System and method for manufacturing custom heat transfer labels

Abstract

In accordance with some embodiments, a system for manufacturing a heat transfer label is disclosed. The system includes an electronic database configured to store a plurality of unit graphics. The system also includes an input device communicably coupled to the electronic database. Furthermore, the system also includes a processor communicably coupled to the input device and the electronic database. In some embodiments, the system also includes a rotatable carousel operatively coupled to the processor. The system also includes, the rotatable carousel includes a plurality of pallets, each of the pallets includes a plurality of recessed cups to contain a plurality of character blocks representing the physical form of the plurality of unit graphics. The system also includes a robotic arm operatively coupled to the processor and positioned to access the rotatable carousel and a carrier sheet.

Description

SYSTEM AND METHOD FOR MANUFACTURING CUSTOM HEAT TRANSFER LABELSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 63 / 597,717 filed November 10, 2023, which is incorporated by reference herein in its entirety.TECHNICAL FIELD

[0002] The present subject matter, in general, relates to the field of label manufacturing systems and methods. In some embodiments, the present subject matter relates to systems and methods for manufacturing heat transfer labels.BACKGROUND

[0003] Heat transfer labels are widely used in various industries for applying designs, logos, text, and other graphics to various surfaces, including textiles, plastics, and other materials. Traditional methods of creating heat transfer labels involve manual processes, which are time-consuming, prone to errors, and lack flexibility in design customization.

[0004] Current methods for producing heat transfer labels typically rely on pre-made designs and offer customers limited or no customization options on demand. Many pre-made designs, even if produced in large volumes, fail to meet alterations or personalized customer demands and trends.

[0005] A significant limitation of these methods is the reliance on skilled labor for both label production and application. Precisely placing heat transfer labels on garments is challenging, even for experienced workers. This manual process can lead to inconsistencies, misalignment, and damage to the labels or garments. Furthermore, each screen used in the production process accommodates only a single design. This limits flexibility and makes alterations difficult. Any change in color, design, or character requires preparing a new screen, a costly and time-consuming process that can significantly hinder production. Existing methods of pre-made heat transfer labels and the need for skilled hands to apply the labels to garments often make it difficult to efficiently handle complex, multi-element designs or provide the precision and flexibility required for high-quality, customized, and / or personalized labels.

[0006] The increasing demand for personalized and small-batch products as opposed to mass-produced labels has created a need for more versatile and efficient heat transfer label production systems. Industry requires solutions that can quickly adapt to changing design requirements, maintain high accuracy, and minimize waste while maximizing production speed.

[0007] Additionally, existing methods and practices often face challenges in accurately applying designs to garments, mainly when dealing with intricate layouts or specific positioning requirements. This can lead to inconsistencies between the intended design and the final product, resulting in quality control issues and customer dissatisfaction.

[0008] The industry is growing in need of an efficient system that can bridge the gap between pre-made heat transfer labels and customized production of heat transfer labels for easy application of intended garments for sports, events, or the like. Such a system should be capable of handling complex designs, ensuring precise placement of individual elements, and offering the flexibility to modify and customize designs as needed easily.

[0009] Therefore, in light of the foregoing discussion, there is a need to overcome the limitations and disadvantages related to the application and use of conventional heat transfer labels and to develop efficient and flexible systems for labeling garments and fabrics.SUMMARY

[0010] Some embodiments provide a system for manufacturing a custom heat transfer label. Other embodiments of the present subject matter provide a method for manufacturing a custom heat transfer label. Some embodiments of the present subject matter provide an efficient and flexible system and method for manufacturing heat transfer labels that bridges the gap between digital design and physical production. In some embodiments, the system provides unprecedented flexibility, accuracy, and efficiency in creating customized heat transfer labels. The key components of the system and functions associated therewith are described below, highlighting the inventive merits of the invention. Furthermore, in various embodiments, the system comprises mechanical and electrical components along with hardware and software to facilitate manufacturing heat transfer labels. In accordance with the present subject matter, the system provides an accuracy and efficiency in manufacturing the customized heat transfer labels. Additionally, the system also provides flexibility of choosing desired graphic design with alternate designs, shape, color, style, and combinations thereof in a single system.

[0011] In some embodiments, the system includes an electronic database configured to store a plurality of unit graphics. The system also includes an input device communicably coupled to the electronic database, and configured to receive input for a graphic design including the plurality of unit graphics retrieved from the electronic database. Furthermore, the system also includes a processor coupled to the input device and the electronic database.

[0012] In some embodiments, the system includes a rotatable carousel operatively coupled to the processor. Furthermore, the rotatable carousel includes a plurality of pallets. In some embodiments, each pallet includes a plurality of recessed cups to contain a plurality of character blocks representing the physical form of the plurality of unit graphics. Furthermore, each of the plurality of character blocks are heat transfer labels including physical characters comprising transfer portions and release layers, such as at a rear surface of the physical characters, with extended release layers of the release layer at the perimeter of the character blocks. Moreover, each of the plurality of character blocks may form an artwork including alphanumeric characters, signs, symbols and combinations thereof.

[0013] In some embodiments, the system includes a robotic arm operatively coupled to the processor and positioned to access the rotatable carousel and a carrier sheet. In some embodiments, the robotic arm may be configured to pick up one or more of the plurality of character blocks from the rotatable carousel and place the one or more of the plurality of character blocks on the carrier sheet. In some embodiments, the processor is configured to generate instructions for the robotic arm to perform one or more of selection, pick, and placement of the character blocks such that the graphic design represented by the character block in the carrier sheet is identical to the graphic design provided as the input.

[0014] In other embodiments, the carrier sheet includes a tacky adhesive on a receiving side to retain the plurality of character blocks thereon. In some embodiments, the system also includes a feeder configured to feed a roll of carrier sheet with a feeder configured to feed a roll of the carrier sheet with a release cover. In some embodiments, the system also includes an unwinder configured to detach the release cover from the roll of the carrier sheet and expose the tacky adhesive on the receiving side of the carrier sheet for placement of the plurality of character blocks. In some embodiments, the system also includes a rewinder configured to re-attach the release cover over the carrier sheet along with the plurality of character blocks placed on the carrier sheet. In some embodiments, the graphic design is fed into the interface with one of the alphanumeric characters, signs, symbols and a combination thereof. The plurality of unit graphics comprises graphical characters and extended portions at the perimeter of the unit graphics.

[0015] In some embodiments, the processor is configured to analyze each of the unit graphics in the graphic design, and to determine through the analysis one or more of the relative position, spacing, size, and orientation of each of the unit graphics and / or sequence of placement of each of the unit graphics in the graphic design.

[0016] In some embodiments, the processor is configured to align the plurality of unit graphics in reference to one or more virtual reference points displayed on an interface of the input device.

[0017] In some embodiments, the processor is configured to assess the relative positions of placement of the plurality of character blocks representing each of the plurality of unit graphics of the graphic design physically and mapping it identical to the plurality of unit graphics virtually in the graphic design.

[0018] In some embodiments, the processor is configured to coordinate the rotation of the rotatable carousel to present the plurality of character blocks representing each of the plurality of unit graphics of the graphic design to the robotic arm based on the analysis.

[0019] In some embodiments, each of the plurality of character blocks is a heat transfer label, wherein the heat transfer label comprises a transfer portion, and a release layer. Furthermore, the transfer portion comprises one or more layers of ink, a coating, a heat transfer adhesive, and combinations of those layers in varying orders. In some embodiments, each of the plurality of character blocks may be or include one or more of a letter, a numerical digit, a sign, a logo, a graphic, a design, a symbol, or any combination thereof. In some embodiments, the carrier sheet is an acetate sheet. In some embodiments, each pallet of the rotatable carousel comprises an Radio Frequency Identification (RFID) Tag and is configured to communicate with an RFID reader.

[0020] In some embodiments, the processor is communicatively coupled with the RFID reader and configured to receive identification information of the RFID tag from the RFID reader. In some embodiments, the processor is configured for determining the sequence of character blocks for selection and picking through analyzing the spatial arrangement of plurality of character blocks, dimensions of the plurality of character blocks, a character style, orientation of the plurality of character blocks, color grouping, a rotatable carousel position, the identification information, alignment of the plurality of unit graphics in reference to one or more virtual reference points, character availability, design symmetry or any combination thereof.

[0021] In some embodiments, the robotic arm comprises a vacuum-assisted gripper for picking and placing the plurality of character blocks. In some embodiments, the system also includes one or more sensors including an imaging device, proximity sensors, and a combination thereof.

[0022] In some embodiments, the method for manufacturing a custom heat transfer label includes storing a plurality of unit graphics in an electronic database. Furthermore, the method also includes receiving one or more inputs for a graphic design comprising the plurality of unit graphics via an input device, the input device being communicably coupled to the database. In some embodiments, themethod also includes assessing the relative positions of placement of a plurality of character blocks representing each of the unit graphics of the graphic design physically and mapping it identical to the unit graphics virtually in the graphics design. Furthermore, the plurality of character blocks being present in a plurality of pallets of a rotatable carousel, each of the pallets comprises a plurality of recessed cups to contain the plurality of character blocks. In some embodiments, the method also includes coordinating rotation of the carousel to present the plurality of character blocks representing each of the plurality of unit graphics of the graphic design to a robotic arm based on the analysis. In some embodiments, the method also includes generating instructions for the robotic arm to perform the picking and placement of the plurality of character blocks such that the graphic design is represented identically by the plurality of character blocks on a carrier sheet.

[0023] In other embodiments, the method also includes performing analysis of the relative positions of each of the unit graphics in the graphic design received at the input device, the analysis being is associated with determining at least any of the relative position, spacing, size, or orientation of each of the unit graphics and / or sequence of each of the unit graphics in the graphic design. In other embodiments, the method also includes aligning the plurality of unit graphics in reference to one or more virtual reference points displayed on an interface of the input device.

[0024] These and other features, aspects, embodiments, and advantages of the present subject matter will be better understood with reference to the following description and appended claims. This summary is provided to introduce a selection of concepts in a simplified form. This summary is not intended to identify key features or essential features of the claimed or disclosed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF DRAWINGS

[0025] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present subject matter, exemplary constructions of the subject matter are shown in the drawings. However, the present subject matter is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[0026] Embodiments of the present subject matter will now be described, by way of example only, with reference to the following diagrams wherein:

[0027] FIG. 1 is a block diagram of a system for manufacturing a heat transfer label, in accordance with an embodiment;

[0028] FIG. 2A is a front view of the rotatable carousel, in accordance with an embodiment;

[0029] FIG. 2B is a front view of a plurality of pallets, in accordance with an embodiment;

[0030] FIG. 3A is a front perspective view of a system for manufacturing a custom heat transfer label, in accordance with an embodiment;

[0031] FIG. 3B is a rear perspective view of the system for manufacturing the custom heat transfer label, in accordance with an embodiment;

[0032] FIG. 4 is a flow chart of steps performed by the processor, in accordance with an exemplary embodiment;

[0033] FIG. 5A is a front view of the interface depicting a first interface template, in accordance with an embodiment;

[0034] FIG. 5B is a front view of the interface 108 depicting a second interface template, in accordance with an embodiment;

[0035] FIG. 5C is a front view of a plurality of unit graphics, in accordance with an embodiment;

[0036] FIG. 5D is a front view of the interface depicting an interface template with a virtual pallet, in accordance with an embodiment;

[0037] FIG. 6 is a perspective view of the robotic arm depicting a vacuum-assisted gripper, in accordance with an embodiment;

[0038] FIG. 7A is a front perspective view of a sheet roller, in accordance with an embodiment;

[0039] FIG. 7B is a schematic view of the sheet roller, in accordance with an embodiment;

[0040] FIG. 8A is a rear view of a carrier sheet, in accordance with an embodiment;

[0041] FIG. 8B is a front view of the carrier sheet, in accordance with an embodiment; and

[0042] FIG. 9, there is a flow chart of a method for manufacturing a custom heat transfer label, in accordance with an exemplary embodiment of the present subject matter.

[0043] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non - underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.DETAILED DESCRIPTION

[0044] In overview, some embodiments of the present subject matter relate to systems and methods for manufacturing and / or assembly of heat transfer labels and associated products. Some embodiments include customizing and / or manufacturing the heat transfer labels, and the associations may be determined based on at least one of shape, size, margins, extended portion, interference, proximity, efficiency, accuracy, and customization in heat transfer label production and semantics thereof.

[0045] The following detailed description illustrates various embodiments of the present subject matter and ways in which they can be implemented. Although some modes of carrying out the present subject matter have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present subject matter are also possible. Some disclosed embodiments include one or more methods, devices, and / or systems for manufacturing a heat transfer, such as for a label, garment, tag, or other product.Definitions:

[0046] "Heat transfer label" as used herein refers to a label or a tag of a printed indicia (such as a letter, letters, a word, words, a logo, a trademark, a design, a pattern, a graphic, an artwork, and combinations thereof). Garments and fabrics (e.g., T-shirts, shirts, sweatshirts, hats, jackets, shoes, jerseys, towels, bed linens, tablecloths, etc.) may be labeled with the printed indicia applied to the garment to attach the indicia on the garment. The heat transfer label includes a transfer portion (for example transfer portion) that is transferred to the garments or fabrics. In some embodiments, the transfer portion may be a layer or a film of printable ink or printable material prepared by ink printing or screen printing. The heat transfer label may also include a heat transfer adhesive (for example or heat activated adhesive) disposed at the underside of the transfer portion.

[0047] "Electronic database" as used herein refers to a structured collection of data stored and accessed electronically, typically through a computer system or an interface that may be a graphical user interface. Furthermore, the electronic database is organized for efficient search and retrieval of information. In other words, the electronic database may be interpreted as a digital filing cabinet but with much more powerful search and sorting capabilities. In some embodiments of the present disclosure, the electronic database may refer to a server adapted to store and retrieve data virtually.

[0048] "Input device" as used herein refers to refers to electronic or digital electronic devices or hardware, adapted to provide input into a computing system or hardware. Furthermore, the inputdevices may include, but are not limited to a keyboard, a mouse, a joystick, an imaging device, a scanner, and a cellphone or mobile phone.

[0049] "Interface" as used herein refers to a digital display or a screen adapted to display data, signal, characters (such as alphanumeric characters or special characters), icons, and the like. Furthermore, the interface herein may include a human-machine interface or a graphical user interface. For example, the interface may be a touchscreen display that interchangeably acts as an input device and as an interface.

[0050] "Processor" as used herein refers to an electronic circuit that performs operations on data. Furthermore, the processor is the brain of a computing system, executing instructions and manipulating data to achieve specific tasks. Furthermore, the processor may be configured to perform based on training models or language models on text data or metadata. In some embodiments, the processor may be adapted to analyze and extract information from a text, an image or a video to link extracted information to a knowledge base and storage to derive insights and relationships from the extracted information. Moreover, the processor is a data pre-processing unit configured to process and transform input data to predict outcomes and generate insights using a trained model. In accordance with an embodiment herein, the processor is configured to receive inputs, process the inputs, and provide outcomes and / or instructions for the devices connected with the processor.

[0051] "Rotatable carousel" as used herein refers to a rotatable table, container, or plate. In some embodiments, the rotatable carousel may be a container configured to rotate, and a plurality of objects such as labels (for example, heat transfer labels) may be contained in the rotatable carousel. The rotatable carousel is operatively coupled to the processor. In some embodiments, the processor provides instructions to rotate the rotatable carousel using a motor or a servo motor.

[0052] "Robotic arm" as used herein refers to an automated robot assembly that includes a plurality of rigid links interconnected by moveable joints. One or more of the joints may be actuated by a servo motor, an electric motor with an integrated position sensor, hydraulics, pneumatics, or other force or torque delivery devices. The robotic arm may include an end effector comprising a gripper, which may include force sensors. Furthermore, the robotic arm used herein is controlled by the processor.

[0053] These and other features, aspects, embodiments, and advantages of the present subject matter will be better understood with reference to the below-stated description and appended claims. These definitions are provided to introduce a selection of concepts in a simplified form. These definitions are not intended to identify key features or essential features or keywords of the claimed ordisclosed subject matter, nor are they intended to be used to limit the scope of the claimed subject matter.

[0054] The heat transfer label manufacturing system and method as disclosed in this document is described in detail by way of examples and with reference to the figures. Unless otherwise specified, like numbers in the figures indicate references to the same, similar, or corresponding elements throughout the figures. It will be appreciated that modifications to disclosed and described examples, arrangements, configurations, components, elements, apparatuses, methods, materials, etc., may be made and may be desired for a specific application.

[0055] In the present subject matter, any identification of specific shapes, materials, techniques, arrangements, etc., is either related to a specific example presented or is merely a general description of such a shape, material, technique, arrangement, etc. Identifications of specific details or examples are not intended to be, and should not be, construed as mandatory or limiting unless specifically designated as such. Selected examples of apparatuses and methods are hereinafter disclosed and described in detail with reference made to FIGURES.

[0056] FIG. 1 is a block diagram of a system 100 for manufacturing a custom heat transfer label, in accordance with an embodiment. The system 100 as described herein may refer to a machine or machine equipment that facilitates the manufacturing of the custom heat transfer label. The system 100 includes an electronic database 102. The system 100 also includes an input device 104 communicably coupled to the electronic database 102. In some embodiments, the input device 104 includes an interface 106 to receive inputs. The system 100 also includes a processor 108 communicably coupled to the electronic database 102 and the input device 104 including the interface 106. The system 100 also includes a rotatable carousel 110 including a plurality of pallets 112. In some embodiments, the plurality of pallets 112 includes a plurality of RFID tags, one or more of which are used for each of the plurality of pallets 112. The system 100 also includes a robotic arm 118 operatively coupled to the processor 108 and positioned to access the rotatable carousel 110. In some embodiments, the robotic arm 118 includes an RFID reader 120.

[0057] In some embodiments, the electronic database 102 is configured to store a plurality of unit graphics virtually. The electronic database 102 refers to electronic circuits programmed with software including, but not limited to, data training models, electronic database access languages, and the like. As used herein, the phrase "unit graphics" refers to virtual or digital illustrations that may in some embodiments be designed on computing platforms, and may be used in various embodiments for creating virtual artworks and virtual designs (e.g., graphic designs), which may in turn be used to create physicalartworks and / or physical designs. Furthermore, each of the unit graphics may include a brand logo, a brand name, a brand design, a cartoon character, a shape, or other designs, and combinations thereof. In some embodiments, each of the plurality of unit graphics includes a graphical character (e.g., a letter or number). In some embodiments, the electronic database 102 includes a memory that stores and retrieves geometrical shapes, dimensions, relative positions, alignments, orientations, and margins of pre-stored graphic designs and / or artworks for each unit graphic.

[0058] In some embodiments, the input device 104 is configured to receive an input for a graphic design. Furthermore, the input device 104 is adapted to receive inputs such as alphanumeric characters, special characters, signs, symbols, and a combination thereof for the graphic design. In some examples, the input device 104 including the interface 106 includes a touchscreen display or keyboard to provide inputs about the graphic design including the one or more unit graphics. In an example, interface 106 displays the inputs received from input device 104 depicting the graphic design including the plurality of unit graphics retrieved from the electronic database 102. It may be appreciated that the electronic database 102 is configured to store a library of graphic designs including the plurality of unit graphics with a plurality of font style, character designs, shapes, colors, contours, and the like. In an event, when the electronic database 102 receives an input from the input device 104, requesting a graphic design with a set of plurality of unit graphics. In such an event, the electronic database 102 retrieves the pre-stored graphic designs and displays a proposed graphic design.

[0059] In some embodiments, the processor 108 is configured to analyze the inputs received at the input device 104 for the graphic design. In some embodiments, the processor 108 may include, but is not limited to, one or more processing units and / or microprocessors that facilitate in creation of one or more of a plurality of unit graphics that may include brand logos, brand names, brand designs, cartoon characters, shapes, and such designs. Furthermore, the processor 108 analyses the nature, style, color, or character of the input as the plurality of unit graphics that form the graphic design. Subsequently, the processor 108 provides instructions to the electronic database 102 to compare the input of the graphic design from the pre-stored graphic designs. Moreover, the electronic database 102 retrieves the prestored graphic designs and displays a proposed graphic design based on either the most recommended for the input provided, historical inputs, or relevant data, required alignment, favorable relative positions, a compact design, decorative design, and the like as a result of a recommendation for the proposed graphic design on the interface 106. Notably, the processor 108 is configured to store and save the inputs provided by the input device 104 for the graphic design.

[0060] In some embodiments, the rotatable carousel 110 includes the plurality of pallets 112, configured to rotate on the instructions of the processor 108. In some embodiments, the plurality of pallets 112 are sections of the rotatable carousel 110 adapted to receive and retain objects such as labels therein. Furthermore, each of the plurality of pallets 112 includes a plurality of recessed cups (shown in figures herein below) or other holding mechanisms such as bars, frames, posts, or other recessed or nonrecessed structures. Each of the plurality of recessed cups may be a receptacle configured with one or more protrusions, walls, recesses, cavities, or chambers to receive and contain objects such as labels. In some embodiments, one or more of the plurality of recessed cups is adapted to contain a plurality of character blocks (shown in figures herein below).

[0061] As used in the present subject matter, each of the plurality of character blocks is the physical representative of a corresponding one of the plurality of unit graphics stored in the electronic database 102. Furthermore, each of the plurality of character blocks corresponds to a corresponding one of the plurality of unit graphics with respect to dimensions, style, color, shapes or a combination thereof. In some embodiments, the plurality of character blocks is physically identical to the plurality of unit graphics depicted on the interface 106. In various embodiments, each of the plurality of character blocks may include one or more of letters, numerical digits, signs, logos, graphics, design, symbols, or any combination thereof

[0062] In some embodiments, the plurality of character blocks are the heat transfer labels. Notably, the processor 108 assesses a relative position of the plurality of character blocks in the rotatable carousel 110. In some embodiments, the position of the character blocks maps identically to the plurality of unit graphics depicted virtually on the interface 106. In some embodiments, the system 100 comprises one or more sensors to detect the plurality of character blocks in the rotatable carousel 110. For example, the one or more sensors may include an imaging device, proximity sensors, and / or combinations thereof. In other words, in some embodiments, the plurality of character blocks is the physical translation of the plurality of unit graphics depicted on the interface 106.

[0063] In some embodiments, the one or more sensors are communicably coupled to the processor 108, and the RFID reader 120, to provide information about the plurality of character blocks available in the rotatable carousel 110. In some embodiments, the information about the plurality of character blocks may include, but not be limited to, an availability, an orientation, a shape, one or more dimensions such as length, width, height, width at varying heights, color, count, and combinations thereof. In some embodiments, the processor 108 stores the availability of the plurality of character blocks present in the rotatable carousel 110 in the electronic database 102. Furthermore, the processor108 displays the available plurality of character blocks on the interface 106, when inputs are received through the input device 104. Beneficially, in some embodiments, the system 100 provides a unique solution that creates a digital-physical correlation between each of the plurality of character blocks in physical reality to the corresponding one of the plurality of unit graphics depicted virtually on the interface 106.

[0064] In some embodiments, system 100 also includes a robotic arm 118 operatively coupled to the processor 108 and adapted to pick one or more of the plurality of character blocks from the rotatable carousel 110 to create the graphic design in real. In some embodiments, the robotic arm 118 is positioned to access the rotatable carousel 110 and a carrier sheet (shown in figures and described in greater detail below). In some embodiments, the robotic arm 118 communicates with the RFID reader 120 to detect one or more RFID tags on the rotatable carousel 110, such as an RFID tag on a pallet, and to thereby locate the target one of the plurality of character blocks from the rotatable carousel 110. In some embodiments, the RFID reader 120 detects at least one pallet from the plurality of pallets 112 that contains the plurality of character blocks that includes the target character block corresponding to a target unit graphic of the graphic design. In accordance with an embodiment herein, the processor 108 provides instructions to the robotic arm 118 to move over the rotatable carousel 110, and to detect coordinates of one or more of the plurality of character blocks in the plurality of pallets 112 of the rotatable carousel 110. For example, the RFID reader 120, and / or one or more sensors provides information about coordinates, relative positions, orientations of the plurality of character blocks. In other embodiments, the location of the character blocks is stored in memory, and no detection is needed for the robotic arm 118 and the rotatable carousel 110 to be coordinated by the processor to pick up the correct character block.

[0065] In some embodiments, the RFID reader 120 is used to detect an RFID tag coupled to a specific character block. In some examples, the robotic arm 118 is a robot that facilitates four degrees of movements, such as rotation of a laterally extending arm over the rotatable carousel 110 or over a contact sheet, extension of a vertically extending segment towards and away from the rotatable carousel 110, rotation of the laterally extending segment of the robot arm around a laterally extending axis of the laterally extending segment, and / or rotation of the vertically extending segment around a vertically extending axis of the vertically extending segment. These degrees of movement may allow a part of the robotic arm 118 to be rotated or otherwise extended over the rotatable carousel 110 or over a carrier sheet, to be extended vertically (or in other directions as needed) toward the rotatable carousel 110 or carrier sheet, thus facilitating pick up and / or placement of a character block.

[0066] In various embodiments, the robotic arm 118 accurately and efficiently picks each of the plurality of character blocks from the rotatable carousel 110 that is required for a proposed graphic design and precisely places each of the plurality of character blocks on the carrier sheet. In some embodiments herein, the processor 108 is configured to generate instructions for the robotic arm 118 to perform one or more selection, pick, and placement of the character blocks such that the graphic design represented by the plurality of character blocks in the carrier sheet is identical to the graphic design provided as the input. Furthermore, the processor 108 is configured to define the placement of the plurality of character blocks on the carrier sheet, by creating an efficient path for the movement of the robotic arm 118. Thus, the processor 108 analyses the proposed graphic design and provides instructions to the robotic arm 118 to follow a path of movement to precisely place the plurality of character blocks on the carrier sheet in the position and in the sequence mapped by the plurality of unit graphics for the proposed graphic design depicted virtually on the interface 106. In some embodiments, the carrier sheet may be an acetate sheet.

[0067] FIG. 2A is a front perspective view of the rotatable carousel 110, in accordance with an embodiment. It may be appreciated that the rotatable carousel 110 is an embodiment of the rotatable carousel 110 shown in FIG. 1, and that other embodiments may have differing appearance or forms. The rotatable carousel 110 includes the plurality of pallets 112, as shown in FIG. 1, 2A, and 2B. As depicted in FIG. 2A and 2B, the plurality of pallets 112 includes a plurality of recessed cups 202. In some embodiments, the plurality of recessed cups 202 may include one or more of hollow chambers, pockets, towers, posts, cages, or other receiving structures that are formed in and / or attached to pallet 112 of the rotatable carousel 110 to receive objects (such as heat transfer labels) therein. In an embodiment, the rotatable carousel 110 includes a plurality of pallets 112, each being formed with a plurality of the areas (e.g., recessed cups 202). In some embodiments, the rotatable carousel may be formed with one or more hollow chambers, pockets, towers, posts, cages, or other receiving structures that are formed in and / or attached to the rotatable carousel 110 to receive objects (such as heat transfer labels or pallets 112) therein. In an example embodiment, the rotatable carousel 110 may be a circular disc type configured to support six of the pallets 112.

[0068] In some embodiments, each of the recessed cups 202 is configured to contain one type of a plurality of character blocks 204 therein. Furthermore, the plurality of character blocks 204 may refer to a single unit of a heat transfer label produced with a single character or sign or symbol of identity such as an alphabetical letter (e.g., "A", "B" or "C") and / or a number (e.g., "5", "7" or "9"). It may be appreciated that one or more of the plurality of character blocks 204 may also be or include othercharacters such as special characters or signs, or may be a combination of multiple alphanumeric characters, symbols, and / or other special characters. Moreover, the heat transfer label may include a transfer portion and a release layer (e.g., a substrate coated with a release coating, a release coating, or a substrate) adhered to a rear side of the transfer portion. In some embodiments, the transfer portion includes one or more layers of ink, a coating, and a heat transfer adhesive, and combinations thereof. In an embodiment, when the heat transfer label is applied on a fabric and then pressed with heat, the transfer portion is adhered to the fabric via the heat transfer adhesive. Subsequently, the release layer is peeled off from the adhered transfer portion, and the transfer portion remains adhered on the fabric, thereby creating an embellishment on the fabric or other material to be embellished for various types of products. Types of products may include clothing or accessories, such as shirts, pants, shorts, shoes, hats, jackets. Products may also include bags, product coverings, or other items.

[0069] In some embodiments, one or more dimensions (e.g., length, width, height) of the release layer are substantially greater than the corresponding dimensions of the transfer portion. For example, from a top view the release layer may appear to form a border of continuous and / or varying width around the transfer portion that forms the appearance of the embellishment to be attached to a product. The release layers may be transparent or opaque. According to some embodiments, the release layer extends to the perimeters of the transfer portion. Furthermore, the heat transfer labels may include extended release layers that surrounds the transfer portions. In some embodiments, when the heat transfer labels are heat pressed to surface such as garments or fabrics, the extended release layers enable a release action of the release layers off of or out of the transfer portions. In an embodiment, each of the plurality of character blocks 204 are heat transfer labels including physical characters i.e., the transfer portions, and release layers at a rear surface of the physical characters. Furthermore, the transfer portions are provided with extended release layers of the release layer at the perimeter of the plurality of character blocks 204 to enable a release action, when detached from the transfer portions.

[0070] FIG. 2B is a front perspective view of the plurality of pallets 112, in accordance with an embodiment. The plurality of pallets 112 includes the plurality of character blocks 204 arranged therein. In some embodiments, the plurality of pallets 112 includes an RFID label 206 for each of the plurality of pallets 112. In some embodiments, an RFID label 206 is included for each of the plurality of character blocks 204. It may be appreciated that each of the plurality of character blocks 204 may be identified from the RFID label 206 and / or a location, a relative position, an appearance of the character block 204, and combinations thereof, in the plurality of pallets 204.

[0071] FIG. 3A is a front perspective view of a system 300 for manufacturing a custom heat transfer label, in accordance with an embodiment. FIG. 3B is a rear perspective view of the system 300 for manufacturing the custom heat transfer label, in accordance with an embodiment. In some embodiments, the system 300 includes a rotatable carousel 302, a robotic arm 304, a human machine interface 306, a collection panel 308 and a sheet roller 310.

[0072] In some embodiments, the system 300 is same as the system 100, but differs in other embodiments. In some embodiments, the system 300 may comprise or be part of machine equipment or a machine assembly for manufacturing custom heat transfer labels. The system 300 as machine equipment may comprise a plurality of components that are assembled together to facilitate the manufacturing of custom heat transfer labels. In an embodiment, system 300 is provided as a cuboidal box 312 with the rotatable carousel 302 at the base of the cuboidal box 312. As used herein, the rotatable carousel 302 may refer to a disc or a plate provided with areas (e.g., containers, receptacles, cups, supports, posts, trays, or pegs) to receive one or more objects (such as heat transfer labels). In some embodiments, the system 300 is also provided with the robotic arm 304 mounted on the rotatable carousel 302. Furthermore, the robotic arm 304 is provided with four degrees of freedom, allowing it to rotate 360 degrees in all three axes (e.g., X, Y, and Z axes of a Cartesian coordinate system). In some embodiments, the robotic arm 304 may be configured to pick objects from the rotatable carousel 302.

[0073] FIG. 4 is a flow chart of a process flow 400 of steps performed by the processor 108, in accordance with an exemplary embodiment of the present subject matter.

[0074] The process flows 400 as shown in the FIG. 4 represents the functions performed by the processor 108(as shown in FIG. 1). Furthermore, the processor 108 provide to various components of the system 100 (as shown in FIG. 1).

[0075] At a step 402, the processor 108 is configured to analyze (e.g., perform analysis of) each of the unit graphics in a graphic design. Furthermore, the analysis determines at least any of the relative position, spacing, size, and orientation of each of unit graphics of the graphic design and / or sequence of each of the unit graphics in the graphic design. As mentioned herein above, the processor 108 is configured to analyze the input received from the input device 104 for evaluating the parameters involved in the graphic design provided as input. Furthermore, the processor 108 evaluates each of the relevant and available parameters from the graphic design (input) relative position, spacing, size, and orientation of each of unit graphics of the graphic design and / or sequence of each of the unit graphics in the graphic design. In an example, an initiation from from left to right is considered but may varydepending on the input for variable graphic design that requires any coordinate, position, spacing, size, alignment, orientation, and the like.

[0076] At a step 404, the processor 108 is configured to align the plurality of unit graphics in reference to one or more virtual reference points displayed on the interface 106 of the input device 104. Based on the input provide at the plurality of unit graphics are arranged and aligned accordingly. It may be appreciated that in various embodiments, the processor 108 is configured to create a virtual replica of the physical carrier sheet on the interface 106. The virtual replica of the physical carrier sheet may include one or more virtual reference points displayed on the interface 106. In some embodiments, the processor 108 is configured to align the plurality of unit graphics in reference to the one or more virtual reference points based on the inputs provided by the input device 104. In an example, the interface 106 may be a touchscreen display that includes a cursor on the touchscreen display that enables an alignment of the plurality of unit graphics in reference to one or more virtual reference points displayed on the interface 106. For example, a virtual reference point may be a center of a target item and / or piece of apparel, a point located at a fixed distance above or below a reference point or area (e.g., a top or bottom edge or center of a piece of apparel). In some examples, the virtual replica of the physical carrier sheet may include one or more virtual reference lines displayed on the interface 106. For example, the one or more virtual reference lines may include straight lines, curved lines, a parabola, an, ellipse or a combination thereof.

[0077] At a step 404, the processor 108 is configured to assess the relative positions of placement of character blocks representing each of the unit graphics of the graphic design physically and to map each of the unit graphics identically and / or with adjustments as needed to the unit graphics virtually in the graphic design. Based on the provided graphic design and the limitations of the character blocks and their transfer and release portions, and the alignment and relative positions on the interface 106, the processor 108 determines the relative positions of placement of character blocks that corresponds to each of the unit graphics of the graphic design in physical set up, and maps identically with the plurality of unit graphics virtually in the graphic design, as depicted on the interface 106.

[0078] At a step 406, the processor 108 is configured to coordinate the rotation of the rotatable carousel to present the plurality of character blocks representing each of the unit graphics of the graphic design to the robotic arm 118 based on the analysis provide at the input device 104 and the interface 108. In some embodiments, the processor 108 provides instructions for rotation of the rotatable carousel to showcase or represent the required at least one pallet of the rotatable carousel that contains the required at least one-character block present in the graphic design. In some embodiments, the at least one pallet of the rotatable carousel may contain one or more-character blocks that is required to completethe graphic design. For example, the processor 108 may provide instructions for rotation of the rotatable carousel to rotate clockwise and counterclockwise to showcase or make accessible the required at least one pallet of the rotatable carousel that contains the required at least one character block.

[0079] At a step 408, the processor 108 is configured to generate instructions for the robotic arm 118 to perform one or more selection, pick, and placement of the character blocks such that the graphic design represented by the plurality of character blocks 204 in the carrier sheet is identical to the graphic design provided as the input. In some embodiments, the processor 108 is configured to define a sequence of placement of the plurality of character blocks 204 based on the plurality of unit graphics for the graphic design to perform one or more selection, pick, and placement of the plurality of character blocks 204. In accordance with an embodiment, the plurality of unit graphics is inserted into the system 100 through the input device 104 and then the processor 108 provides a sequence of placement for each of the plurality of character blocks, which is represent as a sequence of placement virtually on the plurality of unit graphics for the graphic design. The sequence of placement for each of the plurality virtually of unit graphics may vary and the successively positioned characters may not be in the same sequence for the sequence of placement for each of the plurality of unit graphics.

[0080] As described herein, the phrase "sequence of placement virtually" may refer to an order or series of occurrence of placement of the plurality of unit graphics depicted virtually on the interface 106. Furthermore, in some embodiments, the sequence of placement virtually for each of the plurality of unit graphics may be based on the extended portions of the unit graphics falling adjacent to one another in the graphic design. Moreover, in some embodiments, the sequence of placement for each of the plurality of unit graphics may be adapted to avoid interference of the extended portions of the adjacent unit graphics with the transfer portions of the adjacent unit graphics. For example, the graphic design may include a word "PARK" that has letters "P" as 1st, "A" as 2nd, "R" as 3rd and "K" as 4th. In such an example, the word "PARK" may require a jumbled sequence of placement to avoid interference in between the letters the transfer portions and the release portions of the character blocks. If interference occurs, the release layer of one character block may obscure one or more parts of the transfer portion of one or more adjacent character blocks, resulting in damage to the final product. However, overlap of a release layer over the back of one or more adjacent character blocks may avoid the interference. For example, for a central character block with a release layer that extends farther out from the left and right than for other character blocks, that central character block may be placed after the character blocks to the left and right of the central character block, with the transfer layer of the centralcharacter block extending over the release layer and / or the transfer portion of one or more adjacent character blocks to the central character block.

[0081] In an example embodiment, the sequence of placement virtually for the graphic design might number "P" as 3, "A" as 1, "R" as 4 and "K" as 2. The sequence may start from the left and move to the right, start from the right and move to the left, or start from the middle and work outwards to either the left or right continuously in one direction or in alternating directions. The sequence may be adjusted in order to avoid interference. As used herein, the jumbled sequence of placement refers to a series of sequence of placement virtually for the plurality of unit graphics may be rearranged according to one or more selection, pick, and placement of the plurality of the character blocks based on selection and picking through analyzing the spatial arrangement of character blocks, dimensions of the plurality of the character blocks, a character style, orientation of the plurality of the character blocks, color grouping, a rotatable carousel 110 position, the identification information, alignment of the plurality of unit graphics in reference to the one or more virtual reference points, character availability, design symmetry or any combination thereof. For example, a jumbled sequence may be appropriate to speed placement by sequencing placement in order of most efficient access from the rotatable carousel 110. For example, character blocks may be selected in the order of their location to allow the robot to follow a preferred shorter path along the rotatable carousel 110, such as by picking from the outer edge inwards, picking from the same pallet before moving to the next nearest pallet, picking from the center of a pallet outwards, and / or picking from pallets to the next nearest pallet following a single rotational direction.

[0082] According to embodiments herein, the processor 108 is configured to monitor and control functions of the electronic database 102, the input device 104, the rotatable carousel 110, the robotic arm 118, and the interface 106. Furthermore, the processor 108 analyses the information collected from one or more sensors, the RFID reader 120, and the input device 104 for a sequence of placement of the plurality of character blocks 204 based on the plurality of unit graphics for the graphic design to perform one or more selection, pick, and placement of the plurality of character blocks 204. Accordingly, the placement of the plurality of character blocks 204 on the carrier sheet results in a customized heat transfer label prepared by the system 100. In accordance with the present subject matter, the system 100 provides an accuracy and efficiency in manufacturing the customized heat transfer labels. Additionally, the system 100 also provides flexibility choosing desired graphic design with alternate designs, shape, color, style, and combinations thereof in a single system.

[0083] FIG. 5A is a front view of the interface 106 depicting a first interface template 502, in accordance with an embodiment. In some embodiments, the first interface template 502 includes anoutline of a virtual carrier sheet 504. Furthermore, the virtual carrier sheet 504 may be a virtual replica of a PET sheet or an acetate sheet. As shown in the FIG. 5A, the virtual carrier sheet 502 may include virtual lines such as a straight line, a shallow curve, a youth curve, and / or an adult curve. It may be appreciated that the interface 108 may be a part of a computer display screen or a touch screen display. Furthermore, the first interface template 502 may include, but not limited to, icons, controls, or input options such as Header 506, character input 508, position keys 510, and color tabs 512.

[0084] FIG. 5B is a front view of the interface 108 depicting a second interface template 514, in accordance with an embodiment. In some embodiments, the second interface template 514 includes a graphic design 516 including the plurality of unit graphics 518 A-G. It may be appreciated that the plurality of unit graphics 518 A-G may each be a single unit character and placed individually and automatically on the second interface template 502. As shown in the FIG. 5B, each of the plurality of unit graphics 218 A-G maybe a virtual replica of a corresponding heat transfer label. The plurality of unit graphics 218 A-G may include an order of sequence of placement as a number icon 520A-G corresponding to each of the plurality of unit graphics 518 A-G. It may be appreciated that the order of sequence of placement of each of the plurality of unit graphics 518 A-G may vary according to the graphic design 516 and variation in the plurality of unit graphics 518 A-G. In some embodiments, the plurality of unit graphics 518 A-G may include a gap 522 in between. It may be appreciated that the gap 522 may vary with each of the plurality of unit graphics 518 A-G due to a specific design of each letters such as the letter "A" and the letter "U".

[0085] FIG. 5C is a front view of the plurality of unit graphics 518 A-B depicting the unit graphic 518A and the unit graphic 518B, in accordance with an embodiment. In some embodiments, the plurality of unit graphics 518 A-B may be a virtual replica of heat transfer labels of letter "A" and letter "U". As shown in FIG. 5C, the unit graphic 518A may include a margin extended portion 524A and the unit graphic 518B may include a margin extended portion 524B. It may be appreciated that margin extended portions 524A and 524B may be a virtual replica of the corresponding release layers of the physical heat transfer labels, as stated herein above and as shown in FIG. 2B. As depicted, the unit graphic 518A includes number icon 520A as number "Six" or "6". In such an example, the unit graphic 518A will be placed sixth in the order of placement of the plurality of unit graphics 518 A-G. In a similar fashion, the unit graphic 518B includes number icon 520B as number "four" or "4". In such an example, the unit graphic 518A will be placed fourth in the order of placement of the plurality of unit graphics 518 A-G.

[0086] FIG. 5D is a front view of the interface 108 depicting an interface template 530 with a virtual pallet 532, in accordance with an embodiment. In some embodiments, the virtual pallet 532 is identified with the RFID label 208 (as depicted in FIG. 2B). Furthermore, each virtual pallet 532 may bestored in memory (e.g., within the electronic database 102, external to the electronic database 102) using the processor 106 (as depicted in FIG. 1).

[0087] FIG. 6 is a perspective view of the robotic arm 118 depicting a vacuum assisted gripper 602, in accordance with an embodiment. It may be appreciated that the robotic arm 118 as shown in FIG. 6 is same as the robotic arm 118 (as depicted in FIG. 1). In some embodiments, the robotic arm 118 includes the vacuum assisted gripper 602 to for picking and placing the plurality of character blocks 204 (as depicted in FIG. 2A). The robotic arm 602 may include an RFID reader 120 for detecting one or more RFID tags associated with and / or placed on one of the plurality of pallets 112 (as depicted in FIG. 1) and more specifically identifying a particular pallet bearing a particular character block 204. In some embodiments, the RFID tag may be mounted on or next to each character block 204 on a pallet 112. In some embodiments, the robotic arm 118 is configured to detect a target character block 204 or a target pallet 112 out of the plurality of pallets 112 and pick up one or more target character blocks 204 out of the plurality of character blocks 204 (as depicted in FIG. 2A) therefrom. A pickup sequence of the plurality of character blocks 204 is defined by the processor 106 (as described in FIG. 1). As stated above with reference to FIG. 1, the processor 106 may provide a sequence of placement for each of the plurality of unit graphics for the graphic design. In some embodiments, the processor 106 is configured to determine a path of movement of the robotic arm 304 to sequentially pick up the plurality of character blocks 204 from the rotatable carousel 110 (as shown in FIG. 1) and sequentially place the plurality of character blocks 204 (as depicted in FIG. 2A).

[0088] FIG. 7A is a front perspective view of the sheet roller 310, in accordance with an embodiment. FIG. 7B is a schematic view of the sheet roller 310, in accordance with an embodiment. The sheet roller 310 may include a feeder 702 configured to feed a roll of carrier sheet 704 with a release cover 706 disposed over the carrier sheet 704. In an embodiment, the carrier sheet 704 is an acetate sheet. In some embodiments, the feeder 702 is loaded with a roll of spool including the carrier sheet 704 and the release cover 706 disposed over the carrier sheet 704. Furthermore, the processor 106 actuates the robotic arm 304 to sequentially pick up the plurality of character blocks 204 (as depicted in FIG. 2A) from the rotatable carousel 302 (as shown in FIG. 3A-B) and sequentially place the plurality of character blocks 204 on the carrier sheet 704. In some embodiments, the carrier sheet 704 includes a tacky adhesive on a receiving side to retain the plurality of character blocks 204 thereon. In an example, the carrier sheet 704 is in rectangular shape.

[0089] In other embodiments, the sheet roller 310 may include an unwinder 708 configured to unwind the release cover 706 from the roll of carrier sheet 704 and showing the tacky adhesive on thereceiving side of the carrier sheet 704. Furthermore, the feeder 702 feeds the roll of carrier sheet 704 with the release cover 706 passing through the unwinder 708 that separates the release cover 706 from the roll of carrier sheet 704. In an example, the unwinder 708 aligns the carrier sheet 704 and the release cover 706 in 90 degrees apart in perpendicular directions. As shown in FIG. 7A, there may be a rectangular loop 710 provided to support the unwinding of the carrier sheet 704 and the release cover 706. In some embodiments, the sheet roller 310 may include a rewinder 712 configured to layer the release cover over 706 over the carrier sheet 704 and the artwork (including the plurality of character blocks 204 thereon) affixed on the carrier sheet 704. In some embodiments, the rewinder 712 is configured to re-attach the release cover 706 over the carrier sheet 706 along with the plurality of character blocks 204 placed on the carrier sheet 706. In other embodiments, the sheet roller 310 may include a cutter 714 to cut the carrier sheet 704 including the artwork along with the release cover over 706 over the artwork and the carrier sheet 704 that is collected on the collection panel 308 (as shown in FIG. 3A).

[0090] FIG. 8A is a rear perspective view of a carrier sheet 806 in a reverse position 802, in accordance with an embodiment. As shown in the FIG. 8A, the reverse carrier sheet 802 contains the placement of a plurality of character blocks 808 (heat transfer labels) in a reverse position. In some embodiment, the carrier sheet 806 includes a transfer adhesive to retain the plurality of character blocks 808 in the reverse position 802. FIG. 8B is a front perspective view of the carrier sheet 806 in a flipped position 804, in accordance with an embodiment. As shown in the FIG. 8A, the reverse carrier sheet 806 contains the placement of a plurality of character blocks 810 (heat transfer labels) in a flipped position. It may be appreciated that the flipped position of the plurality of character blocks 810 is a mirror image of the of the plurality of character blocks 808 (heat transfer labels) in a reverse position. It may be appreciated that the carrier sheet 806 shown in both the figures 8A and 8B are finished customized heat transfer labels. As shown, the carrier sheet 806 includes the plurality of character blocks 808 that forms the required artwork manufactured from the system 100. Furthermore, the front perspective view of the carrier sheet 806 in a flipped position 804 depicts the real position of the customized heat transfer label that will be placed on the fabric or cloth, and then heat pressed to adhere there to the fabric or cloth.

[0091] FIG. 9 includes a flow chart of a method 900 for manufacturing a custom heat transfer label, in accordance with an exemplary embodiment of the present subject matter.

[0092] At an operation 902, a plurality of unit graphics is stored in an electronic database. Furthermore, the plurality of unit graphics may include brand logos, brand names, brand designs, shapes and such designs. In some embodiments, each of the plurality of plurality of unit graphics includes graphical characters and extended portions at the perimeter of the unit graphics. In other embodiments,the electronic database 102 includes a physical memory that stores one or more of geometrical shapes, relative positions, orientations, dimensions and margins of prestored graphic designs and / or artworks.

[0093] At an operation 904, one or more inputs for a graphic design comprising the plurality of unit graphics are received via an input device 104. In some embodiments, the input device being communicably coupled to the electronic database 102 to receive input for the graphic design is provided on an interface 106. In some embodiments, the input device 104 is configured to receive an input for the graphic design including the plurality of unit graphics retrieved from the electronic database 102. Furthermore, the input device 104 is adapted to receive inputs such as alphanumeric characters, signs, symbols and combination thereof for the graphic design.

[0094] At an operation 906, relative positions are assessed by the processor 108 for placement of a plurality of character blocks representing each of the unit graphics of the graphic design physically and mapping it identical to the unit graphics virtually in the graphics design, the plurality of character blocks being present in a plurality of pallets of a rotatable carousel. Furthermore, each of the pallets includes a plurality of recessed cups to contain the plurality of character blocks.

[0095] At an operation 908, the processor 108 is configured to coordinate the rotation of the rotatable carousel to present the plurality of character blocks representing each of the unit graphics of the graphic design to the robotic arm 118 based on the analysis provide at the input device 104 and the interface 108. In some embodiments, the processor 108 provides instructions for rotation of the rotatable carousel to showcase at least one pallet of the rotatable carousel that contains the required at least one- character block present in the graphic design.

[0096] At an operation 910, the processor 108 is configured to generate instructions for the robotic arm to perform the picking and placement of the plurality of character blocks such that the graphic design is represented identically by the plurality of character blocks on a carrier sheet. The processor 108 is configured to generate a sequence of placement of the plurality of unit graphics that corresponds to the selection, picking, and placement of the plurality of character blocks to obtain the custom heat transfer label. Furthermore, the sequence of placement for each of the plurality of unit graphics is based on the spatial arrangement of character blocks, character block size, character style, orientation, color grouping, carousel position, the identification information, alignment of the plurality of unit graphics in reference to one or more virtual reference points, character availability, design symmetry or any combination thereof. Moreover, the sequence of placement for each of the plurality of unit graphics is adapted to avoid interreference of the extended portions of the adjacent unit graphics. In some embodiments, the robotic arm 118 accurately and efficiently picks the plurality of character blocks fromthe rotatable carousel 110 that is required for a proposed graphic design and precisely places the plurality of character blocks on the carrier sheet. Furthermore, the processor 108 is configured to define the placement of the plurality of character blocks on the carrier sheet, by creating an efficient path for the movement of the robotic arm 118.

[0097] Operations 902 to 910 are only illustrative and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.

[0098] In other embodiments, the method 900 also includes adjusting the position of each of the plurality of unit graphics to assume a uniform geometrical shape of the graphic design. For example, in some embodiments, the method 900 further includes adjusting the position of each of the plurality of unit graphics to assume a uniform geometrical shape of the graphic design. The uniform geometrical shape may define an equidistant placement of the plurality of unit graphics to avoid interference with each other. For example, equidistant placement of the plurality of unit graphics may mean spacing each of the unit graphics apart by the same distance as measured by the distance between each unit graphic's centroid. Alternatively, equidistant placement may mean spacing each of the unit graphics such that the minimum distance between the transfer portions of any two adjacent unit graphics is the same, with the closest portions of any two adjacent unit graphics being dependent on the shape of the character (e.g., a number, a letter, a special character, a symbol). In some embodiments, equidistant placement may depend only on or additionally on whether an adjacent pair of unit graphics causes a release layer or other potentially blocking portion of one of the adjacent pairs of unit graphics to cover or otherwise block a transfer portion of the other of the adjacent pair of unit graphics. In other words, the uniform distance for a set of unit graphics (e.g., for a row, for a word, for a garment, for an artwork, for fonts of a certain size) may be determined by the minimum distance needed to prevent blocking of a unit graphic's transfer portion by the transfer portion and / or the release layer of its adjacent transfer portion.

[0099] In some embodiments, the method 900 also includes providing a plurality of character blocks in a rotatable carousel. The method 900 also includes crafting an artwork from a plurality of character blocks for the custom heat transfer label. In other embodiments, crafting the artwork includes executing the graphic design to craft the artwork on a carrier sheet. The method 900 also includes feeding a roll of the carrier sheet with a release cover using a feeder. Furthermore, the method 900 also detaching includes release cover from the roll of the carrier sheet and exposing a tacky adhesive on the receiving side of the carrier sheet for placement of the plurality of character blocks of the graphic design using an unwinder. In some embodiments, the method 900 also includes re-attaching the release cover over thecarrier sheet along with the plurality of character blocks affixed on the carrier sheet using a rewinder. In some embodiments, the method 900 also includes detecting using one or more sensors including an imaging device, proximity sensors, and a combination thereof.

[0100] Modifications to embodiments of the present subject matter described in the foregoing are possible without departing from the scope of the present subject matter as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe and claim the present subject matter are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Claims

CLAIMSWhat is claimed is:

1. A system for manufacturing a heat transfer label, comprising: an electronic database configured to store a plurality of unit graphics virtually; an input device communicably coupled to the electronic database and configured to receive an input for a graphic design, the graphic design comprising the plurality of unit graphics; a processor communicably coupled to the input device and the electronic database; a rotatable carousel operatively coupled to the processor, the rotatable carousel comprising a plurality of pallets, wherein each of pallets comprises a plurality of recessed cups to contain a plurality of character blocks representing the physical form of the plurality of unit graphics; and a robotic arm operatively coupled to the processor and positioned to access the rotatable carousel and a carrier sheet, wherein the processor is configured to generate instructions for the robotic arm to perform one or more of selecting, picking, and placement of the plurality of character blocks such that the graphic design represented by the plurality of character blocks in the carrier sheet is identical to the graphic design provided as the input.

2. The system of claim 1, wherein the processor is configured to: analyze each of the unit graphics in the graphic design, and determine by the analysis at least one of the relative position, spacing, size, and orientation of each of the unit graphics in the graphic design or the sequence of placement of each of the unit graphics in the graphic design; align the plurality of unit graphics in reference to one or more virtual reference points displayed on an interface of the input device; assess the relative positions of placement of the plurality of character blocks representing each of the plurality of unit graphics of the graphic design and map the unit graphic virtually in the graphic design; and coordinate the rotation of the rotatable carousel to present the plurality of character blocks representing each of the plurality of unit graphics of the graphic design to the robotic arm based on the analysis.

3. The system of any of claims 1 to 2, wherein each of the plurality of character blocks is a heat transfer label, wherein the heat transfer label comprises a transfer portion, and a release layer, andwherein the transfer portion comprises one or more layers of ink, a coating, and a heat transfer adhesive, and combinations thereof.

4. The system of any of claims 1 to 3, wherein each of the plurality of character blocks is at least one of a letter, a numerical digit, a sign, a logo, a graphic, a design, a symbol, or any combinations thereof.

5. The system of any of claims 1 to 4, wherein the carrier sheet is an acetate sheet.

6. The system of any of claims 1 to 5, wherein each pallet of the rotatable carousel comprises a Radio Frequency Identification (RFID) Tag and is configured to communicate with an RFID reader.

7. The system of claim 6, wherein the processor is communicatively coupled with the RFID reader and configured to receive identification information of the RFID tag from the RFID reader.

8. The system of claim any of claims 1 to 7, wherein the processor is further configured for determining the sequence of plurality of character blocks for selection and placement through analyzing one or more of the spatial arrangement of plurality of character blocks, dimensions of the plurality of character blocks, a character style, orientation of the plurality of character blocks, color grouping, a rotatable carousel position, the identification information, alignment of the plurality of unit graphics in reference to one or more virtual reference points, character availability, design symmetry or any combination thereof.

9. The system of any of claims 1 to 8, wherein the robotic arm comprises a vacuum- assisted gripper for picking and placing the plurality of character blocks.

10. The system of any of claims 1 to 9, further comprises one or more sensors including an imaging device, a proximity sensor, and a combinations thereof.

11. The system of any of claims 1 to 10, further comprising: a feeder configured to feed a roll of the carrier sheet with a release cover; an unwinder configured to detach the release cover from the roll of the carrier sheet and expose the tacky adhesive on the receiving side of the carrier sheet for placement of the plurality of character blocks; and a rewinder configured to re-attach the release cover over the carrier sheet along with the plurality of character blocks placed on the carrier sheet.

12. A method for manufacturing a heat transfer label, comprising: storing a plurality of unit graphics in an electronic database;receiving one or more inputs for a graphic design comprising the plurality of unit graphics via an input device, the input device being communicably coupled to the electronic database; assessing, by a processor, the relative positions of placement of a plurality of character blocks representing each of the unit graphics of the graphic design physically and mapping to the unit graphic virtually in the graphic design, the plurality of character blocks being present in a plurality of pallets of a rotatable carousel, wherein each of the pallets comprises a plurality of recessed cups to contain the plurality of character blocks; coordinating, by the processor, rotation of the carousel to present the plurality of character blocks representing each of the plurality of unit graphics of the graphic design to a robotic arm based on the analysis; and generating, by the processor, instructions for the robotic arm to perform the picking and placement of the plurality of character blocks such that the graphic design is represented identically by the plurality of character blocks on a carrier sheet.

13. The method of claim 12, further comprising: performing analysis, by the processor, of the relative positions of each of the unit graphics in the graphic design received at the input device, the analysis being is associated with determining at least one of the relative position, spacing, size, or orientation of each of the unit graphics or sequence of each of the unit graphics in the graphic design; and aligning the plurality of unit graphics in reference to one or more virtual reference points displayed on an interface of the input device.

14. The method of any of claims 12 to 13, wherein each of the plurality of character blocks is a heat transfer label comprising a transfer portion and a release layer, wherein the transfer portion comprises one or more layers of an ink, a coating, and a heat transfer adhesive.

15. The method of any of claims 12 to 14, wherein each of the character blocks is at least one of a letter, a numerical digit, a sign, a logo, a graphic, a design, a symbol, or any combinations thereof.

16. The method of any of claims 12 to 15, wherein the carrier sheet is an acetate sheet.

17. The method of any of claims 12 to 16, further comprising reading a Radio Frequency Identification (RFID) Tag on each pallet of the rotatable carousel using an RFID reader.

18. The method of any of claims 12 to 17, further comprising receiving, by the processor, identification information of an RFID tag from the RFID reader.

19. The method of any of claims 12 to 18, further comprising assessing by the processor at least one of the following parameters for determining the sequence of character blocks for selection and picking: a spatial arrangement of character blocks, a character block size, a character style, an orientation, a color grouping, a carousel position, an identification information, alignment of the plurality of unit graphics in reference to one or more virtual reference points, a character availability, a design symmetry or any combinations thereof.

20. The method of any of claims 12 to 19, wherein the robotic arm comprises a vacuum- assisted gripper for picking up and placing the character blocks.

21. The method of any of claims 12 to 20, further comprising: feeding a roll of the carrier sheet with a release cover using a feeder; detaching the release cover from the roll of the carrier sheet and exposing a tacky adhesive on the receiving side of the carrier sheet for placement of the plurality of character blocks of the graphic design using an unwinder; and re-attaching the release cover over the carrier sheet along with the plurality of character blocks affixed on the carrier sheet using a rewinder.

22. The system of any of claims 1 to 11, further comprising one or more sensors comprising at least one of an imaging device, a proximity sensor, and combinations thereof, wherein the processor is configured to detect the position of either a target pallet or a target character block using the one or more sensors.

Images