Cutting materials

Abstract

A cutting material comprises an insoluble ink stack, a laminating layer and a backing layer, wherein the laminating layer is arranged between the insoluble ink stack and the backing layer.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. 119(e) to U.S. Patent Application No. 62 / 856,502, filed on June 3, 2019, the disclosure of which is considered part of the disclosure of this application and the entire disclosure of which is hereby incorporated by reference herein. Technical Field

[0003] The present disclosure generally relates to sublimation printing components, apparatus, systems, and methods. Background Art

[0004] This section provides background information related to the present disclosure which is not necessarily prior art.

[0005] Generally speaking, sublimation is a chemical process in which a solid material becomes a gas without passing through a liquid state. Sublimation printing, also known as dye sublimation printing, is a popular printing method used to transfer images onto suitable materials.

[0006] Although known sublimation printing components, apparatuses, systems and methods have proven to be acceptable for various applications, such sublimation printing components, apparatuses, systems and methods are still susceptible to improvements that can enhance their overall performance and cost-effectiveness. Therefore, there is a need to develop improved sublimation printing components, apparatuses, systems and methods that advance the prior art. Summary of the invention

[0007] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0008] Embodiments of the present disclosure generally relate to cutting material systems, methods, and apparatus. Specifically, the present disclosure relates to pre-installed ink sublimation cutting materials. For example, in one embodiment of the present disclosure, a cutting material includes an insoluble ink stack, a laminate layer, and a backing layer. In such an embodiment, the laminate layer is disposed between the insoluble ink stack and the backing layer.

[0009] Embodiments of the present disclosure may include one or more of the following optional features. In some embodiments, the insoluble ink stack includes an insoluble sublimation material layer and a sublimation material carrier layer. The laminate layer may be disposed against the sublimation material carrier layer. In some embodiments, the cut material includes an adhesive layer disposed between the backing layer and the laminate layer. The adhesive layer may removably secure the backing layer to the laminate layer.

[0010] In some embodiments, the cutting material includes a printing layer disposed between the backing layer and the laminating layer. In some embodiments, the cutting material includes an adhesive layer disposed between the printing layer and the laminating layer. The printing layer and the backing layer can be removably fixed to the laminating layer by the adhesive layer.

[0011] In some embodiments, the cutting material includes a printed layer. The backing layer may be disposed between the printed layer and the laminate layer. In some embodiments, the cutting material includes an adhesive layer disposed between the backing layer and the laminate layer. The adhesive layer may removably secure the backing layer to the laminate layer.

[0012] In one embodiment of the present disclosure, a cut material comprises an insoluble ink layer, a paper layer, a laminate layer and a backing layer. In such an embodiment, the paper layer is disposed between the insoluble ink layer and the laminate layer, and the laminate layer is disposed between the paper layer and the backing layer.

[0013] In one embodiment of the present disclosure, a method of injecting ink into an article includes: providing a cut material including an ink sublimation stack and a backing layer, the ink sublimation stack including a sublimation ink; performing a cutting operation on the cut material; removing a portion of the ink sublimation stack from the backing layer of the cut material; placing the ink sublimation stack against the article; and sublimating the sublimation ink into the article.

[0014] Another aspect of the present disclosure provides a cutting material, which may include an infusible sublimation material layer, a backing layer, a sublimation material carrier layer disposed between the infusible sublimation material layer and the backing layer, and a laminate layer disposed between the sublimation material carrier layer and the backing layer.

[0015] This aspect can include one or more of the following optional features. In some embodiments, the laminate layer includes pulp and calcium carbonate.

[0016] In some embodiments, the laminate layer is about 40-60 g / m 2 between.

[0017] In some embodiments, the laminating layer includes a silicone oil coating disposed between the laminating layer and the backing layer.

[0018] In some embodiments, the backing layer comprises PET.

[0019] In some embodiments, the backing layer has a thickness between about 40-60 μm.

[0020] In some embodiments, the cut material includes an adhesive layer disposed between the laminate layer and the backing layer. The adhesive layer may include a pressure sensitive adhesive.

[0021] Another aspect of the present disclosure provides a method of injecting ink. The method may include cutting a cut material. The cut material may include an ink sublimation stack and a backing layer. The ink sublimation stack may include sublimation ink. The method may also include removing a first portion of the ink sublimation stack from the backing layer of the cut material. The method may also include placing the cut material against an article. The method may also include sublimating the sublimation ink of a second portion of the sublimation ink stack into the article.

[0022] This aspect may include one or more of the following optional features. In some embodiments, the cut material further includes a laminate layer disposed between the ink sublimation stack and the backing layer. Cutting the cut material may include cutting through the ink sublimation stack but not cutting through the backing layer.

[0023] In some embodiments, the method includes removing a portion of the laminate layer from the backing layer after cutting the cut material. The portion of the laminate layer removed from the backing layer can correspond in position to and be removably secured to the first portion of the ink sublimation laminate removed from the backing layer.

[0024] Each of the above-mentioned independent embodiments of the present disclosure, as well as those embodiments described in the detailed description below, may include any features, options and possibilities set forth in the present disclosure and the drawings (including those features, options and possibilities in the case of other independent embodiments), and may also include any combination of features, options and possibilities set forth in the present disclosure and the drawings.

[0025] Additional features and advantages of exemplary embodiments of the present disclosure will be set forth in the following description, and in part will be apparent from the description, or may be understood by the practice of such exemplary embodiments. The features and advantages of such embodiments may be realized and obtained by means of the tools and combinations specifically pointed out in the appended claims. These and other features will become more fully apparent from the following description and the appended claims, or may be understood by the practice of such exemplary embodiments set forth below.

[0026] The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings described herein are for illustrative purposes only of selected configurations and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0028] Figure 1 is a perspective view of a sublimation system according to the principles of the present invention, the sublimation system including a laminate, a handling device, a cutting mat, a heating device, and a workpiece arranged on a workbench.

[0029] Figure 2 is based on Figure 1 A cross-sectional view of the laminate at line 2-2.

[0030] Figure 2 ' is arranged in a partially separated orientation according to the principles of the present disclosure Figure 2 Another cross-sectional view of a laminated sheet.

[0031] Figure 3 yes Figure 1 Another perspective view of a system including a laminate sheet disposed on a cutting mat and both disposed within a processing device.

[0032] Figure 4 is a perspective view of a laminated sheet arranged on a cutting mat, the laminated sheet and the cutting mat being arranged according to Figure 3 The arrow 4 is arranged in the processing device.

[0033] Figure 5 is based on Figure 4 A cross-sectional view of line 5-5.

[0034] Figure 6 is based on Figure 4 Another perspective view of the laminated sheet showing a post-cutting operation performed by a processing device.

[0035] Figure 7 is based on Figure 6 A cross-sectional view of line 7-7.

[0036] Figure 8 is based on Figure 6 Another perspective view of the laminated sheet showing the laminated sheet in a cut and peeled configuration.

[0037] Fig. 9 is based on Figure 8 A cross-sectional view of line 9-9.

[0038] Fig.10 yes Figure 1 Another perspective view of a system including a heating device disposed on a cut and peeled laminate disposed on a workpiece.

[0039] Fig.11 is based on Fig.10 A cross-sectional view along line 11-11 of FIG. 1 shows the sublimation material layers of the laminated sheet arranged in a pre-sublimation orientation relative to the workpiece.

[0040] Fig.11 'It is based on Fig.11 Another cross-sectional view of FIG. 1 showing the layers of sublimated material of the laminated flakes arranged in a post-sublimation orientation sublimated into a workpiece.

[0041] Fig. 12A is based on Fig.11 An enlarged view of line 12A.

[0042] Fig. 12B is based on Fig. 12A Another enlarged view of .

[0043] Fig. 12C is based on Fig. 12B Another enlarged view of .

[0044] Fig.12D is based on Fig. 12C And according to Fig.11 Another enlarged view of line 12D of '.

[0045] Fig.13 The invention is a method for showing the invention according to the principle of the present disclosure. Figure 1 A flowchart of a method associated with a system.

[0046] Fig.14 is a cross-sectional view of another laminate according to the principles of the present invention.

[0047] Fig.15 is a cross-sectional view of another laminate according to the principles of the present invention.

[0048] Fig.16 is a cross-sectional view of another laminate according to the principles of the present invention.

[0049] Fig.17 is a cross-sectional view of another laminate according to the principles of the present invention.

[0050] Fig.18 is a cross-sectional view of another laminate according to the principles of the present invention.

[0051] Corresponding reference numerals indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0052] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to enable a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0053] Embodiments of the present disclosure generally relate to sublimation printing components, apparatus, systems, and methods. In some examples, the present disclosure describes configurations of laminated sheets including sublimation inks.

[0054] For example, some aspects described herein are configured for ink sublimation processes that are used in, for example, processing equipment (see, e.g., Figure 1 and Figure 3-7 The board processing device 100) before and after printing and / or cutting materials is easy to produce and is highly customizable.

[0055] In some cases, the laminated sheets may be processed (eg, cut, processed, etc.) and stored at a user's residence or home without the use of expensive and complex industrial equipment, machinery, or storage facilities.

[0056] In at least one aspect of the present disclosure, cutting the material minimizes the risk of damage to the custom sublimation print and minimizes undesirable changes thereto during handling and use.

[0057] In some embodiments, the present disclosure describes configurations of laminated sheets that may include multiple layers (eg, two or more of a sublimation material layer, a lamination layer, and a backing layer) to provide a more robust material for improved handling, shipping, and storage.

[0058] In some cases, the present disclosure describes exemplary laminated sheets that, once processed (e.g., cut) by the processing device 100, provide easy "removability" (i.e., the ability to remove undesired portions of cut material from the backing layer of the laminated sheet) so that design elements of a sublimation print of the laminated sheet remain in place during processing and sublimation, but are also easily repositionable as desired.

[0059] In other embodiments, the present disclosure describes exemplary laminated sheets that are less susceptible to curling, or at least excessive curling, during handling, shipping, and storage.

[0060] refer to Figure 1-2 The laminated sheet is generally shown at 10. Figure 2As shown, the laminate sheet 10 may include a plurality of different layers arranged together to form a single laminate (see, e.g. Figure 2 As used herein, the term "laminate" may define multiple layers disposed together or adjacent to each other. Two or more of the multiple layers 16, 18, 20, 22, and 24 forming the laminate sheet 10 may be separable or separate (see, e.g., Figure 2 '). In addition, when two or more of the multiple layers 16, 18, 20, 22, and 24 of the laminated sheet 10 are acted upon (e.g., by heat or mechanical force), two or more of the multiple layers 16, 18, 20, 22, and 24 of the laminated sheet 10 are typically held together to form a single functional sheet when handled or used.

[0061] Continue to refer Figure 1 , also shows a system, the system includes and for performing a method (see for example Fig.13 32) of the laminated sheet 10. For example, in addition to the laminated sheet 10, the system may also include, for example: Figure 3 and Figure 10-12D The workpiece 28 (eg, cloth products, ceramic products, etc.) seen in FIG. 1 ; and the heating device 150 (see also, for example, Figure 3 and Figure 10-12D In other embodiments, the system may also include, for example, a processing device 100 (e.g., a household cutting machine); and a cutting mat 102 (see also, for example, Figure 3-9 ). In other embodiments, the system may also include, for example, a support surface or workbench 200. The components of the system and how they engage or work on the laminated sheet 10 will be described in more detail in the following disclosure.

[0062] refer to Figure 2 In some configurations, the laminate sheet 10 may include a multilayer material defined by five different material layers 16, 18, 20, 22, 24. The plurality of material layers 16, 18, 20, 22, 24 are stacked or disposed adjacent to one another to define a thickness T of the laminate sheet 10. The length L of the laminate sheet 10 (see, e.g., Figure 1 ) and width W (see e.g. Figure 1 ) can be, for example, 8.5"×11", 12"×12", etc., and the thickness T of the laminated sheet 10 can be on the order of less than one millimeter or several millimeters.

[0063] refer to Figure 2-8 and Figure 11-11', each of the plurality of material layers 16, 18, 20, 22, 24 of the laminate sheet 10 is shown to have a substantially equal thickness; however, each of the plurality of material layers 16, 18, 20, 22, 24 may be defined to have a different thickness.

[0064] like Figure 2 As shown, several layers 16, 18, 20, 22, 24 of the laminate sheet 10 can be grouped into separate laminates 12, 14. For example, the layers 16, 18 of the plurality of material layers 16, 18, 20, 22, 24 can define the sublimation laminate 12, and the material layers 20, 22, 24 of the plurality of material layers 16, 18, 20, 22, 24 can define the support laminate 14. In general, the ink sublimation laminate 12 provides a sublimation ink (see, e.g., material layer 16) and a sublimation ink carrier material (see, e.g., material layer 18) such that when heated by a heating device (e.g., Fig.11 and Fig. 12B The design or artwork can be sublimated onto the article when pressure is applied thereto (see, e.g., arrow 30 in FIG. 1 ). Figure 11-11 'In the material workpiece layer 28, which can be, for example, a cloth product or a ceramic product). The sublimation ink 16 is transferred from the sublimation stack 12 to the product by sublimation (see, for example Figure 11-11 The workpiece material layer 28) in ' will be described in more detail below.

[0065] The support laminate 14 is configured to provide rigidity to the laminate sheet 10 for handling the sublimation laminate 12. The support laminate 14 may include a carrier material or backing material (see, e.g., material layer 24), a barrier material, or a laminate material (see, e.g., material layer 20). The support laminate 14 may improve / allow: (1) a user to successfully perform cutting of the sublimation laminate 12 with the processing device 100; and (2) a sublimation process of the sublimation laminate 12 performed by the heating device 150.

[0066] In some configurations, refer to Figure 2 , sublimation stack 12 includes: (1) sublimation material layer 16; and (2) sublimation material carrier layer 18. In some cases, support stack 14 may include: (1) lamination layer 20; (2) adhesive layer 22; and (3) backing layer 24. Figure 2 As shown, the sublimation material carrier layer 18 is disposed between the sublimation material layer 16 and the laminate layer 20. The laminate layer 20 is disposed between the sublimation material carrier layer 18 and the adhesive layer 22. The adhesive layer 22 is disposed between the laminate layer 20 and the backing layer 24.

[0067] In some configurations, the sublimation material carrier layer 18 may include, for example, a paper-based material. The sublimation material layer 16 carried by the sublimation material carrier layer 18 may include, for example, ink, such as a sublimation ink.

[0068] With respect to the sublimation material layer 16, the act of “sublimation” (see, e.g. Figures 12A-12D ) is defined as a chemical process in which Fig. 12A The solid material shown (which defines the sublimation material layer 16) becomes a gas (see e.g. Fig. 12B ), without passing through a liquid state. "Sublimation printing", which may also be referred to as "dye sublimation printing", can be used to transfer an image to a suitable material. When the sublimation material carrier layer 18 (including the sublimation material layer 16 disposed thereon) is arranged near a heating device 150 that generates heat 30 (see, for example, Fig.11 and Fig. 12B ), the sublimation material layer 16 is: (1) arranged in Fig. 12A The solid state of the sublimation material carrier layer 18 shown begins to change; then becomes (2) penetrates into the fibers of, for example, the workpiece 28 (see, for example Fig.11 'and Figures 12C-12D ) Fig. 12B The gas state shown.

[0069] When heat 30 is removed from the sublimation material carrier layer 18 and the workpiece 28, the solid state (e.g. Fig. 12A ) into the workpiece 28 (as shown Figures 12C-12D The gaseous state (as shown) Fig. 12B The sublimation material layer 16 is permanently fixed in place within the workpiece 28 (as shown in FIG. Fig.12D In addition, refer to Figures 12A-12B The released heat 30 not only changes the state of the sublimation material layer 16, but can also open pores in the material of the workpiece 28 that defines the sublimation material layer 16 that changes from a solid state to a gaseous state (e.g., as Fig. 12C As shown in FIG. 1 ), once the heat 30 and pressure are released, the layer of sublimated material 16 that entered the workpiece 28 “in gaseous form” returns to a solid state, and, as shown in FIG. Figures 12C-12D As shown, the hole of the workpiece 28 is switched from an open state back to a closed state, thereby capturing the sublimation material layer 16 within the workpiece 28, as shown in FIG. Fig.12D shown.

[0070] The thickness and specific material composition of each of the multiple material layers 16, 18, 20, 22, 24 of the embodiment of the laminate sheet 10, combined with the thickness and material of other layers (e.g., the thickness and / or material of the workpiece 28), achieves a number of advantages. For example, the selected materials and / or thicknesses of each of the multiple material layers 16, 18, 20, 22, 24 of the laminate sheet 10 enable appropriate heat transfer through them to achieve successful sublimation of the sublimation material layer 16 into the workpiece 28 (such as a cloth product or a ceramic product).

[0071] And, in some cases, the thickness and / or selected material of each of the multiple material layers 16, 18, 20, 22, 24 of the laminate sheet 10 affects the rigidity of the laminate sheet 10, which can provide users with advantageous handling and storage options discussed herein. In addition, in some examples, the selected material and / or thickness of each of the multiple material layers 16, 18, 20, 22, 24 of the laminate sheet 10 affects the permeability of certain barrier layers, so that the sublimation material layer 16 is successfully sublimated into the workpiece 28 during use and does not damage the hot pressing surface of the heating device 150 or other equipment used during sublimation. Further, in some embodiments, the selected material and / or thickness of each of the multiple material layers 16, 18, 20, 22, 24 of the laminate sheet 10 affects, for example, the peel force and / or adhesion of the adhesive layer 22. Thus, the selected materials and / or thicknesses of each of the plurality of material layers 16, 18, 20, 22, 24 of the laminate sheet 10 described herein may be selected to provide an optimal solution for providing a modified workpiece 28 having a design of at least a portion of the sublimation material layer 16 of the sublimation stack 12 comprising the laminate sheet 10.

[0072] refer to Figure 2 , the sublimation material layer 16 of the sublimation stack 12 may include one or more sublimation inks, dye particles, etc. For example, in some configurations, the sublimation material layer 16 includes a sublimation ink containing diethylene glycol, glycerol, and water. In other configurations, the sublimation material layer 16 may also include dye particles. In other configurations, the sublimation material layer 16 may include other components for stabilizing the dye particles in the solution defining the sublimation material layer 16, and the other components may include those components mentioned above.

[0073] In some examples, the composition of the material forming sublimation material layer 16 may include a diethylene glycol component in the range of about 0.15%-1.65% by weight of laminate sheet 10. In other embodiments, the composition of the material forming sublimation material layer 16 may include a diethylene glycol component in the range of about 0.3%-1.5% by weight of laminate sheet 10.

[0074] In other examples, the composition of the material forming the sublimation material 16 may include a glycerin component in the range of about 0.99%-2.31% by weight of the laminate sheet 10. In other embodiments, the composition of the material forming the sublimation material layer 16 may include a glycerin component in the range of about 1.2%-2.1% by weight of the laminate sheet 10.

[0075] In yet other examples, the composition of the material forming the sublimation material 16 may include a water component in the range of about 0.84%-3.96% by weight of the laminate sheet 10. In other embodiments, the composition of the material forming the sublimation material layer 16 may include a water component in the range of about 1.2%-3.6% by weight of the laminate sheet 10.

[0076] According to the exemplary embodiments of the sublimation material layer 16 described above, in some configurations, the composition of the material forming the sublimation material layer 16 may be in the range of about 1.98%-7.92% by weight of the laminate sheet 10. In other configurations, the composition of the material forming the sublimation material layer 16 may be in the range of about 2.7%-7.2% by weight of the laminate sheet 10. The described sublimation material layer 16 and its component compounds are given as examples of suitable types of compositions for sublimation inks for forming the sublimation material layer 16 that can be incorporated into the design of the laminate sheet 10.

[0077] In some examples, the sublimation material carrier layer 18 may include one or a combination of wood fibers, pigments, and binders. In some configurations, the wood fibers may include carbon and oxygen ranging between about 26.7%-37.3% by weight of the laminate sheet 10. In other configurations, the wood fibers including carbon and oxygen may range between about 30.1%-33.9% by weight of the laminate sheet 10.

[0078] In some examples, the pigment may include silicon in a range between about 0.8%-3.3% by weight of the laminated flake 10. In other examples, the pigment includes silicon in a range between about 1.1%-3.0% by weight of the laminated flake 10.

[0079] In some embodiments, the binder may include polyvinyl alcohol or the like and may range between about 0.8%-3.3% by weight of the laminate sheet 10. In other embodiments, the binder including polyvinyl alcohol may range between about 1.1%-3.0% by weight of the laminate sheet 10.

[0080] According to the exemplary embodiments of the sublimation material carrier layer 18 described above, the sublimation material carrier layer 18 can be in the range of about 28.3%-43.9% by weight of the laminate sheet 10. In other configurations, the sublimation material carrier layer 18 can be in the range of about 32.3%-39.9% by weight of the laminate sheet 10. The sublimation material carrier layer 18 and its component compounds described can be given as exemplary types of sublimation papers for the sublimation material carrier layer 18 in the design of the laminate sheet 10. Other material compositions defining other types of sublimation papers can also be used in the design of the sublimation material carrier layer 18.

[0081] During formation of the sublimation stack 12, the sublimation material layer 16 may be printed on the outer surface of (and thus disposed on) the sublimation material carrier layer 18. However, in other embodiments, some or all of the sublimation material layer 16 may be impregnated or disposed within at least a portion of the thickness of the sublimation material carrier layer 18, such that the sublimation material carrier layer 18 and the sublimation material layer 16 form a layer of material defined by the thickness of the sublimation material carrier layer 18.

[0082] In at least one embodiment, the sublimation laminate 12 has a weight of about 80-120 grams per square meter (g / m 2 ). In some embodiments, the sublimation laminate 12 may be between about 90 and 110 grams per square meter (g / m 2 In other embodiments, the sublimation laminate 12 may be between about 97 g / m 2 In other embodiments, the sublimation laminate 12 may be between about 100 g / m 2 Thus, in some configurations, the sublimation laminate 12 can be between about 30.3% and 51.5% by weight of the laminate sheet 10. In other configurations, the sublimation laminate 12 can be between about 35% and 47.1% by weight of the laminate sheet 10.

[0083] refer to Figure 2 In some embodiments of the laminated sheet 10, the laminating layer 20 is disposed between the sublimation material carrier layer 18 and the adhesive layer 22. The laminating layer 20 provides a barrier layer between the sublimation laminate 12 and other layers, such as, for example, the adhesive layer 22 and the backing layer 24. In this exemplary configuration, the laminating layer 20 can mitigate or reduce the likelihood that the sublimation material layer 16 will sublimate or otherwise transfer to other layers of the laminated sheet 10, such as, for example, the backing layer 24, and further transfer to other devices, such as, for example, the heating device 150 or other equipment, that may be in contact with the laminated sheet 10 during the sublimation of the sublimation material layer 16 into the workpiece 28. In some examples, as will be described in more detail below, during the sublimation process, the heating plate of the heating device 150 may be in contact with the backing layer 24 of the laminated sheet 10 to heat 30 (see, for example, Fig.11 and Fig. 12B ) sublimates the laminate 12 and sublimates the sublimation material layer 16 into the workpiece 28. During the contact between the heating plate of the heating device 150 and the laminate sheet 10, the laminating layer 20 acts as a barrier layer to prevent or reduce the heated sublimation material layer 16 from being transferred or sublimated onto the heating plate of the heating device 150; the heating plate is thus isolated and protected from damage by the laminating layer 20. Therefore, the sublimation ink of the sublimation material layer 16 will be pressed into and guided to sublimate into the workpiece 28.

[0084] In addition to the aforementioned functions provided by the laminate layer 20, the laminate layer 20 also provides a cleaning capability. For example, during the process of transferring an image or design from the sublimation layer 16 of the laminate sheet 10 to the workpiece 28, the laminate sheet 10 can be engaged with the processing device 100 and undergo a cutting operation to cut the workpiece 26 (see, e.g., Figure 6-7 ), and then selectively removed from the laminate 10 (see e.g. Figure 8-9 ) one or more layers or portions of the sublimation laminate 12. Thus, the laminating layer 20 enables a user to easily and quickly remove one or more layers or portions of the sublimation laminate 12 from the laminate sheet 10 (see, e.g. Figure 8-9 ).

[0085] refer to Figure 2 ', showing an exemplary removal of the laminate layer 20 from the backing layer 24. In some configurations, the laminate layer 20 can be removably secured to the backing layer 24 with the adhesive layer 22.

[0086] like Figure 2 As shown, the laminating layer 20 can be peeled from the adhesive layer 22, which in some embodiments may result in one or more portions or layers of the sublimation stack 12 secured to the laminating layer 20 also being removed as the laminating layer 20 is peeled from the adhesive layer 22. In some embodiments, a permanent glue (not shown) that may define a relatively small thickness (compared to other layers of the laminate sheet 10) in some configurations may be disposed between the laminating layer 20 and the sublimation material carrier layer 18 (or the sublimation stack 12 in general) such that any removal of the laminating layer 20 also results in the removal of one or more portions or layers of the sublimation stack 12.

[0087] Thus, in some cases, the laminating layer 20 may define or form a layer or coating on the sublimation material carrier layer 18 that is engaged with the adhesive layer 22. As described above, the material defining the laminating layer 20 allows the laminating layer 20 to be easily separated from the adhesive layer 22 after, for example, a cutting operation has been performed on the laminate sheet 10 by the processing device 100. For example, portions of the laminating layer 20 may be removed from the adhesive layer 22 as a uniform, intact portion of material along with corresponding portions of the sublimation laminate 12 that are secured to the removed laminating layer 20, which may be done without tearing or otherwise damaging any remaining portions of the sublimation laminate 12 that have not been removed. Thus, the laminating layer 20 of the laminate sheet 10 is configured in a manner that allows a user to cleanly and easily remove certain portions of the sublimation layer 12 from the laminate sheet 10 (i.e., "clear" the laminate sheet 10) after the laminate sheet 10 has been subjected to a cutting operation (e.g., a cutting operation performed by the processing device 100) in order to form a custom design for sublimation into an article.

[0088] Although some configurations of the laminate sheet 10 may include the lamination layer 20, some configurations may be implemented without the lamination layer 20 (e.g., the lamination layer 20 may be optional). However, in such configurations, separating the sublimation material carrier layer 18 from the backing layer 24 and the adhesive layer 22 in the absence of the lamination layer 20 may, in some but not all cases, result in inconsistent results, such as, for example, torn or localized portions of the sublimation material carrier layer 18 remaining in the laminate sheet 10 after removal. Thus, in some configurations, if the material defining the sublimation material carrier layer 18 is arranged in direct contact with the adhesive layer 22, the material may not be cleanly peeled from the adhesive layer 22; when such an exemplary configuration is provided, when the sublimation laminate 12 is peeled from the backing layer 24 (i.e., without providing the lamination layer 20), a portion of the thickness of the sublimation material carrier layer 18 may undesirably remain on the adhesive layer 22, thereby leaving a residual portion of the sublimation laminate 12 on the adhesive layer 22.

[0089] In clearing the cut 26 (see e.g. Figure 7 ), the laminate layer 20 of the remaining portions of the laminated sheet 10 cut 26 can be removed and reapplied to the adhesive layer 22 so that those portions of the user's design can be rearranged and reoriented as desired, and the laminate layer 20 can be part of the desired design to be sublimated into the workpiece 28. In this way, the user can change the custom design as desired and maintain those portions of the design in relative position on the cut material during the processing and sublimation process, whether rearranged or not.

[0090] Furthermore, in the configuration of the laminated sheet 10 including the laminated layer 20, such a configuration can improve the quality of one or more cuts 26 defined by the laminated sheet 10 when the processing device 100 operates on the laminated sheet 10. In some cases, the blade 101 ( Figure 5 and Figure 7 ) is set to cut into the thickness of the laminate sheet 10 at a depth or distance through, for example, the sublimation laminate 12, which can include the thickness of the sublimation material carrier layer 18 and the thickness of the laminate layer 20. Therefore, due to the material properties of, for example: silicon; pulp; and / or calcium carbonate (which can define the material selected to form the laminate layer 20), some configurations of the laminate sheet 10 can provide one or more layers that can be cut cleanly without tearing (even when cutting complex small shapes). In some configurations of the laminate sheet 10 that do not include the laminate layer 20, the sublimation material carrier layer 18 may tear when impacted by the blade 101 of the processing device 100, but this is not always the case.

[0091] Some configurations of the laminate layer 20 may be defined by one or more materials including, for example, pulp and calcium carbonate. In other configurations, the laminate layer 20 may be defined by one or more materials including, for example: pulp, calcium carbonate; and silicon; in such configurations, the silicon material component may be in the form of a silicon coating that faces, is disposed opposite or adjacent to the backing layer 24, or alternatively, is between and in adjacent contact with the laminate layer 20 and the adhesive layer 22, such as Figure 2 Including a silicone coating material in the design of the laminate layer 20 can improve the releasability of the laminate layer 20 from the adhesive layer 22 during removal.

[0092] In some embodiments, the laminate layer 20 may be between about 20% and 26% by weight of the laminate sheet 10. In other embodiments, the laminate layer 20 may be about 23% by weight of the laminate sheet 10. In some examples, the laminate layer 20 may be about 40 g / m 2 -60g / m 2 In other examples, the laminate layer 20 may be between about 45 g / m 2 -55g / m 2 In other examples, the laminate layer 20 may be, for example, about 50 g / m 2 .

[0093] In some configurations, the combined thickness of the lamination layer 20 and the sublimation stack 12 may be between about 0.17 mm and 0.25 mm. In other configurations, the combined thickness of the lamination layer 20 and the sublimation stack 12 may be between about 0.23 mm and 0.19 mm. In other configurations, the combined thickness of the lamination layer 20 and the sublimation stack 12 may be about, for example, 0.21 mm.

[0094] In some configurations, the laminate sheet 10 may optionally include at least one adhesive layer 22. The adhesive layer 22 may be disposed between and connect the laminate layer 20 and the backing layer 24. The adhesive layer 22 removably secures the laminate layer 20 to the backing layer 24 so that the laminate sheet 10 may be handled and stored as a single sheet of material. However, in some examples, during the sublimation process, the user may peel the laminate layer 20 from the adhesive layer 22 to separate one or more portions of the sublimated laminate 12 from one or more other layers defining the laminate sheet 10. In some embodiments, the adhesive layer 22 may be defined by a pressure-sensitive adhesive.

[0095] In order to provide the above-mentioned removal, peeling and (adjacent layer) holding power functional points to the laminated sheet 10, the material defining the adhesive layer 22 can be quantified by one or more exemplary "peel forces" (e.g., the force that causes the laminating layer 20 to separate from the adhesive layer 22) as follows. In some configurations, the material defining the adhesive layer 22 can be defined by a peel force between about 15 grams-force / 25 millimeters (gf / 25mm)-60gf / 25mm. In other configurations, the material defining the adhesive layer 22 can be defined by a peel force between about 20gf / 25mm-55gf / 25mm. In other configurations, the material defining the adhesive layer 22 can be defined by a peel force between about 25gf / 25mm-50gf / 25mm.

[0096] In some embodiments, adhesive layer 22 can be defined by an acrylic polymer adhesive. In some configurations, adhesive layer 22 can be between about 12%-16% of the weight of laminated sheet 10. In other configurations, adhesive layer 22 can be between about 13%-15% of the weight of laminated sheet 10. In other configurations, adhesive layer 22 can be about 14% of the weight of laminated sheet 10. In addition, in some examples, adhesive layer 22 can be between about 12 μm-18 μm. In other examples, adhesive layer 22 can be between about 13.5 μm-16.5 μm. In other examples, adhesive layer 22 can be about 15 μm.

[0097] refer to Figure 2 , some configurations of the laminated sheet 10 may also include a backing layer 24, which may be alternatively referred to as: a support layer; a release layer; or a layer portion disposed on a first surface of the adhesive layer 22, the first surface being opposite to a second surface of the adhesive layer 22 disposed on the laminated layer 20. In some cases, the backing layer 24 provides structural rigidity, which facilitates, for example, handling or cutting operations when, for example, the laminated sheet 10 is engaged with a household cutting machine (such as the processing device 100). In other cases, the backing layer 24 may also provide a base portion layer from which the laminated layer 22 can be separated after, for example, the processing device 100 has performed a cutting operation on the laminated sheet 10, thereby providing the cleanability of the laminated sheet 10 as described above.

[0098] In addition, the backing layer 24 may also be provided with a pad engaging surface 25 (see e.g. Figure 2-2 'and Figure 4-9 ), the pad engaging surface 25 can be configured to be placed on an upper surface of a cutting pad 102 (e.g., a cutting pad having a pressure sensitive adhesive 104 disposed on a portion or all of an upper surface of the cutting pad 102) (see, e.g., Figure 1 and Figure 3-9), so that the laminate sheet 10 can be held in place while being engaged with and cut 26 by the processing device 100. Thus, the one or more materials selected to define the backing layer 24 can define the functional properties of the backing layer 24, for example, allowing the pad engaging surface 25 of the backing layer 24 to adhere to the appropriate position adjacent the pressure sensitive adhesive 102 of the cutting pad 102 and thereafter be removed as desired before or after cutting 26 the laminate sheet 10 without damaging the sublimation laminate 12 of the laminate sheet 10.

[0099] Additionally, the backing layer 24 may also be formed by allowing heat 30 from a heating device 150, a heating plate, or another heat source (see, e.g., Fig.11 and Fig. 12B ) to move to sublimate the sublimation material layer 16. Thus, the material and thickness defining the backing layer 24 can be selected so as to provide the desired structural rigidity of the laminated sheet 10 without hindering the heat transfer 30 through the thickness of the laminated sheet 10. In addition, the material defining the backing layer 24 can functionally provide the elasticity of the laminated sheet 10 so as to prevent, for example, the blade 101 of the processing device 100 (e.g., a household cutting machine) from passing therethrough when the processing device 100, for example, is set to be expected to cause the cutting blade 101 to cut the upper layers of the laminated sheet 10 (such as, for example, the layers defining the sublimation laminate 12 and, for example, the laminating layer 20). In this manner, the backing layer 24 provides a carrier portion of the laminate sheet 10 that allows one or more first portions of the sublimation laminate 12 to be cut, for example, by a processing device 100 (e.g., a household cutting machine), and allows one or more second portions of the sublimation laminate 12 to remain in a position supported by the backing layer 24 after removal so that the user can selectively arrange and customize the design before sublimation. Thus, the one or more materials selected to form the backing layer 24 can be formed to define a thickness that can withstand the cutting blade 101 while also providing the handling and removal advantages described above.

[0100] In some cases, the backing layer 24 can be formed of polyethylene terephthalate (PET) or the like; such materials can be defined with heat-resistant properties. In some configurations, the thickness of the backing layer 24 can be between about 40 μm-60 μm. In other configurations, the backing layer 24 can be between about 45 μm-55 μm. In other configurations, the backing layer 24 can be about 50 μm. In some examples, the backing layer 24 can be between about 16%-24% of the weight of the laminated sheet 10. In other examples, the backing layer 24 can be between 18%-22% of the weight of the laminated sheet 10. In other examples, the backing layer 24 can be about 19.8% of the weight of the laminated sheet 10.

[0101] Therefore, in some configurations, such as Figure 2The total thickness of the laminate sheet 10 shown can be between about 0.21 mm and 0.31 mm. In other configurations, the total thickness of the laminate sheet 10 can be between about 0.23 mm and 0.29 mm. In other configurations, the total thickness of the laminate sheet 10 can be about 0.26 mm. In some configurations, the total thickness and material defined by all layers of the laminate sheet 10, which can include, for example, the backing layer 24, the adhesive layer 22, the laminating layer 20, and the sublimation material carrier layer 18, can include one or more silicone oil coatings or one or more adhesive layers located, for example, between the sublimation material carrier layer 18 and the laminating layer 20.

[0102] In some cases, the selected number of layers and the material composition of the layers defining the laminated sheet 10 are selected so as to allow for the transfer of heat 30 generated by the contact of the laminated sheet 10 with the plate of the heating device 150. In some embodiments, the laminated sheet 10 can be configured to be heated with the heat 30, which results in the laminated sheet 10 being heated to a temperature of about 400° F. for about 240 seconds to sublime the sublimation material layer 16 onto, for example, a workpiece 28 defined by, for example, a ceramic material, so that a vivid, clear design can be transferred from the laminated sheet 10 to the ceramic workpiece 28. Alternatively, the laminated sheet 10 can be configured to be heated with the heat 30, which results in the laminated sheet 10 being heated to a temperature of about 385° F. for about 40 seconds to sublime the sublimation material layer 16 onto, for example, a workpiece 28, for example, a workpiece 28 defined by, for example, a T-shirt 28 (see, e.g., FIG. 20 ). Figure 1 ) of cloth material. Thus, a workpiece 28 that may be defined by materials other than, for example, cloth and ceramic may have to be subjected to heat 30 at various temperatures and durations in order to sublime the sublimation material layer 16 onto the particular workpiece 28.

[0103] In some cases, various temperature settings and durations may be selected to sublime the sublimation material layer 16 of the laminate sheet 10 into the workpiece 28. In some embodiments, the selected temperature may be in the range of about 350°F-450°F, and the selected duration may be in the range of about 25 seconds-300 seconds. Such exemplary temperatures and durations are sufficient to be achieved using, for example, a "home" heating device 150 configured for use by a user who may be, for example, a novice or a home expert.

[0104] In some cases, the laminate sheet 10 can be manufactured by first disposing or laminating (e.g., printing) a sublimation material layer 16 on a sublimation material carrier layer 18 to form a sublimation laminate 12. Thereafter, a laminating layer 20 can be disposed or laminated on the sublimation material carrier layer 18 of the sublimation laminate 12. Then, a backing layer 24 and an adhesive layer 22 can be applied to the laminating layer 20. In some cases, the adhesive layer 22 can first be applied to the backing layer 24 to define a multi-layer sub-component of the support laminate 14 before the adhesive layer 22 of the multi-layer sub-component of the support laminate 14 is disposed on or laminated over the laminating layer 20. In addition, during the process of manufacturing the laminate sheet 10, the manufacturing process may optionally include: coating the laminate layer 20 with silicone oil after the laminate layer 20 is placed or laminated on the sublimation material carrier layer 18, and before the adhesive layer 22 of the multi-layer sub-component supporting the laminate 14 (defined by the adhesive layer and the backing layer 24) is placed or laminated on the laminate layer 20.

[0105] refer to Figure 3-12D , describes a sublimation method, which in Fig.13 32. Although the method includes several steps, shown generally at 34, 36, 38, 40, and 42, one or more of steps 34, 36, 38, 40, and 42 may be optional. For example, one or more of the components of the system (e.g., the processing device 100 and the cutting pad 102) may be optional; in some cases, the laminated sheet may be pre-processed or pre-cut, and, therefore, steps 36 and 38 associated with handling or cutting the laminated sheet 10 may be omitted from the method 32. In addition, although Figure 3-12D It shows the use of Figure 1-2 'The method 32 of laminating the sheet 10 shown and described, but with Figure 3-12D The associated method 32 is also applicable to other laminated sheets, such as, for example, Fig.14 , Fig.15 , Fig.16 , Fig.17 and Fig.18 Exemplary laminated sheets 10a, 10b, 10c, 10d and 10e are shown in FIG.

[0106] First, if Figure 1-2 'shown, providing 34 (see e.g. Fig.13 ) laminated sheet 10. In addition, Figure 1 As shown, the laminate 10 may be included as a component of a system that includes one or more other components (eg, the workpiece 28 , the processing device 100 , the cutting mat 102 , the heating device 150 , and the work station 200 ) for performing the method 32 .

[0107] Then, if Figure 3-7As shown, the method 32 may optionally include performing a cutting operation 36 on the laminated sheet 10. For example, in some configurations, the processing device 100 may be used to cut 26 (see, e.g., Figure 4-7 ) a laminated sheet 10, a processing device 100 such as, for example, an electronic cutter having a cutting blade 101, which strikes downward into the laminated sheet 10. Figure 3 and Figure 4-5 , before performing the cutting operation 36, the laminate sheet 10 can be positioned on the cutting mat 102. After positioning the laminate sheet 10 on, for example, the pressure sensitive adhesive 104 disposed on a portion or all of the upper surface of the cutting mat 102 so that the laminate sheet 10 is removably fixed to the pressure sensitive adhesive 104 disposed on a portion or all of the upper surface of the cutting mat 102, the cutting mat 102 and the laminate sheet 10 are then disposed within the processing device 100 (where the sublimation material layer 16 of the laminate sheet 10 is relatively facing the blade 101 disposed within the processing device 100). As described above, the backing layer 24 provides a surface that can be placed on the pressure sensitive adhesive 104, which defines the upper surface of the cutting mat 102. The material defining the backing layer 24 allows the rear surface of the backing layer 24 to be adhesively fixed to the upper surface of the cutting mat 102 and selectively removed before or after cutting 26 as needed without compromising the integrity of the sublimation laminate 12.

[0108] refer to Figure 6-7 , one or more cuts 26 defined by the laminated sheet 10 are formed, for example, by a blade 101 of the processing device 100. In other cases, one or more cuts 26 may be preformed, and, therefore, step 36, which may be performed by a domestic cutting machine (e.g., the processing device 100) in some embodiments, may be optional and thus omitted from the method 32.

[0109] In some embodiments, one or more cuts 26 can extend through an upper layer of the laminate sheet 10 that can define at least a layer that defines, for example, a sublimation laminate 12. In some cases, one or more cuts 26 can extend through: (1) the sublimation material layer 16; (2) the sublimation material carrier layer 18; and (3) the laminate layer 20. In other cases, one or more cuts 26 can further extend partially or completely through the adhesive layer 22. In addition, while the backing layer 24 can be configured to withstand the pressure setting of the cutting blade 101 of the processing device 100, the one or more cuts 26 formed by the blade 101 of the processing device 100 can also partially or completely pass through the thickness of the backing layer 24. In some cases, the processing device 100 can be calibrated to apply a force to the blade 101 of the processing device 100 so that the blade 101 cuts through the laminate layer 20 without cutting through the adhesive layer 22 or the backing layer 24, such as, for example Figure 7In one or more embodiments, one or more cuts 26 may pass completely or partially through adhesive layer 22 but into or through backing layer 24. Even if blade 101 forms one or more cuts 26 extending into one or both of adhesive layer 22 and backing layer 24, laminated sheet 10 may still function normally during the act of performing sublimation 42 (see, e.g., Fig.13 ).

[0110] refer to Figure 6 , one or more cuts 26 may define a cut perimeter that forms or creates a closed portion or region of the laminate 10. Next, as Figure 8-9 As shown, 38 can be peeled off and removed (see for example Fig.13 ) one or more enclosed portions or areas of the laminate sheet 10; in some cases, one or more enclosed portions or areas of the laminate sheet 10 can be peeled off and removed 38 before or after the laminate sheet 10 is removably separated from the pressure-sensitive adhesive 104 disposed on the cutting pad 102, the cutting pad 102, and a portion or all of the upper surface of the laminate sheet 10.

[0111] like Figure 8 As shown, in some examples, some but not all of the layers defining the laminate sheet 10 may be peeled off and then removed 38, while some of the remaining layers of the laminate sheet 10 are not peeled off for subsequent removal 38. In some cases, the layers of the laminate sheet that are peeled off for subsequent removal 38 may include, for example: (1) the sublimation material layer 16; (2) the sublimation material carrier layer 18; and (3) the laminate layer 20. Thus, portions of the sublimation material layer 16 and the sublimation material carrier layer 18 (i.e., the sublimation laminate 12) that correspond in position to and are removably secured to the portion of the laminate layer 20 that is removed 38 from the adhesive layer 22 and the backing layer 24 are also removed 38. The above-described process of removing 38 portions of the laminate sheet 10 after performing the cutting operation 36 may be referred to as "removing" as described above. Removing may be performed manually and / or using one or more removal tools (not shown).

[0112] During the removal process, the laminate layer 20 is peeled away from the adhesive layer 22 and thus from the backing layer 24. Therefore, the adhesive layer 22 has a greater holding force on the backing layer 24 than on the laminate layer 20, which may optionally include a silicone oil coating as described above. Even if one or more cuts 26 penetrate the adhesive layer 22 and / or the backing layer 24, as described above, the laminate layer 20 will still be separated from the adhesive layer 22. Fig. 9A perspective view of a portion of the laminate sheet 10 being peeled away during the removal process is shown. In addition, once the laminate sheet 10 is removed, the remaining portions of the laminate layer 20 of the laminate sheet 10 (which may be a portion of the desired design to be sublimated 42 into the workpiece 28) can be removed and reapplied to the adhesive layer 22 while enjoying these advantages, so that these portions of the user's design can be rearranged and reoriented as desired. In this way, the user can change the custom design as desired and maintain those portions of the design in relative position on the laminate sheet 10 during sublimation 42, whether rearranged or not.

[0113] refer to Fig.10 , Fig.11 and Fig. 12A After the laminate 10 has been cut 36 and cleaned 38 as desired, it may be placed 40 against the workpiece 28 (see, e.g. Fig.13 ) laminated sheet 10, workpiece 28 may be formed of any desired material, such as, for example, cloth material, ceramic material, or other material. In some cases, workpiece 28 may be placed on a support surface or table 200 before the cut 36 and cleaned 38 laminated sheet 10 is placed on workpiece 28. After the heating device 150 is placed on or near the workpiece 28, the heating device 150 may be activated (see, for example, Fig.11 and Fig. 12B ) so that heat 30 can pass through the laminate sheet 10 to sublime 42 the sublimation material layer 16 (see, e.g. Figures 12A-12D ) into workpiece 28, such as Fig.11 'and Fig.12D shown.

[0114] refer to Fig.10 The workpiece 28 may define an article of clothing, such as, for example, a cloth T-shirt comprising a plurality of fibers. As described above, the heat 30 generated by the heating device 150 not only changes the state of the sublimation material layer 16, but may also, for example, open the pores of the fibers defining the workpiece 28, such as Figures 12A-12B In addition, Figures 12A-12C As shown, as a result of applying heat 30 to the laminated sheet 10, the sublimation material layer 16 is changed from a solid state (eg, a solid state) fixed to the sublimation material carrier layer 18 to a solid state (eg, a solid state) of the laminated sheet 10. Fig. 12A ) changes and separates from the sublimation material carrier layer 18 in the form of gas (as shown Fig. 12B As shown), the gas penetrates into (as shown Fig. 12C ) defines an open hole fiber of the workpiece 28. When the heating device 150 is deactivated to stop applying heat 30 (as shown in FIG. Fig.11 'and Fig.12D), the sublimation material layer 16 has effectively "gassed" into the fibers defining the workpiece 28 as a result of the pores of the fibers defining the workpiece 28 transitioning from an open state back to a closed state due to the removal of heat 30 from the workpiece 28.

[0115] In some cases, the heating device 150 can be, for example, a heat press or an iron, which can be designed for home use at the above-mentioned temperatures, such as Fig.11 Shown pressed against the backing layer 24. Heat 30 from such a heating device 150 passes through the various layers of the laminate 10 to heat 30 and thereby sublime 42 the layer of sublimation material 16 into the workpiece 28.

[0116] As described above, during the period when the heating device 150 is in contact with the laminated sheet 10, the laminating layer 20 forms a barrier to prevent or reduce the heated sublimation material layer 16 from transferring or sublimating onto the heating device 150. The heating device 150 is thus prohibited from directly contacting the sublimation material layer 16; therefore, the sublimation ink of the sublimation material layer 16 can be limited to be allowed to sublimate only into the workpiece 28 disposed on the opposite side of the laminated sheet 10 adjacent to the heating device 150. In this way, including the laminating layer 20 in the design of the laminated sheet 10 can facilitate the sublimation of the sublimation material layer 16 (such as the sublimation material layer 16) into the workpiece 28. Fig.11 'and Fig.12D In addition, the backing layer 24 can provide a layer to which the design portion of the sublimation stack 12 is fixed so that the design transferred to the workpiece 28 will not shift or stretch during sublimation 42.

[0117] As described above, the material and thickness of each layer of the laminate sheet 10 can affect the heat transfer performance of the laminate sheet 10 and is therefore adjusted to optimize heat transfer into the sublimation material layer 16. In addition, as described above, the laminate layer 20 can also serve as a barrier layer so that the gases of the sublimated sublimation material layer 16 do not pass through the laminate layer 20 and other layers above the laminate layer 20 during the sublimation process, such as, for example, the adhesive layer 22 and the backing layer 24. In this way, the sublimated sublimation material layer 16 gases cannot escape through the laminate sheet 10 and are therefore primarily directed to be forced into the workpiece 28, which results in a more consistent design transfer from the laminate sheet 10 to the workpiece 28.

[0118] The user can customize the design transferred into the workpiece 28 by customizing the portions of the laminate sheet 10 that are cut and removed. For example, Fig.11A portion of the laminated sheet 10 shown may be free of the sublimation material layer 16, such that no sublimation ink will sublimate into the workpiece 28 in that portion. In addition, as described above, the remaining portion of the laminated sheet 10 including the sublimation material layer 16 may be peeled off by separating the lamination layer 20 from the adhesive layer 22, and then reapplied to the adhesive layer 22 at a different location. In this manner, the user may rearrange and customize the design even after one or more cuts 26 are formed in the laminated sheet 10 by, for example, the blade 101 of the processing device 100. Thus, the embodiments of the laminated sheet 10 described herein enable a high level of customization until the sublimation material layer 16 of the laminated sheet 10 is transferred into the workpiece 28.

[0119] refer to Fig.11 ', after applying heat 30 (see e.g. Fig.11 and Fig. 12B ) after a suitable duration and the sublimation material layer 16 has been partially or completely sublimated into the workpiece 28, the laminate sheet 10 can be lifted from the workpiece 28. In this step, the portion of the sublimation material layer 16 that has been sublimated into the workpiece 28 remains in the workpiece 28 and is then separated from the sublimation material carrier layer 18 when the laminate sheet 10 is peeled off. The result of the method 32 is that the cutout 26 design of the laminate sheet 10 is transferred into the workpiece 28 by sublimation.

[0120] In addition to the aforementioned steps of method 32 described above, some embodiments of method 32 may further include the following steps: (1) after sublimating 42 the sublimation material layer 16 into the workpiece 28, removing the cut material from the workpiece 28; and (2) leaving a portion of the sublimated sublimation material layer 16 in the workpiece 28 (see, e.g., Fig.11 'and Fig.12D ), the sublimated sublimation material layer 16 may be defined by a sublimation ink. Additionally, other embodiments of the method 32 may include steps of rearranging portions of the laminate sheet 10 after the laminate sheet 10 has been cut 36 and before the sublimation material layer 16 is sublimated 42 into the workpiece 28. For example, such steps may include removing portions of the sublimation laminate 12 that were removed with corresponding portions of the lamination layer 20 and then reapplying the portions to the backing layer 24 via the adhesive layer 22 at one or more different locations.

[0121] In other embodiments, the method 32 of transferring one or more sublimated portions of the sublimation material layer 16 into the workpiece 28 may be reversed so that heat 30, such as from the heating device 150, is first applied to the workpiece 28 instead of the backing layer 24 of the laminate 10; for example, referring to Fig.11, reverse stacking (where the workpiece 28 comprises a ceramic material) will include applying heat 30 to the workpiece 28, wherein the workpiece 28 is disposed between the heat 30 and the sublimated sublimation material layer 16 of the laminate sheet 10. This reverse stacking method step may be advantageous when using a domestic heating device 150; in such cases, the user may find it more difficult to apply uniform pressure on the workpiece 28 (especially for rigid materials such as ceramics) with the heating device 150. The reverse stacking step allows the various layers of the laminate sheet 10 to be located between the workpiece 28 and the sublimated sublimation material layer 16 to more evenly distribute the pressure to the workpiece 28 to compensate for the uneven pressure of the user manually pressing the heating device 150 against the workpiece 28.

[0122] In addition to the above and Figure 1-12D In addition to the laminated sheet 10 shown in FIG. 1 , other exemplary laminated sheets 10a, 10b, 10c, 10d and 10e are also respectively disclosed in the present disclosure. Fig.14 , Fig.15 , Fig.16 , Fig.17 and Fig.18 Therefore, in view of the substantial similarity in structure and function of the components associated with laminate sheets 10a, 10b, 10c, 10d, 10e relative to laminate sheet 10, like reference numerals are used hereinafter and in the accompanying drawings to identify like components, while like reference numerals including letter suffixes (e.g., "a," "b," "c," "d," and "e") are used to identify those components that have been modified.

[0123] refer to Fig.14 , an additional print layer 44a is printed on the backing layer 24a, so that the backing layer 24a is disposed between the adhesive layer 22a and the print layer 44a. In such an embodiment, the print layer 44a may include an ink that is not defined by a sublimation ink (i.e., the ink defining the print layer 44a may be, for example, a standard printing ink or other non-sublimation ink).

[0124] In some embodiments, the printed layer 44a may include, for example: logos; grid lines; fiducials; alignment aids; or other markings or combinations thereof. Such markings may provide information about the appropriate temperature and duration for sublimation by the heating device 150 or iron, as well as other instructions for using the laminate sheet 10a. In other embodiments, the printed layer 44a may include markings that help a user align the laminate sheet 10a to the workpiece 28, or otherwise guide the placement of the laminate sheet 10a on the workpiece 28 for performing the subsequent sublimation step 42.

[0125] Alternatively or additionally, in some configurations not shown in the drawings, the laminated sheet 10a may also include an additional backing layer on the printed layer 44a similar to the backing layer 24a described herein, such as Fig.14 In this embodiment, the print layer 44a is disposed between two backing layers 24a; in this manner, the additional backing layer 24a will prevent the ink defining the print layer 44a from transferring to the surface of the heating device 150 during sublimation 42.

[0126] refer to Fig.15 In some configurations, the exemplary laminate sheet 10b may include a print layer 44b disposed between the adhesive layer 22b and the backing layer 24b. In such an embodiment, the ink defining the print layer 44b may be isolated from the backing layer 24b and the heating surface of the heating device 150, which is pressed into and disposed near the laminate sheet 10b by the backing layer 24b during sublimation 42; such an arrangement of the layers defining the laminate sheet 10b may prevent the ink defining the print layer 44b from being transferred to the heating surface of the heating device 150 during sublimation 42.

[0127] In addition, the laminate sheets 10a, 10b may also include other layers. In some cases, the other layers may include a silicone oil coating of the laminate layers 20a, 20b and / or one or more other adhesive layers disposed between the laminate layers 20a, 20b and the sublimation material carrier layers 18a, 18b.

[0128] refer to Fig.16 , exemplary laminated sheets 10c may include two separate sheets of material that may be removably secured together. For example, any laminated sheet 10c may include a first sheet 46c and a separate second sheet 48c. The first sheet 46c may include a laminate layer 20c below other layers, such as, for example, a sublimation material carrier layer 18c and a sublimation material layer 16c and other layers (such as, for example, any adhesive layer between the above-mentioned laminate layer 20c and the sublimation material carrier layer 18c and, for example, a silicon coating on the laminate layer 20c). The second sheet 48c may include an adhesive layer 22c, a backing layer 24c, and any other layers discussed herein, such as, for example, a printed layer 44c.

[0129] If a laminate sheet 10c is used, the method 32 may include an additional step of pressing the first sheet 46c and the second sheet 48 together before performing the cutting step 36. In addition, the laminate sheet 10c may also include a removable layer 50c that may be disposed on the adhesive layer 22c of the second sheet 48c to protect the adhesive layer 22c before pressing the first sheet 46c onto the adhesive layer 22c. The user will remove the removable layer 50c before pressing the first sheet 46 and the second sheet 48 together to form a single sheet defining the laminate sheet 10c.

[0130] like Fig.17 As shown, another exemplary laminate sheet 10d can include two separate sheets 46d and 48d; however, the sheets 46d, 48d may not include a lamination layer. In such a configuration, when the first sheet 46d and the second sheet 48 are pressed together, the sublimation material carrier layer 18d can be directly applied to the adhesive layer 22d. In addition, the laminate sheet 10d can include a removable layer 50d that protects the adhesive layer 22d until the first sheet 46d and the second sheet 48 are pressed together.

[0131] refer to Fig.18 , another exemplary laminate is generally shown at 10e. The laminate 10e includes a second backing layer 52e disposed between the print layer 44e and the adhesive layer 22e. In this manner, the print layer 44e is sandwiched between the two backing layers 24e, 52e, which can further prevent the print layer 44e from traveling through the layers of the laminate 10e during sublimation 42 to subsequently transfer to the workpiece 28 or the heated surface of the heating device 150.

[0132] In some configurations, the second backing layer 52e may include materials and properties similar or different from the backing layer 24e. For example, in some embodiments, the second backing layer 52e may include PET or other similar materials, such as, for example, other heat-resistant materials and films. In addition, in some examples, the sum of the thickness of the backing layer 24e and the second backing layer 52e may be between about 40 μm-60 μm, and preferably between 45 μm-55 μm. In some configurations, the sum of the thickness of the backing layer 24e and the second backing layer 52e may be, for example, about 50 μm. In other examples, the thickness of the second backing layer 52e is approximately the same as the thickness of the backing layer 24e. In other examples, the thickness of the second backing layer 52e is different from the thickness of the backing layer 24e.

[0133] In some configurations, the backing layer 24e and the second backing layer 52e together can define between about 16%-24% of the weight of the laminate sheet 10e. In other configurations, the backing layer 24e and the second backing layer 52e can define between about 18%-22% of the weight of the laminate sheet 10e. In other configurations, the backing layer 24e and the second backing layer 52e can define between, for example, about 19.8% of the weight of the laminate sheet 10e.

[0134] Alternatively, or in addition to the various embodiments of the laminated sheets 10, 10a, 10b, 10c, 10d, 10e described herein, one or more embodiments may include a perforated backing layer (not shown). The perforated backing layer may include a plurality of holes extending through the thickness of the perforated backing layer. Such a perforated backing layer may increase ventilation and thus allow gases, such as, for example, moisture from the surrounding air or any other gas in the surrounding environment, to pass through the backing layer 24, 24a, 24b, 24c, 24d, 24e during sublimation 42. One effect of such ventilation of gases passing through the backing layer 24, 24a, 24b, 24c, 24d, 24e may include cooling the backing layer 24, 24a, 24b, 24c, 24d, 24e during sublimation 42.

[0135] In some cases, due to the cooling advantage of the perforated backing layer, the thickness of the perforated backing layer can be less than those described above with reference to other backing layers 24, 24a, 24b, 24c, 24d, 24e without negatively affecting the laminated sheet 10, 10a, 10b, 10c, 10d, 10e. That is, the thickness described for the backing layer 24, 24a, 24b, 24c, 24d, 24e or any related layer is based in part on the melting point and thickness of the material used. For example, the above-mentioned backing layer 2424a, 24b, 24c, 24d, 24e, which includes, for example, PET and has a thickness between about 40μm-60μm, will withstand a temperature range of about 350°F-450°F for a duration of about 25 seconds-300 seconds without melting or negatively affecting the sublimation of the laminated sheet 10, 10a, 10b, 10c, 10d, 10e. However, a perforated backing layer of less than 40 μm can withstand temperatures over 450° F. and heating times in excess of 300 seconds.Alternatively or additionally, the perforated backing layer may comprise a material that is less heat resistant than PET but may be less expensive or lighter.

[0136] In addition to the foregoing, because sublimation inks are typically sensitive to humidity, some configurations of the laminated sheets 10, 10a, 10b, 10c, 10d, 10e may include dry environment packaging (not shown). The dry environment packaging reduces the exposure of the sublimation material layer 16, 16a, 16b, 16c, 16d, 16e to moisture from the air or the user's hands, either of which can cause the sublimation material layer 16, 16a, 16b, 16c, 16d, 16e to become dirty. For example, in some cases, the laminated sheets 10, 10a, 10b, 10c, 10d, 10e may preferably be packaged in an airtight sealed package and may include a silicon bag or other hygroscopic material to keep the package dry. The laminated sheets 10, 10a, 10b, 10c, 10d, 10e can be packaged in a dry environment, and the packaging maintains an appropriate humidity level during transportation and storage to maintain the quality of the sublimation material layer 16, 16a, 16b, 16c, 16d, 16e. Such packaging is advantageous to retailers and distributors as well as users because it allows them to store the laminated sheets 10, 10a, 10b, 10c, 10d, 10e for a longer period of time before sale or use. By using the dry environment packaging described herein, the laminated sheets 10, 10a, 10b, 10c, 10d, 10e can be placed on store shelves, in shipping trucks or ships, and in the storage of users for an extended period of time, such as, for example, a week or more.

[0137] As described above, each of the embodiments described in the above detailed description may include any features, options, and possibilities set forth in the present disclosure (including those in other independent embodiments), and may also include any combination of any features, options, and possibilities set forth in the present disclosure and the accompanying drawings. Other examples consistent with the present teachings described herein are set forth in the following numbered clauses:

[0138] Item 1: A cut material comprising: an insoluble ink stack; a backing layer; and a laminate layer disposed between the insoluble ink stack and the backing layer.

[0139] Clause 2: The cut material of Clause 1, wherein the insoluble ink stack comprises an insoluble sublimation material layer and a sublimation material carrier layer.

[0140] Clause 3: The cut-out layer of Clause 2, wherein the laminate layer is disposed against the sublimation material carrier layer.

[0141] Clause 4: The cut material of any one of Clauses 1 to 3, further comprising an adhesive layer disposed between the backing layer and the laminate layer, wherein the adhesive layer removably secures the backing layer to the laminate layer.

[0142] Clause 5: The cut material of any one of Clauses 1 to 3, further comprising a printing layer disposed between the backing layer and the laminate layer.

[0143] Item 6: The cut material of Item 5, further comprising a printing layer, wherein the backing layer is disposed between the printing layer and the lamination layer.

[0144] Clause 7: The cut material of any one of Clauses 1 to 3, further comprising a print layer, wherein the backing layer is disposed between the print layer and the laminate layer.

[0145] Clause 8: The cut material of Clause 7, further comprising an adhesive layer disposed between the backing layer and the laminate layer, wherein the adhesive layer removably secures the backing layer to the laminate layer.

[0146] Item 9: A cut material comprising: an insoluble sublimation material layer; a sublimation material carrier layer; a laminate layer; and a backing layer. The sublimation material carrier layer is disposed between the insoluble sublimation material layer and the laminate layer, and the laminate layer is disposed between the sublimation material carrier layer and the backing layer.

[0147] Clause 10: The cut material of Clause 9, wherein the laminate layer comprises pulp and calcium carbonate.

[0148] Clause 11: The cut material of clause 9 or 10, wherein the laminate layer has a thickness of about 40-60 g / m 2 between.

[0149] Clause 12: The cut material according to any one of clauses 9 to 11, wherein the laminate layer further comprises a silicone oil coating, wherein the silicone oil coating is disposed between the laminate layer and the backing layer.

[0150] Clause 13: The cut material of any of Clauses 9 to 12, wherein the backing layer comprises PET.

[0151] Clause 14: The cut material of any of Clauses 9 to 13, wherein the backing layer has a thickness between approximately 40-60 μm.

[0152] Clause 15: The cut material of any one of Clauses 9 to 14, further comprising an adhesive layer disposed between the laminate layer and the backing layer.

[0153] Clause 16: The cut material of Clause 15, wherein the adhesive layer comprises a pressure sensitive adhesive.

[0154] Item 17: A method of injecting ink into an article, comprising: providing a cut material comprising an ink sublimation stack and a backing layer, the ink sublimation stack comprising a sublimation ink; performing a cutting operation on the cut material; removing a portion of the ink sublimation stack from the backing layer of the cut material; placing the ink sublimation stack against the article; and sublimating the sublimation ink into the article.

[0155] Clause 18: The method of Clause 17, wherein the cut material further comprises a laminate layer disposed between the ink sublimation laminate and the backing layer.

[0156] Clause 19: The method of clause 17 or 18, wherein performing a cutting operation on the cut material comprises cutting through the ink sublimation laminate but not cutting through a backing layer.

[0157] Item 20: The method of claim 18 or 19, further comprising removing a portion of the laminate layer from the backing layer after performing the cutting operation, the portion of the laminate layer removed from the backing layer corresponding in position to and removably secured to the portion of the ink sublimation laminate removed from the backing layer.

[0158] The articles "a," "an," and "the" are intended to indicate the presence of one or more elements in the preceding description. The terms "comprising," "including," and "having" are intended to be inclusive, and mean that there may be additional elements in addition to the listed elements. In addition, it should be understood that reference to "one embodiment" or "an embodiment" of the present disclosure is not intended to be interpreted as excluding the existence of additional implementations that also include the described features. As understood by those of ordinary skill in the art included in the embodiments of the present disclosure, the numbers, percentages, ratios, or other values ​​described herein are intended to include the value, as well as other values ​​that are "approximately" or "approximately" the described value. Therefore, the values ​​should be interpreted broadly enough to include values ​​that are at least close enough to the described values ​​to perform the desired function or achieve the desired results. The values ​​include at least the variations expected in suitable manufacturing or production processes, and may include values ​​within 5%, within 1%, within 0.1%, or within 0.01% of the described values.

[0159] In view of this disclosure, those of ordinary skill in the art should recognize that equivalent constructions do not depart from the spirit and scope of the disclosure, and that various changes, substitutions, and modifications may be made to the embodiments disclosed herein without departing from the spirit and scope of the disclosure. Equivalent constructions, including functional "means plus function" clauses, are intended to cover structures described herein that perform the functions described, including structural equivalents that operate in the same manner and equivalent structures that provide the same functions. It is the express intent of the applicant not to invoke means plus function or other functional claims for any claim unless the word "means" appears with the associated function. The claims will include every addition, deletion, and modification to the embodiments that falls within the meaning and scope of the claims.

[0160] As used herein, the terms "substantially," "approximately," and "substantially" refer to an amount close to a stated amount that still performs a desired function or achieves a desired result. For example, the terms "substantially," "approximately," and "substantially" may refer to an amount that is less than 5%, less than 1%, less than 0.1%, and less than 0.01% of a stated amount. Furthermore, it should be understood that any directions or reference frames in the foregoing description are merely relative directions or movements. For example, any reference to "up" and "down" or "above" or "below" is merely a description of the relative position or movement of the associated elements.

[0161] The present invention may be embodied in other specific forms without departing from its spirit and essential characteristics. The described embodiments are to be considered in all respects as illustrative only and not restrictive. Therefore, the scope of the present invention is indicated by the appended claims rather than by the preceding description. All changes within the equivalent meaning and scope of the claims are included within the scope of the claims.

Claims

1. A laminated sheet comprising: a sublimation material layer, wherein the sublimation material layer includes sublimation ink; A sublimation material carrier layer; Lamination layer; Adhesive layer; and Backing layer; in: The sublimation material carrier layer is disposed between the sublimation material layer and the lamination layer; The laminating layer is disposed between the sublimation material carrier layer and the adhesive layer to provide a barrier layer and provide removal capability; The adhesive layer is disposed between the laminating layer and the backing layer; The outer surface of the laminated sheet is formed by the sublimation material layer; said outer surface is not covered by a layer of said laminated sheet; The outer surface is configured to face and contact the article during use of the laminate sheet to transfer at least a portion of the layer of sublimation material to the article via sublimation, and Wherein, the material defining the backing layer is capable of functionally providing the elasticity of the laminated sheet and defining a thickness capable of withstanding a blade of a processing device, so that when the blade of the processing device cuts the laminated sheet, the blade can only extend through the sublimation material layer, the sublimation material carrier layer and the laminate layer.

2. The laminate sheet according to claim 1, wherein the lamination layer is disposed against the sublimation material carrier layer.

3. The laminate sheet of claim 1, wherein the adhesive layer removably secures the backing layer to the laminate layer.

4. The laminate sheet according to claim 1, further comprising an auxiliary marking attached to the backing layer.

5. The laminate sheet of claim 4, wherein the auxiliary markings include grid lines configured to facilitate alignment of the laminate sheet with the article.

6. The laminated sheet according to claim 4, wherein the auxiliary mark includes information on at least one of a temperature and a duration of a sublimation transfer process.

7. The laminate according to claim 1, wherein: A rear surface of the laminate sheet opposite to the outer surface is formed by the backing layer; The rear surface is not covered by a layer of the laminate; and The rear surface is configured to face a heating plate of a heating device during use of the laminate sheet to transfer the at least a portion of the layer of sublimation material to the article via sublimation.

8. A laminated sheet comprising: a sublimation material layer, wherein the sublimation material layer includes sublimation ink; A sublimation material carrier layer; Lamination layer; Adhesive layer; Backing layer; and an auxiliary indicia attached to the backing layer; in: The sublimation material carrier layer is disposed between the sublimation material layer and the lamination layer; The laminating layer is disposed between the sublimation material carrier layer and the adhesive layer to provide a barrier layer and provide removal capability; The adhesive layer is disposed between the laminating layer and the backing layer; and The laminate sheet is configured to be cut so that a first portion of the sublimation material layer can be removed from the backing layer of the laminate sheet and the sublimation ink of a second portion of the sublimation material layer remaining in a position supported by the backing layer can sublime into an article, and Wherein, the material defining the backing layer is capable of functionally providing the elasticity of the laminated sheet and defining a thickness capable of withstanding a blade of a processing device, so that when the blade of the processing device cuts the laminated sheet, the blade can only extend through the sublimation material layer, the sublimation material carrier layer and the laminate layer.

9. The laminate sheet of claim 8, wherein the auxiliary markings include grid lines configured to facilitate alignment of the laminate sheet with the article.

10. The laminated sheet according to claim 8, wherein the auxiliary mark includes information on at least one of a temperature and a duration of a sublimation transfer process.

11. The laminated sheet according to claim 8, the laminating layer further comprising a silicone oil coating layer disposed between the laminating layer and the backing layer.

12. The laminated sheet according to claim 8, wherein the backing layer comprises PET.

13. The laminated sheet according to claim 8, wherein the thickness of the backing layer is between 40-60 μm.

14. The laminate sheet of claim 8, wherein the adhesive layer releasably secures the backing layer to the laminate layer.

15. The laminate according to claim 14, wherein the adhesive layer comprises a pressure sensitive adhesive.

16. A method comprising: cutting a laminate sheet, the laminate sheet comprising a sublimation laminate, a laminating layer and a backing layer, wherein the sublimation laminate comprises a sublimation material layer and a sublimation material carrier layer, and wherein the laminating layer is disposed between the sublimation laminate and the backing layer to provide a barrier layer and provide a clean-out capability; removing a first portion of the sublimation laminate from the backing layer of the laminate sheet; placing the laminate sheet against an article so that the layer of sublimation material is in direct contact with the article; as well as sublimating at least a portion of the layer of sublimation material of a second portion of the sublimation stack into the article, wherein the sublimating comprises pressing a heating plate of a heating device against the rear surface of the backing layer, and wherein the second portion of the sublimation stack is the portion that remains in a position supported by the backing layer after removing the first portion of the sublimation stack, Wherein, the material defining the backing layer is capable of functionally providing the elasticity of the laminated sheet and defining a thickness capable of withstanding a blade of a processing device, so that when the blade of the processing device cuts the laminated sheet, the blade can only extend through the sublimation material layer, the sublimation material carrier layer and the laminate layer.

17. The method of claim 16, wherein the laminate sheet further comprises an auxiliary indicia attached to the backing layer, wherein placing the laminate sheet against the article comprises utilizing the auxiliary indicia to facilitate a desired position or alignment of the laminate sheet relative to the article.

18. The method of claim 16, wherein cutting the laminate sheet comprises cutting through the cut ink sublimation laminate but not cutting through the backing layer.

19. The method of claim 16, further comprising removing a portion of the laminate layer from the backing layer after cutting the laminate sheet, the portion of the laminate layer removed from the backing layer corresponding in position to and secured to the first portion of the sublimation laminate removed from the backing layer.

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