System and apparatus for transferring image to article and method of making same

Abstract

Transfer assemblies, transfer sheets, and release papers for transferring images to articles such as textiles, fabrics, etc. are provided. In addition, improved methods of making transfer sheets and articles are provided. The transfer sheet includes a support layer and an image transfer layer including an ink acceptor and a barrier agent. The barrier is configured to prevent or hinder transfer of the ink composition to the substrate in the non-printed area of the image, while substantially permit transfer of the ink composition to the substrate in the printed area of the image. The systems and methods described herein provide a "self-culling" single step process that at the same time minimizes defects in images printed onto articles, and are particularly suited for transfer of white or colored images to dark or black textiles and other fabrics.

Description

[0001] Citation of Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 417,294, filed on Oct. 18, 2022, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This specification 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 manufacturing transfer sheets and articles. Background Art

[0004] In recent years, an important industry has developed that involves applying customer-selected designs, words, numbers, messages, illustrations, etc. (collectively referred to herein as “images”) to articles such as T-shirts, sweatshirts, leather goods, etc. These images can be commercially available products customized for a particular end use and printed on release paper or transfer paper, or the customer can generate an image on heat transfer paper. The transfer sheet is brought into contact with the article to be printed, and heat and pressure are applied to the backing layer, causing the adhesive present in the image transfer layer to be released from the backing layer and flow onto the article together with the printed image.

[0005] Typically, only a portion of the image transfer layer is printed with an image, and the remainder of the image transfer layer is blank. However, the heat and pressure applied to the backing layer cause the entire image transfer layer to flow and adhere to the article. Thus, the image printed on the article is surrounded by an adhesive region that corresponds to the total size of the transfer sheet.

[0006] Various methods and transfer sheet assemblies have been proposed to limit the transfer of non-image or non-printed areas of the transfer sheet when printing an image on an article. Some “peelable” papers have been developed, i.e., portions of the transferable coating can be removed from the heat transfer paper prior to transfer to the substrate. Peeling involves cutting around the printed area and removing the coating from the non-printed, non-relevant areas. However, performing such a peeling process can be difficult and time-consuming, especially around complex graphic designs.

[0007] Two-sheet systems have been developed to transfer an image to a substrate while limiting the transfer of non-printed areas to the article or substrate. These two-sheet “self-peeling” systems involve a printable carrier (part A) that includes an image in the form of at least a partial area toner layer, and a part B that includes a carrier and a polymer layer applied to the carrier. Unfortunately, these systems require two different sheets, and the transfer process requires two steps performed under high temperature and high pressure conditions, as well as an additional step of separating parts A and B.

[0008] Another method of using a single-sheet restriction to transfer the non-printing area of a transfer sheet to an article involves using a barrier agent within the transfer sheet. An aqueous ink composition combined with a colorant is printed on the image transfer layer of the transfer assembly. The liquid carrier present in the ink composition penetrates the image transfer layer, causing the destruction of the barrier agent and being absorbed by the ink receptor, but this only occurs in the printed area. In the non-printing area, i.e., in the area where the ink composition is not absorbed, the barrier agent is not destroyed. A transfer sheet containing such a barrier agent is illustrated in U.S. Patent No. 9,399,362, the entire disclosure of which is incorporated herein by reference.

[0009] Although these efforts have generally improved the process of transferring images to articles, they also have many drawbacks. For example, the vividness and brightness of the image colors and the wash resistance of the transferred image are usually not satisfactory, especially for dark and black substrates and fabrics. In addition, the transfer sheets and / or printed images developed by these methods often exhibit "fish eyes" (i.e., circular voids, pits, or separations), white streaks, spots, and / or blisters, especially when transferring white or colored images to darker textiles. These defects all result in a poor presentation of the image.

[0010] Accordingly, there is a desire to provide improved systems and methods for transferring images to articles such as fabrics or textiles. In particular, there is a desire to provide systems and methods that limit or completely eliminate the transfer of non-printing areas while minimizing any defects in the image printed onto the article. SUMMARY OF THE INVENTION

[0011] A concise summary of the claimed subject matter is given below to provide a basic understanding of certain 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 concise form as a prelude to the more detailed description that follows.

[0012] A transfer assembly and a transfer sheet or release paper for transferring an image to an article such as a textile, fabric, etc. are provided. In addition, improved methods for manufacturing the transfer sheet and the article are provided. The systems and methods described herein provide a "self-weed" single-step process and are thus cheaper and less time-consuming than conventional systems. In addition, these systems and methods minimize defects in the image printed onto the article while improving the vividness, shelf-life aging, and wash resistance of the article. The transfer sheets described herein are particularly suitable for transferring white or colored images to dark or black textiles such as T-shirts, hats, sweatshirts, etc.

[0013] In one aspect, a transfer sheet for transferring an image onto a substrate is provided. The transfer sheet is produced by a process including the steps of: providing a support layer and an image transfer layer, the image transfer layer including an ink receptor and a barrier agent that substantially impedes the 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 below about 180 degrees Fahrenheit.

[0014] The applicant has found that applying heat above 180 degrees Fahrenheit to the image transfer layer in this process may result in white streaks, spots, blistering, or other defects, all of which result in a poor presentation of the image. These defects are particularly evident on dark or black textiles. The applicant has also found that these defects can be minimized or substantially eliminated with a lower temperature drying temperature profile. In certain embodiments, the image transfer layer is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit, preferably about 140 degrees Fahrenheit to about 150 degrees Fahrenheit.

[0015] In an embodiment, the transfer sheet further includes a release layer located between the support layer and the image transfer layer. The release layer can include any suitable material that allows the release layer to be removably attached to the support layer. The release coating can serve as a thermal, warm, or cold peel layer. The release layer can be a partially flowing coating having a viscosity of about 25 CPS to about 90 CPS, preferably about 50 CPS to about 60 CPS.

[0016] In an embodiment, the image transfer layer does not contain an anti-foaming agent or foam control agent. The image transfer layers used in some conventional transfer sheets contain anti-foaming agents or other foam control agents to reduce or eliminate foam formed during production. However, these anti-foaming agents may cause fish eyes, white streaks, spots, blistering, or other defects in the article, especially for dark textiles. The applicant has found that removing the anti-foaming agent from the image transfer layer can minimize or eliminate these defects. Reducing the viscosity of the release layer can also reduce the generation of foam during production, resulting in fewer defects in the image presented on the article.

[0017] In an embodiment, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, preferably a solids content of less than about 40% by weight. The viscosity of the image transfer layer can be about 50 CPS to about 200 CPS, preferably about 100 CPS to about 130 CPS.

[0018] In an embodiment, the image transfer layer includes a first layer or printing coating containing an ink receptor and a barrier agent, and a second layer containing an adhesive or bonding coating. The adhesive preferably contains materials that enhance the adhesion between the release layer and the image transfer layer. In certain embodiments, the viscosity of the second layer or the adhesive is from about 100 CPS to about 130 CPS. Suitable materials for the adhesive include waxes, thermoplastic polymers or prepolymers, and combinations thereof. In an exemplary embodiment, the adhesive includes a polyester or polyester blend that allows the use of sublimation ink in the ink composition. In certain embodiments, the adhesive material is hydrophobic and does not swell when in contact with water. The first layer and the second layer can be mixed together, or they can be formed as separate layers that are in contact with or bonded to each other.

[0019] In an embodiment, the transfer sheet further includes a third layer or white undercoat layer located between the printing coating and the bonding coating. The third layer can include an opaque layer containing one or more materials that enhance the overall opacity of the image transfer layer, thereby enhancing the ability of the presented image to "hide" the content behind the image. 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 viscosity of the third layer or the white undercoat layer can be from about 50 CPS to about 150 CPS. The third layer can be mixed with one or both of the first layer and the second layer, or they can be formed as separate layers that are in contact with or bonded to each other.

[0020] In an embodiment, the ink composition contains a colorant and an aqueous liquid carrier. The composition is not limited to a specific type of colorant and includes organic and inorganic pigments, dyes or macromolecular colorants such as poly(alkylene oxide), substituted chromophores and polymers incorporating such compounds such as polyurethanes and polyesters. As another example, the colorant can be selected from sublimation dyes, disperse dyes, reactive dyes, acid dyes and basic dyes, as well as titanium dioxide, carbon black and calcium carbonate.

[0021] The ink composition can be printed on the upper surface of the transfer sheet by any of a variety of conventional techniques. By way of example, the ink composition can be applied by inkjet printing, screen printing, lithographic printing, embossing, gravure printing, or the ink composition can be applied by hand. In an exemplary embodiment, the ink composition is applied by inkjet printing.

[0022] The barrier agent is a hydrophilic component that can form a film that can be destroyed by water. In the printed area, the barrier agent is substantially destroyed by the liquid carrier, while in the non-printed area, the barrier agent is substantially not destroyed by the liquid carrier. This allows the barrier agent to substantially prevent the transfer of the ink composition to the substrate in the non-printed area, while substantially allowing the transfer of the ink composition to the substrate in the printed area. In an embodiment, during the transfer process, 50 wt% or less, or 40 wt% or less, especially 25 wt% or less, or even 15 wt% or less of the non-printed area of the transfer assembly is transferred to the article. Suitable materials for the barrier agent include, but are not limited to, poly(vinyl alcohol), poly(ethylene glycol), poly(vinyl pyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl)methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ether, hyaluronic acid, albumin, and starch and starch derivatives.

[0023] In an exemplary embodiment, the barrier agent includes starch or a starch derivative. In certain embodiments, by weight, the barrier agent accounts for about 30% to about 40% of the printed coating, preferably about 36%.

[0024] In an embodiment, the ink receptor includes a hydrophilic organic material that attaches to ink molecules. Suitable materials for the ink receptor include, but are not limited to, poly(acrylic acid), poly(vinyl imidazole), poly(2-hydroxyethyl methacrylate), poly(vinyl pyrrolidone), poly(vinyl) poly(pyrrolidone), and polyvinyl acetate, cationic polymers and their salts, hygroscopic inorganic salts, silica, and zeolite.

[0025] In certain embodiments, the adhesive, the barrier agent, and the ink receptor are mixed together in a single image transfer layer applied to the release layer. In other embodiments, the image transfer layer is divided into two layers. The first layer contains the adhesive and the ink receptor, and the second layer contains the barrier agent. The first layer adheres to the release layer, and the second layer adheres to the first layer. In another embodiment, the image transfer layer includes three layers. The first layer applied to the release layer contains the adhesive. The second layer applied to the adhesive contains the ink receptor. The third layer applied to the ink receptor layer contains the barrier agent.

[0026] The transfer sheet can be used to transfer an image onto an article by bringing the support layer into contact with the article and applying heat and pressure to transfer the ink composition, thereby presenting the image on the article. The substrate or article can include any suitable article on which an image is desired to be printed. 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 textiles can contain 100% cotton, less than 100% cotton, or a cotton / polyester blend.

[0027] In one embodiment, the temperature for transferring the ink composition to the article is from about 350 degrees Fahrenheit to about 400 degrees Fahrenheit, or from about 365 degrees Fahrenheit to about 374 degrees Fahrenheit. The pressure can be from about 40 psi to 75 psi or from about 50 psi to 60 psi. Heat and pressure can be applied to the article and the transfer sheet for a period of about 10 to 30 seconds, or about 15 to 20 seconds, or about 18 seconds.

[0028] In certain embodiments, the transfer sheet has been produced such that the coating composition does not fully "cure" on the article after the heating and / or drying step. 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%. Partially curing the coating composition with heat and pressure reduces defects in the printed image, thereby improving its appearance.

[0029] The "degree of cure" is defined herein to refer to the extent to which the composition has crosslinked sufficiently to be substantially in its final form (i.e., the composition will not undergo further crosslinking and / or further substantial changes). The degree of cure as defined herein does not necessarily mean that the composition is 100% crosslinked and has thus become a fully cured resin, but rather refers to 100% cure before there is a substantial change in the function or appearance of the composition.

[0030] 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 vividness of the printed image. For example, the article can be aged for about 2 days to about 6 months, or about 1 week to about 3 months, or about 1 to 2 months, which results in an increase in the "degree of cure" (as defined above) of about 20% to about 80%, or about 40% to about 60%. The applicant has found that allowing the coating composition to complete the curing process by aging (rather than directly by heating and drying) can reduce defects caused by the drying process while still ultimately producing a vivid and bright image in the article.

[0031] In another aspect, a transfer sheet for transferring an image onto a substrate includes a support layer and an image transfer layer covering the support layer. The image transfer layer contains an ink receptor and a barrier agent. The ink receptor is configured to receive the ink composition to define a printed area and a non-printed area in the image transfer layer. The transfer sheet further includes a release layer located between the support layer and the image transfer layer. The release layer can be a partially flowing coating having a viscosity of from about 25 CPS to about 90 CPS, preferably from about 50 CPS to about 60 CPS. Reducing the viscosity of the release layer can also reduce the generation of foam during the transfer process, thereby producing fewer defects in the image presented on the article.

[0032] The release layer can include any suitable material that allows the release layer to be removably attached to the support layer. The release coating can be used as a hot, warm, or cold peel layer.

[0033] In an embodiment, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, preferably a solids content of less than about 40% by weight. The viscosity of the image transfer layer can be from about 50 CPS to about 200 CPS, preferably from about 100 CPS to about 130 CPS. This reduces the amount of foam generated during the production process in the absence of an antifoaming agent, thereby minimizing the generation of defects and significantly improving the image presented on the article.

[0034] 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 contains an ink receptor and a barrier agent. The method further includes bringing the support layer into contact 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 below about 180 degrees Fahrenheit during production.

[0035] In certain embodiments, the transfer sheet is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit during production, preferably a temperature of about 140 degrees Fahrenheit to about 150 degrees Fahrenheit.

[0036] The method further includes printing an ink composition onto the surface of the image transfer layer, thereby defining a printed area and a non-printed area such that the barrier agent substantially hinders the transfer of the ink composition to the article in the non-printed area and substantially allows the transfer of the ink composition to the article in the printed area. Then, the transfer sheet can be used to transfer an image onto the article by bringing the support layer into contact with the article and applying heat and pressure to transfer the ink composition, thereby presenting the image on the article. Then the transfer sheet is separated from the article.

[0037] In certain embodiments, heat and pressure are applied to the transfer sheet such that the coating composition is not completely cured on the article after the heating and drying step. In one exemplary embodiment, heat and pressure can be applied for a period of 15 to 20 seconds.

[0038] In certain embodiments, the article is aged for a period of time to increase the degree of curing of the coating composition, thereby increasing the vividness of the printed image. For example, the article can 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.

[0039] In an embodiment, the image transfer layer is a partially flowing coating having a viscosity of from about 50 CPS to about 200 CPS, preferably from about 100 CPS to about 130 CPS.

[0040] In an embodiment, the transfer sheet further includes a release layer located between the support layer and the image transfer layer. The release layer can include any suitable material that allows the release layer to be removably attached to the support layer. Suitable materials for the release layer include heat release layers, cold release layers, thermal separation layers, and the like. The viscosity of the release layer is from about 25 CPS to about 90 CPS, preferably from about 50 CPS to about 60 CPS.

[0041] The recitation herein of the desired objectives satisfied by the various embodiments of this specification is not meant to imply or suggest that any one or all of these objectives, as fundamental features, exist alone or in combination in the most general embodiment of this specification or in any of its more specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 A transfer sheet for transferring an image onto a substrate or an article is shown;

[0043] Figure 2 Another embodiment of a transfer sheet for transferring an image onto a substrate or an article is shown; and

[0044] Figure 3 Another embodiment of a transfer sheet for transferring an image onto a substrate or an article is shown. DETAILED DESCRIPTION

[0045] This specification and the drawings illustrate exemplary embodiments and should not be considered restrictive. The claims (including equivalents) define the scope of this specification. Various mechanical, compositional, structural, and operational changes can be made without departing from the spirit and scope of this specification and the claims (including equivalents). In some cases, well-known structures and techniques are not shown or described in detail so as not to obscure the description. The same numerals in two or more drawings represent the same or similar elements. Additionally, elements and their related aspects described in detail with reference to one embodiment can be included in other embodiments in which they are not specifically shown or described, as long as it is feasible. For example, if an element is described in detail with reference to one embodiment and not described with reference to a second embodiment, that element can still be included in the second embodiment. Further, the descriptions herein are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or the components shown.

[0046] It should be noted that, as used in this specification and the appended claims, the singular forms "a", "an", and "the" and any singular use of any word include plural referents unless clearly and unambiguously limited to one referent. As used herein, the term "comprising" and its grammatical variations are intended to be non-limiting, such that the listing of items in a list does not exclude other similar items that may be substituted or added to the listed items.

[0047] Unless otherwise stated, any numerical values are approximate, whether or not the words "about" or "approximate" are stated. The materials, methods, and examples described herein are merely exemplary and not restrictive.

[0048] Systems and methods are provided for transferring an image to an article such as a textile, fabric, etc. In addition, improved methods for manufacturing transfer components and sheets are provided. The systems and methods provided herein are a one-step "self-removing" process that minimizes the transfer of non-printed areas to the article while reducing or eliminating defects in the image printed onto the article.

[0049] Figure 1 An embodiment of a transfer sheet 10 is shown, which is used to transfer an image to an article 20. The transfer sheet 10 includes a support layer or substrate 30, a release layer 40, and an image transfer layer 50, and the image transfer layer 50 contains at least an adhesive, an ink receptor, and a barrier agent. An ink composition or a printed coating containing an image is applied to the upper surface of the image transfer layer 50. The ink composition may include printed areas 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 the printed coating from the image transfer sheet 50 to the substrate 30, and then to the article 20.

[0050] The ink composition can be printed on the upper 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, embossing, 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 consistency range of the ink composition can range from liquid to paste.

[0051] As is known to those skilled in the art, the ink composition can contain additional components, such as adhesives, wetting agents, surfactants, etc. In addition to water, the aqueous carrier liquid can also be combined with a small amount of organic co-solvents that are miscible with water, such as lower alcohols, ethylene glycol, and glycerin. For example, the organic co-solvent can account for 20% by weight or less of the liquid carrier component of the ink composition.

[0052] In an exemplary embodiment, the ink composition is a sublimation ink applied by inkjet printing in a one-step process.

[0053] The substrate or article can include any suitable article on which an image is desired to be printed. Suitable articles include T-shirts, sweatshirts, hats, leather items, signs, laminates, metals, glass, wood, paper, or other cellulosic materials, etc. The article can be a woven, knitted, or non-woven textile material composed of natural or synthetic fibers or a combination thereof. For example, the textile can include fibers selected from cotton, wool, jute, hemp, polyester, polyamide, polyurethane, and polyolefin.

[0054] The article can include white textiles, dark textiles, or black textiles. In certain embodiments, the article includes dark or black textiles. The textile can contain 100% cotton, less than 100% cotton, or a cotton / polyester blend.

[0055] In this embodiment, the image transfer layer 50 includes three layers: (1) a printing coating 52 containing an ink receptor and a barrier agent; (2) a white undercoat or opaque layer 54; and (3) an adhesive coating 56 containing an adhesive. These three layers can be formed independently and applied to each other such that the adhesive coating 56 is disposed between the other two layers and the release layer 40. Alternatively, one or more of these layers can be mixed together.

[0056] Figure 2 An alternative embodiment of the transfer sheet 10' is shown, in which the printing coating and the white undercoat are mixed together to form a single layer 60 and applied to the adhesive coating 56. Figure 3 Another embodiment of the transfer sheet 10'' is shown, in which all three of these layers are mixed together to form a single layer 70 and applied to the release layer 40. In yet another embodiment, the barrier agent and the ink receptor can be formed in separate layers. These separate layers can include or not include an adhesive or an opaque layer.

[0057] It is noted that the image transfer layer 50 does not contain an antifoaming agent or any other foam control agent. In an embodiment, the image transfer layer has a solids content of less than about 60% by weight, or less than about 50% by weight, preferably a solids content of less than about 40% by weight. Before heating and drying, the viscosity of the image transfer layer 50 is from about 25 centipoise (CPS) to about 200 CPS. In an embodiment, the viscosity of the image transfer layer is from about 50 CPS to about 200 CPS, preferably from about 100 CPS to about 130 CPS.

[0058] After the printing coating has been applied to the article 20, the release layer 40 allows the image transfer layer 50 to be separated from the substrate 30. The release layer 40 can comprise any suitable material that allows the release layer 40 to be removably attached to the substrate 30. Suitable materials for the release layer 40 include heat release layers, cold release layers, thermal separation layers, and the like.

[0059] In one exemplary embodiment, the release layer 40 is a heat release layer comprising ethylene acrylic acid copolymer (EAA) in an aqueous dispersion. The EAA can be present at at least about 50% of the substrate, at least about 75% of the substrate, or at least about 90% of the substrate. In certain embodiments, the substrate can also comprise a surfactant and / or a polyester dispersion. In one exemplary embodiment, the substrate comprises about 94% EAA dispersion, about 2% surfactant, and about 4% polyester dispersion. The EAA dispersion can include, for example, Prime 74994 manufactured by Michelman, Inc. of Cincinnati, Ohio, USA. The surfactant can include, for example, a silicone surfactant, such as -348 manufactured by BYK. The polyester dispersion can include, for example, a sulfonated polyester dispersion, such as Eastek 1200 manufactured by Eastman Chemical Co. TM 1200.

[0060] 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 foam generated during the transfer process in the absence of an anti-foaming agent, thereby minimizing the generation of defects and significantly improving the image presented on the article.

[0061] The substrate 30 can be selected from (i) non-woven meshes, including meshes made of cellulose fibers, such as coated and uncoated papers, parchment papers, and cardboard, and meshes made of 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, polymethacrylates, polycarbonates, polyimides, polyurethanes, ethylene-vinyl acetate, and polytetrafluoroethylene, and thermosetting resins; (iii) metallized films, including metallized biaxially oriented polyethylene terephthalate; (iv) woven and knitted fabric sheets made of natural or synthetic fibers and combinations thereof, and (v) laminates of two or more materials of the above categories, including laminates of non-woven meshes and thermoplastic polymers.

[0062] The substrate can be opaque, translucent, or transparent. The thickness of the substrate can range from about 1 mil to about 10 mil, particularly in the range of 2 mil to about 6 mil. This thickness is desirable to allow sufficient heat to pass through the substrate during the image transfer process.

[0063] The printing coating 52 includes an ink receptor and a barrier agent. The ink receptor is preferably hydrophilic and capable of absorbing the aqueous liquid carrier component of the ink composition used to print an image on the transfer assembly. In particular, an aqueous ink composition is printed on the upper surface of the image transfer layer, and the aqueous component of the ink is absorbed into the image transfer layer. When the aqueous liquid carrier is drawn through the image transfer layer, the barrier agent is disrupted.

[0064] Depending on the nature of the ink composition, the colorant present in the ink composition may be absorbed by the ink receptor together with the liquid carrier, or the colorant will remain concentrated on the upper surface of the transfer sheet. For example, dyes soluble in the aqueous liquid carrier are readily absorbed into the image transfer layer, while pigments, disperse dyes, and macromolecular colorants have poor mobility and penetrate less deeply into the image transfer.

[0065] By way of example, suitable ink receptors can be selected from hydrophilic polymers including poly(acrylic acid), poly(vinyl imidazole), poly(2-hydroxyethyl methacrylate), poly(vinyl pyrrolidone), poly(vinyl) poly(pyrrolidone), and polyvinyl acetate, cationic polymers, and their salts. Such as 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.

[0066] The ink receptor can be present in the printing coating in an amount of about 2% to about 25% by weight, or about 5% to about 15% or about 10%. In one embodiment, the ink receptor includes a crosslinked homopolymer of N-vinyl-2-pyrrolidone, such as Polyplasdone INF-10 manufactured by Ashland TM .

[0067] The barrier agent useful for the transfer sheet described herein is characterized in that it is hydrophilic, capable of forming a film, and capable of being disrupted by the application of water. The barrier agent has a dual function, namely, it impedes or prevents the non-printed areas of the image transfer layer from transferring to the article during the heat transfer process, and it allows the printed areas of the image transfer layer to transfer to the article. The printed areas of the transfer assembly can transfer to the article because the application of the aqueous ink composition disrupts the barrier layer in the printed areas.

[0068] Suitable compositions for the barrier agent include water-soluble polymers selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinyl pyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl)methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ethers including hydroxypropyl methylcellulose (HPMC), methylcellulose (MC), hydroxyethyl cellulose (HEC), ethyl cellulose (EC), hydroxypropyl cellulose (HPC), carboxymethyl cellulose (CMC), and polyanionic cellulose (PAC), hyaluronic acid, albumin, and starches and starch derivatives.

[0069] In one exemplary embodiment, the barrier agent includes starch or a starch derivative. The starch may be present in the printed coating 52 in an amount of about 20% to about 50%, or about 30% to about 40%, or about 36% by weight. In an embodiment, during the transfer process, the barrier agent prevents at least 50 wt%, or 60 wt%, especially 75 wt% or even 85 wt% of the non-printed area from being transferred onto the article.

[0070] The printed coating 52 may contain materials other than the barrier agent and the ink receptor. For example, the printed coating 52 may contain certain silica, surfactants, waxes, and / or thickeners. Suitable surfactants include, but are not limited to, nonionic surfactants, anionic surfactants, cationic surfactants, and amphoteric surfactants such as sodium stearate, 4-(5-dodecyl)benzenesulfonate, sodium dodecylbenzenesulfonate wetting agent, dioctyl sulfosuccinate (sodium salt), alkyl ether phosphate, benzalkonium chloride (BAC), perfluorooctane sulfonate (PFOS), etc. Examples of waxes include, but are not limited to, polyolefins, polyethylene, functionalized waxes such as amines, amides, fluorinated waxes, mixed fluorinated and amide waxes such as esters, quaternary amines, carboxylic acids, or acrylic polymer emulsions, chlorinated polyethylene, natural or synthetic ester waxes, carnauba wax, paraffin wax, etc. Optionally, such waxes may be fractionated or distilled to provide specific fractions that meet specific viscosity and / or temperature criteria. Suitable thickeners include, but are not limited to, starches, gums, pectins, para gum, etc.

[0071] In one exemplary embodiment, the printed coating 52 contains about 5% to about 15%, or about 10% by weight of silica (e.g., silica gel, known in the industry as 23F, manufactured by PQ Corporation). The printed coating 52 also contains about 2% to about 5% by weight of a surfactant (e.g., -348). The printed coating 52 also contains about 20% to about 30%, or about 26% by weight of a wax, such as polyethylene / carnauba wax, etc. (e.g., manufactured by Micropowders, Inc. (295 - 40). The printing coating 52 may also include deionized water and a thickening agent present in an amount of about 10% to about 15%, or about 13% by weight. The thickening agent may include Paragum 265 manufactured by Para-Chem Southern, Inc.

[0072] The white undercoat 54 improves the opacity of the image transfer layer 50. This increased opacity improves the ability of the presented image to "hide" the content behind it. 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 (TiO 2 ) and the like.

[0073] In an exemplary embodiment, the white undercoat 54 contains TiO in an amount of about 20% to about 35%, or about 28% by weight. 2 . The white undercoat 54 may also include surfactants, crosslinking agents, aqueous dispersions, and other materials. In an exemplary embodiment, the white undercoat 54 contains about 35% to about 45%, or about 39% by weight of an EAA dispersion (e.g., Prime 74994); about 2% to about 5%, or about 4% by weight of a surfactant (e.g., -348), about 10% to about 15%, or about 13% by weight of a crosslinking agent (e.g., 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 styrene acrylic (e.g., Unibond SA240 manufactured by Unichem). The white undercoat 54 may also include a thickening agent, such as Paragum 265 manufactured by Para-Chem Southern, Inc.

[0074] The adhesive coating 56 contains an adhesive, which preferably includes a material that promotes adhesion between the printing coating 52 and the white undercoat 54 and the release layer 40. The adhesive preferably includes a material that does not swell when in contact with water, i.e., the material absorbs water (> 5% and < 50% of its own weight). The adhesive is preferably hydrophobic.

[0075] The binder can be wax, a thermoplastic polymer or prepolymer, or a combination thereof. Additional reactive compounds can be used in the binder composition, including crosslinking agents, monomers, and oligomers, which are capable of binding to themselves or other components in the binder composition. The components of the binder composition can be self-crosslinking or capable of binding to functional groups present in the printed article to improve wash resistance. The ink composition for the transfer sheet described herein comprises a colorant and an aqueous liquid carrier. The composition is not limited to a particular type of colorant and includes organic and inorganic pigments, dyes, or macromolecular colorants such as poly(oxyalkylene), substituted chromophores, and polymers incorporating such compounds, such as polyurethanes and polyesters. As another example, the colorant can be selected from sublimation dyes, disperse dyes, reactive dyes, acid dyes, and basic dyes, as well as titanium dioxide, carbon black, and calcium carbonate.

[0076] In an embodiment, the binder comprises a polyester or polyester-based material, preferably at least about 40% polyester or at least about 60% polyester. During transfer, the polyester polymer chains reach their glass transition state (Tg). This means the chains separate, so that when the ink sublimes, these molecules can be located between the chains. After the temperature drops, the polymer chains bind together again with the ink molecules trapped between the chains.

[0077] In an exemplary embodiment, the adhesive coating 56 comprises an EAA dispersion in an amount of about 45% to about 55% by weight, or about 49% (e.g., Prime 74994). The adhesive coating 56 can comprise other components such as surfactants, crosslinking agents, polyurethanes, polyesters, etc. In one such embodiment, the adhesive coating 56 comprises a polyurethane in an amount of about 15% to about 25% by weight, or about 18% (e.g., Sancure 200025F, which is an aliphatic polyester polyurethane dispersion manufactured by Lubrizol), a polyester in an amount of about 15% to about 25% by weight, or about 18% (e.g., Eastek TM 1200), a surfactant in an amount of about 2% to about 8% by weight, or about 4% (e.g., -348), and a crosslinking agent in an amount of about 7% to about 13% or about 10% by weight (e.g., 2794). The adhesive coating 56 can also comprise a thickening agent such as Paragum 265 manufactured by Para-Chem Southern, Inc.

[0078] The process for manufacturing the above-described transfer sheet will now be described. The release layer 40 is applied to the base layer 30, and then the image transfer layer 50 is applied to the release layer 40 or placed in contact with the release layer 40 (or vice versa: the release layer 40 can be attached to the image transfer layer 50 and then placed in contact with the base layer 30).

[0079] Then, the image transfer layer 50 is heated to a temperature below about 180 degrees Fahrenheit. The applicant has found that applying heat above 180 degrees Fahrenheit to the transfer sheet causes white streaks, spots, blistering, and other defects, which all result in a poor presentation of the image. These defects are particularly noticeable on dark or black textiles. The applicant has also found that a lower-temperature drying curve can be used to minimize or substantially eliminate these defects. In certain embodiments, the transfer sheet is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit, preferably about 140 degrees Fahrenheit to about 150 degrees Fahrenheit.

[0080] In an exemplary embodiment, the release layer 40 is first applied to the base layer 30 at a temperature below about 180 degrees Fahrenheit, preferably about 150 degrees Fahrenheit. In an exemplary embodiment, heat is applied by two different zones of an oven. These zones can, for example, have a temperature of about 160 degrees Fahrenheit in zone 1 and 185 degrees Fahrenheit in zone 2.

[0081] Then, the adhesive coating 56 is applied to the release layer 40 at a temperature below about 180 degrees Fahrenheit, preferably about 150 degrees Fahrenheit. In an exemplary embodiment, heat is applied by three different zones of an oven. These zones have, for example, a temperature of about 175 degrees Fahrenheit in zone 3, about 205 degrees Fahrenheit in zone 4, and about 220 degrees Fahrenheit in zone 5.

[0082] Then, the white undercoat 54 can be applied to the adhesive coating 56 at a temperature below about 160 degrees Fahrenheit, preferably about 140 degrees Fahrenheit. In an exemplary embodiment, heat is applied by two different zones of an oven. These zones can, for example, have a temperature of about 130 degrees Fahrenheit in zone 1 and 150 degrees Fahrenheit in zone 2.

[0083] Finally, the printing coating 52 is applied to the white undercoat 54 at a temperature below about 160 degrees Fahrenheit, preferably about 140 degrees Fahrenheit. In an exemplary embodiment, heat is applied by three different zones of an oven. These zones have, for example, a temperature of about 140 degrees Fahrenheit in zone 3, about 170 degrees Fahrenheit in zone 4, and about 185 degrees Fahrenheit in zone 5.

[0084] Each zone of the oven is approximately 20 feet long, and the coater speed can be from approximately 80 fpm to approximately 120 fpm, or approximately 100 fpm.

[0085] Once the transfer sheet is formed, the operator can use the transfer sheet to transfer the image onto an article. In this process, as described above, the image is applied to the upper surface of the image transfer layer 50 with a suitable ink composition or printing coating. Then the base layer 30 is brought into contact with the article 20. A minimal pressure can be applied to the transfer sheet 10 by a printing press or other suitable machine to maintain the contact between the base layer 30 and the article 20. In some cases where the article is a porous article such as a textile, the pressure can be selected to increase the penetration of the ink composition into the voids of the article. The pressure is selected such that it does not cause non-printed areas to be transferred onto the article. The operating conditions of the printing 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 pressure can be in the range of from approximately 1 psi to approximately 100 psi, or from approximately 40 psi to 75 psi or from approximately 50 psi to 60 psi. In one embodiment, the temperature for transferring the ink composition is from approximately 350 degrees Fahrenheit to approximately 400 degrees Fahrenheit, or from approximately 365 degrees Fahrenheit to approximately 374 degrees Fahrenheit.

[0086] In certain embodiments, heat and pressure are applied to the transfer sheet at a certain temperature for a period of time such that the ink composition is not fully cured 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%, preferably from approximately 30% to approximately 80%, or from approximately 40% to approximately 60%. Partially curing the ink composition with heat and pressure reduces defects in the printed image, thereby improving its appearance.

[0087] The "degree of cure" is defined herein to refer to the extent to which the composition has been sufficiently crosslinked to be substantially in its final form (i.e., the composition will not undergo further crosslinking and / or further substantial changes). The degree of cure as defined herein does not necessarily mean that the composition is 100% crosslinked and has thus become a fully cured resin, but rather refers to 100% cure before there is a substantial change in the function or appearance of the composition.

[0088] In an exemplary embodiment, heat and pressure can be applied to the article and the transfer sheet for a period of time lasting from approximately 10 to 30 seconds, or from approximately 15 to 20 seconds, or approximately 18 seconds.

[0089] In certain embodiments, the article is aged for a period of time to increase the degree of cure of the ink composition, thereby enhancing the vividness of the printed image. For example, the article can be aged for about 2 days to about 6 months, or about 1 week to about 3 months, or about 1 to 2 months, which results in an increase in the "degree of cure" (as defined above) of about 20% to about 80%, or about 40% to about 60%. The applicant has found that allowing the ink composition to complete the curing process through aging (instead of directly by heating and drying) can reduce defects caused by the drying process while still ultimately producing a vivid and bright image on the article.

[0090] At the end of the transfer time, the transfer sheet is peeled off from the article, such that the printed area of the image transfer layer remains bonded to the article, while the non-printed area of the image transfer layer remains bonded to the support layer of the transfer sheet. In an embodiment, during the transfer process, 50 wt% or less, or 40 wt% or less, particularly 25 wt% or less, or even 15 wt% or less of the non-printed area of the transfer assembly is transferred to the article.

[0091] Example 1

[0092] The applicant tested a conventional transfer sheet and the transfer sheet described herein. In the first test, the applicant tested a conventional transfer sheet (Sample 1) that included a silicone defoamer in the coating contained in the image transfer layer. In this test, the applicant applied two coatings to the substrate as described above: (1) a first coating that included a release layer, such as the release layer described above, except that the layer contained a silicone defoamer and had a solids percentage of 35.9% and a viscosity of 100 CPS; and (2) a second coating that included an adhesive-containing bonding coating. The bonding coating was substantially as described above, except that after adding paragum as a thickener, the layer had a solids percentage of 37.8% and a viscosity of 350 CPS.

[0093] Before applying pressure and heat, the applicant found that these layers contained multiple visible fish eyes, such as circular voids or pits, in the release coating. When the second coating or the bonding coating was applied over the release coating, the frequency and size of the fish eyes increased.

[0094] The applicant then conducted the same test under substantially similar conditions and parameters, except that the silicone defoamer was removed from the release layer (Sample 2). At the end of this test, it was noted that there were no fish eyes or pits in any of the layers, and the appearance of these layers was significantly improved.

[0095] Example 2

[0096] The applicant conducted a second test on Sample 2 (i.e., without silicone defoamer). The first pass coating or release layer had a solids percentage of 35.2% and a viscosity of 110 CPS. After adding Paraloid, the second pass coating or adhesive coating had a solids percentage of 37.5% and a viscosity of 130 CPS. These two layers were coated on a substrate and dried in an oven with five different heating zones. The temperatures of each zone were as follows (all in degrees Fahrenheit): (1) Zone 1: 205; (2) Zone 2: 235; (3) Zone 3: 220; (4) Zone 4: 240; and (5) Zone 5: 260. The sheet temperature was 180 degrees Fahrenheit.

[0097] After heating and drying, it was noted that the transfer sheet contained multiple raised coating lanes, blisters, and spots, which reduced its appearance quality.

[0098] Then, the applicant applied two additional coatings to the transfer sheet in the second pass. The first coating was a white primer similar to that described above and had a solids content of 43.5% and a viscosity of 120 CPS after adding Paraloid. The second coating was a printing coating similar to that described above and had a solids content of 15.5% and a viscosity of 110 CPS after adding Paraloid. When applying these coatings, the entire sheet was heated and dried at a lower drying temperature profile. The drying temperature profile in the oven was as follows (all in degrees Fahrenheit): (1) Zone 1: 160; (2) Zone 2: 160; (3) Zone 3: 150; (4) Zone 4: 180; and (5) Zone 5: 200. The sheet temperature was 160 degrees Fahrenheit.

[0099] Examination of the sheet after heating showed that the less aggressive drying temperature profile reduced the blister level and the second pass coatings masked some of the defects of the first pass coatings. Although it was noted that the transfer sheet still contained some blisters and some spots, its appearance was significantly improved after the second pass. Therefore, it can be concluded that the less aggressive drying temperature profile, which reduced the transfer sheet temperature from 180 degrees Fahrenheit to 160 degrees Fahrenheit, improved the overall appearance of the transfer sheet.

[0100] Example 3

[0101] The applicant conducted a third test with the first two coatings (release layer and adhesive coating), the differences being as follows: (1) the release layer does not contain a silicone defoamer and has a solids percentage of 34.1% and a significantly reduced viscosity of 50 CPS; and (2) the adhesive coating has a solids percentage of 37.5% and a viscosity of 120 CPS after adding Paraloid. In addition, the applicant further reduced the drying temperature profile as follows (all in degrees Fahrenheit): (1) Zone 1: 160; (2) Zone 2: 185; (3) Zone 3: 175; (4) Zone 4: 205; and (5) Zone 5: 220. The sheet temperature is 150 degrees Fahrenheit.

[0102] Inspection of the sheet after heating showed a significant improvement in the appearance of the sheet in the first pass compared to the previous tests. The combination of foam, bubbles, streaks, and other defects was substantially eliminated from the image.

[0103] Then, the applicant applied a second pass to the transfer sheet with two additional coatings: (1) a white base coat with a solids content of 43.5% and a reduced viscosity of 60 CPS after adding Paraloid; and (2) a printing coating with a solids content of 15.5% and a viscosity of 110 CPS. Similar to the first pass, a reduced drying temperature profile was applied (all in degrees Fahrenheit): (1) Zone 1: 130; (2) Zone 2: 150; (3) Zone 3: 143; (4) Zone 4: 170; and (5) Zone 5: 185. The sheet temperature is 140 degrees Fahrenheit.

[0104] Inspection of the sheet after heating showed that after the second pass on the third test sample, the blistering and spotting in the previous tests were no longer present. In addition, transferring the image newly onto a T-shirt demonstrated good removability (i.e., the non-printed areas did not contain any visible ink composition). The image initially had a relatively low vividness. However, the applicant subsequently conducted an accelerated aging test on the T-shirt, and the results showed that this vividness increased significantly with aging. The accelerated aging of the T-shirt simulated approximately two months.

[0105] Although the apparatus, system, and method are described in detail herein in accordance with some of their preferred embodiments, many modifications and variations can be made thereto by those skilled in the art. Accordingly, the foregoing description should not be construed as being limited thereby, but should be construed as including the obvious variations described above and being limited only by the spirit and scope of the following claims.

[0106] 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 process comprising 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 barrier agent; and applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature below about 180 degrees Fahrenheit during production.

[0107] A second embodiment is the first embodiment, wherein the image transfer layer is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit during production.

[0108] A third embodiment is any combination of the previous two embodiments, wherein the image transfer layer is heated to a temperature of about 140 degrees Fahrenheit to about 150 degrees Fahrenheit during production.

[0109] A fourth embodiment is any combination of the previous three embodiments, further comprising applying a release layer between the support layer and the image transfer layer, wherein the viscosity of the release layer is about 25 CPS to about 90 CPS.

[0110] A fifth embodiment is any combination of the previous four embodiments, wherein the viscosity of the release layer is about 50 CPS to about 60 CPS.

[0111] A sixth embodiment is any combination of the previous five embodiments, further comprising applying an ink composition to the surface of the image transfer layer, thereby defining a printed area and a non-printed area.

[0112] A seventh embodiment is any combination of the previous six embodiments, wherein the ink composition comprises a liquid carrier, wherein in the printed area, the barrier agent is substantially destroyed by the liquid carrier, and in the non-printed area, the barrier agent is substantially not destroyed by the liquid carrier.

[0113] An eighth embodiment is any combination of the previous seven embodiments, wherein the ink composition further comprises a colorant, wherein the colorant adheres to the substrate in the printed area.

[0114] A ninth embodiment is any combination of the previous eight embodiments, wherein the substrate is a dark or black textile.

[0115] A tenth embodiment is any combination of the previous nine embodiments, wherein the textile comprises cotton or a cotton / polyester blend.

[0116] The eleventh embodiment is any combination of the first ten embodiments, wherein the barrier agent substantially prevents at least about 50 wt% of the ink composition from transferring to the article in the non-printing area, while substantially allowing the ink composition to transfer to the article in the printing area.

[0117] The twelfth embodiment is any combination of the first eleven embodiments, wherein the image transfer layer comprises a partially flowable coating having a viscosity of about 25 CPS to about 200 CPS.

[0118] The thirteenth embodiment is any combination of the first twelve embodiments, further comprising bringing the transfer sheet into contact with the substrate.

[0119] The fourteenth embodiment is any combination of the first thirteen embodiments, further comprising applying heat and pressure to the transfer sheet at a certain temperature for a certain period of time such that the degree of curing of the coating composition in the substrate is less than 100%.

[0120] The fifteenth embodiment is any combination of the first fourteen embodiments, wherein the degree of curing is about 30% to about 80%.

[0121] The sixteenth embodiment is any combination of the first fifteen embodiments, wherein the period of time is about 15 seconds to about 20 seconds.

[0122] The seventeenth embodiment is any combination of the first sixteen embodiments, further comprising aging the sheet to increase the degree of curing of the coating composition in the substrate.

[0123] In another aspect, the first embodiment is a transfer sheet for transferring an image onto a substrate. The transfer sheet includes a support layer, an image transfer layer covering the support layer and containing an ink receptor and a barrier agent, and a release layer located between the support layer and the image transfer layer, wherein the release layer has a viscosity of about 25 CPS to about 90 CPS.

[0124] The second embodiment is the first embodiment, wherein the release layer has a viscosity of about 50 CPS to about 60 CPS.

[0125] The third embodiment is any combination of the first two embodiments, wherein the ink receptor is configured to receive an ink composition to define a printing area and a non-printing area in the image transfer layer, wherein the barrier agent is configured to substantially prevent the ink composition from transferring to the substrate in the non-printing area, while substantially allowing the ink composition to transfer to the substrate in the printing area.

[0126] The fourth embodiment is any combination of the first three embodiments, wherein the image transfer layer comprises a partially flowable coating having a viscosity of from about 25 CPS to about 200 CPS.

[0127] The fifth embodiment is any combination of the first four embodiments, wherein the viscosity of the image transfer layer is from about 100 CPS to about 130 CPS.

[0128] The sixth embodiment is any combination of the first five embodiments, wherein the image transfer layer comprises a first layer containing an ink receptor and a barrier agent and a second layer containing an adhesive.

[0129] The seventh embodiment is any combination of the first six embodiments, wherein the first layer and the second layer are mixed together.

[0130] The eighth embodiment is any combination of the first seven embodiments, further comprising a third layer located between the first layer and the second layer, the third layer containing one or more materials for increasing the opacity of the image transfer layer.

[0131] The ninth embodiment is any combination of the first eight embodiments, wherein the first layer and the third layer are mixed together.

[0132] The tenth embodiment is any combination of the first nine embodiments, wherein the substrate is a dark or black textile.

[0133] The eleventh embodiment is any combination of the first ten embodiments, wherein the textile comprises cotton or a cotton / polyester blend.

[0134] The twelfth embodiment is any combination of the first eleven embodiments, wherein the ink composition comprises a liquid carrier, and wherein in the printed area, the barrier agent is substantially destroyed by the liquid carrier, while in the non-printed area, the barrier agent is substantially not destroyed by the liquid carrier.

[0135] The thirteenth embodiment is any combination of the first twelve embodiments, wherein the ink composition is hydrophilic.

[0136] The fourteenth embodiment is any combination of the first thirteen embodiments, wherein the barrier agent is hydrophilic.

[0137] The fifteenth embodiment is any combination of the first fourteen embodiments, wherein the barrier agent is selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinyl pyrrolidone), polyacrylic acid, polyacrylamide, N-(2-hydroxypropyl) methacrylamide, xanthan gum, pectin, dextran, carrageenan, guar gum, cellulose ether, hyaluronic acid, albumin, and starches and starch derivatives.

[0138] The sixteenth embodiment is any combination of the first fifteen embodiments, wherein the barrier agent comprises starch.

[0139] The seventeenth embodiment is any combination of the first sixteen embodiments, 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 zeolite.

[0140] The eighteenth embodiment is any combination of the first seventeen embodiments, wherein the adhesive is selected from the group consisting of wax, thermoplastic polymers or prepolymers, and combinations thereof.

[0141] The nineteenth embodiment is any combination of the first eighteen embodiments, wherein the adhesive comprises a polyester or a polyester blend.

[0142] In another aspect, the first embodiment is an article with a printed image, which is produced by a process. The process includes providing a transfer sheet that includes a support layer and an image transfer layer adhered to the support layer, the image transfer layer including an ink receptor and a barrier agent; applying an ink composition to the surface of the image transfer layer, thereby defining a printed area and a non-printed area; bringing the article into contact with the transfer sheet, applying heat and pressure to the transfer sheet at a certain temperature for a certain 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 and the article.

[0143] The second embodiment is the first embodiment, wherein the degree of cure is from about 30% to about 80%.

[0144] The third embodiment is any combination of the first two embodiments, wherein the period of time is from about 15 seconds to about 20 seconds.

[0145] The fourth embodiment is any combination of the first three embodiments, wherein the temperature is from about 350 degrees Fahrenheit to about 400 degrees Fahrenheit.

[0146] The fifth embodiment is any combination of the first four embodiments, further including aging the article to increase the degree of cure of the coating composition within the article.

[0147] The sixth embodiment is any combination of the first five embodiments, wherein the barrier agent substantially prevents at least about 50 wt% of the ink composition from transferring to the article in the non-printed area, while substantially allowing the ink composition to transfer to the article in the printed area.

[0148] The seventh embodiment is any combination of the first six embodiments, wherein the article is a dark or black textile.

[0149] The eighth embodiment is any combination of the first seven embodiments, wherein the textile comprises cotton or a cotton / polyester blend.

[0150] In another aspect, the first embodiment is a method of manufacturing 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 barrier agent; bringing the support layer into contact 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 below about 180 degrees Fahrenheit during production.

[0151] The second embodiment is the first embodiment, wherein the image transfer layer is heated to a temperature of about 120 degrees Fahrenheit to about 180 degrees Fahrenheit during production.

[0152] The third embodiment is any combination of the first two embodiments, wherein the image transfer layer is heated to a temperature of about 140 degrees Fahrenheit to about 150 degrees Fahrenheit during production.

[0153] The 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 a printed area and a non-printed area, wherein the barrier agent substantially prevents at least about 50 weight percent of the ink composition from transferring to the article in the non-printed area and substantially allows the ink composition to transfer to the article in the printed area.

[0154] The 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 about 25 CPS to about 90 CPS.

Claims

1. A transfer sheet for transferring an image onto a substrate, produced by a process comprising the following steps: 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 barrier agent; and Applying heat and pressure to the image transfer layer such that the image transfer layer is heated to a temperature below about 180 degrees Fahrenheit during production.

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

3. The transfer sheet according to claim 1, wherein the image transfer layer is heated to a temperature of about 140 degrees Fahrenheit to about 150 degrees Fahrenheit during production.

4. The transfer sheet according to claim 1, further comprising applying a release layer between the support layer and the image transfer layer, wherein the release layer has a viscosity of about 25 CPS to about 90 CPS.

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

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

7. The transfer sheet according to claim 6, wherein the ink composition comprises a liquid carrier, wherein in the printed area, the barrier agent is substantially destroyed by the liquid carrier, while in the non-printed area, the barrier agent is substantially not destroyed by the liquid carrier.

8. The transfer sheet according to claim 7, wherein the ink composition further comprises a colorant, wherein the colorant adheres to the substrate in the printed area.

9. The transfer sheet according to claim 1, wherein the substrate is a dark or black textile.

10. The transfer sheet according to claim 9, wherein the textile comprises cotton or a cotton / polyester blend.

11. The transfer sheet according to claim 6, wherein the barrier agent substantially prevents at least about 50 wt% of the ink composition from transferring to the article in the non-printed area, while substantially allowing the ink composition to transfer to the article in the printed area.

12. The transfer sheet according to claim 1, wherein the image transfer layer comprises a partially flowable coating having a viscosity of about 25 CPS to about 200 CPS.

13. The transfer sheet according to claim 1, further comprising bringing the transfer sheet into contact with the substrate.

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

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

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

17. The transfer sheet according to claim 14 further comprises aging the sheet to increase the degree of curing of the coating composition within the substrate.

18. A transfer sheet for transferring an image onto a substrate, the transfer sheet comprising: a support layer; an image transfer layer covering the support layer, the image transfer layer comprising an ink receptor and a barrier agent; and a release layer located between the support layer and the image transfer layer, wherein the release layer has a viscosity of from about 25 CPS to about 90 CPS.

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

20. The transfer sheet according to claim 18, wherein the ink receptor is configured to receive an ink composition to define printed and non-printed areas in the image transfer layer, wherein the barrier agent is configured to substantially impede transfer of the ink composition to the substrate in the non-printed areas and to substantially permit transfer of the ink composition to the substrate in the printed areas.

21. The transfer sheet according to claim 18, wherein the image transfer layer comprises a partial flow coating having a viscosity of from about 25 CPS to about 200 CPS.

22. The transfer sheet according to claim 21, wherein the image transfer layer has a viscosity of from about 100 CPS to about 130 CPS.

23. The transfer sheet according to claim 18, wherein the image transfer layer comprises a first layer comprising an ink receptor and a barrier agent and a second layer comprising an adhesive.

24. The transfer sheet according to claim 23, wherein the first layer and the second layer are mixed together.

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

26. The transfer sheet according to claim 25, wherein the first layer and the third layer are mixed together.

27. The transfer sheet according to claim 18, wherein the substrate is a dark or black textile.

28. The transfer sheet according to claim 27, wherein the textile comprises cotton or a cotton / polyester blend.

29. The transfer sheet according to claim 18, wherein the ink composition comprises a liquid carrier, wherein in the printed areas, the barrier agent is substantially destroyed by the liquid carrier, and in the non-printed areas, the barrier agent is substantially not destroyed by the liquid carrier.

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

31. The transfer sheet according to claim 18, wherein the barrier agent is hydrophilic.

32. The transfer sheet according to claim 18, wherein the barrier agent is selected from the group consisting of poly(vinyl alcohol), poly(ethylene glycol), poly(vinyl pyrrolidone), 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. The transfer sheet according to claim 18, wherein the barrier agent comprises starch.

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

35. The transfer sheet according to claim 23, wherein the adhesive is selected from the group consisting of wax, thermoplastic polymers or prepolymers, and combinations thereof.

36. The transfer sheet according to claim 23, wherein the adhesive comprises a polyester or a polyester blend.

37. An article with a printed image, produced by a process comprising the following steps: Providing a transfer sheet comprising a support layer and an image transfer layer adhered to the support layer, the image transfer layer comprising an ink receptor and a barrier agent; Applying an ink composition to the surface of the image transfer layer, thereby defining a printed area and a non-printed area; Bringing the article into contact with the transfer sheet; Applying heat and pressure to the transfer sheet at a certain temperature for a certain 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.

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

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

40. The article according to claim 37, wherein the temperature is from about 350 degrees Fahrenheit to about 400 degrees Fahrenheit.

41. The article according to claim 37, further comprising aging the article to increase the degree of cure of the coating composition in the article.

42. The article according to claim 37, wherein the barrier agent substantially prevents at least about 50% by weight of the ink composition from transferring to the article in the non-printed area, while substantially allowing the ink composition to transfer to the article in the printed area.

43. The article according to claim 37, wherein the article is a dark or black textile.

44. The article according to claim 43, wherein the textile comprises cotton or a cotton / polyester blend.

45. A method of manufacturing a transfer sheet for transferring an image to an article, the method comprising: Providing a support layer and an image transfer layer, the image transfer layer comprising an ink receptor and a barrier agent; Bringing the support layer into contact with the image transfer layer; and Heat and pressure are applied to the image transfer layer such that the image transfer layer is heated to a temperature below about 180 degrees Fahrenheit during production.

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

47. The method according to claim 45, wherein the image transfer layer is heated to a temperature of about 140 degrees Fahrenheit to about 150 degrees Fahrenheit during production.

48. The method according to claim 45, further comprising printing an ink composition onto the surface of the image transfer layer, thereby defining a printed area and a non-printed area, wherein the barrier substantially prevents at least about 50 weight percent of the ink composition from transferring to the article in the non-printed area, while substantially allowing the ink composition to transfer to the article in the printed area.

49. The method according to 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 about 25 CPS to about 90 CPS.

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