Digital Heat Transfer Labels Without Halos or Multi-Step Printing

Solution Overview

Problem

The existing process of creating heat transfer labels is inefficient and wasteful, requiring separate application of ink and adhesive layers, which cannot be mixed together due to different chemical characteristics, leading to halos and complex multistep processes.

Innovation Solution

A digitally printed heat transfer label method involving a digital image printed on a substrate, with a polymeric coating and adhesive powder applied, then dried and cooled, replacing the multistep process with a sheet or roll-fed process to produce a high stretch, multi-color label.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate application of ink and adhesive layers is used, then the chemical characteristics of each layer are maintained, but the process becomes complex and halos form

Engineering Contradiction:

Improvechemical characteristicsVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines ink and adhesive into a single integrated layer applied in one printing stroke. The composition includes ink particles, adhesive particles, and carrier particles mixed together, eliminating the need for separate application steps while maintaining the distinct chemical properties of each component through their particle-based formulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the ink and adhesive into discrete particles within a carrier system. Each component remains as separate particles (ink particles and adhesive particles) suspended in carrier particles, allowing them to maintain their individual chemical characteristics while being applied together as a unified composition.

Inventive Principle:

Principle #1Segmentation

2Reliability

If separate application of ink and adhesive layers is used, then chemical characteristics are maintained, but waste increases

Engineering Contradiction:

Improvechemical characteristicsVSAvoidmaterial waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent combines ink and adhesive into a single integrated layer applied in one printing stroke. The composition includes ink particles, adhesive particles, and carrier particles mixed together, eliminating the need for separate application steps while maintaining the distinct chemical properties of each component through their particle-based formulation.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If ink and adhesive are mixed together, then application efficiency improves, but adhesive loses thermoplastic characteristics

Engineering Contradiction:

Improveapplication efficiencyVSAvoidadhesive thermoplastic characteristics

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent segments the ink and adhesive into discrete particles within a carrier system. Each component remains as separate particles (ink particles and adhesive particles) suspended in carrier particles, allowing them to maintain their individual chemical characteristics while being applied together as a unified composition.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical state and size of the components by converting them into fine particles. The adhesive is provided as particles with specific size ranges (e.g., 0.1-10 micrometers), which allows it to be mixed with ink in a stable suspension while maintaining its thermoplastic properties for later activation.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If traditional printing methods are used, then the process is established, but halos form around the graphic

Engineering Contradiction:

Improveprocess establishmentVSAvoidgraphic precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical printing methods (gravure, offset, flexographic, screen printing) with digital printing technology. This substitution allows for precise deposition of the particle-based ink-adhesive composition directly from digital files, eliminating the halo effect while maintaining ease of manufacture through established digital printing infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method results in a more efficient process with less waste and prevents halos, providing a high stretch, multi-color photographic quality label for the apparel industry.

Implementation Method 1

applying a polymeric coating over the image, applying adhesive powders, drying the liquid

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

The coatings are then dried either via infrared (IR) lamps or air impingement dryers or oven. The adhesive powder should be melted or at least partially melted at this time

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

The adhesive powder should be melted or at least partially melted at this time, then the resulting images are cooled to set the images for the label

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentEP3303000A1Digitally printed heat transfer label

Publication Date: 2018.04.11 AVERY DENNISON RETAIL INFORMATION SERVICES LLC

AI summary

A digitally printed heat transfer label and method of manufacture is disclosed. The heat transfer label and method of manufacture provides a more efficient process with less waste, as well as prevents halos. The method comprises adding adhesive powder to a digital image printed on a substrate to produce a high stretch, multi-color photographic quality label for the apparel industry.