U.S. patent application number 10/408389 was filed with the patent office on 2003-12-04 for direct thermal printable pull-aparts.
Invention is credited to Fulwiler, Daniel R., Mitchell, Chauncey T. JR..
Application Number | 20030224151 10/408389 |
Document ID | / |
Family ID | 25410770 |
Filed Date | 2003-12-04 |
United States Patent
Application |
20030224151 |
Kind Code |
A1 |
Mitchell, Chauncey T. JR. ;
et al. |
December 4, 2003 |
Direct thermal printable pull-aparts
Abstract
An improved construction for pull-aparts, which take such forms
as game pieces, promotional articles, and report forms, involves
the use or two or more substrates that are rendered opaque for
concealing information. A thermosensitive imaging layer is located
beneath an opaque cover layer through which the concealed
information is direct thermally printed. The concealed information
is revealed by at least partially separating the two substrates for
exposing a view of the thermosensitive imaging layer.
Inventors: |
Mitchell, Chauncey T. JR.;
(Lakeland, TN) ; Fulwiler, Daniel R.; (Algoma,
WI) |
Correspondence
Address: |
THOMAS B. RYAN
EUGENE STEPHENS & ASSOCIATES
56 WINDSOR STREET
ROCHESTER
NY
14605
US
|
Family ID: |
25410770 |
Appl. No.: |
10/408389 |
Filed: |
April 7, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10408389 |
Apr 7, 2003 |
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09899313 |
Jul 5, 2001 |
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6543808 |
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Current U.S.
Class: |
428/195.1 ;
428/43 |
Current CPC
Class: |
B41M 3/005 20130101;
Y10T 428/24802 20150115; B41M 2205/38 20130101; A63F 3/0685
20130101; B41M 2205/40 20130101; Y10S 283/903 20130101; B41M 5/41
20130101; B41M 5/42 20130101; Y10T 428/15 20150115; B41M 2205/04
20130101; B41M 2205/36 20130101 |
Class at
Publication: |
428/195.1 ;
428/43 |
International
Class: |
G09F 003/00 |
Claims
We claim:
1. A direct thermal printable pull-apart comprising: a base
substrate that is at least partially transparent and has front and
back surfaces; a thermosensitive imaging layer on the front surface
of the base substrate; an at least partially opaque layer covering
the thermosensitive imaging layer on the front surface of the base
substrate; a cover substrate being partially bonded to the back
surface of the base substrate; the base substrate and the cover
substrate being at least partially separable for exposing a view of
the thermosensitive imaging layer through the back surface of the
base substrate; and the opaque layer providing for: (a)
transmitting concentrations of heat required to form thermal images
in the thermosensitive imaging layer from a thermal print head; (b)
at least partly obscuring a view of the thermal images formed in
the thermosensitive imaging layer from the front side of the base
layer; and (c) visually contrasting with the thermal images formed
in the thermosensitive imaging layer as a background against which
the thermal images can be distinguished through the back surface of
the base layer.
2. The pull-apart of claim 1 in which a tab formed in one of the
substrates and the tab is at least partially retractable with
respect to the other of the substrates for exposing the view of the
thermosensitive imaging layer through the base substrate.
3. The pull-apart of claim 2 in which the tab is temporarily bonded
to the other of the substrates and a remaining portion of the one
substrate is permanently bonded to the other substrate.
4. The pull-apart of claim 3 in which a permanent adhesive
permanently bonds the remaining portion of the one substrate to the
other substrate.
5. The pull-apart of claim 4 in which a temporary adhesive
temporarily bonds the tab to the other substrate.
6. The pull-apart of claim 2 in which the tab is formed in the
cover substrate.
7. The pull-apart of claim 6 in which the tab is formed by die cuts
in the cover substrate.
8. The pull-apart of claim 2 in which the tab is formed in the base
substrate.
9. The pull-apart of claim 8 in which the tab is formed by die cuts
in the base substrate.
10. The pull-apart of claim 1 in which the cover substrate is
rendered at least partially opaque.
11. The pull-apart of claim 1 further comprising: a thermally
transmissive substrate having front and back surfaces, the
thermosensitive imaging layer being supported on the back surface
of the thermally transmissive substrate, and the back surface of
the thermally transmissive substrate being bonded to the front
surface of the at least partially transparent base substrate.
12. The pull-apart of claim 11 in which the opaque layer covers the
front surface of the thermally transmissive substrate.
13. The pull-apart of claim 11 in which the thermally transmissive
substrate has a thickness of less than ten microns.
14. The pull-apart of claim 1 further comprising a confusion
pattern formed over the opaque layer.
15. A direct thermal printable pull-apart comprising: a direct
thermal printable film having front and back surfaces; a
thermosensitive imaging layer of the direct thermal printable film
being located on the back surface of the direct thermal printable
film; a cover substrate bonded to the back surface of the direct
thermal printable film; an at least partially removable tab formed
in the cover substrate overlapping with a printable area of the
thermosensitive imaging area; an opaque layer apparent on the front
surface of the direct thermal printable film covering at least a
portion of the printable area of the direct thermal printable film
and overlapping with the at least partially removable tab; and the
at least partially removable tab and the opaque layer providing for
obscuring views of thermal images formed in the thermosensitive
imaging layer by direct thermal printing through the direct thermal
printable film.
16. The pull-apart of claim 15 in which a first portion of the
cover substrate includes the at least partially removable tab and a
second portion of the cover substrate is permanently bonded to the
direct thermal printable film.
17. The pull-apart of claim 16 in which the tab is formed by a die
cut pattern in the cover substrate.
18. The pull-apart of claim 15 in which the opaque layer is an
opaque coating on the front surface of the direct thermal printable
film.
19. The pull-apart of claim 18 in which the opaque layer is formed
by an opaque coloring of the direct thermal printable film.
20. The pull-apart of claim 18 in which the opaque coating is an
ink.
21. The pull-apart of claim 15 in which the opaque layer has a
color that contrasts with a color of the thermal images formed in
the thermosensitive imaging layer.
22. The pull-apart of claim 21 further comprising a confusion
pattern formed over the opaque layer.
23. The pull-apart of claim 22 in which the confusion pattern has a
color that does not contrast with the color of the thermal images
formed in the thermosensitive imaging layer.
24. A direct thermal printable medium comprising: a base substrate
having front and back surfaces; a thermosensitive imaging layer
supported on the back surface of the base substrate; a cover
substrate being bonded to the back surface of the base substrate; a
tab formed in one of the substrates overlapping a region of the
thermosensitive imaging layer where thermal images can be formed by
direct thermal printing; both substrates being rendered opaque for
obscuring a view of the thermal images through the base substrate
and through the cover substrate; and the tab formed in the one
substrate being retractable from the other of the substrates for
viewing the thermal images in the thermosensitive imaging
layer.
25. The medium of claim 24 in which the base substrate is a
thermally transmissive substrate for supporting thermal printing of
the thermal images through the base substrate.
26. The medium of claim 25 in which the thermally transmissive
substrate is less than ten microns thick.
27. The medium of claim 25 in which the tab is formed in the cover
substrate overlapping a region of the thermosensitive imaging layer
where thermal images can be formed through the thermally
transmissive substrate by direct thermal printing.
28. The medium of claim 27 in which the tab is retractable with
respect to a remaining portion of the cover substrate for viewing
the thermal images in the thermosensitive imaging layer.
29. The medium of claim 28 in which the remaining portion of the
cover substrate is permanently bonded to the thermally transmissive
substrate.
30. The medium of claim 29 in which a temporary bond is formed
between the tab and the thermally transmissive substrate.
31. The medium of claim 29 in which the remaining portion of the
cover substrate has a closed shape that frames a window surrounding
the tab.
32. The medium of claim 29 in which the tab is formed by a pattern
of perforations in the cover substrate.
33. The medium of claim 24 in which retraction of the tab opens a
window through the cover substrate and the window is at least
partially framed by the remaining portion of the cover
substrate.
34. The medium of claim 33 in which the base substrate is opaque
for (a) obscuring the view of the thermal images through the front
surface of the base substrate and (b) providing contrast for
viewing the thermal images through the window formed in the cover
substrate.
35. The medium of claim 33 in which a coating on the base substrate
is opaque for (a) obscuring the view of the thermal images through
the front surface of the base substrate and (b) providing contrast
for viewing the thermal images through the window formed in the
cover substrate.
36. The medium of claim 35 in which the opaque layer has a color
that contrasts with a color of the thermal images.
37. The medium of claim 36 further comprising a pattern printed on
the front surface of the base substrate for further obscuring the
view of the thermal images through the base substrate.
38. The medium of claim 37 in which the printed pattern includes a
color that matches the color of the thermal images to further
obscure the view of the thermal images.
39. The medium of claim 24 in which the cover substrate is a
thermally transmissive substrate for supporting thermal printing of
the thermal images through the cover substrate.
40. The medium of claim 39 in which the tab is formed in the base
substrate including a region of the thermosensitive imaging layer
where thermal images can be formed through the thermally
transmissive substrate by direct thermal printing.
41. The medium of claim 40 in which the tab is retractable with
respect to a remaining portion of the base substrate for viewing
the thermal images in the thermosensitive imaging layer.
42. A direct thermal printable pull-apart comprising: a base
substrate; a thermally sensitive imaging layer supported on the
base substrate; an opaque layer covering the thermally sensitive
imaging layer; a cover substrate; the cover substrate being
laminated to the base substrate so that the thermally sensitive
imaging layer is concealed between the opaque layer and the cover
substrate; and one of the base substrate and the cover substrate
being arranged as a tab that can be retracted to view thermal
images that are direct thermally printed in the thermosensitive
imaging layer.
43. The pull-apart of claim 42 in which the thermally sensitive
imaging layer is supported on a front surface of the base substrate
and a back surface of the base substrate is bonded to the cover
substrate.
44. The pull-apart of claim 43 in which the base substrate is at
least partially transparent so that the thermal images are viewable
through the base substrate when the tab is retracted.
45. The pull-apart of claim 44 further comprising a thermally
transmissive substrate on which the thermally sensitive imaging
layer is applied, and the thermally transmissive substrate being
laminated to the base substrate such that the thermally sensitive
imaging layer is located between the thermally transmissive
substrate and the base substrate.
46. The pull-apart of claim 42 in which the opaque layer is
supported on a front surface of the base substrate, the thermally
sensitive imaging layer is supported on a back surface of the base
substrate, and the back surface of the base substrate is bonded to
the cover substrate.
47. The pull-apart of claim 46 in which the base substrate is a
thermally transmissive substrate for forming the thermal images
through the base substrate.
48. The pull-apart of claim 47 in which the tab is formed in the
cover substrate overlapping a region of the thermosensitive imaging
layer where thermal images are formed and the tab is retractable
from a remaining portion of the cover substrate for viewing the
thermal images in the thermosensitive imaging layer.
49. The pull-apart of claim 48 in which the remaining portion of
the cover substrate is permanently bonded to the thermally
transmissive substrate and has a closed shape that frames a window
surrounding the tab.
50. A method of making a direct thermal printable pull-apart
comprising the steps of: supporting a thermally sensitive imaging
layer on a base substrate; covering the thermally sensitive imaging
layer with an opaque layer; laminating a cover substrate to the
base substrate so that the thermally sensitive imaging layer is
concealed between the opaque layer and the cover substrate; and
arranging one of the base substrate and the cover substrate as a
tab that can be retracted to view thermal images that are-direct
thermally printed in the thermosensitive imaging layer.
51. The method of claim 50 in which the step of supporting includes
supporting the thermally sensitive imaging layer on a front surface
of the base substrate, and the step of laminating includes bonding
a back surface of the base substrate to the cover substrate.
52. The method of claim 51 in which the base substrate is at least
partially transparent so that the thermal images are viewable
through the base substrate when the tab is retracted.
53. The method of claim 52 including an additional step of
laminating a thermally transmissive substrate on which the
thermally sensitive imaging layer is applied to the base substrate
such that the thermally sensitive imaging layer is located between
the thermally transmissive substrate and the base substrate.
54. The method of claim 50 including additional steps of supporting
the opaque layer on a front surface of the base substrate,
supporting the thermally sensitive imaging layer on a back surface
of the base substrate, and bonding the back surface of the base
substrate to the cover substrate.
55. The method of claim 50 in which the step of arranging includes
forming the tab in a portion of one of the substrates and including
an additional step of bonding a remaining portion of the one
substrate to the other of the substrates.
56. The method of claim 50 including an additional step of
arranging the opaque layer to: (a) transmit concentrations of heat
required to form thermal images in the thermosensitive imaging
layer from a thermal print head; (b) at least partly obscure a view
of the thermal images formed in the thermosensitive imaging layer;
and (c) visually contrast with the thermal images formed in the
thermosensitive imaging layer as a background against which the
thermal images can be distinguished.
Description
RELATED APPLICATIONS
[0001] This is a continuation-in-part of pending U.S. application
Ser. No. 09/899,313, filed on Jul. 5, 2001, and entitled Direct
Thermal Printable Pull Tabs, which application is hereby
incorporated by reference.
TECHNICAL FIELD
[0002] Pull-aparts, also referred to variously as tear-aparts,
tear-opens, break-aparts, break-opens, crack-opens, pull tabs,
rip-offs, jar tickets, and pickle cards, contain information
concealed between layers of a laminate. Direct thermal printing is
used in accordance with this invention to print the concealed
information beneath one or more obscuring layers of the
laminate.
BACKGROUND
[0003] Pull-aparts are printed with concealed information that is
revealed upon disassembly of the pull-apart. Typically, the
information is concealed by being blocked from view between two
substrates that are bonded together. However, the bonding is
patterned or otherwise limited to permit the two bonded substrates
to be separated (e.g., pulled apart) in a manner that reveals the
information concealed between them while permanently evidencing
their separation. Such pull-aparts are used for a variety of
purposes such as game pieces, promotional articles, and report
forms.
[0004] The game pieces, which are often referred to as "pull tabs",
generally contain two layers of paper. The game results are printed
on a base layer and are temporarily obscured by a cover layer.
Perforations in the cover layer form removable tabs, which can be
peeled away to reveal the game results through so-formed windows in
the cover layer.
[0005] Ordinarily, the pull-tab game pieces are manufactured along
high-speed in-line presses. In-line printing is applied to both the
base layer and the cover layer to provide information and images
for promoting and playing the game. A front surface of the base
layer generally contains promotional and instructional information
concerning game play. A back surface of the base layer contains the
game results. Digital printing technology is used for serialization
and for in-line printing of the results. Less expensive rotary
transfer printing technologies are used for repeating patterns. The
base layer and the cover layer are laminated together, and
perforations are cut through the cover layer to form the tabs that
can be peeled back to reveal the game results.
[0006] The preprinted game pieces require odds, prizes, and other
details of game play and promotion be determined well in advance of
play. This limits possibilities for user interaction with
game-piece dispensing machines. Any desired change in the ticket
price, level of risk, or rules of play requires different
pre-printed game pieces. Sometimes, both the number and amounts of
the winnings are known for prepackaged sets of game pieces. Early
winnings can discourage further sales, because the remaining prizes
are known to be diminished.
[0007] In addition, the preprinted game pieces require a high
standard of security to prevent winning game pieces from being
discovered prior to sale. For example, the results must remain
hidden from sight by being completely obscured between two
substrates. Any tampering of the substrates must be clearly
evident. Control over the handling, packaging, and distribution of
the pull-tab game pieces is required to guard against more
sophisticated breeches of security.
[0008] Similar types of games have been developed for play on
machines that print the game results locally prior to dispensing
the game pieces. The game pieces are printed and dispensed on
demand. Odds tables are stored within the machines, allowing for
the calculation of odds and scale of winnings for different games
and game piece prices. The results of any particular play are not
known until the purchased game pieces are printed and
dispensed.
[0009] Locally printed game pieces are provided in the same basic
format, but the base layer is made with micro-encapsulated ink,
which is often referred to as "carbonless paper". An impact printer
used without a ribbon forms images in the base layer through the
cover layer. The pattern of impacts is apparent in the cover layer,
which can detract from the anticipatory nature of the game by
revealing the results before the game piece is opened.
[0010] However, the results are not known prior to the impact
printing of the game piece, so the integrity of the game itself to
fairly return results is not affected. The security requirements of
pull-tab game pieces for protecting results prior to opening
individual game pieces is considerably less if the game piece
results are printed at the point of sale, since the results are not
determined until a sale is made.
[0011] The gaming machines capable of locally printing results for
pull-tab game pieces also benefit from their similarity to gaming
machines used for traditional gambling purposes. However, pull-tab
game pieces are legal in more jurisdictions.
[0012] Although on-demand printed pull-tab game pieces have many
advantages over pre-printed pull-tab game pieces, impact printing
of the game pieces poses problems that detract from the acceptance
of the on-demand printed game pieces. In addition to forming an
impression of the game results in the surface of the game pieces,
which can detract from game play, impact printing is noisy,
generates paper dust, and requires considerable maintenance. Costs
associated with maintaining remote machines with impact printers
can be prohibitively high.
SUMMARY OF INVENTION
[0013] Our invention provides an improved construction for
on-demand printed pull-aparts for supporting the direct thermal
printing of concealed information. The new construction features a
direct thermal imaging layer that is located beneath an obscuring
layer of a laminate. Images can be formed in the thermal imaging
layer through the obscuring layer so that concealed information can
be printed on demand after the laminate is fully assembled. The
pull-aparts can be supplied as media for such purposes as game
pieces, promotional articles, and report forms all capable of
receiving information on demand that remains concealed until the
pull-aparts are individually opened.
[0014] An exemplary pull-apart according to our invention includes
a base substrate that is at least partially transparent. A
thermosensitive imaging layer overlays a front surface of the base
substrate, and an opaque layer covers the thermosensitive imaging
layer. Bonded to a back surface of the base substrate is a cover
substrate. The base substrate and the cover substrate are at least
partially separable for exposing a view of the thermosensitive
imaging layer through the back surface of the base substrate. The
opaque coating on the front surface of the base substrate transmits
concentrations of heat required to form thermal images in the
thermosensitive imaging layer from a thermal print head. However,
the opaque coating at least partly obscures a view of the thermal
images formed in the thermosensitive imaging layer from the front
side of the base layer. When the substrates are separated, the
opaque coating visually contrasts with the thermal images revealed
in the thermosensitive imaging layer as a background against which
the thermal images can be distinguished through the back surface of
the base layer.
[0015] A tab is preferably formed in one of the substrates, and the
tab is at least partially retractable with respect to the other of
the substrates for exposing the view of the thermosensitive imaging
layer through the base substrate. The tab is temporarily bonded to
the other of the substrates, and a remaining portion of the one
substrate is permanently bonded to the other substrate.
[0016] The base substrate is preferably a transparent or
translucent film. The opaque coating is preferably an ink, such as
an ink printable along an in-line press. The ink's color should
differ from the color of thermal images formed in the
thermosensitive imaging layer to provide the desired contrast. To
further obscure the thermal images formed in the thermosensitive
layer, additional coatings, preferably inks, can be applied over
the opaque coating. For example, a confusion pattern having a color
matching the color of the thermal images can be printed over the
opaque coating.
[0017] The removable tab can be formed in a variety of ways. For
example, the tab can be formed by a die-cut pattern of perforations
in the cover substrate. A permanent adhesive responsible for
bonding the cover substrate to the base substrate can be patterned
to avoid areas of overlap between the tab and the base substrate.
Alternatively, the tab can be more completely cut out of the cover
and held in place by a temporary adhesive (e.g., a fugitive
adhesive or a dry release adhesive). Part of the cut-out tab is
preferably permanently bonded to the base substrate or attached to
the remaining cover substrate to avoid producing separate pieces of
scrap.
[0018] Instead of forming the removable tab in the cover substrate,
the removable tab could be formed in the base substrate. When
retracted, the thermal images appear in the back of the retracted
tab. Such tabs can be completely removed for collection,
redemption, or other subsequent use, or can remain attached to the
cover substrate to reduce instances of scrap. The tabs can be
defined in all or just part of the cover or base substrates. For
example, single or multiple tabs can be formed as limited parts of
either substrate, or either substrate can be fashioned entirely as
a single tab.
[0019] Another exemplary pull-apart according to our invention also
includes a base substrate that is at least partially transparent.
However, instead of supporting a thermosensitive imaging layer on
the front surface of the base substrate, the thermosensitive
imaging layer is supported on a back surface of a thermally
transmissive substrate, which is bonded to the front surface of the
base substrate. The thermosensitive imaging layer is oriented
adjacent to the front surface of the base substrate. The thermally
transmissive substrate is at least partially opaque or rendered
opaque by the thermosensitive imaging layer itself or an additional
coating applied to a front surface of the thermally transmissive
substrate. A retractable tab is mounted on the back surface of the
base substrate overlying a region of the thermosensitive imaging
layer intended for direct thermal printing through the thermally
transmissive substrate. Opaque regions of the thermally
transmissive substrate and the retractable tab obscure views of the
direct thermal printable region of the thermosensitive imaging
layer from both sides of the base substrate.
[0020] Retracting the tab allows the printable region to be viewed
through the base substrate. Similar to the opaque layer of the
previous example, the thermally transmissive substrate together
with any immediate coatings or colorings provides contrast for
thermal images formed in the thermosensitive imaging layer by
direct thermal printing. The thermally transmissive substrate can
be made of transmissive materials such as thin paper or film, which
are preferably made in a color that contrasts with the thermal
images formed in the thermosensitive imaging layer. Coatings,
including ink coatings, can be added to provide more color. A
confusion pattern or other printing can be added in place of or in
addition to the coatings to provide for further obscuring the
thermal images viewed from the front surface of the base
substrate.
[0021] The tab can occupy an entire cover substrate or the tab can
be one of one or more tabs that are formed within limited parts of
the cover substrate. Alternatively, the tab could be formed as a
part or all of the combined base and the thermally transmissive
substrates. Upon retraction, the thermal images would appear in the
back of the tab. The cover substrate would function to obscure the
thermal images until the tab is retracted for separating the
combined base and the thermally transmissive substrates from the
cover substrate.
[0022] Yet another exemplary pull-apart includes a thermally
transmissive substrate having front and back surfaces with a
thermosensitive imaging layer supported on the back surface of the
thermally transmissive substrate. A cover substrate is bonded to
the back surface of the thermally transmissive substrate. A tab
formed in the cover substrate overlaps a region of the
thermosensitive imaging layer where thermal images can be formed
through the thermally transmissive substrate by direct thermal
printing. The thermally transmissive substrate is rendered opaque
for obscuring view of the thermal images through the front surface
of the thermally transmissive substrate. The tab is retractable
from a remaining portion of the cover substrate for viewing the
thermal images in the thermosensitive imaging layer.
[0023] Preferably, the remaining portion of the cover substrate is
permanently bonded to the thermally transmissive substrate, and the
tab is temporarily bonded to the thermally transmissive substrate.
The remaining portion of the cover substrate can be arranged in a
closed shape that frames a window surrounding the tab. The closed
shape of the remaining portion of the cover substrate provides
intrinsic support for retracting the tab and enables the thermally
transmissive substrate to be optimized for thermal conductivity.
For example, the thermally transmissive substrate can be made from
a film that is less than ten microns thick.
[0024] Retraction of the tab opens the window through the cover
substrate, which window is at least partially framed by the
remaining portion of the cover substrate. The thermally
transmissive substrate can itself be made opaque or an opaque
coating can be applied to the thermally transmissive substrate for
(a) obscuring the view of the thermal images through the front
surface of the thermally transmissive substrate and (b) providing
contrast for viewing the thermal images through the window formed
in the cover substrate. Patterns can be printed on the front
surface of the thermally transmissive substrate or on either
surface of the cover substrate to further obscure the view of the
thermal images until the tab is retracted.
DRAWINGS
[0025] FIG. 1 is a broken-away front view of a succession of
pull-tab game pieces.
[0026] FIG. 2 is a broken-away back view of a succession of
pull-tab game pieces.
[0027] FIG. 3 is an exaggerated thickness cross-sectional view of
one of the pull-tab game pieces taken along line 3-3 of FIG. 2.
[0028] FIG. 4 is cross-sectional view similar to FIG. 3 of an
alternative game piece.
[0029] FIG. 5 is a back view of an individual pull-away game
piece.
[0030] FIG. 6 is a cross-sectional view of the individual game
piece taken along line 6-6 of FIG. 5.
[0031] FIG. 7 is a front view of an individual promotional article
showing a retracted tab.
[0032] FIG. 8 is a cross-sectional view of the individual
promotional article of FIG. 7 with the tab still in place.
DETAILED DESCRIPTION
[0033] Pull-aparts can be used for a variety of purposes where
printed information is intended to be concealed from view until
revealed by separating layers of a laminate. These purposes include
game pieces, promotional articles, and report forms. The pull-apart
game pieces themselves can be used for a variety of purposes
including low-stakes wagering, fundraising, and advertising. Other
purposes include use as an alternative to scratch-off latex games,
which can be messy. Direct thermal printing of such game pieces at
point of sale or distribution to determine winnings is expected to
provide heightened security over game pieces with preprinted
results while providing a construction that still allows for the
deferred revelation of the results by removing or otherwise
retracting a tab.
[0034] The pull-apart promotional articles provide for distributing
coupons or product offerings in an interactive format. The
pull-apart report forms provide for the controlled distribution of
confidential, proprietary, classified, restricted, or personal
information, particularly to targeted individuals. For example,
information such as test scores, lab results, banking codes,
shipping data, and prize winning announcements can be printed on
demand while concealed from view until the pull-aparts are
irreversibly opened.
[0035] A strip of exemplary pull-aparts in the form of game pieces
10 is depicted in FIGS. 1-3. As shown particularly in FIG. 3, the
pull-apart game pieces 10 are an assembly of two substrates, base
substrate 12 and cover substrate 22. The base substrate 12 is an at
least partially transparent (e.g., translucent) paper or film
having a front surface 14 supporting a thermosensitive imaging
layer 18. Thermal images 20 (e.g., game results) formed in the
thermosensitive imaging layer 18 on the front surface 14 of the
base substrate 12 are visible through a back surface 16 of the base
substrate 12.
[0036] The base substrate 12 and thermosensitive imaging layer 18
are preferably acquired together as a direct thermal printable
paper or film. One example is an 81 micron polypropylene film,
product number C-100 from Kanzaki Specialty Papers of Ware, Mass.,
coated with an ultra-high sensitivity thermosensitive coating for
reacting with heat to form black images. Direct thermal papers are
available from Appleton Papers Inc. of Appleton, Wis.
[0037] The cover substrate 22, which can also be made of paper or
film, has a front surface 24 that is partially bonded to the back
surface 16 of the base substrate 12 with a patterned permanent
adhesive 28. One or more layers of printing ink 30 are applied to a
back surface 26 of the cover substrate 22, which are visible in
FIG. 2 as printed images on a back surface 36 of the pull-apart
game pieces 10. Either the cover substrate 22 or the layers of
printing ink 30, and preferably both, are opaque to obscure any
view of the thermal images 20 through the back surface 36 of the
pull-apart game pieces 10.
[0038] Also shown in FIG. 2 as well as in FIG. 3 are patterns of
perforations 32, which partially surround gaps in the patterned
permanent adhesive 28. The patterns of perforations 32 are cut
through both the layers of printing ink 30 and the cover substrate
22 to form retractable tabs 40 that can be pulled away or otherwise
separated from the base substrate 12 forming window frames 42
within which the thermal images 20 can be viewed through the base
substrate 12.
[0039] A temporary adhesive 38 such as a clean release or fugitive
adhesive can be applied between the retractable tabs 40 and the
base substrate 12 to hold the tabs 40 in place and to prevent the
formation of air pockets within the pull-aparts 10. Such air
pockets can cause undesirable wrinkling or delaminating,
particularly during manufacture. The temporary adhesive 38 forms a
weak bond that prevents the formation of air pockets but is easily
broken to allow retraction of the tabs 40. Hot-melt or water-based
adhesives can be used for this purpose. However, a combination of a
water-based adhesive applied over a layer of release on the back
surface of the base substrate 12 is preferred to provide reliable
release properties without leaving sticky residue on either the
tabs 40 or the base substrate 12.
[0040] One of the retractable tabs 40 is shown in a retracted
position in FIG. 2, revealing thermal images 20 in the form of two
different star burst patterns within one of the window frames 42
formed in a remaining bonded portion of the cover substrate 22. The
window frames 42 limit the viewing area of the thermosensitive
imaging layer 18 to the thermal images 20 immediately beneath the
retractable tabs 40 that are pulled apart from the window frames
42.
[0041] To enhance the visibility of the thermal images 20 through
the windows 42 while obscuring visibility of the same thermal
images 20 from a front surface 34 of the pull-apart game pieces 10
(see FIG. 1), an opaque coating 46 (see FIG. 3) is applied over the
thermosensitive imaging layer 18 on the front surface 14 of the
base substrate 12. The opaque coating 46 is preferably a layer of
printing ink in a color (e.g., white) that contrasts with the color
(e.g., black) of the thermal images 20 to enhance visibility of the
thermal images 20 through the back surface 16 of the translucent
base substrate 12. However, the opaque coating 46 impairs
transmissions of light to at least partially obscure view of the
same thermal images 20 through the front surface 34 of the
pull-apart game pieces 10. One such ink is an opaque UV white sold
as product number UFA 90100 by Akzo Nobel of Plymouth, Minn. Other
colors are also available.
[0042] One or more additional printing layers 48 can be applied
over the top of the opaque coating 46 to form printed images on the
front surface 34 of pull-apart game pieces 10 or to further obscure
the front-side view of the thermal images 20. The printed layers 48
can contain information for playing or promoting the game or
patterns, such as confusion patterns for additionally obscuring the
thermal images 20. However, the opaque coating 46 and printing
layers 48 are sufficiently thermally transmissive (e.g.,
sufficiently thin) to enable the thermal images 20 to be printed by
a conventional direct thermal printer through the front surface 34
of the pull-apart game pieces 10. The required thermal
transmissivity requires heat conduction with a minimum of
dispersion, which can be accomplished by material thinness or
material compositions that preferentially conduct heat in the
thickness dimension over other directions that would tend to blur
the thermal images 20.
[0043] As shown in FIGS. 1 and 2, the pull-apart game pieces 10 are
separated from one another along a continuous strip or web 50 by
lines of perforation 52. The strip 50 of pull-apart game pieces 10
is preferably loaded into a direct thermal printer in a continuous
form such as a roll or fan-folded stack. The direct thermal
printing through the front surface 34 of the pull-apart game pieces
10 should be mirror reversed to permit the desired image to be
viewed from the back surface 36 of the pull-apart game pieces
10.
[0044] Following the direct thermal printing of the thermal images
20 (e.g., game results), the individual pull-apart game pieces 10
are separated in groups of one or more along the lines of
perforation 52. Alternatively, the pull-apart game pieces 10 can be
pre-cut or otherwise separated in sheet form prior to being loaded
into the direct thermal printer. The printer can also be assembled
with a cutting mechanism as an alternative to use of
perforations.
[0045] The first two drawing figures illustrate three retractable
tabs 40 per game piece 10. However, the number of retractable tabs
40 per game piece 10 can vary considerably from one to six or more.
The pattern of perforations 32 preferably leaves some portion of
each of the retractable tabs 40 connected to the cover substrate 22
after retraction to reduce instances of scrap. The remaining
portions of the retractable tabs 40 preferably remain bonded to the
base substrate 12. Alternatively, the tabs 40 could be cut out
along continuous rather than perforated lines and held in place
with a clean release or fugitive adhesive. In addition, the cover
substrate 22 could be formed as one or more retractable tabs 40
without the surrounding window frames 42, and a clean release or
fugitive adhesive could be applied to hold them in place on the
base substrate 12.
[0046] Another exemplary pull-apart game piece 60 shown in FIG. 4
looks and functions similar to the pull-apart game pieces 10 but
has a different cross-sectional configuration. The assembly
requires three substrates: a base substrate 62, a cover substrate
72, and a thermally transmissive substrate 82. Like the preceding
embodiment, the base substrate 62 is an at least partially
transparent (e.g., translucent) paper or film.
[0047] Also similar to the preceding embodiment, a front surface 74
of the cover substrate 72 is bonded by a patterned adhesive layer
68 to a back surface 66 of the base substrate 62. One or more
layers of printing ink 80 cover the back surface 76 of the cover
substrate 72. Preferably, both the cover substrate 72 and the
printed ink layers 80 are opaque. A pattern of perforations 78
formed through the printed layers 80 and the cover substrate 72
form retractable tabs 96 similar to the preceding embodiment.
[0048] A back surface 86 of the thermally transmissive substrate 82
supports a thermosensitive imaging layer 88 within which thermal
images 90 (e.g., game results) are formed. A permanent adhesive
layer 92 bonds the thermally transmissive substrate 82 to a front
surface 64 of the base substrate 62. Preferably, the thermally
transmissive substrate 82 is opaque in a color that contrasts with
a color of the thermal images 90. One or more layers of printing
ink 94 cover the front surface 84 of the thermally transmissive
substrate 82 to further obscure the thermal images 90. Among the
layers of printing ink 94 can be a confusion pattern as well as
information associated with the play or promotion of the pull-apart
game piece 60.
[0049] The thermally transmissive substrate 82 can be a paper or
film, but must be sufficiently thermally transmissive (e.g., having
a thickness around ten microns or less) to support the direct
thermal printing of the thermal images 90 in the thermosensitive
layer 88 through its front surface 84. The direct thermal printing
is preferably accomplished by conventional direct thermal printers
that are widely available with standardized units of heat output
power. Examples of direct thermal printable films laminated to
underlying substrates are described in U.S. Pat. No. 6,124,236,
entitled Direct Thermal Printable Film and Laminate, to one of the
joint inventors herein, which is hereby incorporated by reference.
Thin paper, such as paper referred to as "Bible paper", can also be
used as the thermally transmissive substrate 82. A thin direct
thermal paper is available from Appleton Papers Inc. of Appleton,
Wis., under the trade name OPTIMA POS Plus thermal paper and having
a target thickness of 0.002 inches or 50 microns. Any thermal
insulating layer between the paper substrate and the
thermosensitive imaging layer is preferably removed or replaced by
a more thermally conductive layer.
[0050] The retractable tabs 96 can be pulled apart from remaining
portions of the cover substrate 72 along the lines of perforation
78 to reveal the thermal images 90 through the translucent base
substrate 62. The thermally transmissive substrate 82 through which
the images 90 are printed preferably provides both contrast for
enhancing the view of the images 90 through the base substrate 62
and opacity for obscuring the view of the images 90 through the
thermally transmissive substrate 82.
[0051] Instead of supporting the thermosensitive imaging layer 88
on the back surface 86 of the thermally transmissive substrate 82,
the thermosensitive imaging layer 88 could be supported on the
front surface 64 of the base substrate 62 similar to the preceding
embodiment. However, transmissions of heat from direct thermal
printing would be required to conduct through both the thermally
transmissive substrate 82 and the adhesive layer 92 that
permanently bonds the thermally transmissive substrate 82 to the
base substrate 62.
[0052] Another pull-apart game piece 100, which is depicted in
FIGS. 5 and 6 also includes a thermally transmissive substrate 102
having on its back surface 106 a thermosensitive layer 108 that is
thermally imageable through its front surface 104 similar to the
thermally transmissive substrate 82 of the immediately preceding
embodiment. However, instead of mounting the thermally transmissive
substrate 102 on a transparent base substrate, the thermally
transmissive substrate 102 is mounted directly onto a cover
substrate 112. A patterned permanent adhesive 110 attaches a
perimeter of the thermally transmissive substrate 102 to the cover
substrate 112.
[0053] Along the perimeter pattern of permanent adhesive 110,
die-cut lines of perforation 114 are formed through the cover
substrate 112 to form a retractable tab 116. Through cuts 115 form
an ear of the retractable tab 116 for gripping and retracting the
tab 116. A clean release or fugitive adhesive 118 temporarily
attaches the retractable tab 116 to the back surface 106 of the
thermally transmissive substrate 102. The permanent adhesive 110
permanently bonds a remaining portion 122 of the cover substrate
112 to the thermally transmissive substrate 102. The remaining
portion 122 of the cover substrate 112 has a closed shape that
frames a window 124 that is opened by retracting the tab 116. The
closed shape of the remaining portion 122 provides a frame for
retaining a planar shape for the thermally transmissive substrate
102 as well as an intrinsic support for retracting the tab 116. The
support functions afforded by the closed shape of the remaining
portion 122 of the cover substrate 112 enables the thermally
transmissive substrate 102 to be optimized for thermal
conductivity. For example, the thermally transmissive substrate 102
can be made from a film that is less than ten microns thick.
[0054] The thermally transmissive substrate 102 can (as far as its
thickness permits) be made opaque. However, an opaque coating 126
can also be applied to the thermally transmissive substrate 102 for
obscuring a view of thermal images 128 through the front surface
104 of the thermally transmissive substrate 102 while providing
contrast for viewing the thermal images 128 through the window 124
formed in the cover substrate 112. Patterns 130 can be printed on
the front surface 104 of the thermally transmissive substrate 102
or on either surface of the cover substrate 112 to further obscure
the view of the thermal images 128. Retraction of the tab 116 opens
the window 124 through the cover substrate 112, revealing the
thermal images 128 printed in the thermosensitive imaging layer
108.
[0055] Alternatively, the cover substrate 112 could be made
thermally transmissive, permitting the substrate 102 to be made
more substantial. The thermal images 128 would then be printed
through the cover substrate 112 and the temporary adhesive 118. The
die cuts 114 could then be made through the more substantial
substrate 102 to reveal the thermal images on the back surface of a
retracted tab.
[0056] An exemplary pull-apart in the form of a promotional article
140 is depicted in FIGS. 7 and 8. The promotional article 140 is
built upon two substrates--an at least partially transparent base
substrate 142 and a cover substrate 148. A thermosensitive imaging
layer 154 directly overlies a front surface 144 of the base
substrate 142. An opaque coating 156 and a printed pattern 158
cover the thermosensitive imaging layer 154. Die cuts 160 through
the printed pattern 158, the opaque coating 156, the
thermosensitive imaging layer 154, and the base substrate 142
define a tab 162 that is partially or completely removable from a
surrounding portion 164 of the base substrate 142. The die cuts can
be made in a continuous or discontinuous pattern (e.g.,
perforations) depending upon the degree or manner in which the tab
162 is required to be attached to the remainder of the pull-apart
140.
[0057] A permanent adhesive layer 166 permanently bonds the
surrounding portion 164 of a back surface 146 of the base substrate
142 to a front surface 150 of the cover substrate 148. A temporary
adhesive layer 168 temporarily bonds the tab 142 to the cover
substrate. Although shown as a single layer, the temporary adhesive
168 can be composed of multiple layers, such as a combination of
adhesive and release layers. In addition, in place of separate
permanent and temporary adhesive materials, the same adhesive
material could be used to cover the entire back surface 146 of the
base substrate 142 together with a layer of release applied only in
the region of the tab 162 to provide the desired temporary
bond.
[0058] Graphic layers 170 and 172 are printed onto the front
surface 150 and a back surface 152 of the cover substrate 150. At
least the graphic layer 170 is pre-printed during the assembly of
the pull-apart promotional article 140 as a form of a thermally
printable medium. Prior to distribution or use, thermal images 174
are thermally printed in the thermosensitive imaging layer 154
through the overlying printed pattern 158 and the opaque coating
156. The thermal images 174 are concealed by the printed pattern
158 (which can be printed as a confusion pattern) and the opaque
coating 156 from the front side 144 of the base substrate and by
the cover substrate 148 and its graphic layers 170 and 172 from the
back side 146 of the base substrate 142.
[0059] Retraction of the tab 162, including its complete or partial
removal, exposes the thermal images 174 through the back surface
145 of the at least partially transparent base substrate 142. The
opaque layer 156 is preferably printed with an ink of a color that
contrasts with a color of the thermal images 174. In addition, the
retraction of the tab 162 reveals the pre-printed graphics 170 on
the front surface 150 of the cover substrate 148 through a window
176 bordering the surrounding portion 164 of the base substrate
142.
[0060] Adhesive materials or films that favor the conduction of
heat along one orthogonal axis (i.e., an axis corresponding to a
thickness dimension) over the remaining two orthogonal axes could
be used (for either or both of the adhesive layer 92 and thermally
transmissive substrate 82) to maintain concentrated transmissions
of heat through larger distances. Such materials or arrangements of
materials that exhibit uniaxial anisotropic electrically conductive
properties having metal particle or fiber alignments are also
likely candidates for supporting similar anisotropic thermally
conductive properties. Thermagon, Inc. of Cleveland, Ohio, produces
a range of thermally conductive dielectric polymers, including
T-gon 300 and 400 series paste adhesives, that could be printed
(e.g., screen printed) in a dot matrix form to favor heat transfers
between adjacent layers with a minimum of lateral thermal
diffusion.
[0061] The thermal coupling materials or material arrangements
exhibiting uniaxial anisotropic thermal conductivity have
widespread relevance to imaging thermosensitive materials through
overlying layers and larger distances from thermal print heads.
Such materials in the form of adhesives can provide for bonding
protective layers (e.g., paper or film substrates) over otherwise
supported thermosensitive imaging layers. In other forms, such as
coatings, the materials themselves can provide protection and other
overlying functions. For example, in accordance with the
illustrated embodiments, the thermal coupling layer is preferably
opaque to obscure the image formed in the thermosensitive layer
until the pull-apart is retracted.
[0062] Although the pull-apart game pieces 10, 60, and 100 and
promotional article 140 and their various substrates are referenced
with respect to front and back surfaces, the labels of "front" and
"back" are used for convenience of reference only and can be
altogether exchanged with one another without any structural
implications.
[0063] The new pull-aparts 10, 60, 100, and 140 can be manufactured
along in-line presses for performing sequential operations
involving printing, coating, die cutting, laminating, and rolling
or stacking. The printing operations for repeating patterns are
preferably performed using flexographic printing processes. Digital
printing is preferred for printing security codes or other variable
information.
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