Compressible Multilayer Label for Thermal Transfer Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal transfer printers, especially handheld ones, are limited in processing labels thicker than 300 microns, which prevents them from producing labels that mimic the appearance and feel of hard-plastic identification shields, leading to inventory and cost issues with existing solutions.
Innovation Solution
A thick, compressible multilayer label construction comprising a printable film, adhesives, and foam, which can be fed through standard thermal transfer printers, including handheld models, to achieve a thickness greater than 300 microns, providing the appearance and feel of hard-plastic shields while being printable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard thermal transfer printers are used to print labels, then printing capability is achieved, but label thickness is limited to less than 300 microns
Solution Approach 1:
The label is divided into multiple layers (printable film layer, intermediate adhesive layer, foam layer, and additional adhesive layer) that are laminated together. This segmentation allows each layer to contribute specific properties while achieving overall thickness greater than 300 microns that can still be processed by standard thermal transfer printers
Solution Approach 2:
The label uses a composite structure combining different materials: a printable film (such as polyester or polypropylene), adhesive layers, and a foam layer (such as polyethylene or polyurethane foam). This composite construction achieves the desired thickness and rigidity while maintaining printability through thermal transfer printing
2Shape
If label thickness is increased to mimic hard-plastic shields, then appearance and feel are improved, but compatibility with standard thermal transfer printers deteriorates
Solution Approach 1:
The foam layer uses a compressible material that can be compressed during the printing process to fit within the printer's mechanical constraints, then expands back to its full thickness after printing. This parameter change (compression during printing, expansion afterward) allows thick labels to be compatible with standard printers while maintaining their thick appearance and feel
3Volume of moving object
If hard-plastic identification shields are used, then thickness and rigidity are achieved, but inventory costs and operational expenses increase
Solution Approach 1:
Instead of using expensive hard-plastic shields that require engraving or plotting equipment, the invention uses printable labels that replicate the appearance and feel of hard-plastic shields through a multilayer construction with a foam core. This copying approach allows standard thermal transfer printers to produce shield-like labels, eliminating the need for expensive specialized equipment and reducing inventory costs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multilayer label construction allows for the production of thick, printable labels that resemble hard-plastic shields, reducing inventory costs and operational expenses by enabling printing with conventional thermal transfer printers, while maintaining the feel and appearance of hard-plastic identification shields.
Implementation Method 1
THT printing uses a heat generating print head to transfer an ink layer (typically a wax and/or other binder compounded with carbon black and/or other pigment) or the like, from a THT ribbon to a label. By using digital technology, characters are formed on a label by energizing a sequence of pixels on the print head and when the print head comes in contact with the ribbon, it softens the wax and/or other binder of the ink layer on the ribbon.
Implementation Method 2
The use of thick, i.e., greater than (>) about 300 microns (μm), labeling media in many commercially available THT printers, particularly hand-held printers, is problematic at best. These printers and their operation are described more fully in U.S. Pat. Nos. 5,951,177, 6,113,293 and 6,769,825.
Data Source
AI summary
Thick, compressible, multilayer labels with the appearance and feel of hard plastic identification shields comprise:A. A printable film having first and second opposing facial surfaces;B. A first adhesive having first and second opposing facial surfaces, the first facial surface of the adhesive in intimate contact with the second facial surface of the film; andC. Foam having first and second opposing facial surfaces, the first facial surface of the foam in intimate contact with the second facial surface of the first adhesive.In certain embodiments of the invention, the labels include one or more of a printable coating on the first facial surface of the film, a second adhesive in intimate contact with the second facial surface of the foam, and a release liner in contact with the second adhesive.