate, polycarbonate, polyacrylates and methacrylates, such as polymethylmethacrylate, polyvinylchloride, mixtures thereof, and copolymers thereof. The substrate may alternatively be formed from glass or metal.

The adhesive layer <NUM> is formed from a photo-curable (e.g., UV-curable) adhesive-forming composition which includes one or more photo-curable monomers and/or oligomers (which are defined as containing up to <NUM> monomer units) and generally a photoinitiator, which is capable of initiating free-radical polymerization of the monomers/oligomers. The adhesive-forming composition has a viscosity and a surface tension which allow the composition to be dispensed in droplet form from a printhead of an inkjet printer. The adhesive-forming composition is photo-curable by exposure to a radiation source, such as a UV-emitting light emitting diode (UV-LED). When fully photo-cured (i.e., no further polymerization occurs with further exposure to the curing radiation), the resulting adhesive layer has a higher viscosity than the adhesive-forming composition but remains viscous rather than solid and is tacky. It is therefore able to wet a surface, such as the display structure <NUM> (unlike the cured printed layer <NUM>, which cannot wet another surface). For example, the fully photo-cured adhesive composition may have a viscosity of at least <NUM> cP (mPa·s), or at least <NUM>,<NUM> mPa·s, or up to <NUM>,<NUM>,<NUM> mPa·s, or up to <NUM>,<NUM> mPa·s, at <NUM>, as determined with a Brookfield Dial Reading Viscometer (serial no <NUM>) with an RV/HB-<NUM> spindle setting, available from AMETEK Brookfield, Middleboro, MA <NUM> USA. brookfieldengineering. com /products/viscometers/laboratory-viscometers/dial-reading-viscometer.

The viscosity of the uncured adhesive composition is from <NUM> to <NUM> mPa·s, such as up to <NUM> mPa·s, or at least <NUM> mPa·s, or at least <NUM> mPa·s, such as about <NUM> mPa·s, at <NUM>, as determined with the Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting.

Example monomers for use in the adhesive-forming composition include mono-, di-, and poly-functional acrylates, methacrylates, alkoxylated acrylates, and oligomers thereof. Examples include <NUM>,<NUM>-hexanediol diacrylate, tripropylene glycol diacrylate, propoxylated-<NUM>-neopentyl glycol diacrylate, alkoxylated hexanediol diacrylate, trimethylol propane triacrylate, ethoxylated trimethylolpropane triacrylate, pentaerythritol tetraacrylate, polyfunctional oligomers such as epoxy acrylates, urethane acrylates and polyester acrylates.

UV primers are used currently to provide a tacky surface to allow UV inks to adhere to solid products such as water bottles or other objects being printed in systems such as the Contoura™ printer by Xerox Corporation. One example UV primer composition suitable for forming the adhesive layer is available from Molecule, <NUM>-A Port Chicago Hwy, Concord, CA <NUM> (https://www. ink/) under the tradename MO178 UV Primer, which remains adhesive when <NUM>% cured, and has been formulated for use in drop-on-demand printers suited to printing on contoured surfaces. Other UV-curable inks with adhesive properties which may be used are described, for example, in above-mentioned <CIT>, <CIT>, <CIT>, <CIT>, and <CIT>.

In one embodiment, the adhesive-forming composition is free or substantially free of silicon-containing compounds, including monomers, oligomers, and polymers, such as silicones. By substantially free, it is meant that the adhesive-forming composition contains less than <NUM> wt %, or less than <NUM> wt %, or less than <NUM> wt %, or less than <NUM> wt % of silicon-containing compounds.

The printed layer <NUM> is formed from one or more photo-curable (e.g., UV-curable) ink compositions. Each ink composition includes a colorant, such as a pigment or dye, one or more photo-curable monomers and/or oligomers, generally a photoinitiator capable of initiating free-radical polymerization of the monomers/oligomers, and optionally one or more auxiliary additives. The UV-curable ink composition is of a type that undergoes a polymerization reaction and curing upon exposure to a radiation source, such as a UV-emitting light emitting diode (UV-LED). In contrast to the adhesive composition, however, the ink compositions harden when fully cured and are no longer viscous. For example, the photo-cured inks may have a hardness of at least <NUM> or at least <NUM> on the Mohs' hardness scale and/or a hardness, as measured by indentation, of at least <NUM> MPa, as determined by the Knoop hardness test. The viscosity of the uncured ink composition is from <NUM> to <NUM> mpPa-s, such as up to <NUM> mpPa-s or at least <NUM> mPa-s, at <NUM>, as determined with the Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting.

Example monomers and oligomers for use in the ink composition include unsaturated monomers, such as monofunctional, di-functional, and polyfunctional acrylates, methacrylates, N-vinylamides, acrylamides, and combinations thereof. Example acrylates include isoamyl acrylate, stearyl acrylate, lauryl acrylate, octyl acrylate, decyl acrylate, isoamylstyl acrylate, isostearyl acrylate, <NUM>-ethylhexyl-diglycol acrylate, <NUM>-hydroxybutyl acrylate, <NUM>-acryloyloxyethylhexahydrophthalic acid, butoxyethyl acrylate, ethoxydiethylene glycol acrylate, methoxydiethylene glycol acrylate, methoxypolyethylene glycol acrylate, methoxypropylene glycol acrylate, phenoxyethyl acrylate, tetrahydrofurfuryl acrylate, isobornyl acrylate, <NUM>-hydroxyethyl acrylate, <NUM>-hydroxypropyl acrylate, <NUM>-hydroxy-<NUM>-phenoxypropyl acrylate, vinyl ether acrylate, vinyl ether ethoxy(meth)acrylate, <NUM>-acryloyloxyethyl succinic acid, <NUM>-acryloyloxyethyl phthalic acid, <NUM>-acryloyloxyethyl-<NUM>-hydroxyethyl phthalic acid, lactone modified flexible acrylate, and t-butylcyclohexyl acrylate, triethylene glycol diacrylate, tetraethylene glycol diacrylate, polyethylene glycol diacrylate, dipropylene glycol diacrylate, tripropylene glycol diacrylate, polypropylene glycol diacrylate, <NUM>,<NUM>-butanediol diacrylate, <NUM>,<NUM>-hexanediol diacrylate, <NUM>,<NUM>-nonanediol diacrylate, neopentyl glycol diacrylate, dimethylol-tricyclodecane diacrylate, bisphenol A EO (ethylene oxide) adduct diacrylate, bisphenol A PO (propylene oxide) adduct diacrylate, hydroxypivalate neopentyl glycol diacrylate, propoxylated neopentyl glycol diacrylate, alkoxylated dimethyloltricyclodecane diacrylate and polytetramethylene glycol diacrylate, trimethylolpropane triacrylate, ethoxylated trimethylolpropane triacrylate, tri(propylene glycol) triacrylate, caprolactone modified trimethylolpropane triacrylate, pentaerythritol triacrylate, pentaerithritol tetraacrylate, pentaerythritolethoxy tetraacrylate, dipentaerythritol hexaacrylate, ditrimethylolpropane tetraacrylate, glyceryl propoxy triacrylate, caprolactam modified dipentaerythritol hexaacrylate, caprolactone acrylate, cyclic trimethylolpropane formal acrylate, ethoxylated nonyl phenol acrylate, isodecyl acrylate, isooctyl acrylate, octyldecyl acrylate, alkoxylated phenol acrylate, tridecyl acrylate, alkoxylated cyclohexanone dimethanol acrylate, alkoxylated cyclohexanone dimethanol diacrylate, alkoxylated hexanediol diacrylate, dioxane glycol diacrylate, dioxane glycol diacrylate, cyclohexanone dimethanol diacrylate, diethylene glycol diacrylate neopentyl glycol diacrylate, propoxylated glycerine triacrylate, propoxylated trimethylolpropane triacrylate, di-trimethylolpropane tetraacrylate, dipentaerythritol pentaacrylate, ethoxylated pentaerythritol tetraacrylate, methoxylated glycol acrylates and acrylate esters.

Example methacrylates may be used that correspond to the above-mentioned acrylates. Examples of such methacrylates include methoxypolyethylene glycol methacrylate, methoxytriethylene glycol methacrylate, hydroxyethyl methacrylate, phenoxyethyl methacrylate, cyclohexyl methacrylate, tetraethylene glycol dimethacrylate, and polyethylene glycol dimethacrylate.

Example N-vinylamides include N-vinylcaprolactam and N-vinylformamide. Example acrylamides include acryloylmorpholine.

The monomers and oligomers may together be at least <NUM> wt %, or at least <NUM> wt %, or at least <NUM> wt %, or at least <NUM> wt %, or up to <NUM> wt % of the ink composition.

Example photo-initiators for use in the ink composition(s) and/or adhesive-forming composition include benzophenone, benzoin, acetophenone, thioxanthone, and acylphosphine oxide. The photo-initiator maybe at least <NUM> wt %, or at least <NUM> wt % of the respective composition, such as up to <NUM> wt %, or up to <NUM> wt %, or up to <NUM> wt %, or up to <NUM> wt %.

Example colorants include organic dyes and pigments. Example pigments include milled pigments, including inorganic pigments, such as carbon black, titanium dioxide, cobalt blue, chrome yellow, and iron oxide, and organic pigments.

Example auxiliary additives include defoaming agents, dispersants, wetting agents, surfactants, leveling agents, and the like.

The ink composition may include a liquid medium such as water or an organic solvent, such as an alkane, alcohol, ether, combination thereof, or the like.

Suitable release liners <NUM> include silicone- or polyalkylene-coated release substrates, such as those formed of paper, polyester, polyethylene or a thermoplastic material. Such substrates are often coated with a thermally-cured silicone release coating, such as a cross-linked, vinyl functionalized polydimethylsiloxane, UV curable silicone, or electron-beam curable silicone.

With reference now to <FIG>, an inkjet printing apparatus <NUM> suited to forming the sign (or label) <NUM> in simplex mode is shown. A media feeder <NUM> feeds substrate material <NUM>, in roll or sheet form, in a downstream direction A along a paper path <NUM>. The substrate material <NUM> is transported along the path <NUM> by a transport mechanism composed of driven rollers <NUM>, idler rollers <NUM>, belts, and/or other transport members. Optionally, a pretreatment is applied to the substrate material <NUM> at a pretreatment station (not shown), such as a flame, plasma discharge, or corona discharge. A first printhead assembly <NUM> deposits an adhesive-forming composition <NUM> onto the substrate material <NUM>. A second printhead assembly <NUM>, downstream of the first printhead assembly <NUM>, deposits one or more ink compositions <NUM> onto the adhesive-coated substrate material <NUM>. Optionally, a first UV curing station <NUM>, intermediate the printhead assemblies <NUM>, <NUM>, at least partially cures the adhesive-forming composition prior to application of the adjacent ink composition <NUM>. A second (or only) UV curing station <NUM>, downstream of second printhead assembly <NUM>, cures the ink composition <NUM> and may cure or partially cure the adhesive-forming composition <NUM>. A slitter <NUM>, downstream of the UV curing station <NUM>, receives the UV-cured substrate <NUM> with the adhesive layer <NUM> and printed layer <NUM>. The slitter <NUM> cuts the substrate into sign-sized pieces. A stacker <NUM> collates and stacks the cut pieces into a stack <NUM>, which is output from the printer device. As will be appreciated, the substrate, in sheet form, may be assembled into a stack before final cutting to the desired shape. A release liner <NUM> may be applied to the bottom layer of the stack before or after assembly.

The operating components of the printing apparatus <NUM>, such as media (sheet) feeder <NUM>, print head assemblies <NUM>, <NUM>, curing stations <NUM>, <NUM>, slitter <NUM>, stacker <NUM>, and media transport system <NUM>, <NUM>, may be under the control of a controller <NUM>. The controller receives image data <NUM> for forming one or more images <NUM> on the sheet media <NUM> and may also receive instructions <NUM> regarding a selected size and position of the adhesive layer <NUM>. Since a single sheet of media may be cut to form smaller-sized signs, several images and adhesive layers may be printed on a single sheet <NUM> or continuous roll. The controller may include an input device <NUM>, which receives the image data <NUM> and instructions <NUM>, an input/output device <NUM>, which outputs control instructions to the operational components of the printing device, and which also may receive feedback therefrom, memory <NUM> which stores instructions for operating the printing apparatus, or various operational components thereof, and a processor device <NUM>, in communication with the memory, for executing the instructions. The hardware components <NUM>, <NUM>, <NUM>, <NUM> of the controller <NUM> may be communicatively connected by a data/control bus <NUM>.

The printhead assemblies <NUM>, <NUM> include printheads which eject the adhesive-forming composition and ink composition(s), respectively, onto the media sheets <NUM>. In particular, the assembly <NUM> includes a supply <NUM> of adhesive-forming composition <NUM>, in liquid form. The controller <NUM> modulates the volume of the adhesive drops ejected by the printheads of the assembly <NUM> to form the adhesive layer. The controller <NUM> also modulates the volume of the ink drops ejected by the printheads of the assembly <NUM> to form the selected image <NUM>. In particular, the controller <NUM> is configured to receive image data from an image data source (not shown) and optionally instructions for the adhesive layer, and generate firing signals for the operation of the printheads in the printhead assemblies <NUM>, <NUM> for the formation of the adhesive layer and ink images on media sheets as the sheets pass by the printheads. The controller may operate the media feeder <NUM> to retrieve media sheets from a storage receptacle for the sheets and feed the sheets onto the paper path and the transport system components <NUM>.

The image data <NUM> generally include information in electronic form that the controller renders and uses to operate the inkjet ejectors in printheads in the printer to compensate for moisture in ink and to form an ink image on media sheets. These data can include text, graphics, pictures, and the like. The operation of producing images with colorants on print media, for example, graphics, text, photographs, and the like, is generally referred to herein as printing or marking. The inkjet printing apparatus <NUM> may be a drop-on-demand inkjet printer.

The printheads of assemblies <NUM>, <NUM> are configured with inkjet ejectors to eject drops of the adhesive-forming composition <NUM> or ink composition <NUM> from a supply <NUM>, respectively, onto a receiving surface <NUM> of the substrate <NUM>. A typical printhead suited to use in the assembly <NUM> includes a plurality of inkjet ejectors that eject ink drops of one or more ink colors onto the image receiving surface in response to firing signals that operate actuators in the inkjet ejectors. The inkjets are arranged in an array of one or more rows and columns in the process and cross-process directions. In some embodiments, the inkjets are arranged in staggered diagonal rows across a face of the printhead. Various printer embodiments include one or more printheads that form ink images on an image receiving surface. Some printer embodiments include a plurality of printheads arranged in a print zone. As an example, print head ejectors may be designated for cyan, magenta, yellow, and black (C, M, Y, K) and optionally white inks, respectively. The printhead employed in the assembly <NUM> may be similarly configured, since the adhesive-forming composition are of low enough viscosity to be dispensed as droplets in the same manner.

In the embodiment of <FIG>, the adhesive composition and ink composition(s) are applied to the same side of the substrate, so there is no need to position an inverter between the assemblies <NUM>, <NUM>. To form the signs of <FIG>, the printing apparatus may be similarly configured to that of <FIG>, except that an inverter is positioned between the assemblies <NUM>, <NUM>, e.g., downstream of the first UV curing station <NUM> and upstream of the assembly <NUM>. The inverter, where used, turns the sheet media over, so that the adhesive layer and printed layer are formed on opposed sides of the substrate.

In some embodiments, the positions of the assemblies <NUM>, <NUM> may be reversed, such that the image <NUM> is formed on the substrate prior to forming the adhesive layer. In some embodiments, the assemblies <NUM>, <NUM> may be combined into a single assembly (and the intermediate UV curing station omitted).

As used herein, the term "downstream direction" or "process direction" refers to movement along the path towards the stacker and "cross-process direction" refers to a direction orthogonal to the process direction axis in the plane of the paper path <NUM>.

The UV curing stations <NUM>, <NUM> (or more generally radiation-curing stations) include one or more sources of radiation, such as UV radiation. As an example, each may include a UV-emitting LED or an array of such UVLEDs. The UVLEDs are controlled to apply sufficient radiation to cure the image <NUM> and the adhesive layer <NUM>.

The apparatus <NUM> may include a graphical user interface (GUI) <NUM>, which allows a user to input commands to the processor, such as one or more of the size of the signs, the number of signs to be assembled into a stack, amount of adhesive-forming composition to be used, and the like, or information from which these parameters can be determined. The apparatus <NUM> may include an optical scanner (not shown) as the source of the image data <NUM>.

With reference to <FIG>, a method for forming a stack of printed adhesive signs which can be performed with the printing apparatus of <FIG> is shown. The method begins at S100.

At S102, image data <NUM>, and optionally adhesive layer instructions <NUM> are received by the controller <NUM>.

At S104, print media <NUM>, such as single layer clear stock, is fed by the media feeder <NUM> to a paper path <NUM> of the printing apparatus <NUM>. In some embodiments, the surface <NUM> of the print media may be pretreated, e.g., by flame, corona, or plasma treatment, to improve wettability with the adhesive layer.

At S106, an adhesive-forming composition <NUM> is ink-jetted onto the substrate <NUM>. In one embodiment, the controller <NUM> controls the assembly <NUM> to eject droplets of the adhesive-forming composition.

At S108, the substrate, with the adhesive-forming composition thereon, may be partially or completely cured, e.g., by the curing station <NUM>.

At S110, an ink forming composition <NUM> is ink-jetted onto the substrate <NUM> to form an image <NUM> that corresponds to the received image data <NUM>, leaving at least a portion <NUM> of the adhesive-forming composition/cured adhesive layer exposed to the atmosphere. In one embodiment, the controller <NUM> controls the assembly <NUM> to eject droplets of the ink composition(s) in accordance with the image data <NUM>. For example, the UV inks can be used to print text and images on the substrate and then print a layer of white ink to form a white background. The top portion <NUM> of the sign (left side in <FIG> and <FIG>) can be left transparent for unit pricing visibility.

As will be appreciated, for the sign <NUM> of <FIG>, the substrate <NUM> may be inverted prior to this step.

At S112, the substrate is cured to cure the ink composition <NUM> jetted onto the substrate and to cure or complete the cure of the adhesive-forming composition <NUM>. In particular, the controller controls the UV curing station <NUM> to effect the curing.

At S114, a release liner <NUM> may be applied to some of the cured sheets which are to form a bottom layer in the stack <NUM>.

At S116, the UV-cured, printed and adhesive coated substrate sheets are assembled into a stack and cut to the desired size to form a stack <NUM> of signs <NUM>. The resulting stack <NUM> includes a plurality of signs but has only one release liner <NUM>.

At S118, a sign <NUM> can be peeled from the stack <NUM> and the variably printed top-portion of the sign, which includes an adhesive layer <NUM>, is used to adhere the sign to a shelf edge or end caps of a product display unit. The sign remains adhesive for an extended period of weeks or months and thus can be peeled from the display structure when it is no longer needed.

As will be appreciated, fewer, more or different steps may be performed in the method, and all steps need not be performed in the same order as shown in <FIG>.

The exemplary signs find application in retail displays, although other applications where adhesive signs are used are also contemplated, such as directly on products.

The apparatus and method allow using UV inks and a UV print system to not only print the retail signage but use the unique properties of the UV inks and UV primers to create the signage on one media layer while printing both the sign information and the adhesive in one process.

An additional benefit is the ability of stacking these signs post processing to create a post-it™ type stack where no release liner is needed and aisle sorted stacks can be delivered to each store for application based on sales data.

The method provides for a low cost solution that reduces media substrate complexity, creates less waste due to the reduction in media layers while still being able to provide for a transparent window. The sign cards can be fully cured while still allowing for adhesive properties to adhere signs to the shelving and creating a card that allows for self-adhesive properties to create a variable printed pad of store signage.

Specific advantages reside in: using a cured UV primer to create a variably printed adhesive strip to hold up store signage; using a combination of UV primer and UV ink to create a single media layer sign that uses UV ink and UV primer to combine the functions of adhesion of the sign to the shelves and the marketing printed data without the need for additional media layers; printing UV primer that becomes an adhesive in the print module rather than adding an additional adhesive either post process or pre-process at the converter that needs a release liner; ability to not need a release liner, reducing time in hanging the signs and lowering the amount of scrap generated; avoiding additional adhesive layers; stacking signs one on top of another to create a variable printed store sign stack that can be used to mark each aisle; ability to provide adhesive properties only where needed, and limiting glue buildup issues in the post process cutting systems.

Claim 1:
An adhesive sign comprising:
a transparent substrate layer having opposed first and second surfaces;
an adhesive layer having an inner surface and an outer surface, the inner surface being disposed on the second surface of the substrate layer, the adhesive layer defining an exposed region on the outer surface for attachment to an associated structure, the adhesive layer being derived from a photo-curable adhesive composition suitable for inkjet printing, wherein the viscosity of the uncured photo-curable adhesive composition is from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting; and
an ink layer disposed on the second surface of the substrate layer, the ink layer including an image, the ink layer being derived from a photo-curable ink composition suitable for inkjet printing, the image being visible through the transparent substrate, wherein the viscosity of the uncured photo-curable ink composition is from <NUM> to <NUM> mPa·s at <NUM>, as determined with a Brookfield Dial Reading Viscometer with an RV/HA-<NUM> spindle setting.