CN116653467A

CN116653467A - Thermal transfer ribbon assembly including a metal layer and a protective coating

Info

Publication number: CN116653467A
Application number: CN202310170088.0A
Authority: CN
Inventors: 素威·约翰·桑格卡拉塔纳; 丹尼尔·舒姆斯基
Original assignee: Illinois Tool Works Inc
Current assignee: Illinois Tool Works Inc
Priority date: 2022-02-28
Filing date: 2023-02-27
Publication date: 2023-08-29
Also published as: EP4234265A1; JP2023126182A

Abstract

A method of introducing a reflective, refractive and/or diffractive variable and/or non-variable image onto a substrate using thermal transfer, comprising: the defined portions of each of the protective coating, image layer and adhesive layer are simultaneously transferred from the carrier film of the transfer tape to the substrate by applying heat to the transfer tape. The defined portions of the image layer and the protective coating are adhered to the substrate using an adhesive layer. After the protective coating, image layer and adhesive layer are transferred, the protective coating over the image layer is crosslinked by exposing the protective coating to a radiation source after transfer of defined portions of the protective coating, image layer and adhesive layer from the carrier film, thereby providing durability to the image layer.

Description

Thermal transfer ribbon assembly including a metal layer and a protective coating

Cross Reference to Related Applications

The present application is a continuation-in-part application of U.S. patent application Ser. No. 16/667,190, filed on 10, 29, 2019, which claims priority from U.S. provisional application Ser. No. 62/753,428, filed on 31, 10, 2018. The entire disclosure of the above-mentioned U.S. application is incorporated herein by reference.

Technical Field

The present disclosure relates to thermal transfer ribbons that print reflective, refractive, and/or diffractive images onto a substrate.

Background

Fig. 1 illustrates a cross-sectional view of a known substrate 10, the substrate 10 comprising a metal image with a dried metal layer introduced thereon. The substrate 10 includes a metal layer 14 and an adhesive layer 16 adhered thereto. The metal layer 14 and the adhesive layer 16 may be disposed on the surface 12 of the substrate as part of an image. The adhesive layer 16 adheres the metal layer 14 to the surface 12 of the substrate 10 to form each of the individual metal prints on the surface 12. In alternative embodiments, the metal layer 14 may be an ink or paint that may be ink printed or ink dripped onto the surface 12 of the substrate 10.

However, handling the identification card may compromise the integrity of the metal layer 14. For example, the metal layer 14 may wear away from the substrate 10 when the identification card is moved into and/or out of a purse or pocket. Thus, after adhering the metal layer 14 to the surface 12 of the substrate 10, the laminate film 18 is then placed on top of the metal layer 14 such that the laminate film 18 is coupled with the metal layer 14 and the surface 12 of the substrate 10. For example, the laminate film 18 may be a patch or strip of laminate material that extends over the entire surface of the card.

Such a laminate film 18 may interfere with other components of the identification card (e.g., magnetic strips, holograms, etc.), may be aesthetically undesirable, etc. In addition, applying the laminate film 18 reduces the brightness, reflectance, etc. of the metal layer 14. For example, the metal layer 14 may have a specular-like reflectivity or may be a bright metal finish prior to application of the film 18. After application of the laminate film 18, the laminate film 18 reduces the brightness of the metal finish of the metal layer 14, reduces the reflectivity of the metal layer 14, and so forth. The laminated film may also begin to delaminate from the edge of the card over time.

In alternative embodiments, the metallic image may be introduced onto the substrate as a coating or ink that may be dropped or painted onto the substrate. The metallic image may be introduced onto the substrate by depositing metallic ink or paint onto the surface of the substrate. However, the use of ink is a messy process and additional ink may splash onto one or more surfaces of the substrate. In addition, the amount and size of metal particles used to form a bright, glossy metal image is limited by the size of the dispensing nozzle. Furthermore, the dispensing nozzle may become clogged with dry ink or paint between applications.

Alternatively, the metal layer 14 may be thermally transferred from a carrier tape comprising a highly crosslinked base layer. Such a highly crosslinked base layer may be a polymer layer located between the support carrier of the belt and the metal layer 14. The highly crosslinked base layer may be crosslinked prior to transferring the metal layer 14 to the substrate 10 and may be transferred to the substrate 10 with the metal layer 14 to protect the metal layer 14. However, it may be difficult to transfer a highly crosslinked base layer from a carrier tape due to crosslinking of the base layer. Thus, the transferred portions of the metal layer 14 and the base layer may be less clear or defined than if the base layer were not crosslinked.

Disclosure of Invention

In one or more embodiments of the subject matter described herein, a method of introducing a reflective, refractive, and/or diffractive metal variable and/or non-variable image onto a substrate using thermal transfer includes: the defined portion of each of the protective coating, the metal layer, and the adhesive layer is simultaneously transferred from the carrier film of the thermal transfer ribbon to the substrate by applying heat to the thermal transfer ribbon. The method comprises the following steps: the defined portions of the metal layer and the protective coating that have been transferred to the substrate are adhered using an adhesive layer, and after the defined portions of the protective coating, the metal layer, and the adhesive layer are transferred, the defined portions of the protective coating over the defined portions of the metal layer are crosslinked by exposing the protective coating to a radiation source after the defined portions of the protective coating, the metal layer, and the adhesive layer are transferred from the carrier film, thereby providing durability to the defined portions of the metal layer that are transferred to the substrate.

In one or more embodiments of the subject matter described herein, a system for introducing a reflective, refractive, and/or diffractive metal variable and/or non-variable image onto a substrate using thermal transfer comprises a thermal transfer ribbon comprising a protective coating, a metal layer, and an adhesive layer. The defined portion of each of the protective coating, the metal layer, and the adhesive layer is simultaneously transferred from the carrier film of the thermal transfer ribbon to the substrate by applying heat to the thermal transfer ribbon. The metal layer and the defined portion of the protective coating that have been transferred are adhered to the substrate using an adhesive layer. After transferring the defined portions of the protective coating, the metal layer and the adhesive layer, the defined portions of the protective coating are crosslinked by exposing the protective coating to a radiation source after transferring the defined portions of the protective coating, the metal layer and the adhesive layer from the carrier film. Crosslinking defined portions of the protective coating provides durability to defined portions of the metal layer that are transferred to the substrate.

In one or more embodiments, a method includes: the defined portion of each of the protective coating, the metal layer, and the adhesive layer is simultaneously transferred from the carrier film of the thermal transfer ribbon to the substrate by applying heat to the thermal transfer ribbon. The method comprises the following steps: the defined portions of the metal layer and the protective coating that have been transferred to the substrate are adhered using an adhesive layer, and after the transfer of the defined portions of the protective coating, the metal layer, and the adhesive layer, the defined portions of the protective coating over the defined portions of the metal layer are crosslinked by exposing the protective coating to a radiation source, thereby providing durability to the defined portions of the metal layer that have been transferred to the substrate. The defined portions of the transferred protective coating, metal layer and adhesive layer contain only the necessary amounts of protective coating and metal layer to form one or more variable or non-variable images that are introduced onto the substrate, without containing additional amounts of protective coating or metal layer.

Drawings

The inventive subject matter will be better understood by reading the following description of non-limiting embodiments, with reference to the accompanying drawings (not necessarily to scale), in which:

FIG. 1 illustrates a known substrate;

FIG. 2 illustrates a top view of a substrate according to one or more embodiments of the inventive subject matter described herein;

FIG. 3 illustrates a cross-sectional view of the substrate of FIG. 2;

FIG. 4 illustrates a cross-sectional view of a defined portion of a protective coating, image layer, and adhesive layer transferred onto the substrate of FIG. 2, according to one embodiment;

FIG. 5 illustrates an enlarged cross-sectional view of the defined portion of FIG. 4; and

FIG. 6 illustrates a flow chart of a method of introducing an image onto a substrate, according to one embodiment.

Detailed Description

Although some examples of using the techniques of the present invention are described in connection with substrates represented as cards, such as financial cards, security cards, and identification cards, the techniques may be used in other printing applications. For example, one or more embodiments of the inventive subject matter described herein may be used to print variable information (e.g., that is different for each of several individual units printed thereon) and/or non-variable information (e.g., that is the same for all individual units printed thereon) on medical containers (e.g., IV bags, vials, etc.), packaging (e.g., boxes, bags, envelopes, shipping labels, etc.), clothing labels (e.g., clothing sizes, hangtags, etc.), household items (e.g., labels on items such as trays, bowls, cups, etc.), electronics (e.g., logos, serial numbers, etc.), consumable products (e.g., wine or beer bottles, container labels such as cans or jars, etc.), consumer products (e.g., glasses, sunglasses, jewelry, etc.), point of purchase displays, etc. For example, the substrate upon which heat transfer occurs may comprise any of a variety of surfaces, such as, but not limited to, security cards, identification cards, financial cards, packaging (e.g., luxury packaging, envelopes, boxes, etc.), medical devices (e.g., pill bottles, IV bags, etc.), and the like. The examples provided herein of objects on which printing may occur are not all possible objects on which images may be printed using the inventive subject matter. Any object on which thermal transfer may be performed may be printed using the inventive subject matter described herein. The printed image may contain one or more images such as numbers, letters, characters, logos, shapes, etc. The image may be introduced onto the substrate as a dry layer.

Fig. 2 illustrates a top view of the substrate 102. Fig. 3 illustrates a side view of the substrate 102. The substrate 102 has a surface 104 and an image 106 is thermally printed onto the surface 104 using a thermal transfer ribbon 108. The surface 104 may be a front or rear surface of the substrate 102, and the image 106 may be visible on the front or rear surface of the substrate 102. The substrate 102 may be a planar or substantially planar card, such as an identification card, security card, or financial card. In alternative embodiments, the substrate 102 may have any alternative non-planar shape and/or size. For example, the surface 104 of the substrate 102 may be a curved or contoured surface, may be non-planar with respect to the body of the substrate 102, and so forth. In the illustrated embodiment, the image 106 is the letter "A". The image 106 may be a variable image (e.g., a different letter printed onto each of several separate substrates on which to print) or a non-variable image (e.g., the same letter "a" printed onto all of the separate substrates on which to print). For example, the substrate 102 may be an identification card or a security card. The image 106 on each card may contain the same logo (e.g., a non-variable image), and/or may contain a unique name, number, etc. (e.g., a variable image) for each cardholder. In one or more embodiments, the image 106 may be holographic and may be a reflection, refraction, and/or diffraction hologram.

In one or more alternative embodiments, the substrate 102 may be vials, and each vial may contain the same prescription name (e.g., non-variable information), and/or may contain a unique prescription regimen (e.g., variable information) for each individual user of the drug. In alternative embodiments, the substrate 102 may be shipping containers, and each shipping container may contain the same corporate logo (e.g., non-variable information), and/or may contain a unique shipping address (e.g., variable information) for each container's destination. Alternatively, the substrate 102 may be a surface of a luxury packaging, such as a bag or box that stores the product prior to sale.

The thermal transfer ribbon 108 comprises a plurality of layers of material carried on a carrier film 126, the carrier film 126 spanning the surface 104 of the substrate 102 in the direction 122. The thermal transfer ribbon 108 includes an adhesive layer 116, an image layer 114, and a protective coating 112. In one or more embodiments, the image layer may include one or more materials, such as metals, mixed metal alloys, metal oxides, non-metallic materials, etc., that can display or exhibit an image on a surface of a substrate. The composition of the protective coating 112 will be described in more detail below. The layers of the thermal transfer ribbon 108 are used for illustrative purposes only with the substrate 102 shown in fig. 2 and 3 and may not be drawn to scale. For example, the thickness of each of the plurality of layers of the belt 108 may be common or unique relative to the thickness of each other layer of the belt 108, and the thickness of each layer of the belt 108 may be less than the thickness of the substrate 102.

Heat 124 is applied to the heat transfer tape 108 as the heat transfer tape 108 moves in a direction 122 that is substantially parallel to the surface 104 of the substrate 102. The application of heat 124 causes the defined portions 110A, 110B of each of the protective coating 112, image layer 114, and adhesive layer 116 to be transferred from the carrier film 126 of the thermal transfer ribbon 108 onto the surface 104 of the substrate 102. For example, as illustrated in FIG. 2, the defining portions 110A, 110B define areas of the image 106, and the non-defining portion 120 defines areas outside of the image 106.

The defined portions 110A, 110B are only the portions required to form the image 106 on the substrate 102. For example, only defined portions 110A, 110B of the protective coating 112 and defined portions of the image layer 114 and the adhesive layer 116 are transferred onto the substrate 102. The protective coating 112 does not extend over the sides of the metal layer 114 and the adhesive layer 116, for example, as shown in fig. 1.

Transferring the defined portions 110A, 110B of the image layer 114 onto the substrate 102 causes a continuous shape or image to be formed on the substrate 102 using the transferred portions of the image layer 114. For example, the image layer may comprise a material (metallic, non-metallic, etc.) that may be used to display a shape or image on a substrate. In one embodiment, the continuous shape may be a single letter, a single number, or a logo object having a single body. In alternative embodiments, the continuous shape may be a continuous sheet or coating over the entire substrate 102. In the illustrated embodiment of fig. 2, the image 106 is an image of the letter a, however the image may be any single or multiple different letters, numbers, logo or decorative images, etc. The transferred defined portions 110A, 110B of the image layer 114 form the shape of the image 106 on the substrate 102.

In one or more embodiments, the image may display and/or include security details. For example, the images may be optically variable images such that viewing the images from one view angle may display one display and viewing the images from a different view angle may display a different display or image. Alternatively, the image may display and/or include letters, numbers, shapes, symbols, etc., which may be arranged in a predetermined arrangement on the surface of the substrate. For example, the image may display personal information about the substrate owner, expiration information about the product associated with the substrate, related instructions about the consumption and/or use of the product associated with the substrate, logo designs (e.g., company and/or team logos, etc.), and the like.

The defined portions 110A, 110B of the image layer 114 transferred onto the substrate 102 are reflective, refractive and/or diffractive. For example, in one or more embodiments, the defined portions of the material of the image layer transferred to the surface of the substrate may be reflective, specular, etc. For example, the material may be reflective such that light or other radiation may be reflected out of the material of the image layer. The defined portions 110A, 110B of the image layer 114 forming the image 106 may be specular such that the material of the image layer 114 may provide or be capable of reflecting light or other radiation. Alternatively, the topography of the image layer material may be altered (e.g., embossed, stamped, etched, or otherwise processed). Changing the morphology of the image layer material may render the image layer material refractive and/or diffractive. For example, light or other radiation may be diffracted or bent around certain portions of the image. For example, a defined portion of the image layer 114 material may diffract or bend waves (e.g., light) around the edges of the metal layer 114. As another example, a wave of light or other radiation may change direction as it passes through a defined portion of the image layer.

In one or more embodiments, the image layer or metal layer may be referred to as a reflective layer, a refractive layer, and/or a diffractive layer. For example, the image layer may include one or more materials or material combinations that may reflect, refract, and/or diffract light or other radiation. The defined portions of the material or material composition transferred to the image layer of the substrate may form a reflective, refractive and/or diffractive image on the surface of the substrate. Non-limiting examples of the one or more materials included in the image layer may include aluminum, chromium, indium, bismuth, tin, iron, copper, zinc, niobium, zinc sulfide (ZnS), nickel chromium (NiCr), stainless steel, indium antimonide (InSn) or other solder materials, tin oxide, iron oxide, zinc oxide, indium Tin Oxide (ITO), and the like. Alternatively, the image layer may include alternative metal materials, metal alloys, mixed metal alloys, metal oxides, and the like. Alternatively, the image layer may comprise one or more non-metallic materials.

In one or more embodiments, the image layer may include multiple layers coupled together within the image layer. The defined portions of each of the multiple layers of the image layer may create or generate a reflective, refractive and/or diffractive image on the surface of the substrate. In one embodiment, a first layer of the image layer or the metal layer may comprise a first material and a second layer of the image layer or the metal layer may comprise a second, different material. The first material and the second material may reflect, refract, and/or diffract light or other radiation sources.

The defined portions 110A, 110B of each of the adhesive layer 116, the image layer 114, and the protective coating 112 are simultaneously transferred from the carrier film 126 to the substrate 102 as the thermal transfer ribbon 108 moves in the direction 122 relative to the substrate 102. For example, the adhesive layer 116, the image layer 114, and the defined portions 110A, 110B of the protective coating 112 are all transferred at once and as a group onto the substrate 102. In addition, the undefined portion 120 is not transferred from the carrier film 126 to the substrate 102 as the heat transfer belt 108 moves in the direction 122 relative to the substrate 102. The image layer 114 and the defined portions 110A, 110B of the protective coating 112 are adhered to the substrate 102 using an adhesive layer 116.

The transferred defined portions 110A, 110B contain only the necessary amounts of protective coating 112 and image layer 114 to form the variable and/or non-variable image 106 that is introduced onto the substrate 102, without containing additional amounts of protective coating 112 and image layer 114. For example, only the portion of the protective coating 112 over the portion of the image layer 114 is transferred onto the substrate 102. In one embodiment, the protective coating 112 may be coupled with the image layer 114 such that transferring defined portions of the image layer 114 necessarily transfers defined portions of the corresponding protective coating 112.

The defined portions 110A, 110B of the protective coating 112, image layer 114 and adhesive layer 116 have sharp and non-hazy edges. For example, only the defined portions 110A, 110B are transferred such that a clear outline or clear detail of a clear edge of the image 106 is left relative to transferring an unnecessary amount of the protective coating 112 onto the substrate 102. Only the defined portions 110A, 110B of the image layer 114 that are used to form indicia (e.g., numbers, letters, characters, decorative designs, etc.) on the substrate 102 are transferred onto the substrate 102, while other portions are not transferred. As one example, a sharp edge may illustrate the image 106 as number 8, but a non-sharp or blurred edge may illustrate the image as a snowman. For example, the inner aperture of the numeral 8 may be defined only when each of the layers of the thermal transfer ribbon 108 transferred onto the substrate 102 has a clear edge (e.g., clear detail or outline of the image 106). Alternatively, if the layer of thermal transfer ribbon 108 does not have a clear edge or has a less clear edge (e.g., unclear details or unclear contours of image 106), the inner aperture of numeral 8 may not be visible.

FIG. 4 illustrates a cross-sectional view of the defined portions 110A, 110B of the protective coating 112, the image layer 114, and the adhesive layer 116 transferred onto the substrate 102, according to one embodiment. Fig. 5 illustrates an enlarged cross-sectional view of the defined portion. Although the defined portions 110A, 110B of each layer of the thermal transfer ribbon 108 are illustrated as extending a distance away from the surface 104 of the substrate 102, fig. 4 and 5 are not drawn to scale, and each layer of the defined portions 110A, 110B extends a very small distance away from the substrate 102. For example, the defined portions 110A, 110B may have a thickness such that the defined portions 110A, 110B may be substantially planar visually with the surface 104 of the substrate 102. For example, the thickness of the defined portions 110A, 110B on the surface 104 of the substrate 102 may not be visible unless in an enlarged view.

After transferring the defined portions 110A, 110B of each of the protective coating 112, the image layer 114, and the adhesive layer 116 onto the substrate 102, the defined portions 110A, 110B are exposed to radiation 140 from a radiation source (not shown). The radiation source may be a lamp or alternative light source emitting ultraviolet light, xenon or the like. Exposing the defined portions 110A, 110B to radiation 140 provides durability to the defined portions 110A, 110B by cross-linking the defined portions 110A, 110B of the protective coating 112 over the defined portions 110A, 110B of the image layer 114. The protective coating 112 comprises a polymeric transfer material and a polymeric matrix material combined into a single protective coating 112. In one embodiment, the polymer transfer material may be disposed on the carrier film 126 (of fig. 3) and the polymer matrix material may be disposed between the polymer transfer material and the image layer 114 as the thermal transfer ribbon 108 moves across the substrate 102. The protective coating 112 may be made of a substantially uniform portion of the polymer matrix material and the polymer transfer material. Alternatively, the protective coating 112 may have a greater weight percentage of one of the polymeric transfer material or the substrate than the other. In one or more embodiments, the protective coating 112 can include various layers of a polymer transfer material and a polymer matrix material. For example, the protective coating 112 may be a combination of two or more layers of polymer transfer material and substrate.

In one or more embodiments, partially crosslinking the protective coating 112 can crosslink the polymer transfer material and the polymer matrix material in the defined portions 110A, 110B of the protective coating 112 that have been transferred to each other. For example, exposing the defined portions 110A, 110B of the protective coating 112 to radiation 140 chemically bonds molecules of the polymer transfer material to molecules of the polymer matrix material via covalent or chemical bonds. In addition, the defined portions 110A, 110B of the protective coating 112 do not deform, change, melt, etc. upon exposure to the radiation 140. For example, the radiation 140 crosslinks the protective coating 112 without altering the integrity of the polymer transfer material and/or the polymer matrix material, thereby maintaining the integrity of the image layer 114 corresponding to the defined portions 110A, 110B of the protective coating 112.

The protective coating 112 is crosslinked such that a wear layer and/or chemical resistant layer is formed over the defined portions 110A of the transferred image layer 114. For example, molecules of the chemically bonded transfer material and substrate provide a wear layer over image layer 114 to improve the durability of image layer 114 relative to the case where the transfer material and substrate are not crosslinked or relative to the case where the transfer material is not crosslinked with itself. The wear layer improves the durability (e.g., abrasion resistance, wear resistance, chemical resistance, etc.) of the defined portions 110A, 110B of the image layer 114. For example, the abrasion and chemical resistant layers reduce the risk of scratching or abrading the image 106 from the substrate 102. The crosslinked protective coating 112 provides durability only over the defined portions 110A, 110B of the image layer 114, and not over the non-defined portions 120 (in fig. 2 and 3) outside of the image 106.

By crosslinking the protective coating 112 after the defined portions 110A, 110B of the protective coating 112, image layer 114, and adhesive layer 116 are transferred to the substrate 102, the defined portions 110A, 110B have clearer and non-hazy edges. For example, crosslinking the protective coating 112 increases the durability of the protective coating 112, thereby increasing the difficulty of cutting or transferring clear contours or details of the image. The transfer of the defined portions 110A, 110B of the thermal transfer ribbon 108 to the substrate 102 prior to crosslinking the protective coating 112 results in improved sharpness, contours, details, etc. of the image 106 on the substrate 102 relative to the transfer of the defined portions 110A, 110B after crosslinking the protective coating 112.

FIG. 6 illustrates a flow chart of one embodiment of a method 600 for introducing reflective, refractive, and/or diffractive variable and/or non-variable images onto a substrate 102 using thermal transfer. The method 600 may be used to direct variable and/or non-variable metallic and/or non-metallic images in conjunction with cards such as financial cards, security cards, and identification cards. Alternatively, the method 600 may also be used to introduce variable and/or non-variable images on medical containers, packaging materials, clothing labels, household items, electronics, and the like. The image may be a metallic image and may be a metallic silver or gold shade or hue, or alternatively may contain dyes or colorants such that the metallic image may be a metallic shade or hue of any color of rainbow (such as, but not limited to, metallic red, orange, yellow, green, blue, indigo, violet, etc.). The material used to form the image may be a reflective material, a refractive material, and/or a diffractive material. For example, the material used to form the image may create a reflective image, a refractive image, and/or a diffractive image on the surface of the substrate.

At 602, a defined portion of each of the protective coating 112, the image layer 114, and the adhesive layer 116 is simultaneously transferred from the carrier film 126 of the heat transfer tape 108 to the substrate 102 by applying heat 124 to the heat transfer tape 108. For example, the defined portions of the transferred protective coating 112, image layer 114, and adhesive layer 116 contain only the necessary amounts of protective coating 112 and image layer 114 to form a variable and/or non-variable image that is introduced onto the substrate 102. No additional amount of protective coating 112 or image layer 114 is transferred to substrate 102. For example, only a defined portion of the protective coating 112 over a portion of the image layer 114 is transferred onto the substrate 102.

At 604, the transferred image layer 114 and the defined portion of the protective coating 112 are adhered to the surface 104 of the substrate 102 using the adhesive layer 116. The image layer may include one or more materials, such as metallic materials and/or non-metallic materials. In one or more embodiments, the one or more materials may be reflective, refractive, and/or diffractive materials such that defined portions of the material of the transferred image layer may generate or form a reflective, refractive, and/or diffractive image on the surface of the substrate.

At 606, after transferring the defined portions of the protective coating 112, the image layer 114, and the adhesive layer 116, the defined portions of the protective coating 112 are exposed to radiation from a radiation source to crosslink the defined portions of the protective coating 112 over the defined portions of the image layer 114. For example, crosslinking the protective coating 112 provides durability to defined portions of the image layer 114. In addition, the protective coating 112 includes a polymer transfer material and a polymer matrix material disposed between the polymer transfer material and the image layer 114. Crosslinking the protective coating 112 crosslinks the polymer transfer material and the polymer matrix material to each other. Optionally, the protective coating 112 is crosslinked such that the polymeric transfer material crosslinks with itself. Additionally or alternatively, the protective coating 112 is crosslinked such that a wear layer and/or a chemical resistant layer is formed on defined portions of the transferred image layer 114.

While the above description describes transferring only the amount of protective coating, image layer and adhesive layer material necessary to form letters, numbers, characters, logos on the substrate, nothing else, the thermal transfer ribbon 108 may alternatively apply more image layers and protective coatings to the substrate. For example, the thermal transfer ribbon 108 may apply an image layer and protective coating over a larger area, such as the entire surface of the substrate (e.g., the entire side of a financial or identification card), a majority of the surface of the substrate, only a portion of the surface of the substrate, and the like.

In one or more embodiments of the subject matter described herein, a method of introducing a reflective and/or diffractive metal variable and/or non-variable image onto a substrate by using thermal transfer includes: the defined portion of each of the protective coating, the metal layer, and the adhesive layer is simultaneously transferred from the carrier film of the thermal transfer ribbon to the substrate by applying heat to the thermal transfer ribbon. The method comprises the following steps: the defined portions of the metal layer and the protective coating that have been transferred to the substrate are adhered using an adhesive layer, and after the defined portions of the protective coating, the metal layer, and the adhesive layer are transferred, the defined portions of the protective coating over the defined portions of the metal layer are crosslinked by exposing the protective coating to a radiation source after the defined portions of the protective coating, the metal layer, and the adhesive layer are transferred from the carrier film, thereby providing durability to the defined portions of the metal layer that are transferred to the substrate.

Optionally, defined portions of the protective coating, metal layer, and adhesive layer are transferred to have sharp, clear, and non-hazy edges.

Alternatively, the defined portions of the transferred protective coating, metal layer and adhesive layer contain only the necessary amounts of protective coating and metal layer to form a variable and/or non-variable image that is introduced onto the substrate, without containing additional amounts of protective coating and metal layer.

Optionally, crosslinking the defined portion of the transferred protective coating forms one or more wear or chemical resistant layers over the defined portion of the transferred metal layer.

Optionally, the protective coating comprises a polymer transfer material on the carrier film and a polymer matrix material on the polymer transfer material, and the partial cross-linking of the protective coating causes the polymer transfer material and the polymer matrix material to cross-link with each other in defined portions of the protective coating that have been transferred.

Optionally, the protective coating comprises a polymeric transfer coating. The partial cross-linking of the protective coating cross-links the polymeric transfer material of the defined portion of the protective coating that has been transferred.

Optionally, transferring the defined portion of the protective coating includes transferring only the defined portion of the protective coating over the portion of the metal layer transferred onto the substrate.

Optionally, the protective coating is coupled to the metal layer such that transferring a defined portion of the metal layer necessarily transfers a corresponding defined portion of the protective coating.

Optionally, the defined portion of the transferred metal layer is reflective.

Optionally, the defined portion of the transferred metal layer is diffractive.

Optionally, transferring the defined portion of the metal layer onto the substrate includes forming a continuous metal shape on the substrate using the transferred defined portion of the metal layer.

Alternatively, the image formed on the substrate by the metal layer is a variable image.

Optionally, the image formed on the substrate by the metal layer is a non-variable image.

Optionally, the variable and/or non-variable image is visible on the front or rear surface of the substrate.

Optionally, transferring the defined portions of the protective coating, the metal layer, and the adhesive layer includes printing numbers, letters, or logos on one or more of an identification card, a financial card, a security card, a medical container, a medical device, a packaging material, a garment, an electronic device, a consumable product, or a consumer product.

Optionally, transferring the defined portions of the protective coating, the metal layer, and the adhesive layer includes transferring the metal layer and the protective coating to a majority of the surface of the substrate.

Optionally, the defined portions of the transferred protective coating, metal layer and adhesive layer contain only the necessary amounts of protective coating and metal layer to form the variable and/or non-variable image that is introduced onto the substrate, and no additional protective coating or metal layer material is contained.

Optionally, crosslinking the defined portions of the transferred protective coating such that one or more wear or chemical resistant layers are formed over the defined portions of the transferred metal layer.

Optionally, the protective coating comprises a polymer transfer material on the carrier film and a polymer matrix material on the polymer transfer material. The partial cross-linking of the protective coating causes the polymeric transfer material and the polymeric matrix material to cross-link with each other in defined portions of the protective coating that have been transferred.

Optionally, the protective coating comprises a polymeric transfer material. The partial cross-linking of the protective coating cross-links the polymeric transfer material of the defined portion of the protective coating that has been transferred.

Optionally, only a defined portion of the protective coating over the portion of the metal layer transferred onto the substrate is configured to be transferred.

Optionally, the defined portion of the transferred metal layer is reflective.

Optionally, the defined portion of the transferred metal layer is diffractive.

Optionally, the defined portion of the metal layer is transferred to form a continuous metal shape on the substrate using the defined portion of the metal layer.

Optionally, the transferring of the defined portions of the protective coating, the metal layer, and the adhesive layer includes printing numbers, letters, or logos on one or more of an identification card, a financial card, a security card, a medical container, a medical device, packaging material, apparel, electronics, a consumable product, or a consumer product.

Optionally, the protective coating, the metal layer, and the adhesive layer are configured to be transferred onto a majority of the surface of the substrate.

In one or more embodiments of the subject matter described herein, a method includes: the defined portion of each of the protective coating, the metal layer, and the adhesive layer is simultaneously transferred from the carrier film of the thermal transfer ribbon to the substrate by applying heat to the thermal transfer ribbon. The method comprises the following steps: the defined portions of the metal layer and the protective coating that have been transferred to the substrate are adhered using an adhesive layer, and after the transfer of the defined portions of the protective coating, the metal layer, and the adhesive layer, the defined portions of the protective coating over the defined portions of the metal layer are crosslinked by exposing the protective coating to a radiation source, thereby providing durability to the defined portions of the metal layer that have been transferred to the substrate. The defined portions of the transferred protective coating, metal layer and adhesive layer contain only the necessary amounts of protective coating and metal layer to form one or more variable or non-variable images that are introduced onto the substrate, without containing additional amounts of protective coating or metal layer.

In one or more embodiments of the subject matter described herein, a method of introducing one or more reflective, refractive, and/or diffractive images onto a substrate using thermal transfer may comprise: the defined portion of each of the protective coating, image layer and adhesive layer is simultaneously transferred from the carrier film of the thermal transfer tape to the substrate by applying heat to the defined portion of the thermal transfer tape as the thermal transfer tape moves in the direction of the surface of the substrate. The image layer may include one or more materials that are reflective, refractive, or diffractive. The defined portions of the image layer and protective coating that have been transferred to the substrate may be adhered using an adhesive layer. After transferring the defined portions of the protective coating, image layer and adhesive layer, the defined portions of the protective coating over the defined portions of the image layer are crosslinked by exposing the defined portions to a radiation source after the defined portions of the protective coating, image layer and adhesive layer are transferred from the carrier film, thereby providing durability to the defined portions of the image layer transferred to the substrate.

Optionally, defined portions of the protective coating, image layer and adhesive layer are transferred to have well-defined edges.

Optionally, the defined portions of the transferred protective coating, image layer and adhesive layer contain only the necessary amounts of protective coating and image layer to form one or more variable or non-variable images on the substrate, without containing additional amounts of protective coating or image layer.

Optionally, the defined portions of the transferred protective coating are crosslinked to form a wear layer and/or a chemical resistant layer over the defined portions of the transferred image layer.

Optionally, transferring the defined portion of the protective coating includes transferring only the defined portion of the protective coating over the portion of the image layer transferred onto the substrate.

Optionally, the protective coating is coupled to the image layer such that transferring a defined portion of the image layer necessarily transfers a corresponding defined portion of the protective coating.

Optionally, transferring the defined portion of the image layer onto the substrate includes forming a continuous shape on the substrate using the transferred defined portion of the image layer.

Optionally, the non-defined portion of each of the protective coating, image layer, and adhesive layer is not transferred from the carrier film to the substrate.

Alternatively, the method may include moving the thermal transfer ribbon in a direction parallel to the surface of the substrate to transfer defined portions of each of the protective coating, image layer, and adhesive layer from the carrier film onto the substrate.

In one or more embodiments of the subject matter described herein, a system for introducing one or more reflective, refractive, and/or diffractive images onto a substrate using thermal transfer comprises a thermal transfer ribbon comprising a protective coating, an image layer, and an adhesive layer. The image layer comprises one or more of a reflective material, a refractive material, or a diffractive material. The defined portion of each of the protective coating, image layer and adhesive layer may be transferred simultaneously from the carrier film of the thermal transfer tape onto the substrate by applying heat to the defined portion of the thermal transfer tape as the thermal transfer tape moves in the direction of the surface of the substrate. The defined portions of the image layer and protective coating that have been transferred may be adhered to a substrate using an adhesive layer. After transferring the defined portions of the protective coating, the image layer and the adhesive layer, the defined portions of the protective coating may be crosslinked by exposing the protective coating to a radiation source after transferring the defined portions of the protective coating, the image layer and the adhesive layer from the carrier film. Crosslinking defined portions of the protective coating provides durability to defined portions of the image layer transferred to the substrate.

Alternatively, defined portions of the protective coating, image layer and adhesive layer may be transferred to have well-defined edges.

Optionally, the defined portions of the transferred protective coating, image layer and adhesive layer contain only the necessary amounts of protective coating and image layer to form one or more variable or non-variable images on the substrate, and no additional amounts of protective coating and image layer.

Alternatively, only defined portions of the protective coating over defined portions of the image layer transferred onto the substrate may be transferred.

Alternatively, the protective coating may be coupled to the image layer such that transferring defined portions of the image layer necessarily transfers defined portions of the corresponding protective coating.

Alternatively, the material of the image layer may be a reflective material. The defined portions of the image layer may form a reflective image on the surface of the substrate.

Alternatively, the material of the image layer may be a diffractive material. The defined portions of the image layer may form a diffractive image on the surface of the substrate.

Alternatively, the defined portions of the image layer may be formed in a continuous shape on the substrate using the defined portions of the image layer that are transferred.

In one or more embodiments of the subject matter described herein, a method can include: the defined portion of each of the protective coating, image layer and adhesive layer is simultaneously transferred from the carrier film of the thermal transfer tape to the substrate by selectively applying thermal energy to the thermal transfer tape as the thermal transfer tape moves in the direction of the surface of the substrate. The image layer may comprise one or more of a reflective material, a refractive material, or a diffractive material. Using an adhesive layer, defined portions of the image layer and protective coating that have been transferred to the substrate may be adhered to the substrate. The defined portions of the image layer may form one or more of a reflective image, a refractive image, or a diffractive image. After transferring the defined portions of the protective coating, the image layer and the adhesive layer, the defined portions of the protective coating over the defined portions of the image layer may be crosslinked by exposing the defined portions of the protective coating to a radiation source, thereby providing durability to the defined portions of the image layer transferred onto the substrate. The defined portions of the transferred protective coating, image layer and adhesive layer may contain only the necessary amounts of protective coating and image layer to form one or more reflective, refractive or diffractive images on the substrate, without containing additional amounts of one or more protective coating and image layer.

Alternatively, the defined portion may be transferred to the substrate by selectively applying thermal energy to the thermal transfer ribbon as it moves in the direction of the surface of the substrate. The non-limiting portions defining the non-essential amounts of the protective coating and the image layer may not be transferred to the substrate as the thermal transfer ribbon moves in the direction of the surface of the substrate.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the inventive subject matter without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the inventive subject matter, they are by no means limiting and are exemplary embodiments. Many other embodiments will be apparent to those of ordinary skill in the art upon reviewing the above description. The scope of the inventive subject matter should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "including" and "in which" are used as the plain-english equivalents of the respective terms "comprising" and "in which". Furthermore, in the following claims, the terms "first," "second," "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in a means-plus-function format and are not intended to be interpreted based on 35U.S. c. ≡112 (f), unless and until such time as the claim limitations explicitly use the phrase "means for … …," followed by a functional description lacking further structure. For example, references to "a mechanism for … …", "a module for … …", "a device for … …", "a unit for … …", "a component for … …", "an element for … …", "a component for … …", "an apparatus for … …", "a machine for … …", or "a system for … …" should not be construed as referring to 35u.s.c. ≡112 (f), and any claims referring to one or more of these terms should not be construed as means-plus-function claims.

This written description uses examples to disclose several embodiments of the inventive subject matter, and also to enable any person skilled in the art to practice embodiments of the inventive subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the inventive subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

The foregoing description of certain embodiments of the inventive subject matter will be better understood when read in conjunction with the accompanying drawings. To the extent that the figures illustrate diagrams of the functional blocks of various embodiments, the functional blocks are not necessarily indicative of the division between hardware circuitry. The various embodiments are not limited to the arrangements and instrumentality shown in the drawings.

As used herein, an element or step recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to "one embodiment" or "an embodiment" of the presently described subject matter are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, unless explicitly stated to the contrary, embodiments "comprising", "including", "having" an element or a plurality of elements having a particular property may include additional such elements not having that property.

Claims

1. A method of introducing one or more reflective, refractive or diffractive images onto a substrate using thermal transfer, the method comprising:

simultaneously transferring defined portions of each of a protective coating, an image layer, and an adhesive layer from a carrier film of a thermal transfer ribbon onto the substrate by applying heat to the defined portions of the thermal transfer ribbon as the thermal transfer ribbon moves in a surface direction of the substrate, the image layer comprising one or more of a reflective material, a refractive material, or a diffractive material;

adhering the image layer and the defined portion of the protective coating layer that have been transferred onto the substrate using the adhesive layer; and

after transferring the defined portions of the protective coating, the image layer, and the adhesive layer, the defined portions of the protective coating over the defined portions of the image layer are crosslinked by exposing the defined portions to a radiation source after transferring the defined portions of the protective coating, the image layer, and the adhesive layer from the carrier film, thereby providing durability to the defined portions of the image layer transferred onto the substrate.

2. The method of claim 1, wherein the protective coating, the image layer, and the defined portion of the adhesive layer are transferred to have a well-defined edge.

3. The method of claim 1, wherein the defined portions of the protective coating, the image layer, and the adhesive layer that are transferred contain only the necessary amounts of the protective coating and the image layer to form one or more variable or non-variable images on the substrate without containing additional amounts of the protective coating and the image layer.

4. The method of claim 1, wherein defined portions of the protective coating that have been transferred are crosslinked to form a wear layer and/or a chemical resistant layer over defined portions of the image layer that have been transferred.

5. The method of claim 1, wherein transferring defined portions of the protective coating comprises transferring only defined portions of the protective coating over portions of the image layer transferred onto the substrate.

6. The method of claim 1, wherein the protective coating is coupled to the image layer such that transferring a defined portion of the image layer necessarily transfers a corresponding defined portion of the protective coating.

7. The method of claim 1, wherein transferring the defined portion of the image layer onto the substrate comprises forming a continuous shape on the substrate using the transferred defined portion of the image layer.

8. The method of claim 1, wherein the non-defined portion of each of the protective coating, the image layer, and the adhesive layer is not transferred from the carrier film to the substrate.

9. The method of claim 1, further comprising moving the thermal transfer ribbon in a direction parallel to a surface of the substrate to transfer the defined portion of each of the protective coating, the image layer, and the adhesive layer from the carrier film onto the substrate.

10. A system for introducing one or more reflective, refractive, or diffractive images onto a substrate using thermal transfer, the system comprising:

a thermal transfer ribbon comprising a protective coating, an image layer, and an adhesive layer, wherein the image layer comprises one or more of a reflective material, a refractive material, or a diffractive material, wherein defined portions of each of the protective coating, the image layer, and the adhesive layer are configured to be simultaneously transferred from a carrier film of the thermal transfer ribbon onto the substrate by application of heat to the defined portions of the thermal transfer ribbon as the thermal transfer ribbon is moved in a surface direction of the substrate,

Wherein the transferred image layer and the defined portion of the protective coating are configured to adhere to the substrate using the adhesive layer, and

wherein after transferring the defined portions of the protective coating, the image layer, and the adhesive layer, the defined portions of the protective coating are configured to crosslink by exposing the protective coating to a radiation source after transferring the defined portions of the protective coating, the image layer, and the adhesive layer from the carrier film, wherein crosslinking the defined portions of the protective coating provides durability to the defined portions of the image layer transferred onto the substrate.

11. The system of claim 10, wherein the protective coating, the image layer, and the defined portion of the adhesive layer are transferred to have a well-defined edge.

12. The system of claim 10, wherein the defined portions of the protective coating, the image layer, and the adhesive layer that are transferred contain only the necessary amounts of the protective coating and the image layer to form one or more variable or non-variable images on the substrate without containing additional amounts of the protective coating and the image layer.

13. The system of claim 10, wherein crosslinking the defined portions of the protective coating that have been transferred causes a wear layer and/or chemical resistant layer to form over the defined portions of the image layer that have been transferred.

14. The system of claim 10, wherein only a defined portion of the protective coating over a defined portion of the image layer transferred onto the substrate is configured to be transferred.

15. The system of claim 10, wherein the protective coating is coupled with the image layer such that transferring a defined portion of the image layer necessarily transfers a corresponding defined portion of the protective coating.

16. The system of claim 10, wherein the material of the image layer is a reflective material, wherein the defined portion of the image layer is configured to form a reflective image on the surface of the substrate.

17. The system of claim 10, wherein the material of the image layer is a diffractive material, wherein the defined portion of the image layer is configured to form a diffractive image on the surface of the substrate.

18. The system of claim 10, wherein the defined portion of the image layer is configured to form a continuous shape on the substrate using the transferred defined portion of the image layer.

19. A method, comprising:

simultaneously transferring defined portions of each of a protective coating, an image layer, and an adhesive layer from a carrier film of a thermal transfer ribbon onto a substrate by selectively applying thermal energy to the thermal transfer ribbon as the thermal transfer ribbon moves in a surface direction of the substrate, the image layer comprising one or more of a reflective material, a refractive material, or a diffractive material;

adhering, using the adhesive layer, the defined portions of the image layer and the protective coating that have been transferred onto the substrate, the defined portions of the image layer configured to form one or more of a reflective image, a refractive image, or a diffractive image; and

after transferring the defined portions of the protective coating, the image layer and the adhesive layer, crosslinking the defined portions of the protective coating over the defined portions of the image layer by exposing the defined portions of the protective coating to a radiation source to provide durability to the defined portions of the image layer transferred onto the substrate,

wherein the defined portions of the protective coating, the image layer, and the adhesive layer that are transferred contain only the necessary amounts of the protective coating and the image layer to form one or more of the reflective image, the refractive image, or the diffractive image on the substrate, without containing additional amounts of one or more of the protective coating and the image layer.

20. The method of claim 19, wherein the defined portion is transferred to the substrate by selectively applying thermal energy to the thermal transfer ribbon as the thermal transfer ribbon moves in a direction along the surface of the substrate, and wherein an unnecessary amount of the non-defined portion defining the protective coating and the image layer is not transferred to the substrate as the thermal transfer ribbon moves in the direction along the surface of the substrate.