Systems and devices for transferring images to articles and methods of making same

Abstract

A transfer assembly, transfer sheet, and release paper are provided for transferring an image to an article such as a textile, fabric, or the like. Additionally, improved methods for manufacturing the transfer sheet and article are provided. The transfer sheet includes a support layer and an image transfer layer including an ink receptor and a blocking agent. The blocking agent is configured to block or prevent the transfer of the ink composition to the substrate in the non-printed areas of the image and to substantially allow the transfer of the ink composition to the substrate in the printed areas of the image. The systems and methods described in this disclosure provide a "self-removing," single-step process that minimizes defects in the image printed on the article and is particularly useful for transferring white or colored images to dark or black textiles and other fabrics.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Application No. 63 / 417,294, filed October 18, 2022, the entire disclosure of which is incorporated herein by reference for all purposes. This description generally relates to transfer assemblies, transfer sheets, and / or release papers for transferring messages, designs, pictures, or other images to articles such as textiles and other fabrics, and methods for making such transfer sheets and articles. [Background technology]

[0002] In recent years, a significant industry has developed involving the application of consumer-selected designs, words, numbers, messages, illustrations, and the like (hereinafter collectively referred to as "images") to articles such as T-shirts, sweatshirts, leather goods, and the like. These images may be commercially available products tailored for a particular end use and printed onto peel-off or transfer paper, or consumers may create the images on heat transfer paper. The transfer paper is contacted with the article to be printed, and heat and pressure are applied to the backing layer, causing the binder present in the image transfer layer to peel from the backing and flow onto the article along with the printed image. Typically, only a portion of the image transfer layer is printed with an image, with the remainder of the image transfer layer being blank. Nevertheless, heat and pressure applied to the backing layer causes the entire image transfer layer to flow and bond to the article. As a result, the image printed on the article is surrounded by an area of ​​binder corresponding to the overall dimensions of the transfer sheet.

[0003] Various methods and transfer sheet assemblies have been proposed to limit the transfer of non-image or non-printing areas of a transfer sheet when printing an image onto an article. Several types of papers have been developed that are "weedable," i.e., allow portions of the transferable coating to be removed from the heat transfer paper before transferring to a substrate. The removal operation involves cutting around the printed area and removing the coating from the outer non-printing areas. However, such a removal process can be difficult and time-consuming, especially around complex graphic designs. Two-sheet systems have been developed that transfer an image onto a substrate while limiting the transfer of non-printed areas to the article or substrate. These two-sheet "self-weeding" systems include a printable carrier (Component A) that contains an image in the form of at least a partial-area toner layer, and Component B, which includes the carrier and a polymer layer applied thereto. Unfortunately, these systems require two different sheets, and the transfer process requires two steps under high temperature and pressure conditions, as well as an additional separation step for Components A and B.

[0004] Another method for limiting the transfer of non-printed areas of a transfer sheet to an article using a single sheet involves the use of a blocking agent in the transfer sheet. An aqueous ink composition incorporating a colorant is printed onto the image transfer layer of a transfer assembly. The liquid carrier present in the ink composition penetrates the image transfer layer, disrupting the blocking agent and allowing it to be absorbed by the ink receptor, but only in the printed areas. The blocking agent does not disrupt in the non-printed areas, i.e., in areas where the ink composition has not been absorbed. One such transfer sheet containing a blocking agent is described in U.S. Pat. No. 9,399,362, the entire disclosure of which is incorporated herein by reference. While these attempts have generally improved the process of transferring images to articles, they also suffer from several drawbacks. For example, the color vibrancy and brightness of the image and the wash resistance of the transferred image are generally unsatisfactory, especially for dark and black substrates and fabrics. Furthermore, transfer sheets and / or printed images developed from these methods often exhibit "fisheyes" (i.e., circular voids, scrapes, or separations), white streaks, spots, and / or bulges, especially when white or colored images are transferred to darker textiles. All of these defects contribute to relatively poor image rendering. It would therefore be desirable to provide improved systems and methods for transferring images to articles such as fabrics or textiles, and in particular, to provide systems and methods that limit or completely eliminate the transfer of non-printed areas while minimizing any imperfections in the image printed on the article. Summary of the Invention

[0005] The following presents a simplified summary of the claimed subject matter in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview of the claimed subject matter. It is not intended to identify key elements of the claimed subject matter or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed description that is presented later. Transfer assemblies and transfer sheets or release papers for transferring images to articles such as textiles, fabrics, or the like are provided. Additionally, improved methods for manufacturing transfer sheets and articles are provided. The systems and methods described in this disclosure provide a single-step process that is "self-weeding" and therefore less expensive and time-consuming than conventional systems. Furthermore, these systems and methods minimize defects in images printed on articles while improving the article's vibrancy, shelf-life aging, and washability. The transfer sheets described in this disclosure are particularly useful for transferring white or colored images to dark or black textiles, such as T-shirts, hats, sweatshirts, and the like.

[0006] In one aspect, a transfer sheet for transferring an image onto a substrate is provided. The transfer sheet is produced by a process that includes providing a support layer and an image transfer layer that includes an ink-receptor and a blocking agent that substantially prevents transfer of non-printed areas of the image. The process further includes contacting the support layer with the image transfer layer and applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature of less than about 82.2 degrees Celsius (about 180 degrees Fahrenheit). Applicant has discovered that applying heat to the image transfer layer greater than 180°F during this process can result in white streaks, spots, blisters, or other defects, all of which contribute to relatively poor rendering of the image. These defects are particularly noticeable on darker or black textiles. Applicant has further discovered that these defects can be substantially minimized or eliminated with a lower temperature drying profile. In certain embodiments, the image transfer layer is heated to a temperature of between 120°F and 180°F, preferably between 140°F and 150°F.

[0007] In embodiments, the transfer sheet further includes a release layer between the support layer and the image transfer layer. The release layer may include any suitable material that removably adheres the release layer to the support layer. The release coating may function as a hot, warm, or cold peel. The release layer may be a partially fluid coating having a viscosity of about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS), preferably about 50 mPa·s (50 CPS) to about 60 mPa·s (60 CPS). In embodiments, the image transfer layer does not contain an antifoaming agent or foam control agent. The image transfer layers used in certain conventional transfer sheets contain antifoaming agents or other foam control agents that reduce or eliminate foam formation during the production process. However, these antifoaming agents can cause fish eyes, white streaks, spots, blisters, or other defects to appear in the article, especially on darker fabrics. Applicant has discovered that removing the antifoaming agent from the image transfer layer minimizes or eliminates these defects. Reducing the viscosity of the release layer can also reduce foam formation during the production process, resulting in fewer defects in the image obtained on the article. In embodiments, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, and preferably the solids content is less than about 40% by weight. The viscosity of the image transfer layer can be from about 50 mPa·s (50 CPS) to about 200 mPa·s (200 CPS), preferably from about 100 mPa·s (100 CPS) to about 130 mPa·s (130 CPS).

[0008] In embodiments, the image transfer layer includes a first layer or print coating including an ink-receptor and a blocking agent, and a second layer including a binder or tie coating. The binder preferably includes a material that improves adhesion between the release layer and the image transfer layer. In certain embodiments, the second layer or binder has a viscosity of about 100 mPa·s (100 CPS) to about 130 mPa·s (130 CPS). Materials suitable for the binder include waxes, thermoplastic polymers or prepolymers, and combinations thereof. In exemplary embodiments, the binder includes a polyester or polyester blend that allows sublimation inks to be used in the ink composition. In certain embodiments, the binder material is hydrophobic and does not swell when contacted with water. The first and second layers may be mixed together or may be formed as separate layers that are placed in contact with or bonded to each other.

[0009] In embodiments, the transfer sheet further includes a third layer or white base coating between the print coating and the tie coating. The third layer may include an opaque layer comprising one or more materials that increase the overall opacity of the image transfer layer, thereby improving the ability to "hide" the image behind the image that appears. This allows the user to read or view the front of the image without being distracted by the printed image on the back. Suitable materials for the third layer include titanium dioxide and the like. In certain embodiments, the third layer or white base coating may have a viscosity of about 50 mPa·s (50 CPS) to about 150 mPa·s (150 CPS). The third layer may be mixed with either or both of the first and second layers, or they may be formed as separate layers that are placed in contact with or bonded to each other. In embodiments, the ink composition comprises a colorant and an aqueous liquid carrier. The composition is not limited to a particular type of colorant, including organic and inorganic pigments, dyes, or polymeric colorants, such as poly(oxyalkylenes), substituted chromophores, and polymers incorporating such compounds, such as polyurethanes and polyesters. By way of further example, the colorant may be selected from sublimation dyes, disperse dyes, reactive dyes, acid dyes, and basic dyes, as well as titanium dioxide, carbon black, and calcium carbonate.

[0010] The ink composition can be printed onto the top surface of the transfer sheet by any of a variety of conventional techniques. For example, the ink composition can be applied by inkjet printing, screen printing, lithographic printing, stamping, gravure printing, or the ink composition can be applied by hand. In an exemplary embodiment, the ink composition is applied by inkjet printing. The blocking agent is a hydrophilic component capable of forming a film that can be disintegrated by water. The blocking agent is substantially disintegrated by the liquid carrier in the printed areas, and is substantially not disintegrated by the liquid carrier in the non-printed areas. This allows the blocking agent to substantially block transfer of the ink composition to the substrate in the non-printed areas, while simultaneously allowing transfer of the ink composition to the substrate in the printed areas. In embodiments, 50% or less by weight, or 40% or less by weight, particularly 25% or less by weight, or even 15% or less by weight of the non-printed areas of the transfer assembly are transferred to the article during the transfer process. Materials suitable for the blocking agent include, but are not limited to, poly(vinyl alcohol), poly(ethylene glycol), poly(vinylpyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl)methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ethers, hyaluronic acid, albumin, and starch and starch derivatives.

[0011] In exemplary embodiments, the blocking agent comprises a starch or starch derivative. In certain embodiments, the blocking agent comprises about 30% to about 40%, and preferably about 36%, by weight of the print coating. In embodiments, the ink-receiver comprises a hydrophilic organic material attached to the ink molecules. Suitable materials for the ink-receiver include, but are not limited to, poly(acrylic acid), poly(vinylimidazole), poly(2-hydroxyethyl methacrylate), poly(vinylpyrrolidone), poly(vinyl)poly(pyrrolidone), and polyvinyl acetate, cationic polymers and their salts, hygroscopic inorganic salts, silica, and zeolites. In certain embodiments, the binder, blocking agent, and ink-receptor are mixed together in a single image transfer layer that is applied to a release layer. In other embodiments, the image transfer layer is separated into two layers. The first layer comprises a binder and an ink-receptor, and the second layer comprises a blocking agent. The first layer is adhered to the release layer, and the second layer is adhered to the first layer. In yet another embodiment, the image transfer layer comprises three layers. The first layer, applied to the release layer, comprises a binder. The second layer, applied to the binder, comprises an ink-receptor. The third layer, applied to the ink-receptor, comprises a blocking agent.

[0012] The transfer sheet can be used to transfer an image onto an article by contacting the support layer with the article and applying heat and pressure to transfer the ink composition, thereby causing the image to appear on the article. The substrate or article can include any suitable article on which it is desired to print an image. For example, the article can include white, dark, or black textiles or other fabrics. In certain embodiments, the article includes dark or black textiles. The textile can include 100% cotton, less than 100% cotton, or a cotton / polyester blend. In one embodiment, the temperature for transferring the ink composition to the article is between about 176.7 degrees Celsius (about 350 degrees Fahrenheit) and about 204.4 degrees Celsius (about 400 degrees Fahrenheit), or between about 185.0 and 190.0 degrees Celsius (about 365 and about 374 degrees Fahrenheit). The pressure can be between about 275,790 and 517,107 Pa (about 40 and 75 psi), or between about 344,738 and 413,685 Pa (about 50 and 60 psi). The heat and pressure can be applied to the article and transfer sheet for a period of between about 10 and 30 seconds, or between about 15 and 20 seconds, or for about 18 seconds.

[0013] In certain embodiments, the transfer sheet has been produced so that the coating composition is not completely "cured" on the article after the heating and / or drying steps. In other words, the "degree of cure" of the ink composition in the article is less than 100%, preferably from about 30% to about 80%, or from about 40% to about 60%. Partial curing of the coating composition by heat and pressure reduces defects in the printed image, thereby improving its appearance. "Degree of cure" is defined in this disclosure to mean the extent to which a composition is sufficiently crosslinked so that it is substantially in its final form (i.e., no further crosslinking and / or further substantial changes will occur to the composition). Degree of cure, as defined in this disclosure, does not necessarily mean that the composition is 100% crosslinked to become a fully cured resin, but rather means 100% of the cure that will occur before the function or appearance of the composition is substantially unchanged.

[0014] In certain embodiments, the article is aged for a period of time to increase the degree of cure of the ink composition, thereby increasing the clarity of the printed image. For example, the article may be aged for a period of about 2 days to about 6 months, or about 1 week to about 3 months, or about 1 to 2 months, resulting in an increase in "degree of cure" (as defined above) of about 20% to about 80%, or about 40% to about 60%. Applicant has discovered that completing the curing process of the coating composition through aging (rather than immediately by heating and drying) reduces defects caused by the drying process and ultimately results in a brighter, more lustrous image on the article. In another embodiment, a transfer sheet for transferring an image onto a substrate includes a support layer and an image transfer layer overlying the support layer. The image transfer layer includes an ink receptor and a blocking agent. The ink receptor is configured to accept an ink composition to define printed and non-printed areas in the image transfer layer. The transfer sheet further includes a release layer between the support layer and the image transfer layer. The release layer can be a partial fluid coating having a viscosity of about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS), preferably about 50 mPa·s (50 CPS) to about 60 mPa·s (60 CPS). Reducing the viscosity of the release layer may also reduce the creation of bubbles during the transfer process, resulting in fewer defects in the image rendered on the article.

[0015] The release layer may comprise any suitable material that allows for releasable attachment of the release layer to the support layer. The release coating may function as a hot, warm, or cold peel. In embodiments, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, and preferably the solids content is less than about 40% by weight. The viscosity of the image transfer layer can be from about 50 mPa·s (50 CPS) to about 200 mPa·s (200 CPS), preferably from about 100 mPa·s (100 CPS) to about 130 mPa·s (130 CPS). This reduces the amount of foam created during the production process without the presence of a defoamer, thereby minimizing the creation of defects and dramatically improving the image rendered on the article.

[0016] In another aspect, a method for manufacturing a transfer sheet includes providing a support layer and an image transfer layer in contact with the support layer. The image transfer layer includes an ink-receptor and a blocking agent. The method further includes contacting the support layer with the image transfer layer and applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature of less than about 82.2 degrees Celsius (about 180 degrees Fahrenheit) during formation. In certain embodiments, the transfer sheet is heated during production to a temperature of about 48.9 degrees Celsius (about 120 degrees Fahrenheit) to about 82.2 degrees Celsius (about 180 degrees Fahrenheit), preferably about 60.0 degrees Celsius (about 140 degrees Fahrenheit) to about 65.6 degrees Celsius (about 150 degrees Fahrenheit). The method further includes printing an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas, such that the blocking agent substantially prevents transfer of the ink composition to the article in the non-printed areas and substantially allows transfer of the ink composition to the article in the printed areas. The transfer sheet can then be used to transfer the image onto the article by contacting the support layer with the article and applying heat and pressure to transfer the ink composition and render the image on the article. The transfer sheet is then separated from the article.

[0017] In certain embodiments, heat and pressure are applied to the transfer sheet such that the coating composition does not completely cure on the article after the heating and drying step. In an exemplary embodiment, heat and pressure may be applied for a period of 15 to 20 seconds. In certain embodiments, the article is aged for a period of time to increase the degree of cure of the coating composition, thereby increasing the clarity of the printed image. For example, the article may be aged for a period of from about 2 days to about 6 months, or from about 1 week to about 3 months, or from about 1 to 2 months. In embodiments, the image transfer layer is a partial fluid coating having a viscosity of from about 50 mPa·s (50 CPS) to about 200 mPa·s (200 CPS), preferably from about 100 mPa·s (100 CPS) to about 130 mPa·s (130 CPS).

[0018] In embodiments, the transfer sheet further includes a release layer between the support layer and the image transfer layer. The release layer can include any suitable material that removably attaches the release layer to the support layer. Suitable materials for the release layer include hot peel, cold peel, hot split, and the like. The viscosity of the release layer is from about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS), preferably from about 50 mPa·s (50 CPS) to about 60 mPa·s (60 CPS). The enumeration in this disclosure of desirable objects met by various embodiments of the present description is not meant to suggest or suggest that any or all of these objects, individually or collectively, are exemplified as essential features in either the most general embodiment of the description or its more specific embodiments. [Brief explanation of the drawings]

[0019] [Figure 1] 1 shows a transfer sheet for transferring an image onto a substrate or article. [Figure 2] 1 shows another embodiment of a transfer sheet for transferring an image onto a substrate or article. [Figure 3] 1 shows another embodiment of a transfer sheet for transferring an image onto a substrate or article. DETAILED DESCRIPTION OF THE INVENTION

[0020] This description and the accompanying drawings illustrate exemplary embodiments and should not be construed as limiting; the claims, including equivalents, define the scope of this description. Various mechanical, compositional, structural, and operational changes, including equivalents, may be made without departing from the scope of this description and claims. In some instances, well-known structures and techniques have not been shown or described in detail to avoid obscuring the description. Like reference numerals in two or more figures represent the same or similar elements. Furthermore, elements and their related aspects described in detail with reference to one embodiment may, whenever practical, be included in other embodiments not specifically shown or described. For example, if an element is described in detail with respect to one embodiment and not with respect to a second embodiment, the element may nevertheless be claimed as being included in the second embodiment. Furthermore, the representations in this disclosure are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the systems or illustrated components.

[0021] It should be noted that, as used in this disclosure and the appended claims, the singular forms "a," "an," and "the," as well as the use of any singular form of any word, include plural referents unless expressly and unambiguously limited to one referent. The term "include" and its grammatical variations, as used in this disclosure, are intended to be open-ended, and thus the recitation of items in a list does not exclude other similar items that may substitute for or add to the listed items. Unless otherwise noted, any quantitative value is approximate, whether or not stated with "about" or "approximately" or similar words. The materials, methods, and examples described in this disclosure are illustrative only and not limiting.

[0022] Systems and methods are provided for transferring images to articles such as textiles, fabrics, or the like. Additionally, improved methods for manufacturing transfer assemblies and sheets are provided. The systems and methods provided in this disclosure are single-step, "self-weeding" processes that minimize transfer from non-printed areas to the article while reducing or eliminating defects in the image printed on the article. 1 shows one embodiment of a transfer sheet 10 for transferring an image to an article 20. The transfer sheet 10 includes a support or base sheet 30, a release layer 40, and an image transfer layer 50 including at least a binder, an ink receptor, and a blocking agent. An ink composition or print coating containing an image is applied to the top surface of the image transfer layer 50. The ink composition may include printed and non-printed areas. As discussed in detail below, heat and pressure are applied to the transfer sheet 10 to transfer the ink composition or print coating from the image transfer sheet 50 to the base sheet 30 and then to the article 20. The ink composition can be printed onto the top surface of the transfer sheet by any of a variety of conventional techniques. For example, the ink composition can be applied by inkjet printing, screen printing, lithography printing, stamping, gravure printing, or the ink composition can be applied by hand. The formulation of the ink composition can be adjusted to be compatible with the selected printing method. The ink composition can range in consistency from a liquid to a paste.

[0023] The ink composition may contain additional ingredients such as binders, humectants, surfactants, and the like, as known to those skilled in the art. Aqueous carrier liquids incorporate, in addition to water, small amounts of water-miscible organic cosolvents, such as lower alcohols, glycols, and glycerin. By way of example, the organic cosolvents may constitute 20% or less by weight of the liquid carrier components of the ink composition. In an exemplary embodiment, the ink composition is a sublimation ink that is applied by inkjet printing in a one-step process. The substrate or article may include any suitable article on which it is desired to print an image. Suitable articles include T-shirts, sweatshirts, hats, leather goods, signs, laminates, metal, glass, wood, paper, or other cellulosic materials, and the like. The article may be a woven, knitted, or nonwoven textile material made from natural or synthetic fibers, or a combination thereof. By way of example, the textile may include fibers selected from cotton, wool, jute, hemp, polyester, polyamide, polyurethane, and polyolefin.

[0024] The article may comprise a white, dark, or black textile. In certain embodiments, the article comprises a dark or black textile. The textile may comprise 100% cotton, less than 100% cotton, or a cotton / polyester blend. In this embodiment, image transfer layer 50 includes three layers: (1) print coating layer 52, which includes an ink-receptor and a blocking agent; (2) a white base coating or opaque layer 54; and (3) a tie coating layer 56, which includes a binder. The three layers may be formed separately and applied together such that tie coating layer 56 is disposed between the other two layers and release layer 40. Alternatively, one or more of the layers may be mixed together. FIG. 2 shows an alternative embodiment of transfer sheet 10′ in which the print coating layer and the white base coating layer are mixed together to form a single layer 60 and applied to tie coating layer 56. FIG. 3 shows yet another embodiment of transfer sheet 10″ in which all three layers are mixed together to form a single layer 70 and applied to release layer 40. In yet another embodiment, the blocking agent and ink-receiver may be formed in separate layers. These individual layers may or may not include a binder or opacifying layer.

[0025] Image transfer layer 50 specifically does not include an antifoaming agent or any other foam control agent. In embodiments, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, and preferably the solids content is less than about 40% by weight. The viscosity of image transfer layer 50 before heating and drying is from about 25 centipoise (CPS) to about 200 mPa·s (200 CPS). In embodiments, the image transfer layer has a viscosity of from about 50 CPS to about 200 mPa·s (200 CPS), preferably from about 100 CPS to about 130 mPa·s (130 CPS). Release layer 40 separates image transfer layer 50 from base sheet 30 after the print coating is applied to article 20. Release layer 40 can comprise any suitable material that removably adheres release layer 40 to base sheet 30. Suitable materials for release layer 40 include hot peel, cold peel, hot split, and the like.

[0026] In an exemplary embodiment, the release layer 40 is a hot peel adhesive comprising ethylene acrylic acid copolymer (EAA) in an aqueous dispersion. The EAA may be present in at least about 50% of the base sheet, at least about 75% of the base sheet, or at least about 90% of the base sheet. In certain embodiments, the base sheet may further comprise a surfactant and / or a polyester dispersion. In one exemplary embodiment, the base sheet comprises about 94% EAA dispersion, about 2% surfactant, and about 4% polyester dispersion. The EAA dispersion may comprise, for example, Michem® Prime 74994 manufactured by Michelman, Inc. of Cincinnati, Ohio. The surfactant may comprise, for example, a silicone surfactant, such as BYK®-348 manufactured by BYK. The polyester dispersion may comprise, for example, a sulfopolyester dispersion, such as Eastek™ 1200 manufactured by Eastman Chemical Co.

[0027] The release layer 40 is preferably designed to have a viscosity of about 25 centipoise (CPS) to 90 CPS, preferably about 50 CPS to about 60 CPS, prior to the heating and drying steps discussed below. This reduces the amount of bubbles created during the transfer process without the presence of an antifoaming agent, thereby minimizing the creation of defects and dramatically improving the image rendered on the article. The base layer 30 may be selected from (i) nonwoven webs, including those made from cellulose fibers such as coated and uncoated paper, parchment paper, and paperboard, and those made from synthetic polymers such as polyethylene, polypropylene, polystyrene, and other polyolefins; (ii) synthetic polymer sheets, including thermoplastic polymers such as polyesters (e.g., PET and PEN), poly(vinyl chloride), polystyrene, polymethacrylate, polycarbonate, polyimide, polyurethane, ethylene-vinyl acetate, and polytetrafluoroethylene, and thermosetting resins; (iii) metallized films, including metallized biaxially oriented polyethylene terephthalate; (iv) woven and knitted textile sheets made from natural or synthetic fibers, and combinations thereof, and (v) laminates of two or more materials from the foregoing categories, including laminates of nonwoven webs and thermoplastic polymers.

[0028] The base sheet can be opaque, translucent, or transparent. The thickness of the base sheet can range from about 25.4 μm (1 mil) to about 254 μm (10 mils), particularly from 50.8 μm (2 mils) to about 152.4 μm (6 mils). This thickness is desirable because it allows sufficient heat to pass through the base sheet during image transfer. The print coating layer 52 includes an ink-receptor and a blocking agent. The ink-receptor is preferably hydrophilic and capable of absorbing the aqueous liquid carrier components of the ink composition used to print the image on the transfer assembly. In particular, an aqueous ink composition is printed on top of the image transfer layer, and the aqueous components of the ink are absorbed into the image transfer layer. As the aqueous liquid carrier is drawn through the image transfer layer, the blocking agent disintegrates. Depending on the nature of the ink composition, the colorant present in the ink composition may be absorbed into the ink receiver along with the liquid carrier, or the colorant may remain concentrated on top of the transfer sheet. For example, dyes that are soluble in the aqueous liquid carrier may be readily absorbed into the image transfer layer, whereas pigments, disperse dyes, and polymeric colorants are less mobile and do not penetrate as deeply into the image transfer layer.

[0029] By way of example, suitable ink-receivers may be selected from hydrophilic polymers, cationic polymers, and salts thereof, including poly(acrylic acid), poly(vinylimidazole), poly(2-hydroxyethyl methacrylate), poly(vinylpyrrolidone), poly(vinyl)poly(pyrrolidone), and polyvinyl acetate; for example, polydiallyldimethylammonium chloride, polyacrylamide, and poly(epichlorohydrin-dimethylamine); hygroscopic inorganic salts, including calcium nitrate and sodium chloride; silica; zeolites; and other hydrophilic compounds used as flocculants, coagulants, and desiccants. The ink-receiver may be present in the print coating layer in an amount of from about 2% to about 25% by weight, or from about 5% to about 15%, or about 10%. In one embodiment, the ink-receiver comprises a crosslinked homopolymer of N-vinyl-2-pyrrolidone, such as Polyplasdone™ INF-10 from Ashland™. The blocking agent useful in the transfer sheet described in this disclosure is characterized as being hydrophilic, capable of forming a film, and disintegrable upon application of water. The blocking agent serves the dual function of preventing or inhibiting the non-printed areas of the image transfer layer from being transferred to an article during thermal transfer printing, while allowing the printed areas of the image transfer layer to be transferred to the article. The printed areas of the transfer assembly can be transferred to the article because application of the aqueous ink composition causes the blocking layer to disintegrate in the printed areas.

[0030] Suitable compositions for blocking agents include water-soluble polymers selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinylpyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl) methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ethers including hydroxypropylmethylcellulose (HPMC), methylcellulose (MC), hydroxyethylcellulose (HEC), ethylcellulose (EC), hydroxypropylcellulose (HPC), carboxymethylcellulose (CMC), and polyanionic cellulose (PAC), hyaluronic acid, albumin, and starch and starch derivatives. In exemplary embodiments, the blocking agent comprises starch or a starch derivative. The starch may be present in print coating layer 52 in an amount of from about 20% to about 50% by weight, or from about 30% to about 40%, or about 36% by weight. In embodiments, the blocking agent prevents transfer of at least 50%, or 60%, particularly 75%, or even 85% by weight of the non-printed areas to the article during the transfer process.

[0031] The print coating layer 52 may include materials other than blocking agents and ink-receptors. For example, the print coating layer 52 may include certain silicas, surfactants, waxes, and / or thickeners. Suitable surfactants include, but are not limited to, nonionic, anionic, cationic, and amphoteric surfactants, such as sodium stearate, 4-(5-dodecyl)benzenesulfonate, sodium dodecylbenzenesulfonate wetting agent, docusate (dioctyl sodium sulfosuccinate), alkyl ether phosphates, benzalkonium chloride (BAC), perfluorooctane sulfonate (PFOS), and the like. Examples of waxes include, but are not limited to, polyolefins, polyethylene, functionalized waxes, such as amine, amide, fluorinated waxes, mixed fluorinated and amide waxes, such as ester, quaternary amine, carboxylic acid, or acrylic polymer emulsions, chlorinated polyethylene, natural or synthetic ester waxes, carnauba wax, paraffin, and the like. Such waxes may optionally be fractionated or distilled to provide specific cuts that meet certain viscosity and / or temperature criteria. Suitable thickening agents include, but are not limited to, starches, gums, pectins, paragum, and the like.

[0032] In an exemplary embodiment, print coating layer 52 includes silica (such as a silica gel known in the industry as Gasil® 23F manufactured by PQ Corporation) at about 5% to about 15%, or about 10% by weight. Print coating layer 52 further includes a surfactant (such as BYK®-348) at about 2% to about 10%, or about 5% by weight. Print coating layer 52 further includes a wax, such as polyethylene / carauba wax or the like (e.g., Microspersion® 295-40 manufactured by Micropowders, Inc.), at about 20% to about 30%, or about 26% by weight. Print coating layer 52 may also include deionized water and a thickener present at about 10% to about 15%, or about 13% by weight. The thickener may include Paragum 265 manufactured by Para-Chem Southern, Inc.

[0033] The white base coating layer 54 provides increased opacity to the image transfer layer 50. This increased opacity improves the ability of the rendered image to "hide" what is behind it, allowing the user to read or view the front of the image without being distracted by the printed image on the back. Suitable materials for the third layer include titanium dioxide (TiO2) and the like. In an exemplary embodiment, the white base coating layer includes TiO in an amount of about 20% to about 35%, or about 28% by weight. The white base coating layer 54 may further include surfactants, crosslinkers, aqueous dispersions, and other materials. In an exemplary embodiment, the white base coating layer 54 includes about 35% to about 45%, or about 39% by weight of an EAA dispersion (such as Michem® Prime 74994); about 2% to about 5%, or about 4% by weight of a surfactant (such as BYK®-348); about 10% to about 15%, or about 13% by weight of a crosslinker (such as Imprafix® 2794); about 7% to about 13%, or about 10% by weight of ethyl acrylate; and / or about 3% to about 8%, or about 5% by weight of a styrene acrylic (such as Unibond SA240 manufactured by Unichem). The white base coating layer 54 may include a thickening agent, such as Paragum 265 manufactured by Para-Chem Southern, Inc.

[0034] The tie coating layer 56 preferably includes a binder, which comprises a material that facilitates bonding between the print coating layer 52 and the white coating layer 54 and the release layer 40. The binder preferably includes a material that does not swell, i.e., absorbs water (>5% and <50% of its own mass), when in contact with water. The binder is preferably hydrophobic. The binder may be a wax, a thermoplastic polymer, or a prepolymer, or a combination thereof. Additional reactive compounds may be used in the binder composition, including crosslinkers, monomers, and oligomers, which may be combined with themselves or other components in the binder composition. The components of the binder composition may be self-crosslinking or capable of bonding with functional groups present on the printed article to improve washfastness. Ink compositions useful in the transfer sheets described herein include a colorant and an aqueous liquid carrier. The composition is not limited to a particular type of colorant, but includes organic and inorganic pigments, dyes, or polymeric colorants, such as poly(oxyalkylene)-substituted chromophores, and polymers incorporating such compounds, such as polyurethanes and polyesters. As a further example, the colorant may be selected from sublimation dyes, disperse dyes, reactive dyes, acid dyes, and basic dyes, as well as titanium dioxide, carbon black, and calcium carbonate.

[0035] In embodiments, the binder comprises polyester or a polyester-based material, preferably at least about 40% polyester or at least about 60% polyester. During transfer, the polyester polymer chains will reach a glass transition state (Tg). This means that the chains will separate, so that these molecules can reside between the chains as the ink sublimes. After the temperature drops, the polymer chains will rejoin, and the ink molecules become trapped between the chains.

[0036] In an exemplary embodiment, the tie coating layer 56 includes an EAA dispersion (such as Michem® Prime 74994) in an amount of about 45% to about 55%, or about 49% by weight. The tie coating layer 56 may include other ingredients, such as surfactants, crosslinkers, urethanes, polyesters, and the like. In one such embodiment, the tie coating layer 56 comprises a urethane (e.g., Sancure 200025F, an aliphatic polyester urethane dispersion manufactured by Lubrizol) in an amount of about 15% to about 25%, or about 18% by weight, a polyester (e.g., Eastek™ 1200) in an amount of about 15% to about 25%, or about 18% by weight, a surfactant (e.g., BYK®-348) in an amount of about 2% to about 8%, or about 4% by weight, and a crosslinker (e.g., Imprafix® 2794) in an amount of about 7% to about 13%, or about 10% by weight. The tie coating layer 56 may also include a thickener, such as Paragum 265 manufactured by Para-Chem Southern, Inc. A method for producing the above-described transfer sheet will now be described: Release layer 40 is applied to base layer 30, and then image transfer layer 50 is applied to or placed in contact with release layer 40 (or vice versa: release layer 40 can be attached to image transfer layer 50 and then placed in contact with base layer 30).

[0037] The image transfer layer 50 is then heated to a temperature below about 82.2° C. (about 180° F.). Applicant has discovered that applying heat greater than about 82.2° C. (about 180° F.) to the transfer sheet can result in white streaks, specks, blisters, and other defects, all of which contribute to relatively poor rendering of the image. These defects are particularly noticeable on darker or black textiles. Applicant has further discovered that these defects can be substantially minimized or eliminated with a lower temperature drying profile. In one particular embodiment, the transfer sheet is heated to a temperature of about 48.9° C. (about 120° F.) to about 82.2° C. (about 180° F.), preferably about 60.0° C. (about 140° F.) to about 65.6° C. (about 150° F.). In an exemplary embodiment, the release layer 40 is first applied to the base layer 30 at a temperature less than about 180 degrees Fahrenheit, preferably about 150 degrees Fahrenheit. In an exemplary embodiment, heat is applied through two different zones of an oven. The zones may have temperatures, for example, about 160 degrees Fahrenheit in Zone 1 and about 185 degrees Fahrenheit in Zone 2.

[0038] The tie coating layer 56 was then applied to the release layer 40 at a temperature of less than about 180°F (82.2°C), preferably about 150°F (65.6°C). In an exemplary embodiment, heat is applied through three different zones of an oven. For example, the zones have temperatures of about 175°F (79.4°C) in Zone 3, about 205°F (96.1°C) in Zone 4, and about 220°F (104.4°C) in Zone 5. A white base coating layer 54 may then be applied to the tie coating layer 56 at a temperature of less than about 160° F., preferably about 140° F. In an exemplary embodiment, heat is applied through two different zones of an oven, such as zone 1 having a temperature of about 130° F. and zone 2 having a temperature of 150° F. Finally, the print coating layer 52 is applied to the white base coating layer 54 at a temperature of less than about 160° F., preferably about 140° F. In an exemplary embodiment, heat is applied through three different zones of an oven, such as zone 3 having temperatures of about 140° F., zone 4 having temperatures of 170° F., and zone 5 having temperatures of 185° F. Each furnace zone is about 20 feet long, and the applicator speed can be about 80 fpm to about 120 fpm, or about 100 fpm.

[0039] Once the transfer sheet is formed, an operator can use it to transfer the image to an article. In this process, the image is applied to the top surface of the image transfer layer 50 with a suitable ink composition or print coating, as discussed above. The base layer 30 is then contacted to the article 20. Minimal pressure can be applied to the transfer sheet 10 in a press or other suitable machine to maintain contact between the base layer 30 and the article 20. In certain cases where the article is porous, such as a textile, the pressure can be selected to increase penetration of the ink composition into the interstices of the article. The pressure is selected to prevent the non-printed areas from transferring to the article. The operating conditions of the press can vary depending on the exact composition of the image transfer layer, the type of colorant in the ink formulation, and the composition of the article being printed. Suitable pressures may range from about 1 psi to about 100 psi, or from about 40 psi to about 75 psi, or from about 50 psi to about 60 psi. In one embodiment, the temperature for transferring the ink composition is between about 350 and about 400 degrees Fahrenheit (176.7 and about 204.4 degrees Celsius), or between about 365 and about 374 degrees Fahrenheit (185.0 and about 190.0 degrees Celsius).

[0040] In certain embodiments, heat and pressure are applied to the transfer sheet for a time and at a temperature such that the ink composition does not completely cure on the article, i.e., the "degree of cure" of the ink composition in the article is less than 1. In other words, the "degree of cure" of the ink composition in the article is less than 100%, and preferably from about 30% to about 80%, or from about 40% to about 60%. Partial curing of the ink composition by heat and pressure reduces defects in the printed image, thereby improving its appearance. "Degree of cure" is defined in this disclosure to mean the extent to which a composition is sufficiently crosslinked so that it is substantially in its final form (i.e., no further crosslinking and / or further substantial changes will occur to the composition). Degree of cure, as defined in this disclosure, does not necessarily mean that the composition is 100% crosslinked to become a fully cured resin, but rather means 100% of the cure that will occur before the function or appearance of the composition is substantially unchanged.

[0041] In exemplary embodiments, heat and pressure may be applied to the article and transfer sheet for about 10-30 seconds, or for about 15-20 seconds, or for about 18 seconds. In certain embodiments, the article is aged for a period of time to increase the degree of cure of the ink composition, thereby increasing the clarity of the printed image. For example, the article may be aged for a period of about 2 days to about 6 months, or about 1 week to about 3 months, or about 1 to 2 months, resulting in an increase in "degree of cure" (as defined above) of about 20% to about 80%, or about 40% to about 60%. Applicant has discovered that completing the ink composition curing process through aging (rather than immediately with heat and drying) reduces defects caused by the drying process while still ultimately resulting in a vivid, shiny image on the article.

[0042] At the end of the transfer period, the transfer sheet was peeled away from the article, leaving the printed areas of the image transfer layer bonded to the article and the non-printed areas of the image transfer layer bonded to the support layer of the transfer sheet. In embodiments, 50% or less, or 40% or less, particularly 25% or less, or even 15% or less by weight of the non-printed areas of the transfer assembly are transferred to the article during the transfer process. [Example]

[0043] Example 1 Applicant conducted tests of conventional transfer sheets and the transfer sheets discussed in this disclosure. In a first test, Applicant tested a conventional transfer sheet (Sample 1) that included a siloxane defoamer in the coating containing the image transfer layer. In this test, Applicant applied two coatings, such as those described above, to a base layer: (1) the first coating included a release layer, such as those described above, except that the layer included a siloxane defoamer and had a solids percentage of 35.9% and a viscosity of 100 mPa·s (100 CPS); and (2) the second coating included a tie coating layer containing a binder. The tie coating layer was substantially as described above, except that after the addition of paragum as a thickener, the layer had a solids percentage of 37.8% and a viscosity of 350 mPa·s (350 CPS). Prior to applying pressure and heating, applicants discovered that the layer contained numerous visible fisheyes, such as circular voids or depressions in the release coating. When a second pass coating or tie coating layer was applied to the release coating, the frequency and size of the fisheyes increased. Applicant then performed the same test under substantially similar conditions and parameters except that the siloxane antifoam agent was removed from the release layer (Sample 2). After completion of this test, it was found that there were no fisheyes or pits in either layer and the appearance of the layers was significantly improved.

[0044] Example 2 Applicant performed a second test of Sample 2 (i.e., without the siloxane antifoam agent). The first pass coating, or release layer, contained a solids percentage of 35.2% and a viscosity of 110 mPa·s (110 CPS). The second pass coating, or tie coating layer, after the addition of paragum, contained a solids percentage of 37.5% and a viscosity of 130 mPa·s (130 CPS). The two layers were coated onto a base sheet and dried in an oven with five different heating zones. The zone temperatures were as follows (all in degrees Fahrenheit): (1) Zone 1: 205 (approximately 96.1 degrees Celsius); (2) Zone 2: 235 (approximately 112.8 degrees Celsius); (3) Zone 3: 220 (approximately 104.4 degrees Celsius); (4) Zone 4: 240 (approximately 115.6 degrees Celsius); and (5) Zone 5: 260 (approximately 126.7 degrees Celsius). The sheet temperature was approximately 82.2 degrees Celsius (180 degrees Fahrenheit). After heating and drying, the transfer sheet was found to contain numerous raised coating lanes, blisters, and spots that detracted from its appearance.

[0045] Applicant then applied two additional coatings to the transfer sheet in a second pass. The first coating was a white base coating layer similar to that described above, with a solids content of 43.5% and a viscosity of 120 mPa·s (120 CPS) after the addition of paragum. The second coating was a print coating layer similar to that described above, with a solids content of 15.5% and a viscosity of 110 mPa·s (110 CPS) after the addition of paragum. After application of these coatings, the entire sheet was heated and dried using a slower drying profile. The drying profile in the oven was as follows (all in degrees Fahrenheit): (1) Zone 1: 160 (approximately 71.1 degrees Celsius); (2) Zone 2: 160 (approximately 71.1 degrees Celsius); (3) Zone 3: 150 (approximately 65.6 degrees Celsius); (4) Zone 4: 180 (approximately 82.2 degrees Celsius); and (5) Zone 5: 200 (approximately 93.3 degrees Celsius). The sheet temperature was approximately 71.1 degrees Celsius (160 degrees Fahrenheit). Inspection of the sheet after heating showed that the less aggressive drying profile reduced the level of blistering, and the second pass coating masked some of the defects in the first pass coating. Although the transfer sheet was found to still contain some blistering and some mottle, the appearance after the second pass was significantly improved. Therefore, it was concluded that a less aggressive drying profile, reducing the temperature of the transfer sheet from 180°F (82.2°C) to 160°F (71.1°C), improved the overall appearance of the transfer sheet.

[0046] Example 3 Applicant performed a third test with the first two coatings (release layer and tie coating layer) with the following differences: (1) the release layer did not contain a siloxane antifoam agent and had a significantly reduced viscosity of 34.1% solids and 50 mPa·s (50 CPS); (2) the tie coating layer, after the addition of paragum, had a solids percentage of 37.5% and a viscosity of 120 mPa·s (120 CPS). In addition, Applicant further reduced the drying profile as follows (all in degrees Fahrenheit): (1) Zone 1: 160 (approximately 71.1 degrees Celsius); (2) Zone 2: 185 (approximately 85.0 degrees Celsius); (3) Zone 3: 175 (approximately 79.4 degrees Celsius); (4) Zone 4: 205 (approximately 96.1 degrees Celsius); and (5) Zone 5: 220 (approximately 104.4 degrees Celsius). The seat temperature was approximately 65.6 degrees Celsius (150 degrees Fahrenheit).

[0047] Inspection of the sheet after heating showed that the sheet appearance from the first pass was significantly improved from the previous test: bubbles, blisters, streaks, and other defects were significantly eliminated from the image. Applicant then performed a second pass of the transfer sheet with two additional coatings: (1) a white base coating layer with 43.5% solids and a viscosity of 60 mPa·s (60 CPS) after the addition of paragum; and (2) a print coating layer with 15.5% solids and a viscosity of 110 mPa·s (110 CPS). Similar to the first pass, a reduced drying profile was applied (all in degrees Fahrenheit): (1) Zone 1: 130 (approximately 54.4°C); (2) Zone 2: 150 (approximately 45.6°C); (3) Zone 3: 143 (approximately 61.7°C); (4) Zone 4: 170 (approximately 76.7°C); and (5) Zone 5: 185 (approximately 85.0°C). The sheet temperature was approximately 60.0°C (140°F).

[0048] Inspection of the sheet after heating showed that the blistering and mottling from the previous test were no longer present after the second pass for the third test sample. Furthermore, a new transfer of the image to a T-shirt demonstrated good removability (i.e., the non-printed areas did not contain any visible ink composition). The image initially had relatively low clarity. However, Applicant then performed accelerated aging tests on the T-shirts and demonstrated that this clarity increased dramatically with aging. The accelerated aging of the T-shirts was simulated over a period of approximately two months. While the devices, systems, and methods have been described in detail in this disclosure according to certain preferred embodiments thereof, many modifications and variations therein may be effected by those skilled in the art. Accordingly, the foregoing description should not be construed as limited thereby, but should be construed to include such obvious variations as set forth above, and should be limited only by the spirit and scope of the following claims.

[0049] For example, in a first aspect, a first embodiment is a transfer sheet for transferring an image onto a substrate. The transfer sheet is produced by a method including the steps of providing a support layer and an image transfer layer in contact with the support layer, the image transfer layer comprising an ink-receptor and a blocking agent, and applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature of less than about 82.2 degrees Celsius (about 180 degrees Fahrenheit) during production. The second embodiment is the first embodiment in which the image transfer layer is heated to a temperature of about 120°F to about 180°F during production. A third embodiment is any combination of the first two embodiments, where the image transfer layer is heated to a temperature of about 60.0 degrees Celsius (about 140 degrees Fahrenheit) to about 65.6 degrees Celsius (about 150 degrees Fahrenheit) during production.

[0050] A fourth embodiment is any combination of the first three embodiments, further comprising applying a release layer between the support layer and the image transfer layer, wherein the release layer has a viscosity of from about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS). In a fifth embodiment, the release layer has a viscosity of about 50 mPa·s (50 CPS) to about 60 mPa·s (60 CPS).Any combination of the first four embodiments. A sixth embodiment is any combination of the first five embodiments, further comprising the step of applying an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas. A seventh embodiment is any combination of the first six embodiments, wherein the ink composition comprises a liquid carrier, and the blocking agent is substantially disintegrated by the liquid carrier in the printed areas, and the blocking agent is not substantially disintegrated by the liquid carrier in the non-printed areas. An eighth embodiment is a combination of any of the first seven embodiments, wherein the ink composition further comprises a colorant, the colorant being adhered to the substrate in the printed area.

[0051] A ninth embodiment is any combination of the first eight embodiments, wherein the substrate is a dark or black textile. A tenth embodiment is any combination of the first nine embodiments, wherein the fabric comprises cotton or a cotton / polyester blend. An eleventh embodiment is any combination of the first ten embodiments, wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to the article in the non-printed areas, and substantially allows the transfer of the ink composition to the article in the printed areas. A twelfth embodiment is any combination of the first eleven embodiments, wherein the image transfer layer comprises a partial fluid coating having a viscosity of from about 25 mPa·s (25 CPS) to about 200 mPa·s (200 CPS). A thirteenth embodiment is any combination of the first twelve embodiments, further comprising contacting a transfer sheet with a substrate.

[0052] A fourteenth embodiment is any combination of the first thirteen embodiments, further comprising applying heat and pressure to the transfer sheet at a temperature and for a period of time such that the degree of cure of the coating composition in the substrate is less than 100%. A fifteenth embodiment is any combination of the first fourteen embodiments, wherein the degree of cure is from about 30% to about 80%. A sixteenth embodiment is any combination of the first fifteen embodiments, wherein the duration is from about 15 to about 20 seconds. A seventeenth embodiment is any combination of the first sixteen embodiments, further comprising aging the sheet to increase the degree of cure of the coating composition within the substrate.

[0053] In another aspect, a first embodiment is a transfer sheet for transferring an image onto a substrate, the transfer sheet including a support layer, an image transfer layer overlying the support layer, the image transfer layer including an ink-receptor and a blocking agent, and a release layer between the support layer and the image transfer layer, the release layer having a viscosity of about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS). The second embodiment is the first embodiment, in which the viscosity of the release layer is about 50 mPa·s (50 CPS) to about 60 mPa·s (60 CPS). A third embodiment is any combination of the first two embodiments, wherein the ink-receiver is configured to receive the ink composition to define printed and non-printed areas in the image transfer layer, and the blocking agent is configured to substantially prevent transfer of the ink composition to the substrate in the non-printed areas and to substantially allow transfer of the ink composition to the substrate in the printed areas.

[0054] A fourth embodiment is any combination of the first three embodiments, wherein the image transfer layer comprises a partial fluid coating having a viscosity of from about 25 mPa·s (25 CPS) to about 200 mPa·s (200 CPS). A fifth embodiment is any combination of the first four embodiments, wherein the viscosity of the image transfer layer is from about 100 mPa·s (100 CPS) to about 130 mPa·s (130 CPS). A sixth embodiment is any combination of the first five embodiments, wherein the image transfer layer comprises a first layer comprising an ink-receptor and a blocking agent, and a second layer comprising a binder. A seventh embodiment is any combination of the first six embodiments, where the first and second layers are mixed together. An eighth embodiment is any combination of the first seven embodiments, further comprising a third layer between the first and second layers, the third layer comprising one or more materials that increase the opacity of the image transfer layer.

[0055] A ninth embodiment is any combination of the first eight embodiments, where the first and third layers are mixed together. A tenth embodiment is any combination of the first nine embodiments, wherein the substrate is a dark or black textile. An eleventh embodiment is any combination of the first ten embodiments, wherein the fabric comprises cotton or a cotton / polyester blend. A twelfth embodiment is any combination of the first eleven embodiments, wherein the ink composition comprises a liquid carrier, and wherein the blocking agent is substantially disintegrated by the liquid carrier in the printed areas, and wherein the blocking agent is not substantially disintegrated by the liquid carrier in the non-printed areas. A thirteenth embodiment is any combination of the first twelve embodiments, wherein the ink composition is hydrophilic.

[0056] A fourteenth embodiment is any combination of the first thirteen embodiments, wherein the blocking agent is hydrophilic. A fifteenth embodiment is any combination of the first fourteen embodiments, wherein the blocking agent is selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinylpyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl)methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ethers, hyaluronic acid, albumin, and starch and starch derivatives. A sixteenth embodiment is any combination of the first fifteen embodiments, wherein the blocking agent comprises starch. A seventeenth embodiment is any combination of the first sixteen embodiments, wherein the ink-receiver is selected from the group consisting of poly(acrylic acid), poly(vinylimidazole), poly(2-hydroxyethyl methacrylate), poly(vinylpyrrolidone), poly(vinyl)poly(pyrrolidone), and polyvinyl acetate, cationic polymers and their salts, hygroscopic inorganic salts, silica, and zeolites.

[0057] An eighteenth embodiment is any combination of the first seventeen embodiments, wherein the binder is selected from the group consisting of waxes, thermoplastic polymers or prepolymers, and combinations thereof. A nineteenth embodiment is any combination of the first eighteen embodiments, wherein the binder comprises a polyester or a blend of polyesters. In another aspect, a first embodiment is an article having a printed image produced by a method, the method including the steps of providing a transfer sheet including a support layer and an image transfer layer bonded to the support layer, the image transfer layer including an ink receptor and a blocking agent, applying an ink composition onto a surface of the image transfer layer thereby defining printed and non-printed areas, contacting the article with the transfer sheet, applying heat and pressure to the transfer sheet at a temperature and for a period of time to cure the ink composition in the article such that the degree of cure of the ink composition in the article is less than 100%, and separating the transfer sheet from the article.

[0058] The second embodiment is the first embodiment, with a degree of cure of about 30% to about 80%. A third embodiment is any combination of the first two embodiments, with the duration being about 15 to about 20 seconds. A fourth embodiment is any combination of the first three embodiments, where the temperature is from about 176.7 to about 204.4 degrees Celsius (about 350 to about 400 degrees Fahrenheit). A fifth embodiment is any combination of the first four embodiments, further comprising aging the article to increase the degree of cure of the coating composition within the article. A sixth embodiment is any combination of the first five embodiments, wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to the article in the non-printed areas and substantially allows the transfer of the ink composition to the article in the printed areas.

[0059] A seventh embodiment is any combination of the first six embodiments, wherein the article is a dark or black textile. An eighth embodiment is a combination of any of the first seven embodiments, wherein the fabric comprises cotton or a cotton / polyester blend. In another aspect, a first embodiment is a method for producing a transfer sheet for transferring an image to an article. The method includes providing a support layer and an image transfer layer, the image transfer layer comprising an ink-receptor and a blocking agent, contacting the support layer with the image transfer layer, and applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature of less than about 82.2 degrees Celsius (about 180 degrees Fahrenheit) during formation. The second embodiment is the first embodiment in which the image transfer layer is heated to a temperature of about 120°F to about 180°F during production. A third embodiment is any combination of the first two embodiments, where the image transfer layer is heated to a temperature of about 60.0 degrees Celsius (about 140 degrees Fahrenheit) to about 65.6 degrees Celsius (about 150 degrees Fahrenheit) during production.

[0060] A fourth embodiment is any combination of the first three embodiments, further comprising printing an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas, and wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to the article in the non-printed areas, and substantially allows the transfer of the ink composition to the article in the printed areas. A fifth embodiment is any combination of the first four embodiments, further comprising applying a release layer between the support layer and the image transfer layer, wherein the release layer has a viscosity of from about 25 mPa·s (25 CPS) to about 90 mPa·s (90 CPS).

Claims

1. providing a support layer and an image transfer layer in contact with the support layer, the image transfer layer comprising an ink-receptor and a blocking agent; applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature of less than about 180 degrees Fahrenheit during formation; A transfer sheet for transferring an image onto a substrate produced by a method comprising:

2. 10. The transfer sheet of claim 1, wherein the image transfer layer is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit during formation.

3. 10. The transfer sheet of claim 1, wherein the image transfer layer is heated during formation to a temperature of about 60.0 degrees Celsius (about 140 degrees Fahrenheit) to about 65.6 degrees Celsius (about 150 degrees Fahrenheit).

4. 10. The transfer sheet of claim 1, further comprising the step of applying a release layer between the support layer and the image transfer layer, wherein the release layer has a viscosity of about 25 mPa·s to about 90 mPa·s.

5. 5. The transfer sheet according to claim 4, wherein the release layer has a viscosity of about 50 mPa·s to about 60 mPa·s.

6. The transfer sheet of claim 1 further comprising the step of applying an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas.

7. 7. The transfer sheet of claim 6, wherein the ink composition comprises a liquid carrier, the blocking agent being substantially disintegrated by the liquid carrier in the printed areas, and the blocking agent being substantially not disintegrated by the liquid carrier in the non-printed areas.

8. The transfer sheet of claim 7 , wherein the ink composition further comprises a colorant, and the colorant is applied to the substrate in the printed area.

9. The transfer sheet of claim 1 , wherein the substrate is a dark or black woven fabric.

10. The transfer sheet of claim 9 wherein the fabric comprises cotton or a cotton / polyester blend.

11. 7. The transfer sheet of claim 6, wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to an article in the non-printed areas and substantially allows the transfer of the ink composition to an article in the printed areas.

12. The transfer sheet of claim 1, wherein the image transfer layer comprises a partial fluid coating having a viscosity of from about 25 mPa·s to about 200 mPa·s.

13. The transfer sheet of claim 1 , further comprising the step of contacting the transfer sheet with the substrate.

14. 14. The transfer sheet of claim 13, further comprising the step of applying heat and pressure to the transfer sheet at a temperature and for a period of time such that the coating composition in the substrate is less than 100% cured.

15. 15. The transfer sheet according to claim 14, wherein the degree of cure is from about 30% to about 80%.

16. 15. The transfer sheet of claim 14, wherein the period is from about 15 to about 20 seconds.

17. 15. The transfer sheet of claim 14, further comprising the step of aging the sheet to increase the degree of cure of the coating composition within the substrate.

18. A transfer sheet for transferring an image onto a substrate, comprising: support layer, an image transfer layer overlying the support layer, the image transfer layer comprising an ink-receptor and a blocking agent; and a release layer between the support layer and the image transfer layer, the release layer having a viscosity of about 25 mPa·s to about 90 mPa·s; A transfer sheet.

19. 19. The transfer sheet according to claim 18, wherein the release layer has a viscosity of about 50 mPa·s to about 60 mPa·s.

20. 20. The transfer sheet of claim 18, wherein the ink receiver is configured to receive an ink composition to define printed and non-printed areas in the image transfer layer, and the blocking agent is configured to substantially prevent transfer of the ink composition to the substrate in the non-printed areas and to substantially allow transfer of the ink composition to the substrate in the printed areas.

21. 20. The transfer sheet of claim 18, wherein the image transfer layer comprises a partial fluid coating having a viscosity of from about 25 mPa·s to about 200 mPa·s.

22. 22. The transfer sheet of claim 21, wherein the viscosity of the image transfer layer is from about 100 mPa·s to about 130 mPa·s.

23. 20. The transfer sheet of claim 18, wherein the image transfer layer comprises a first layer comprising the ink-receptor and the blocking agent, and a second layer comprising a binder.

24. 24. The transfer sheet of claim 23, wherein the first and second layers are mixed together.

25. 24. The transfer sheet of claim 23, further comprising a third layer between the first and second layers, the third layer comprising one or more materials that increase the opacity of the image transfer layer.

26. 26. The transfer sheet of claim 25, wherein the first and third layers are mixed together.

27. 19. The transfer sheet of claim 18, wherein the substrate is a dark or black woven fabric.

28. 28. The transfer sheet of claim 27, wherein the fabric comprises cotton or a cotton / polyester blend.

29. 20. The transfer sheet of claim 18, wherein the ink composition comprises a liquid carrier, and the blocking agent is substantially disintegrated by the liquid carrier in the printed areas, and the blocking agent is substantially not disintegrated by the liquid carrier in the non-printed areas.

30. 19. The transfer sheet according to claim 18, wherein the ink composition is hydrophilic.

31. The transfer sheet of claim 18, wherein the blocking agent is hydrophilic.

32. 19. The transfer sheet of claim 18, wherein the blocking agent is selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinylpyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl)methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ether, hyaluronic acid, albumin, and starch and starch derivatives.

33. 20. The transfer sheet of claim 18, wherein the blocking agent comprises starch.

34. 19. The transfer sheet of claim 18, wherein the ink receptor is selected from the group consisting of poly(acrylic acid), poly(vinylimidazole), poly(2-hydroxyethyl methacrylate), poly(vinylpyrrolidone), poly(vinyl)poly(pyrrolidone), and polyvinyl acetate, cationic polymers and their salts, hygroscopic inorganic salts, silica, and zeolites.

35. 24. The transfer sheet of claim 23, wherein the binder is selected from the group consisting of waxes, thermoplastic polymers or prepolymers, and combinations thereof.

36. 24. The transfer sheet of claim 23, wherein the binder comprises a polyester or a blend of polyesters.

37. providing a transfer sheet comprising a support layer and an image transfer layer bonded to the support layer, the image transfer layer comprising an ink-receptor and a blocking agent; applying an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas; contacting an article with the transfer sheet; applying heat and pressure to the transfer sheet at a temperature and for a period of time to cure the ink composition in the article so that the ink composition in the article is less than 100% cured; and Separating the transfer sheet from the article; 1. An article bearing a printed image produced by a method comprising:

38. 38. The article of claim 37, wherein the degree of cure is from about 30% to about 80%.

39. 38. The article of claim 37, wherein the period of time is from about 15 to about 20 seconds.

40. 38. The article of claim 37, wherein the temperature is from about 176.7 to about 204.4 degrees Celsius (about 350 to about 400 degrees Fahrenheit).

41. 38. The article of claim 37, further comprising the step of aging the article to increase the degree of cure of the coating composition within the article.

42. 38. The article of claim 37, wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to the article in the non-printed areas and substantially allows the transfer of the ink composition to the article in the printed areas.

43. 38. The article of claim 37, wherein the article is a dark or black woven fabric.

44. 44. The article of claim 43, wherein the fabric comprises cotton or a cotton / polyester blend.

45. 1. A method for producing a transfer sheet for transferring an image to an article, comprising: providing a support layer and an image transfer layer, the image transfer layer comprising an ink-receptor and a blocking agent; contacting the support layer with the image transfer layer; and applying heat and pressure to the image transfer layer to heat the image transfer layer to a temperature of less than about 180 degrees Fahrenheit during formation; A method comprising:

46. 46. ​​The method of claim 45, wherein the image transfer layer is heated to a temperature of from about 120 degrees Fahrenheit to about 180 degrees Fahrenheit during formation.

47. 46. ​​The method of claim 45, wherein the image transfer layer is heated to a temperature of about 60.0 degrees Celsius (about 140 degrees Fahrenheit) to about 65.6 degrees Celsius (about 150 degrees Fahrenheit) during formation.

48. 46. ​​The method of claim 45, further comprising printing an ink composition onto the surface of the image transfer layer, thereby defining printed and non-printed areas, wherein the blocking agent substantially blocks the transfer of at least about 50% by weight of the ink composition to the article in the non-printed areas and substantially allows the ink composition to be transferred to the article in the printed areas.

49. 44. The method of claim 43, further comprising applying a release layer between the support layer and the image transfer layer, wherein the release layer has a viscosity of from about 25 mPa·s to about 90 mPa·s.

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