Patent Description:
Labels having indicia and/or graphics are used in the garment industry to decorate clothing articles and/or to mark the articles (e.g., to identify the manufacture, size, washing instructions, etc.). These labels may be used with durable goods as well.

Heat transfer labels including graphics and/or markings may be made using screen printing, flexographic printing, gravure printing, or rotogravure priming processes. These printing processes use ink and heat activated adhesive systems that can provide necessary properties for heat transfer labels, such as adhesion to a target article, and other chemical and environmental resistance properties. Document <CIT> is considered the closest prior art.

Digital printing can provide superior quality graphics than the above printing processes with tight tolerances, fine details, and multi-color capabilities. Further, digital printing can allow for variable data to be easily printed onto articles (e.g., personalized information that is different for different articles), as digital printing does not require pre-fabricated printing plates.

Some heat transfer labels are hybrid labels that combine non-digital printing processes (e.g., screen printing, flexographic printing, or rotogravure priming processes) and digital printing processes to create the labels. These labels may have a carrier layer with a digitally printed layer (e.g., images and/or indicia) on the carrier layer, a polymeric coating layer on the digitally printed layer, and adhesive(s) on the coating layer. The coating layer and/or adhesive(s) can be printed using a non-digital printing process, while an image and/or indicia in the digitally printed layer may be printed using a digital printer. The label can be transferred to an article (e.g., a garment) by placing the adhesive against the article and applying heat or heat and pressure to separate the digitally printed layer and the protective layer from the carrier layer. The adhesive secures the digitally printed layer and the coating layer to the article.

One issue with these types of hybrid labels is that the digitally printed layer may be susceptible to damage or other effects after transfer to the article. This can deteriorate the appearance of the image and/or indicia. Another issue with these types of hybrid labels is that dyes within the article may seep into the label and interfere with the appearance of the image and/or indicia.

In one embodiment, a hybrid heat transfer label assembly according to claim <NUM> is provided. The label assembly includes a carrier layer, a non-digitally printed protective layer disposed above the carrier layer, a digitally printed layer disposed above the non-digitally printed protective layer, and a non-digitally printed layer disposed above the digitally printed layer. The non-digitally printed protective layer, the digitally printed layer, and the non-digitally printed layer form a label that is configured to separate from the carrier layer and adhere to an article upon application of heat to the carrier layer.

A method for producing a hybrid heat transfer label assembly according to claim <NUM> also is provided. The method includes printing a protective layer above a carrier layer using a first non-digital printer, digitally printing a digitally printed layer above the non-digitally printed protective layer, and printing a non-digitally printed layer above the digitally printed layer using the first non-digital printer or a second non-digital printer. The protective layer, the digitally printed layer, and the non-digitally printed layer form a label that is configured to separate from the carrier layer and adhere to an article upon application of heat to the carrier layer.

In another embodiment, another method for producing a hybrid heat transfer label assembly is provided. The method includes screen printing a protective layer onto a carrier layer, digitally printing one or more of a graphic or indicia above the protective layer, screen printing one or more additional layers above the one or more of the graphic or the indicia that are digitally printed, and applying an adhesive above the one or more additional layers to form a hybrid heat transfer label assembly.

The inventive subject matter may be understood from reading the following description of non-limiting embodiments, with reference to the attached drawings, wherein below:.

The inventive subject matter described herein provides hybrid heat transfer label assemblies and methods for manufacturing and applying the same. The label assemblies combine both digital and non-digital printing processes to provide the label assemblies that can be applied to a wide variety of surfaces while having the benefits of digital printing and non-digital printing. For example, with respect to digital printing part of the label assemblies, the images and/or indicia that are digitally printed can be higher quality, higher resolution, and more photorealistic than the same images and/or indicia printed using non-digital printing. The digitally printed images and/or indicia can be printed using a wide variety of colors, including (but not limited to) cyan, magenta, yellow, black, white, invisible (or translucent), taggant, spot colors, metallic colors, foils, fluorescents, clear matte, and gloss inks. These images and/or indicia can be printed in a single pass through a digital printer. This reduces re-insertions of the label assemblies when compared to some known printing methods. This also provides more reliable registration between colors that are digitally printed.

Digital printing also provides the ability to incorporate variable data, such as images and/or indicia that are different for each or at least several label assemblies. Variable designs, embellishments, effects, variable barcodes (e.g., 1D or 2D barcodes), quick response (QR) codes, sequential numbering, etc., can be digitally printed all in one pass through the digital printer.

Digital printing also provides the ability to incorporate security features into the label assemblies. These security features can include watermarks (which may be invisible to the naked or unmagnified eye), marks that are detectable by a scanner or mobile device, etc. These watermarks also or alternatively can be used to provide consumer engagement, brand authenticity, and track and trace functionality using marks that are almost imperceptible to the naked and unmagnified human eye. Invisible ultraviolet (UV) ink can be digitally printed into the label assemblies to provide covert identification, sequential numbering, and other variable data design. This type of ink can then be seen by exposing the label assembly using UV light. Machine taggant inks, magnetic inks, or other inks can be digitally printed into the label assemblies. These inks can be electronically detected and authenticated by hand held scanner. Additionally, other inks providing special effects, gloss, matte, foiling, embossing, etc. can be done in the label assembly on the same single printing pass on digital printer which further reduces the need for additional conventional screen print passes to create the desired effect. Using digital printing to provide some or all of these inks can simplify the manufacturing process of the label assemblies by reducing the number of printing passes (e.g., the number of times that ink is applied to the same footprint or area above a carrier layer), time, and materials otherwise needed to create the same label assembly but using only non-digital printing processes.

The hybrid label assembly also obtains the benefits of the digital printing processes described above, as well as benefits provided by non-digital printing. The security features described herein optionally can be printed using one or more of the non-digital printing processes or techniques described herein. For example one or more layers in the assembly can be screen printed, which provides highly opaque back up layers (e.g., layers that are behind the digitally printed images and/or indicia when the label assembly is adhered to a garment), the addition of hard to match spot colors, extended gamut colors (or other colors that are not possible to obtain via digital printing), and the incorporation of metallic inks and the non-digitally printed security features described above. Additionally, the non-digital printing of one or more layers of the label assembly allows for the incorporation of different tie coat and/or adhesive layers for adhesion to a wide range of substrates (e.g., surfaces of articles), such as plastics (e.g., polyester, copolyester, polypropylene cosmetic containers and toothbrush handles; ABS, SAN, PS, and HIPS razor handles and appliance components; PVC for automotive visor labels, etc.); fabrics used for automotive visor labels and seat belt labels; engineering resins (e.g., polycarbonate, nylon and various blends); metal and painted metal appliance components and sports equipment; painted graphite sports equipment; glass; and rubber used for belts, hoses, tires, etc. The non-digitally printed layers can provide for improved durability of the underlying digitally printed images and/or indicia, such as scratch and abrasion resistance due to thicker deposits, as well as improved chemical resistance and durability through incorporation of a first down protective layer (e.g., a layer that is deposited between the carrier layer and the digitally printed layer, as described below).

A heat transfer label for application to various substrates includes a carrier (usually in the form of a roll-to-roll web or cut down into sheets), a release coat applied to the carrier, an optional protective layer applied to the release coat, and a composition including a digitally printed graphic design, a screen printed back-up layer(s) applied to the digitally printed graphic design, and an adhesive applied either directly to the digitally printed graphic design or to the screen printed back up layers. Depending upon the digital print engine, a tie layer may be screen printed between the digitally printed graphic design and any subsequent screen printed layers. The digitally printed design and screen printed layers are printed and cured to form a storable film on the carrier web. Some examples of screen printable inks suitable for use in this invention include solvent-based inks, water-based inks, UV curable inks as well as <NUM>% solids inks as described by Downs et. <CIT> and Penrose et. The composition is heat transferred to the substrate and the carrier web is removed. A method for making the label and a method for marking an item are also disclosed.

Hybrid heat transfer labels made using a combination of digital printing and at least one other conventional printing method, such as screen printing, are provided according to various embodiments. The hybrid heat transfer labels include a heat activated adhesive layer and an optional protective layer, which are printed via screen, flexographic, rotogravure, or pad printing method to provide excellent adhesion to a target article and good chemical and other environmental resistance. Further, the hybrid heat transfer labels include a digitally printed layer offering superior quality graphic images and markings that can be customized quickly and easily to provide cost effective specialty heat transfer labels.

The label assemblies described herein can be hybrid digital and screen printed heat transfer labels for application to a variety of surfaces, such as plastics, metals, glass, automotive fabrics and rubber compounds, fabrics for outdoor sporting and safety equipment, fabrics for medical use applications, and the like. One or more of the printers used to generate the label assemblies can include printers such as the HP INDIGO Liquid Electrophotographic digital offset presses, 'solid' or 'dry toner' printers or presses, water based pigment dye, sublimation or latex inkjet printers and presses, UV curable inkjet printheads and presses, vegetable or mineral oil based direct imaging offset lithographic or flexographic presses, etc..

<FIG> illustrates one example of a hybrid heat transfer label assembly <NUM>. The assemblies shown in the Figures are not necessarily drawn to scale. One or more layers in the assemblies may be thicker or thinner than one or more other layers, even though the relative thicknesses of the layers shown in the Figures may show a different relative thickness. Stated differently, a first layer that is shown in a Figure as being thinner than a second layer may actually be thicker than the second layer.

The label assembly <NUM> includes a carrier layer <NUM> having an upper surface <NUM> that supports a multi-layered label <NUM> and an adhesive <NUM>. As described herein, the multi-layered label <NUM> is formed on the upper surface <NUM> of the carrier layer <NUM> from several layers with at least one layer being digitally printed (e.g., by one or more digital printers in one or more passes) and at least one layer being non-digitally printed (e.g., screen printed, flexographic printed, gravure printed, rotogravure printed, pad printed, etc.).

The carrier layer <NUM> can be formed from a paper or plastic film. Suitable materials for the carrier layer <NUM> include polypropylene film, as well as polyester films, with polyester being more heat resistant. MYLAr® and MELINEX® are two trademarks under which these materials are commercially available. Paper is less costly than plastic films, however, the dimensional stability of paper is less desirable unless printing is conducted in a controlled environment with regard to temperature and relative humidity. The carrier layer <NUM> can be a release coated paper or plastic film. The release coating can be silicone based, or the release coating can include other coatings. In one embodiment, both surfaces <NUM>, <NUM> of the carrier layer <NUM> are coated with release coatings, in which the release coatings have different release characteristics. For example, the printed surface <NUM> will generally have a tighter release than the non-printed surface <NUM>, alternatively it could be the same release value to help prevent curling issues, or it could be on the print side <NUM> only.

The adhesive <NUM> may be non-digitally printed onto the multi-layered label <NUM> or may be applied to the multi-layered label <NUM> as a powder or printable adhesive. For an example, the adhesive <NUM> may be applied to the multi-layered label <NUM> as a powder while an upper surface or layer on which the powder adhesive <NUM> is applied is wet. The adhesive <NUM> may be a heat activated adhesive, such as one or more powdered resins including polyamide, polyester, and polyurethane. Examples of polyamide resins include GRILTEX® IA and other polyamides from EMS-GRILTECH, a unit of EMS-CHEMIE, as well as UNEX®PA T11 and other polyamides from DAKOTA COATINGS N. Examples of polyester resins include GRILTEX® 6E and other polyesters from EMS-GRILTECH and UNEX®PES T6 and other polyesters from DAKOTA COATING N. Examples of polyurethane resins include UNEX® <NUM> and other polyurethanes from DAKOTA COATINGS N. If applied as a powder, the adhesive powder resin can be dispersed in a resin solution, solvent, or water prior to application to create a printable adhesive.

The adhesive <NUM> may also be a non-digitally printed adhesive based on a combination of one or more rosin and/or one or more resins. These can be solvent-borne, water-borne or UV-curable. These can be heat-activated combinations of polyolefins, polyesters, polyacrylics, polyvinyl chloride/polyvinyl acetate (PVC/PVA) resins and terpene-based rosins. Examples of polyolefin-type resins can be ADVANTIS 510W, CP343 or others provided by EASTMAN CHEMICAL COMPANY as well as LICOCENE PP2602, LICOCENE PP MA4221 or others provided by CLARIANT PLASTICS & COATINGS LTD. , a unit of CLARIANT INTERNATIONAL. Examples of polyesters can be AROPLAZ® <NUM>-WG4-<NUM>, FINE-TONE® T-<NUM> or others provided by REICHOLD, LLC as well as VITEL 2200B, VITEL 3300B or others provided by BOSTIK, INCORPORATED. Examples of polyacrylics can be PARALOID® B-48N or others provided by DOW COATING MATERIALS, a division of DOW CHEMICAL CORPORATION. PVC/PVA resins can be VINNOL® E <NUM>/48A, VINNOL ® H <NUM>/<NUM> of others provided by WACKER CHEMIE AG. Examples of terpene rosins include SYLVARES® <NUM>, SYLVARES® TR7125 or others from KRATON CORPORATION as well as STABELITE ™ ESTER <NUM>-E, LEWISOL™ <NUM>-M and others from EASTMAN CHEMICAL COMPANY. These can be blended in varying percentages in solvent, water and/or liquid monomer prior to application to create a printable adhesive.

<FIG> illustrate application of the label assembly <NUM> shown in <FIG> to an article <NUM>. The article <NUM> can represent an object to which the multi-layered label <NUM> is to be affixed, such as a garment, plastics such as a cosmetic or personal care object or container, a medical fabric, a sports fabric, a safety fabric, an automotive fabric, a rubber object, a vulcanized rubber object, a metal object, a fibrous object, a glass object, etc. The label assembly <NUM> is positioned onto the article <NUM> so that the adhesive <NUM> contacts a surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> can be applied onto the non-printed surface <NUM> of the carrier layer <NUM> that is opposite the printed surface <NUM> of the carrier layer <NUM>. As shown, the label assembly <NUM> may be flipped over relative to the perspective in <FIG> when applied to the article <NUM>. The heat <NUM> or heat <NUM> and pressure <NUM> can cause the multi-layered label <NUM> to separate from the release coating of or on the carrier layer <NUM> and for the adhesive <NUM> to couple the multi-layered label <NUM> to the article <NUM>.

For example, when the heat <NUM> or heat <NUM> and pressure <NUM> are applied, the adhesive <NUM> may soften and permanently adhere to the article <NUM>. Since the adhesion strengths between the layers of the multi-layered label <NUM> are greater than that between the multi-layered label <NUM> and the carrier layer <NUM>, the layers of the multi-layered label <NUM> remain attached to each other and transfer together to the article <NUM> upon application of the heat <NUM> or heat <NUM> and pressure <NUM>, as shown in <FIG>. After this heat transfer process, the carrier layer <NUM> is peeled off or otherwise removed from the multi-layered label <NUM> and the multi-layered label <NUM> is permanently attached on the article <NUM> via the adhesive <NUM>, as shown in <FIG>.

Each of the non-digitally printed layers and digitally printed layers described herein can be formed from a single printing pass or multiple printing passes. For example, any of the layers can be formed by a single pass of a digital printer or non-digital printer over the underlying layer(s), or can be formed by several successive printing passes (e.g., as multiple layers printed directly onto each other in the successive printing passes).

<FIG> illustrates one example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. The multi-layered label <NUM> can be formed (e.g., printed) onto the carrier layer <NUM> described above. The multi-layered label <NUM> includes a coated protective layer <NUM> that can be non-digitally printed directly onto the carrier layer <NUM>. Optionally, part or all of the protective layer <NUM> can be digitally printed onto the carrier layer <NUM>. The protective layer <NUM> can be referred to as the first down layer. The protective layer <NUM> can be clear, translucent, light-transmissive, etc., so that one or more of the layers printed onto the protective layer <NUM> are visible through the protective layer <NUM> after the multi-layered label <NUM> is adhered to the article <NUM>. The protective layer <NUM> can be formed from polymer material through which the one or more of the layers printed onto the protective layer <NUM> are visible.

For example, the protective layer <NUM> can be printed from a composition comprising about <NUM>% by weight Estane®<NUM> resin solution (comprised of about <NUM>% polyester type thermoplastic polyurethane in a cyclohexanone/ethyl <NUM>-ethoxypropionate mixture) (Lubrizol Advanced materials, Inc. ), about <NUM>% CAB-<NUM>-<NUM> resin solution (comprised of about <NUM>% cellulose acetate butyrate in a cyclohexanone/ethyl <NUM>-ethoxypropionate mixture) (Eastman Chemical Company), about <NUM>% cyclohexanone (Ashland Inc. ), about <NUM>% Cab-O-Sil® TS-<NUM> fumed silica (Cabot Corp), and about <NUM>% TEGO® Foamex-N defoamer (Evonik industries AG). The above composition contains about <NUM>%, by weight, solids and about <NUM>%, by weight, VOCs. Optionally, the protective top clear can contain any of several crosslinking agents to improve the toughness and chemical resistance of the protective top clear, e.g. <NUM>% of Desmodur® N-<NUM> aliphatic polyisocyanate (Bayer Material Science). The term "about" includes the value stated above, as well as other values within manufacturing tolerances (e.g., within a <NUM>% range, within a <NUM>% range, or within a <NUM>% range in different embodiments).

A surface treatment layer <NUM> can be printed onto the protective layer <NUM>. The surface treatment layer <NUM> can be printed using a non-digital printing process described herein. Alternatively, part or all of the surface treatment layer <NUM> can be digitally printed. The surface treatment layer <NUM> can be formed from one or more primers or coatings to provide a surface on which a digitally printed layer <NUM> can be digitally printed. For example, the protective layer <NUM> may be too smooth for the digital printer (e.g., an ink jet printer) to digitally print the digitally printed layer <NUM> directly onto the protective layer <NUM>. The surface treatment layer <NUM> may provide a less smooth surface that is more receptive to the digitally printed inks of the digitally printed layer <NUM> (e.g., a higher or lower surface energy to prevent unintended smearing, beading or blending of the digitally or post-printed inks of an incompatible surface tension). Alternatively, the surface treatment layer <NUM> is not provided but the exposed surface of the protective layer <NUM> is treated to improve adhesion between the protective layer and the digitally printed layer <NUM>. For example, instead of printing or coating the surface treatment layer <NUM> on the protective layer <NUM>, the surface of the protective layer <NUM> (e.g., the surface that faces away from the carrier layer <NUM>) can be treated to change energy of the surface (e.g., by changing the surface energy of the protective layer <NUM>), to roughen, clean and prepare the surface, or the like, to thereby improve adhesion between the protective layer <NUM> and the digitally printed layer <NUM>. The surface can be treated using one or more of a variety of techniques, such as by exposing the surface to a gas flame, exposing the surface to air plasma, using a corona treatment, exposing the surface to a chemical plasma, or the like.

The digitally printed layer <NUM> can include one or more inks that are digitally printed to form one or more images and/or indicia. As described above, these images can include variable data (e.g., different images and/or indicia for different labels) and/or non-variable data (e.g., the same image and/or indicia for each label). For example, the digitally printed layer <NUM> can include bar codes, variable embellishments and effects, QR codes, sequential numbering (e.g., between or among different labels), etc. The digitally printed layer <NUM> can include security features such as data and watermarks, watermarks with invisible marks for security detection (e.g., by hand held scanner or mobile device). The watermarks formed in the digitally printed layer <NUM> can be optically detected by an optical sensor (e.g., a camera on a mobile phone) and can cause the mobile device to take one or more actions, such as, performing a security validation check or loading a website connected with the article <NUM> to which the digitally printed layer <NUM> is eventually interconnected. The digitally printed layer <NUM> can include UV sensitive ink so that the images and/or indicia are only visible when exposed to UV light. The digitally printed layer <NUM> can include machine taggant inks or magnetic inks that can be electronically detected by a scanner. As another example, the digitally printed layer <NUM> can include inks that provide a unique effect, such as a gloss appearance, a matte appearance, a foil or metallic appearance, embossing, etc. These detectable designs, watermarks or inks can also be printed into the label by the non-digital parts of the process i.e. screen printing of the magnetic or coded inks, to provide a more reliable functionality or detection by increase of deposit thickness or visibility.

A tie layer <NUM> can be printed onto the digitally printed layer <NUM>. Optionally, the tie layer <NUM> is not included in the label assembly <NUM>. The tie layer <NUM> can be printed using a non-digital printing process, such as screen printing. The tie layer <NUM> assists in coupling the underlying layers <NUM>, <NUM>, <NUM> to the article <NUM> via the adhesive <NUM>. The tie layer <NUM> can be formed from a polymeric material that softens and bonds with the article <NUM> when subjected to heat <NUM> or a combination of heat <NUM> and pressure <NUM>. The adhesive <NUM> can be applied onto the tie layer <NUM> or onto the digitally printed layer <NUM> (if the tie layer <NUM> is not included in the label assembly <NUM>).

Alternatively, the tie layer <NUM> and the adhesive <NUM> can be combined into a single layer. For example, the tie layer <NUM> and the adhesive <NUM> shown in <FIG> (and in other Figures where the tie layer <NUM> directly contacts or otherwise abuts the adhesive <NUM>) may be replaced by a single layer representing a combination of the materials forming the tie layer <NUM> and the adhesive <NUM>.

One or more surfaces of the label assembly <NUM> can be treated to change the energy, surface tension, or smoothness of the surfaces and thereby improve the adhesion of a layer to the treated surface. For example, surfaces of one or more of the layers <NUM>, <NUM>, <NUM>, and/or <NUM> can be exposed to an air plasma (e.g., a corona treatment), chemical plasma, gas flame, or the like, to roughen the surface (e.g., on a microscopic scale), to change the surface tension of the layers <NUM>, <NUM>, <NUM>, and/or <NUM>, or to otherwise improve adhesion between the surface and another layer <NUM>, <NUM>, <NUM>, or <NUM>.

As described above, the label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to articles <NUM> such as cosmetic containers, personal care products (e.g., toothbrushes, hairbrushes, etc.), other polymer surfaces, etc..

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. The label assembly <NUM> and the label <NUM> can represent another embodiment of the label assembly <NUM> and the label <NUM> shown in <FIG>. One difference between the label assemblies <NUM>, <NUM> and the labels <NUM>, <NUM> is the presence of an additional graphic layer <NUM> and, optionally, a backup or backer layer <NUM>. The graphic layer <NUM> can be printed onto the tie layer <NUM> or onto the digitally printed layer <NUM> (if the tie layer <NUM> is not included in the label <NUM>). The graphic layer <NUM> can include one or more images and/or indicia that are printed in a non-digital manner (e.g., using screen printing). The graphic layer <NUM> is printed above the digitally printed layer <NUM> such that the digitally printed layer <NUM> is on top of the graphic layer <NUM> once the label <NUM> is adhered to the article <NUM>.

The graphic layer <NUM> can be printed using a non-digital technique, such as screen printing. The graphic layer <NUM> can be a layer of a solid (e.g., the same) color of ink, or may include different colored inks in different areas of the graphic layer <NUM>. Optionally, the graphic layer <NUM> can include images and/or indicia. The digitally printed layer <NUM> overlaying the graphic layer <NUM> can provide for various appearances, such as a different background color (than the article <NUM>), increased contrast between the digitally printed layer <NUM> and the article <NUM>, or the like.

The backup layer <NUM> can be printed using a non-digital technique, such as screen printing. The backup layer <NUM> can be a layer of a solid (e.g., the same) color of ink, such as white, black, or the like. In one embodiment, the backup layer <NUM> is printed using a white pigment. For example, the backup layer <NUM> can be formed of a white ink formulation including a resin solution (formulated from <NUM> percent by weight ethyl <NUM>-ethoxypropionate, <NUM> percent by weight cyclohexanone, <NUM> percent by weight Estane® <NUM> thermoplastic polyurethane resin and <NUM> percent by weight CAB-<NUM>-<NUM> cellulose ester resin), <NUM> percent by weight Nanomer® <NUM>. 28E nanoclay, white paste (formulated from <NUM> percent by weight ethyl <NUM>-ethoxypropionate, <NUM> percent by weight cyclohexanone, <NUM> percent by weight Estane® <NUM>, and <NUM> percent by weight TIOXIDE® TR90 titanium dioxide), <NUM> percent by weight INEOS® IJI silica gel, <NUM> percent by weight TEGO® Foamex N defoamer and <NUM> percent Desmodur® N-<NUM> aliphatic polyisocyanate. The white ink can be screen printed through a stainless steel mesh, for example, with <NUM> lines per inch, on top of the tie layer <NUM>. The white ink can be applied once or via multiple passes.

Optionally, the backup layer <NUM> can include images and/or indicia. The backup layer <NUM> can make the images, indicia, and/or colors of the digitally printed layer <NUM> and/or graphic layer <NUM> clearer and/or have increased contrast relative to the label <NUM> not including the backup layer <NUM>. For example, the backup layer <NUM> can prevent the color of the underlying article <NUM> (once the label <NUM> is applied to the article <NUM>) from strikethrough or making the images and/or indicia harder to see.

In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM>, the tie layer <NUM>, and/or the backup layer <NUM>. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to articles <NUM> such as cosmetic containers, personal care products (e.g., toothbrushes, hairbrushes, etc.), other polymer surfaces, etc..

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the carrier layer <NUM>, the protective layer <NUM> and the digitally printed layer <NUM>, and optionally can include the surface treatment layer <NUM>. In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM>.

The label assembly <NUM> includes a backup layer <NUM> that can be the same as the backup layer <NUM>, except that the backup layer <NUM> can be formed from a single printing pass while the backup layer <NUM> can be formed from multiple printing passes. For example, the backup layer <NUM> can be printed from a single application of ink via screen printing while the backup layer <NUM> can be printed from several applications of ink via screen printing. As a result, the backup layer <NUM> may be thicker than the backup layer <NUM> and/or provide increased contrast between the digitally printed layer <NUM> and the underlying article <NUM>. Alternatively, the backup layer <NUM> can be printed in multiple passes and/or the backup layer <NUM> can be printed in a single pass.

The label assembly <NUM> includes an adhesive <NUM> that can represent the adhesive <NUM>. The adhesive <NUM> can be the same as the adhesive <NUM>, except that the adhesive <NUM> can be formed from a single printing pass of the adhesive material while the adhesive <NUM> can be formed from multiple printing passes. For example, the adhesive <NUM> can be printed from a single application of adhesive via screen printing while the adhesive <NUM> can be printed from several applications of adhesive via screen printing. As a result, the adhesive <NUM> may be thicker than the adhesive <NUM> and/or provide increased adhesion or coupling to the underlying article <NUM>. Alternatively, the adhesive <NUM> can be printed in multiple passes and/or the adhesive <NUM> can be printed in a single pass. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

As described above, the label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to fabric articles <NUM>, such as medical fabrics, sports and safety fabrics, automotive fabrics, and the like. The increased adhesive <NUM> can assist in keeping the label <NUM> affixed to the fabric (relative to the labels <NUM>, <NUM>).

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the carrier layer <NUM>, the protective layer <NUM>, the digitally printed layer <NUM>, the backup layer <NUM>, and the adhesive <NUM>, and optionally can include the surface treatment layer <NUM>. In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM>.

The label assembly <NUM> includes a blocker layer <NUM> that can prevent dyes, stains, etc. migrating from the article <NUM> to the backup layer <NUM> and/or the digitally printed layer <NUM>. The blocker layer <NUM> can be formed from the same materials as the protective layer <NUM> or from carbons, polyamides, acrylics or other polymers that can be applied in a non-digital printer and that can form a barrier to dyes, stains, etc. The blocker layer <NUM> can be printed onto the backup layer <NUM>. This can help ensure that the color other features of the appearance of the digitally printed layer <NUM> and/or the backup layer <NUM> is not changed by dyes, stains, or the like, from the article <NUM>. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to fabric articles <NUM>, such as medical fabrics, sports and safety fabrics, automotive fabrics, and the like. The blocker layer <NUM> can help prevent sweat, bodily fluids, dyes, or other sources of stains from changing the appearance of the label <NUM>.

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the carrier layer <NUM>, the digitally printed layer <NUM>, the backup layer <NUM>, the blocker layer <NUM>, and the adhesive <NUM>, and optionally can include the surface treatment layer <NUM>. In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM> and/or the blocker layer <NUM>.

The label assembly <NUM> includes a tie layer <NUM> that can be printed (using a non-digital technique) onto the backup layer <NUM>. For example, the tie layer <NUM> can be screen printed on the backup layer <NUM>. The tie layer <NUM> can attach the underlying layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, where these layers are included, to the blocker layer <NUM>. The tie layer <NUM> can be formed from a polymeric material that softens and bonds with blocker layer <NUM> when subjected to heat and pressure during transfer of the label <NUM> to the article <NUM>. For example, the tie layer <NUM> can be formed from a lacquer or other light-transmissive (e.g., clear) material.

In one embodiment, the backup layer <NUM> can be a multiple strike or pass layer. For example, the backup layer <NUM> can be formed by several passes or printing operations instead of a single printing pass, as described above. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

<FIG> illustrates label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the carrier layer <NUM>, the surface treatment layer <NUM>, the digitally printed layer <NUM>, and the adhesive <NUM>. In another embodiment, the label assembly <NUM> does not include the protective layer <NUM>, the surface treatment layer <NUM> and/or the adhesive <NUM>.

The label assembly <NUM> includes a rubber layer <NUM> that is be printed (using a non-digital technique) onto the digitally printed layer <NUM>. For example, the rubber layer <NUM> can be formed from rubber or ink with rubber that is screen printed on the digitally printed layer <NUM>. The rubber layer <NUM> can enable the label <NUM> to be adhered to a rubber surface as the article <NUM>, such as an automotive component (e.g. a tire, hose or a belt) or other vulcanized material. The label <NUM> may be remain adhered to the rubber article <NUM> without the rubber layer <NUM> in one embodiment. The rubber layer <NUM> can be black or white in color to also function as a backer layer, as described above. Alternatively, the rubber layer <NUM> may have another color or combination of colors. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> or the rubber layer <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to rubber or vulcanized articles <NUM>, such as automotive hoses, tires, or the like.

<FIG> illustrates another embodiment of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes a carrier layer <NUM>, the surface treatment layer <NUM>, the digitally printed layer <NUM>, the tie layer <NUM>, the additional graphic layer <NUM>, the rubber layer <NUM>, and the adhesive <NUM>. In another embodiment, the label assembly <NUM> does not include the protective layer <NUM>, the surface treatment layer <NUM> and/or the additional graphic layer <NUM>.

The carrier layer <NUM> can be carrier layer <NUM> shown in <FIG> but without a release coating already on the carrier layer <NUM>. For example, while the carrier layer <NUM> may be obtained with the release coating already present on the carrier layer <NUM>, the carrier layer <NUM> may not have any release coating. A release coating <NUM> can be printed (e.g., in a non-digital way, such as via screen, gravure or flexographic printing) onto the carrier layer <NUM>. For example, silicone, wax, or other materials that release the carrier layer <NUM> from the other layers <NUM>, <NUM>, <NUM>, <NUM>, and/or <NUM> may be added to the carrier layer <NUM>. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> or the rubber layer <NUM> contacts the surface <NUM> of the article <NUM>. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>. The label <NUM> can be adhered to rubber articles <NUM>, such as automotive belts, hoses, tires, or the like.

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the carrier layer <NUM>, the surface treatment layer <NUM>, the digitally printed layer <NUM>, the tie layer <NUM>, the additional graphic layer <NUM>, and the adhesive <NUM>. In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM>, the tie layer <NUM>, and/or the additional graphic layer <NUM>. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. The article <NUM> can be formed of metal, fiber, or glass, and/or the surface <NUM> of the article <NUM> may include metal, fiber, or glass. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the pre-heated article <NUM>.

<FIG> illustrates another example of a hybrid heat transfer label assembly <NUM>. The label assembly <NUM> can represent the label assembly <NUM> shown in <FIG>, and includes a multi-layered label <NUM> that can represent the multi-layered label <NUM> shown in <FIG>. As shown, the label assembly <NUM> includes the uncoated carrier layer <NUM>, the release layer <NUM>, a protective or special effects layer <NUM>, the surface treatment layer <NUM>, the digitally printed layer <NUM>, the additional graphic layer <NUM>, the backup layer <NUM>, and the adhesive <NUM>. In another embodiment, the label assembly <NUM> does not include the surface treatment layer <NUM>, the additional graphic layer <NUM>, and/or the backup layer <NUM>.

The protective or special effects layer <NUM> can include one or more materials that add a gloss appearance to the underlying digitally printed layer <NUM> or a matte appearance to the underlying digitally printed layer <NUM>. Optionally, the special effects layer <NUM> can include a metal foil (or HRI High Reflective Index ZnS foil) to provide a metallic appearance to the label <NUM>. This metal foil may be sufficiently thin that the digitally printed layer <NUM> is visible through the layer <NUM> once the label <NUM> is applied to the article <NUM> and the carrier layer <NUM> is removed. The special effects layer <NUM> can be an embossed layer that has one or more graphics or indicia embossed into the layer <NUM>. The special effects layer <NUM> can be digitally printed using the same digital printer that prints the digitally printed layer <NUM> or using another digital or analogue printing method. Alternatively, the layer <NUM> can be the protective layer <NUM>. One or more surfaces of the label assembly <NUM> can be treated to change the energy of the surface(s), change the surface tension of the surface(s), or roughen the surfaces and thereby improve the adhesion of a layer to the treated surface, as described above.

The label assembly <NUM> can be placed into contact with the article <NUM> such that the adhesive <NUM> contacts the surface <NUM> of the article <NUM>. The article <NUM> can be formed of metal, fiber, or glass, and/or the surface <NUM> of the article <NUM> may include metal, fiber, or glass. Heat <NUM> or a combination of heat <NUM> and pressure <NUM> is applied to the surface <NUM> of the carrier layer <NUM> to separate the label <NUM> from the carrier layer <NUM> and adhere the label <NUM> to the article <NUM>.

<FIG> illustrates one example of an in-line printing system <NUM> that can be used to create one or more of the hybrid digital heat transfer label assemblies described herein. The in-line printing system <NUM> can print several or all of the layers in the label assembly <NUM> without removing the partially formed label assembly from the printing system <NUM>. For example, the carrier layer <NUM> of the label assembly <NUM> can be inserted into the printing system <NUM> in an input end <NUM> of an outer housing <NUM> of the printing system <NUM> and not removed from the housing <NUM> of the printing system <NUM> (via an outlet end <NUM> of the housing <NUM>) until manufacture of the label assembly <NUM> is complete.

For example, the carrier layer <NUM> can be provided as individual sheets 102A (e.g., in sheet form) or as a continuous roll 102B (e.g., in roll form) into the printing system <NUM>. One or more conveyors, cylinders or rollers <NUM> can carry the carrier layer <NUM> to and/or through several printers <NUM> (e.g., printers 1352A-E). The number of printers <NUM> is provided as one example. Each of the printers <NUM> can print one or more additional layers <NUM> onto the carrier layer <NUM> and/or other layers <NUM> already on the carrier layer <NUM>, as shown in <FIG>. The layers <NUM> can represent the layers <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and/or <NUM>, as described above.

At least one of the printers <NUM> can be a digital printer (e.g., an ink jet printer) while at least one other printer <NUM> can be a printer that is not a digital printer (e.g., a screen printer). For example, a digital printer (e.g., 1352B) can be disposed downstream of one non-digital printer (e.g., 1352A) and upstream of another non-digital printer (e.g., 1352C) such that the digitally printed layer printed by the digital printer is disposed between the non-digitally printed layers. Optionally, one or more of the printers <NUM> can include and/or one or more of the printers <NUM> can represent a heating device that heats, dries, and/or cures the uppermost layer on the carrier layer <NUM> as the layers on the carrier layer <NUM> pass through the printer <NUM> or heating device. Examples of such a heating device include air impingement driers, ovens, infrared lamps, or the like.

As shown, the carrier layer <NUM> passes through or beneath the printers <NUM> so that the various layers in the label assembly <NUM> are sequentially printed without removing the carrier layer <NUM> or the printed layers from the printing system <NUM>. As described above, one or more of the printers <NUM> may deposit a layer in a single pass or strike, or by depositing the layer in multiple passes or strikes. Once the layers forming the label <NUM> are printed onto the carrier layer <NUM>, the label <NUM> (in roll or sheet form) may be removed from the printing system <NUM>. The in-line printing system <NUM> can form the label assembly <NUM> and decrease the number of times that the label assembly <NUM> is handled by an operator, thereby decreasing registration errors between the layers, reducing printing time, and the like.

<FIG> illustrates another example of a printing system <NUM> that can be used to create one or more of the hybrid digital heat transfer label assemblies described herein. In contrast to the in-line printing system <NUM>, the printing system <NUM> has two or more separate printers <NUM> that do not directly supply the carrier layer <NUM> (and any printed layers) from one printer <NUM> to the next printer <NUM>. Instead, the carrier layer <NUM> and any printed layers are removed from one printer <NUM> (e.g., by an operator of the printing system <NUM>) and then inserted into the next printer <NUM>.

A method for creating a hybrid heat transfer label assembly can include obtaining a carrier layer. The method can be used to create one or more of the label assemblies described herein. If the carrier layer does not include a release coating or layer, the method can include subsequently printing (e.g., in a non-digital manner) a release coating or layer onto the carrier layer. The method also can include subsequently printing, in a non-digital manner, one or more underlying layers on the carrier layer (with the release coating). These underlying layers can include one or more of the protective layer, the surface treatment layer, and/or the special effects layer.

Claim 1:
An label assembly (<NUM>) comprising:
a plastic carrier layer (<NUM>);
a non-digitally printed protective layer (<NUM>)
a digitally printed layer (<NUM>) disposed with the non-digitally printed protective layer between the digitally printed layer and the plastic carrier layer; and
a non-digitally printed second layer (<NUM>) disposed with the digitally printed layer between the non-digitally printed protective layer and the non-digitally printed second layer, wherein the non-digitally printed protective layer, the digitally printed layer, and the non-digitally printed second layer form a label that is configured to separate from the plastic carrier layer and adhere to an article upon application of heat to the plastic carrier layer;
wherein the non-digitally printed second layer (<NUM>) includes a rubber layer.