US20030203818A1 - Direct thermal printable film and laminate - Google Patents
Direct thermal printable film and laminate Download PDFInfo
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- US20030203818A1 US20030203818A1 US10/441,560 US44156003A US2003203818A1 US 20030203818 A1 US20030203818 A1 US 20030203818A1 US 44156003 A US44156003 A US 44156003A US 2003203818 A1 US2003203818 A1 US 2003203818A1
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- film
- substrate
- layer
- thermosensitive imaging
- laminate
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/06—Interconnection of layers permitting easy separation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/26—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
- B41M5/30—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used using chemical colour formers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/26—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
- B41M5/40—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography
- B41M5/42—Intermediate, backcoat, or covering layers
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
- G09F3/00—Labels, tag tickets, or similar identification or indication means; Seals; Postage or like stamps
- G09F3/08—Fastening or securing by means not forming part of the material of the label itself
- G09F3/10—Fastening or securing by means not forming part of the material of the label itself by an adhesive layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/41—Opaque
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/26—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used
- B41M5/40—Thermography ; Marking by high energetic means, e.g. laser otherwise than by burning, and characterised by the material used characterised by the base backcoat, intermediate, or covering layers, e.g. for thermal transfer dye-donor or dye-receiver sheets; Heat, radiation filtering or absorbing means or layers; combined with other image registration layers or compositions; Special originals for reproduction by thermography
- B41M5/41—Base layers supports or substrates
Definitions
- the invention relates to the field of direct thermal printing and especially to media used for such printing.
- Direct thermal printable media is most widely used as facsimile paper but is also used in printers and in other applications requiring permanent imaging such as tags, tickets, and labels.
- direct thermal printing uses a special printable media that incorporates a color developing mechanism. Images are formed by exposing the color developing mechanism to concentrations of heat that produce localized chemical reactions involving a change of color (usually light to dark).
- the color developing mechanism is provided by a thermosensitive imaging material containing heat reactive chemicals such as leuco dyes or metallic salts.
- thermosensitive imaging material is susceptible to damage from exposure to various environmental conditions including abrasion, heat, light, and chemicals such as oils, fats, blood, alcohol, solvent, and water. Much of this damage can be limited by applying protective coatings that block unwanted environmental interactions with the thermosensitive imaging material.
- U.S. Pat. No. 4,711,874 to Yuyama et al. suggests use of a water-soluble polymeric material as a protective overcoating for providing physical and chemical resistance.
- U.S. Pat. No. 4,717,709 to Suzuki suggests use of a polyolefin resin for similar purposes.
- U.S. Pat. No. 4,886,774 to Doi discloses a protective overcoating containing UV blockers.
- U.S. Pat. No. 5,286,703 to Wachi et al. discloses use of multiple protective overcoat layers including a first layer of water-soluble or water-insoluble polymers for chemical resistance and a second layer containing UV blockers.
- thermosensitive imaging material is applied as a coating to a substrate surface.
- Printing takes place by exposing the coating to a pattern of heat conducted from a thermal print head located adjacent to the substrate surface containing the coating of thermosensitive imaging material.
- the coating takes the form of the substrate surface including any irregularities or roughness in the surface. Accordingly, any surface irregularities in the thermosensitive coating vary spacing between the thermal print head and different points on the coating, causing unwanted dissipations of heat that interfere with image quality.
- thermosensitive coating Two solutions are known to limit irregularities in the thermosensitive coating. One is to use only substrates with smooth surfaces. The other is to apply an undercoating between the substrate and the thermosensitive coating. The undercoating covers irregularities in the substrate surface and provides a smooth base for applying the thermosensitive coating.
- An example is found in U.S. Pat. No. 4,711,874 to Yuyama et al.
- thermosensitive imaging material can be used with a wider variety of underlying substrates without resort to undercoatings, because surface features of the thermosensitive coating are no longer linked to the surface features of the underlying substrates.
- An example of my invention as a direct thermal printable laminate includes two adjacent substrates, one of which is preferably an optically and thermally transmissive film.
- a thermosensitive imaging layer is located adjacent to a back surface of the transmissive film, and the back surface of the transmissive film is bonded to a front surface of the other substrate for laminating the transmissive film to the other, substrate.
- the thermosensitive imaging layer is reactive to transmissions of heat through the film (which is thermally transmissive) for forming images within the thermosensitive imaging layer that are visible through the same film (which is also optically transmissive).
- thermosensitive imaging layer is bonded directly to the back surface of the film and indirectly to the front surface of the other substrate through the intermediacy of an adhesive layer. Accordingly, the thermosensitive imaging layer takes the form of the back surface of the film rather than the form of the front surface of the other substrate.
- My new laminate is printable by applying concentrations of heat from a thermal print head to the front surface of the film resulting in the formation of images within the thermosensitive imaging layer.
- the film is preferably much thinner in thickness than the other substrate to more efficiently transmit heat from the thermal print head to the thermosensitive imaging layer. Thicknesses less than 10 microns are preferred.
- thermosensitive imaging layer is applied to a back surface of the film.
- the thermosensitive imaging layer is reactive to transmissions of heat through the film for forming images within the thermosensitive imaging layer.
- Adhesive layers are applied to front and back surfaces of a substrate. A first of the adhesive layers bonds the substrate to the film, and a second of the adhesive layers is intended for bonding the film and substrate to another substrate or object.
- the film and substrate Prior to bonding the film and substrate to another substrate or object, the film and substrate are unwindable from a roll in which the second adhesive layer is in contact with the release layer.
- thermosensitive imaging layer provides the thermosensitive imaging layer with a desired form as well as a protective covering against exposure to environmental hazards.
- the release layer on the front surface of the film eliminates any need for a separate release liner to protect the second adhesive layer prior to use. Also, since the thermosensitive imaging material is first coated on the film rather than on the underlying substrate, smaller production runs are more economical because the coated film can be divided for runs with different substrates.
- a thin thermally transmissive film coated with a thermosensitive imaging material in accordance with my invention can be made as either an intermediate product intended for lamination to another substrate or as a final product that can be imaged prior to or in conjunction with its use.
- the film is both thermally and optically transmissive and has a thickness no greater than 10 microns.
- FIG. 1 is a schematic cross section of a first embodiment of my invention as a new direct thermal printable laminate.
- FIG. 2 is a schematic cross section of a second embodiment of my invention as a similar laminate having additional layers.
- FIG. 3 is a schematic cross section of a third embodiment of my invention as a new direct thermal printable tape.
- FIG. 4 is a schematic cross section of the third embodiment wound into a roll.
- FIG. 6 is a diagram of a production line for coating a substrate and for laminating the coated film to the coated substrate.
- FIG. 7 is a diagram of a printing sequence for direct thermal printing of the new laminate.
- FIG. 1 Illustrated by FIG. 1 is a direct thermal printable laminate 10 having two adjacent substrates 12 and 14 joined by a layer 16 of thermosensitive imaging material and by a layer 18 of adhesive.
- the layer 16 of thermosensitive imaging material is bonded to the substrate 12 , and the two substrates 12 and 14 are bonded to each other by the adhesive layer 18 .
- Concentrations of heat from a thermal print head (not shown until FIG. 7) can be applied to the first substrate 12 for forming images in the layer 16 of thermosensitive imaging material.
- the substrate 12 which is preferably an optically and thermally transmissive film, has thickness “T 1 ” measured between front and back surfaces 20 and 22 .
- the thickness “T 1 ” is preferably limited to 10 microns or less (e.g., 6 microns) to avoid interfering with transmissions of heat through the film 12 required for forming images within the thermosensitive imaging layer 16 .
- the images so formed are visible through the film 12 .
- the film 12 is made from a strip of flexible material such as polyester, which is capable of making the required transmissions of light and heat as well as capable of retaining its form at the required thickness “T 1 ”.
- Other possible film materials include polyethylene, polypropylene, acetate, or other polyolefins.
- thermosensitive imaging layer 16 forms exposure to potentially damaging environmental conditions.
- the film 12 can be coated with UV blockers as described in U.S. Pat. No. 4,886,774 to Doi, which is hereby incorporated by reference.
- the thermosensitive imaging layer 16 preferably contains a dye precursor such as a pale or colorless leuco dye and a color former such as an acidic developer that causes the leuco dye to undergo a color transformation in the presence of heat.
- a dye precursor such as a pale or colorless leuco dye
- a color former such as an acidic developer that causes the leuco dye to undergo a color transformation in the presence of heat.
- the dye precursor and color former are separately microencapsulated or otherwise separated to prevent their interaction prior to the application of a predetermined amount of heat.
- Other color developing mechanisms could also be used including metallic salt color former chemical systems.
- the adhesive layer 18 can be applied as a coating on the front surface 24 of the substrate 14 .
- the adhesive layer 18 is formed by a pressure-sensitive adhesive to form a permanent bond with the film 12 . If mutually compatible, the adhesive layer 18 can be bonded directly in contact with the thermosensitive imaging layer 16 . Possible examples include acrylics, water-borne adhesives, hot melts, and rubber-based extrusions.
- a direct thermal laminate 30 shown in FIG. 2 includes additional layers for performing specialized functions. Similar to the preceding laminate 10 , the laminate 30 includes an optically and thermally transmissive film 32 and a substrate 34 .
- the film 32 has front and back surfaces 40 and 42
- the substrate 34 has front and back surfaces 44 and 46 .
- Layer 36 of thermosensitive imaging material is located adjacent to the back surface 42 of the film 32 .
- Layer 38 of adhesive is located adjacent to the front surface 44 of the substrate 34 .
- thermosensitive layer 36 is preferably bonded directly to the back surface 42 of the film 32 and is bonded indirectly to the front surface 44 of the substrate 34 through the intermediacy of the adhesive layer 38 .
- a friction-reducing coating 50 such as silicone or poly(tetrafluororthene), can be applied to the front surface 40 of the film 32 to protect thermal print heads from excessive wear. This permits a wider range of materials to be used as the film 32 .
- a suitable coating that also functions to clean the thermal print heads is disclosed in my recently issued U.S. Pat. No. 5,658,661 entitled “Matted Release Coat for Self-wound Thermal Printable Facestock”, which is hereby incorporated by reference.
- the front surface 40 can also be matted or otherwise made receptive to conventional printing inks.
- printing inks 52 and 54 can be applied to the front and back surfaces 44 and 46 of the substrate 34 . The printing ink 52 is visible through the film 32 .
- FIGS. 3 and 4 My invention arranged as a direct thermal printable tape 60 is illustrated by FIGS. 3 and 4.
- the tape 60 has a laminate construction similar to the preceding embodiments 10 and 30 but is also arranged for being affixed to another substrate or object (not shown).
- a film 62 and a substrate 64 give form to the tape 60 and to various layers applied to them.
- a release layer 80 is applied to a front surface 70 of the film 62
- a thermosensitive imaging layer 66 is applied to a back surface 72 of the film 62 .
- Adhesive layers 68 and 78 are applied to front and back surfaces 74 and 76 of the substrate 64 .
- the adhesive layer 68 is in contact with the thermosensitive layer 66 for bonding the film 62 and the substrate 64 together.
- the adhesive layer 78 provides for attaching the tape 60 to another substrate or object.
- the composition and pattern of the adhesive layer 78 are adjusted to meet the requirements of its use.
- the adhesive layer 78 is expected to be pressure sensitive, but the adhesive layer 78 could also exhibit other qualities such as co-adhesion, repositionability, removability, and resistance to cold.
- a release layer 80 protects the adhesive layer 78 prior to use.
- the composition of the release layer 80 is tied to the composition of the adhesive layer 78 so that the release layer 80 exhibits low adhesion to the adhesive layer 78 .
- Liquid-curable silicone generally works well as a release coat.
- the release layer is preferably applied with a matted finish to prevent the accumulation of debris on the print head. An example of such a finish is disclosed in my above-identified U.S. Pat. No. 5,658,661.
- any one of the films 12 , 32 , or 62 in the preceding embodiments could be made opaque in combination with making their corresponding substrates 14 , 34 , or 64 transparent, thereby requiring images in the corresponding thermosensitive layers 16 , 36 , and 66 to be viewed in reverse through the substrates 14 , 34 , or 64 .
- the films 12 , 32 , or 62 could also be made opaque to visible light but used in combination with a thermosensitive material that is infrared readable through the films.
- thermosensitive imaging material can be viewed (or read) through either the films 12 , 32 , or 62 or their corresponding substrates 14 , 34 , or 64 but is preferably imaged by transmissions of heat through the films 12 , 32 , or 64 alone.
- FIG. 5 illustrates an in-line process for separately preparing a film 92 similar to the films 12 , 32 , and 62 of the preceding embodiments.
- the film 92 is unwound from a roll 116 and is fed through a series of coaters 118 , 120 , and 122 .
- the coater 118 applies a layer of friction-reducing material 110 to a front surface 100 of the film 92 .
- the coater 120 applies a layer of thermosensitive imaging material 96 to a back surface 102 of the film 92 .
- the coater 122 applies a layer of barrier material 108 over the layer of thermosensitive imaging material 96 .
- the coated film 92 is then fed through a longitudinal slicer 124 that divides the coated film 92 into narrower strips 92 a , 92 b , and 92 c , which are wound onto rolls 126 a , 126 b , and 126 c .
- Each of the rolls 126 a , 126 b , and 126 c is an intermediate product that can be combined with a number of different substrates.
- the separate roll 126 a is unwound together with a roll 128 of a substrate 94 similar to the substrates 14 , 34 , and 64 .
- the substrate 94 is fed through a printer 130 for applying ink 112 and 114 to front and back surfaces 104 and 106 of the substrate 94 and through a coater 132 for applying an layer of adhesive 98 to the front surface 104 .
- the printer 1.30 can be a thermal or a non-thermal printer.
- a laminator 134 joins the back surface 102 of film 92 a containing the successive layers of thermosensitive imaging material 96 and barrier material 108 to the front surface 104 of the substrate 94 containing the layer of adhesive 98 creating a new direct thermal printable laminate 140 .
- the new laminate 140 is wound into a roll 142 ready for direct thermal printing.
- a method of printing the new laminate 140 is shown in FIG. 7.
- the laminate 140 joining the film 92 a and the substrate 94 is unwound from the roll 142 and is fed into a thermal printer 144 having a thermal print head 146 .
- the thermal print head 146 applies heat to the front surface 100 of the film 92 a for producing images within the layer of thermosensitive imaging material 96 .
- the layer of friction-reducing material (or release) 110 on the front surface 100 of the film 92 a protects the thermal print head 146 from excessive wear.
- a lateral slicer 148 divides the laminate 140 into individual sheets 150 according to their purpose (e.g., tag, ticket, or label). Alternatively, the laminate 140 could be perforated or aligned with a tear bar for manually separating the laminate into the individual sheets 150 .
- the laminate 140 could also be sliced into sheets 150 prior to printing.
- lamination could take place in the printer 144 .
- the film 92 a and substrate 94 could be separately fed into the printer 144 ; and either prior to or after imaging the thermosensitive imaging material 96 , the film 92 a and the substrate 94 could be laminated together. This would enable direct thermal printing of a variety of different substrates at the printer 144 , using the film 92 a as both a print medium and a portion of the laminate.
- thermosensitive imaging layer a thin film containing the thermosensitive imaging layer to a more substantial substrate using a layer of adhesive
- other well-known types of bonding can also be used, including heat or static seals.
- the various layers, including the layer of thermosensitive imaging material, while preferably continuous, can also be laid down in patterns to suit particular applications.
Abstract
Description
- This application claims the benefit of U.S. Provisional Application No. 60/026,501, filed on Sep. 23, 1996, which provisional application is incorporated by reference herein.
- The invention relates to the field of direct thermal printing and especially to media used for such printing.
- Direct thermal printable media is most widely used as facsimile paper but is also used in printers and in other applications requiring permanent imaging such as tags, tickets, and labels. In contrast to printing technologies that involve the transfer of ink from one location to another, direct thermal printing uses a special printable media that incorporates a color developing mechanism. Images are formed by exposing the color developing mechanism to concentrations of heat that produce localized chemical reactions involving a change of color (usually light to dark). The color developing mechanism is provided by a thermosensitive imaging material containing heat reactive chemicals such as leuco dyes or metallic salts.
- Since direct thermal printing only involves the transfer of heat, printing of direct thermal media is simple and clean. Other advantages include low cost, low noise, and high speed. However, the thermosensitive imaging material is susceptible to damage from exposure to various environmental conditions including abrasion, heat, light, and chemicals such as oils, fats, blood, alcohol, solvent, and water. Much of this damage can be limited by applying protective coatings that block unwanted environmental interactions with the thermosensitive imaging material.
- For example, U.S. Pat. No. 4,711,874 to Yuyama et al. suggests use of a water-soluble polymeric material as a protective overcoating for providing physical and chemical resistance. U.S. Pat. No. 4,717,709 to Suzuki suggests use of a polyolefin resin for similar purposes. U.S. Pat. No. 4,886,774 to Doi discloses a protective overcoating containing UV blockers. U.S. Pat. No. 5,286,703 to Wachi et al. discloses use of multiple protective overcoat layers including a first layer of water-soluble or water-insoluble polymers for chemical resistance and a second layer containing UV blockers.
- The thermosensitive imaging material is applied as a coating to a substrate surface. Printing takes place by exposing the coating to a pattern of heat conducted from a thermal print head located adjacent to the substrate surface containing the coating of thermosensitive imaging material. The coating takes the form of the substrate surface including any irregularities or roughness in the surface. Accordingly, any surface irregularities in the thermosensitive coating vary spacing between the thermal print head and different points on the coating, causing unwanted dissipations of heat that interfere with image quality.
- Two solutions are known to limit irregularities in the thermosensitive coating. One is to use only substrates with smooth surfaces. The other is to apply an undercoating between the substrate and the thermosensitive coating. The undercoating covers irregularities in the substrate surface and provides a smooth base for applying the thermosensitive coating. An example is found in U.S. Pat. No. 4,711,874 to Yuyama et al.
- Protective overcoatings shield thermosensitive coatings from environmental interactions, and undercoatings provide a smooth base for applying thermosensitive coatings; but both add cost and complexity to direct thermal printable media. Also, the undercoatings can change the appearance or other desired properties of the substrates. However, without an undercoating, the choice of substrate is even more limited.
- My invention obviates the need for both overcoatings and undercoatings that separately protect and support coatings of thermosensitive imaging material in direct thermal printable media. Coatings of thermosensitive imaging material can be used with a wider variety of underlying substrates without resort to undercoatings, because surface features of the thermosensitive coating are no longer linked to the surface features of the underlying substrates.
- An example of my invention as a direct thermal printable laminate includes two adjacent substrates, one of which is preferably an optically and thermally transmissive film. A thermosensitive imaging layer is located adjacent to a back surface of the transmissive film, and the back surface of the transmissive film is bonded to a front surface of the other substrate for laminating the transmissive film to the other, substrate. The thermosensitive imaging layer is reactive to transmissions of heat through the film (which is thermally transmissive) for forming images within the thermosensitive imaging layer that are visible through the same film (which is also optically transmissive).
- Preferably, the thermosensitive imaging layer is bonded directly to the back surface of the film and indirectly to the front surface of the other substrate through the intermediacy of an adhesive layer. Accordingly, the thermosensitive imaging layer takes the form of the back surface of the film rather than the form of the front surface of the other substrate.
- In addition to functioning as a transmitter of both light and heat, the film can perform two other main functions—first, as a protective covering for the thermosensitive imaging layer and second, as a base for giving desired form to the thermosensitive imaging material. Thus, my invention permits many more materials to be used as substrates for direct thermal printing while protecting the thermosensitive imaging layer from unwanted environmental interactions.
- My new laminate is printable by applying concentrations of heat from a thermal print head to the front surface of the film resulting in the formation of images within the thermosensitive imaging layer. The film is preferably much thinner in thickness than the other substrate to more efficiently transmit heat from the thermal print head to the thermosensitive imaging layer. Thicknesses less than 10 microns are preferred.
- Another example of my invention as self-wound direct thermal printable tape includes a similarly transmissive film. A release layer is applied to a front surface of the film, and a thermosensitive imaging layer is applied to a back surface of the film. The thermosensitive imaging layer is reactive to transmissions of heat through the film for forming images within the thermosensitive imaging layer. Adhesive layers are applied to front and back surfaces of a substrate. A first of the adhesive layers bonds the substrate to the film, and a second of the adhesive layers is intended for bonding the film and substrate to another substrate or object.
- However, prior to bonding the film and substrate to another substrate or object, the film and substrate are unwindable from a roll in which the second adhesive layer is in contact with the release layer.
- Again, a wider selection of substrates can be used with my new direct thermal printable tape, because the transmissive film provides the thermosensitive imaging layer with a desired form as well as a protective covering against exposure to environmental hazards. The release layer on the front surface of the film eliminates any need for a separate release liner to protect the second adhesive layer prior to use. Also, since the thermosensitive imaging material is first coated on the film rather than on the underlying substrate, smaller production runs are more economical because the coated film can be divided for runs with different substrates.
- In fact, a thin thermally transmissive film coated with a thermosensitive imaging material in accordance with my invention can be made as either an intermediate product intended for lamination to another substrate or as a final product that can be imaged prior to or in conjunction with its use. Preferably, the film is both thermally and optically transmissive and has a thickness no greater than 10 microns.
- FIG. 1 is a schematic cross section of a first embodiment of my invention as a new direct thermal printable laminate.
- FIG. 2 is a schematic cross section of a second embodiment of my invention as a similar laminate having additional layers.
- FIG. 3 is a schematic cross section of a third embodiment of my invention as a new direct thermal printable tape.
- FIG. 4 is a schematic cross section of the third embodiment wound into a roll.
- FIG. 5 is a diagram of a production line for coating thermosensitive imaging material on a thin film.
- FIG. 6 is a diagram of a production line for coating a substrate and for laminating the coated film to the coated substrate.
- FIG. 7 is a diagram of a printing sequence for direct thermal printing of the new laminate.
- Illustrated by FIG. 1 is a direct thermal
printable laminate 10 having twoadjacent substrates layer 16 of thermosensitive imaging material and by a layer 18 of adhesive. Thelayer 16 of thermosensitive imaging material is bonded to thesubstrate 12, and the twosubstrates first substrate 12 for forming images in thelayer 16 of thermosensitive imaging material. - The
substrate 12, which is preferably an optically and thermally transmissive film, has thickness “T1” measured between front and back surfaces 20 and 22. The thickness “T1” is preferably limited to 10 microns or less (e.g., 6 microns) to avoid interfering with transmissions of heat through thefilm 12 required for forming images within thethermosensitive imaging layer 16. The images so formed are visible through thefilm 12. Preferably, thefilm 12 is made from a strip of flexible material such as polyester, which is capable of making the required transmissions of light and heat as well as capable of retaining its form at the required thickness “T1”. Other possible film materials include polyethylene, polypropylene, acetate, or other polyolefins. - Various coatings (not shown) can be applied to the
film 12 to provide additional Protection for thethermosensitive imaging layer 16 form exposure to potentially damaging environmental conditions. For example, thefilm 12 can be coated with UV blockers as described in U.S. Pat. No. 4,886,774 to Doi, which is hereby incorporated by reference. - The
thermosensitive imaging layer 16 preferably contains a dye precursor such as a pale or colorless leuco dye and a color former such as an acidic developer that causes the leuco dye to undergo a color transformation in the presence of heat. The dye precursor and color former are separately microencapsulated or otherwise separated to prevent their interaction prior to the application of a predetermined amount of heat. Other color developing mechanisms could also be used including metallic salt color former chemical systems. - The
substrate 14 can be selected from a wider variety of materials including those that do not have physical and chemical properties required for directly supporting thermosensitive imaging material. Examples include high-ground wood content paper, high-strength films such as polyvinyl plastics, and woven or non-woven fabrics, as well as other coarse materials that would otherwise not be suitable for direct thermal printing. Front and back surfaces 24 and 26 of thesubstrate 14 are separated by a thickness “T2” that can be much greater than the thickness “T1”. For example, the thickness “T2” can exceed the thickness “T1” by an order of magnitude or more. - Preferably, the
layer 16 of thermosensitive imaging material is applied as a coating that takes the form of theback surface 22 of thefilm 12. Accordingly, theback surface 22 of the film must be smooth for mounting thelayer 16 of thermosensitive imaging material at a constant distance from a print head. However, thefront surface 24 of thesubstrate 14 can be much rougher. For example, thefront surface 24 of the substrate can have an average peak-to-valley roughness that is larger than an average peak-to-valley roughness of theback surface 22 of the film. In fact, the peak-to-valley roughness of thefront surface 24 can exceed an average thickness of thethermosensitive imaging layer 16 while the similarly measured roughness of theback surface 22 is preferably much less. - The adhesive layer18 can be applied as a coating on the
front surface 24 of thesubstrate 14. Preferably, the adhesive layer 18 is formed by a pressure-sensitive adhesive to form a permanent bond with thefilm 12. If mutually compatible, the adhesive layer 18 can be bonded directly in contact with thethermosensitive imaging layer 16. Possible examples include acrylics, water-borne adhesives, hot melts, and rubber-based extrusions. - A direct
thermal laminate 30 shown in FIG. 2 includes additional layers for performing specialized functions. Similar to the precedinglaminate 10, the laminate 30 includes an optically andthermally transmissive film 32 and asubstrate 34. Thefilm 32 has front and back surfaces 40 and 42, and thesubstrate 34 has front and back surfaces 44 and 46. Layer 36 of thermosensitive imaging material is located adjacent to theback surface 42 of thefilm 32.Layer 38 of adhesive is located adjacent to thefront surface 44 of thesubstrate 34. - However, between the thermosensitive layer36 and the
adhesive layer 38 is abarrier layer 48 that prevents migration of contaminants from theadhesive layer 38 to the thermosensitive layer 36. This permits a wider range of materials to be used in theadhesive layer 38. Suitable barrier materials include water-borne or UV curable varnishes or primers. - The thermosensitive layer36 is preferably bonded directly to the
back surface 42 of thefilm 32 and is bonded indirectly to thefront surface 44 of thesubstrate 34 through the intermediacy of theadhesive layer 38. Any layers located between the thermosensitive layer 36 and theadhesive layer 38, such as thebarrier layer 48, are preferably bonded in succession to the thermosensitive layer 36 so that theadhesive layer 38 provides the final connection between thefilm 32 and thesubstrate 34. - A friction-reducing
coating 50, such as silicone or poly(tetrafluororthene), can be applied to thefront surface 40 of thefilm 32 to protect thermal print heads from excessive wear. This permits a wider range of materials to be used as thefilm 32. A suitable coating that also functions to clean the thermal print heads is disclosed in my recently issued U.S. Pat. No. 5,658,661 entitled “Matted Release Coat for Self-wound Thermal Printable Facestock”, which is hereby incorporated by reference. Thefront surface 40 can also be matted or otherwise made receptive to conventional printing inks. In addition,printing inks substrate 34. Theprinting ink 52 is visible through thefilm 32. - My invention arranged as a direct thermal
printable tape 60 is illustrated by FIGS. 3 and 4. Thetape 60 has a laminate construction similar to the precedingembodiments - A
film 62 and asubstrate 64 give form to thetape 60 and to various layers applied to them. Arelease layer 80 is applied to afront surface 70 of thefilm 62, and athermosensitive imaging layer 66 is applied to aback surface 72 of thefilm 62. Adhesive layers 68 and 78 are applied to front and back surfaces 74 and 76 of thesubstrate 64. Theadhesive layer 68 is in contact with thethermosensitive layer 66 for bonding thefilm 62 and thesubstrate 64 together. - The
adhesive layer 78 provides for attaching thetape 60 to another substrate or object. The composition and pattern of theadhesive layer 78 are adjusted to meet the requirements of its use. Ordinarily, theadhesive layer 78 is expected to be pressure sensitive, but theadhesive layer 78 could also exhibit other qualities such as co-adhesion, repositionability, removability, and resistance to cold. - A
release layer 80 protects theadhesive layer 78 prior to use. The composition of therelease layer 80 is tied to the composition of theadhesive layer 78 so that therelease layer 80 exhibits low adhesion to theadhesive layer 78. Liquid-curable silicone generally works well as a release coat. The release layer is preferably applied with a matted finish to prevent the accumulation of debris on the print head. An example of such a finish is disclosed in my above-identified U.S. Pat. No. 5,658,661. - When wound together into a
roll 82 as shown in FIG. 4, theadhesive layer 78 on theback surface 76 of thesubstrate 64 contacts therelease layer 80 on thefront surface 70 of thefilm 62. Thefilm 62 andsubstrate 64 can be unwound together from theroll 82 by separating the layers of adhesive andrelease - The
film 62 is ordinarily transparent (or at least translucent) to provide an optical path for viewing the images produced in thethermosensitive layer 66, and thesubstrate 64 is ordinarily opaque to provide a background for the images. However, thesubstrate 64, like thefilm 62, could be made optically transmissive for substituting other backgrounds. For example, the other substrates or objects to which thetape 60 is attached could be visible through both thefilm 62 and thesubstrate 64. - Alternatively, any one of the
films corresponding substrates thermosensitive layers substrates films films corresponding substrates films - My
new laminates film 92 similar to thefilms film 92 is unwound from aroll 116 and is fed through a series ofcoaters coater 118 applies a layer of friction-reducingmaterial 110 to afront surface 100 of thefilm 92. Thecoater 120 applies a layer ofthermosensitive imaging material 96 to aback surface 102 of thefilm 92. After curing, thecoater 122 applies a layer ofbarrier material 108 over the layer ofthermosensitive imaging material 96. Thecoated film 92 is then fed through a longitudinal slicer 124 that divides thecoated film 92 intonarrower strips 92 a, 92 b, and 92 c, which are wound onto rolls 126 a, 126 b, and 126 c. Each of the rolls 126 a, 126 b, and 126 c is an intermediate product that can be combined with a number of different substrates. - In FIG. 6, the separate roll126 a is unwound together with a
roll 128 of a substrate 94 similar to thesubstrates printer 130 for applying ink 112 and 114 to front and back surfaces 104 and 106 of the substrate 94 and through a coater 132 for applying an layer of adhesive 98 to the front surface 104. The printer 1.30 can be a thermal or a non-thermal printer. A laminator 134 joins theback surface 102 of film 92 a containing the successive layers ofthermosensitive imaging material 96 andbarrier material 108 to the front surface 104 of the substrate 94 containing the layer of adhesive 98 creating a new direct thermalprintable laminate 140. Thenew laminate 140 is wound into a roll 142 ready for direct thermal printing. - The coating stations can be used in different combinations, and additional coating stations can be used to apply other layers to the
film 92 or substrate 94. For example, the layer of friction-reducingmaterial 110 on thefront surface 100 of thefilm 92 could be fashioned as a release, and another layer of adhesive could be applied to the back surface 106 of the substrate 94 for making a self-wound tape. With the friction-reducingmaterial 110 functioning as a release, the layer ofadhesive material 98 could alternatively be applied over the layer ofbarrier material 108 on theback surface 102 of thefilm 92 before winding thefilm 92 onto separate rolls 126 a, 126 b, and 126 c. Separate steps could also be used to prepare the substrate 94 before unwinding from the roll 128 (such as adding perforations), or more steps could be performed on the film 92 a and the substrate 94 in parallel. - A method of printing the
new laminate 140 is shown in FIG. 7. The laminate 140 joining the film 92 a and the substrate 94 is unwound from the roll 142 and is fed into a thermal printer 144 having athermal print head 146. Thethermal print head 146 applies heat to thefront surface 100 of the film 92 a for producing images within the layer ofthermosensitive imaging material 96. The layer of friction-reducing material (or release) 110 on thefront surface 100 of the film 92 a protects thethermal print head 146 from excessive wear. A lateral slicer 148 divides the laminate 140 intoindividual sheets 150 according to their purpose (e.g., tag, ticket, or label). Alternatively, the laminate 140 could be perforated or aligned with a tear bar for manually separating the laminate into theindividual sheets 150. The laminate 140 could also be sliced intosheets 150 prior to printing. - In addition, lamination could take place in the printer144. For example, the film 92 a and substrate 94 could be separately fed into the printer 144; and either prior to or after imaging the
thermosensitive imaging material 96, the film 92 a and the substrate 94 could be laminated together. This would enable direct thermal printing of a variety of different substrates at the printer 144, using the film 92 a as both a print medium and a portion of the laminate. - While the invention has been described with respect to its preferred embodiments, many other applications of the invention will be apparent to those of skill in the art. For example, I have described the special advantages of my invention for use with self-wound thermally printable labels. However, conventional layer label structures with release liners can also be constructed in accordance with my invention, as well as a broad variety of other direct thermal print media including substrates that are normally not susceptible to direct thermal printing.
- Although I prefer to bond a thin film containing the thermosensitive imaging layer to a more substantial substrate using a layer of adhesive, other well-known types of bonding can also be used, including heat or static seals. The various layers, including the layer of thermosensitive imaging material, while preferably continuous, can also be laid down in patterns to suit particular applications.
Claims (75)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/441,560 US20030203818A1 (en) | 1996-09-23 | 2003-05-20 | Direct thermal printable film and laminate |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US2650196P | 1996-09-23 | 1996-09-23 | |
US08/935,322 US6124236A (en) | 1996-09-23 | 1997-09-22 | Direct thermal printable film and laminate |
US09/639,646 US6608002B1 (en) | 1996-09-23 | 2000-08-16 | Direct thermal printable film with friction-reducing layer |
US10/441,560 US20030203818A1 (en) | 1996-09-23 | 2003-05-20 | Direct thermal printable film and laminate |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/639,646 Division US6608002B1 (en) | 1996-09-23 | 2000-08-16 | Direct thermal printable film with friction-reducing layer |
Publications (1)
Publication Number | Publication Date |
---|---|
US20030203818A1 true US20030203818A1 (en) | 2003-10-30 |
Family
ID=21832201
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/935,322 Expired - Lifetime US6124236A (en) | 1996-09-23 | 1997-09-22 | Direct thermal printable film and laminate |
US09/639,646 Expired - Fee Related US6608002B1 (en) | 1996-09-23 | 2000-08-16 | Direct thermal printable film with friction-reducing layer |
US10/441,560 Abandoned US20030203818A1 (en) | 1996-09-23 | 2003-05-20 | Direct thermal printable film and laminate |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US08/935,322 Expired - Lifetime US6124236A (en) | 1996-09-23 | 1997-09-22 | Direct thermal printable film and laminate |
US09/639,646 Expired - Fee Related US6608002B1 (en) | 1996-09-23 | 2000-08-16 | Direct thermal printable film with friction-reducing layer |
Country Status (2)
Country | Link |
---|---|
US (3) | US6124236A (en) |
WO (1) | WO1998012053A1 (en) |
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CN104900140A (en) * | 2015-06-15 | 2015-09-09 | 深圳市摩泰电子材料有限公司 | Heat-sensitive label and preparation method thereof |
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WO1998012053A1 (en) * | 1996-09-23 | 1998-03-26 | Media Solutions, Inc. | Direct thermal printable film and laminate |
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US20030207066A1 (en) * | 2002-05-03 | 2003-11-06 | Green Bay Packaging, Inc. | Thermally printed ticket structure |
US6764813B2 (en) | 2002-05-17 | 2004-07-20 | Eastman Kodak Company | Lamination of emissions prevention layer in photothermographic materials |
AU2003275394A1 (en) * | 2002-10-02 | 2004-04-23 | General Data Company, Inc | Direct thermal imaging on plastic film john finger |
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US20110041370A1 (en) * | 2005-04-21 | 2011-02-24 | Saint Andre M | Face sheet, identification band, and related methods |
GB0524673D0 (en) | 2005-12-02 | 2006-01-11 | Sherwood Technology Ltd | Laser-imageable marking composition |
WO2007136767A2 (en) | 2006-05-18 | 2007-11-29 | Max International Converters, Inc. | Thermally printable adhesive label |
US7829162B2 (en) | 2006-08-29 | 2010-11-09 | international imagining materials, inc | Thermal transfer ribbon |
US20080241770A1 (en) * | 2007-03-26 | 2008-10-02 | Ws Packaging Group, Inc. | Topcoat for initializing thermally rewritable media |
KR20110031375A (en) * | 2008-07-11 | 2011-03-25 | 미쓰비시 쥬시 가부시끼가이샤 | Solar cell backsheet |
DE102010001794A1 (en) * | 2010-02-11 | 2011-08-11 | Kreutz, Kerry Wilhelm, 51109 | Method and device for the production of labels |
JP2015087757A (en) * | 2013-09-26 | 2015-05-07 | サトーホールディングス株式会社 | Roll state mount-less label |
US10131177B2 (en) * | 2014-02-07 | 2018-11-20 | Entrust Datacard Corporation | Barrier coating for a substrate |
JP6617436B2 (en) * | 2015-04-30 | 2019-12-11 | 凸版印刷株式会社 | Image forming method |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8932706B2 (en) | 2005-10-27 | 2015-01-13 | Multi-Color Corporation | Laminate with a heat-activatable expandable layer |
CN104900140A (en) * | 2015-06-15 | 2015-09-09 | 深圳市摩泰电子材料有限公司 | Heat-sensitive label and preparation method thereof |
Also Published As
Publication number | Publication date |
---|---|
WO1998012053A1 (en) | 1998-03-26 |
US6608002B1 (en) | 2003-08-19 |
US6124236A (en) | 2000-09-26 |
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