Thermal transfer roller apparatus and related methods of use

Abstract

A thermal transfer roller device is disclosed that is configured to transfer at least one design onto a substrate. In at least one embodiment, with the substrate sandwiched between a support frame and a support base of the device, and with a thermal transfer compatible transfer sheet containing at least one design positioned on the substrate within a frame boundary defined by the support frame, at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined temperature, pressure, and traverse time set by a controller to adhere the at least one design on the transfer sheet to the substrate, and then a carrier of the device separates the transfer sheet from the substrate while the transfer sheet is still hot.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and is entitled to the benefit of the filing date of U.S. Provisional Patent Application Serial No. 63 / 315816, filed March 2, 2022, the contents of which are incorporated herein by reference.

[0002] TECHNICAL FIELD The subject matter of this application relates generally to thermal transfer technology, and more particularly to a thermal transfer roller apparatus and related methods of use for more safely and effectively transferring designs onto a substrate.

[0003] Applicant hereby incorporates by reference any and all patents and published patent applications cited or referenced herein. [Background technology]

[0004] By way of background, heat transfer printing is a technique for transferring a desired decoration (i.e., text, artwork, and other types of two-dimensional designs (hereinafter, for simplicity, generally referred to as "design") onto a fabric or other material (hereinafter, for simplicity, generally referred to as "substrate"). Conventionally, the design is first printed onto a heat transfer compatible transfer sheet (e.g., a sheet of paper or plastic coated with a wax and pigment polymer film, etc.) using a heat transfer compatible transfer ink (e.g., inkjet ink, pigment ink, or sublimation ink, etc.). The substrate (e.g., a shirt, etc.) is manually positioned over the heating pad of a heated press, and the design is printed onto a heat transfer compatible transfer sheet (e.g., a sheet of paper or plastic coated with a wax and pigment polymer film, etc.). The transfer sheet is manually positioned in the desired location on the substrate. Once the heated platens of the heated press reach the required temperature (typically between approximately 250 and 400 degrees Fahrenheit), the heated press is closed by moving the flat heated platen downward against the heat pad, sandwiching the transfer sheet and substrate between them. The desired pressure of the heated press, along with the press time, is set according to the thickness of the substrate and the particular type of transfer sheet and transfer ink used. The heated press bonds the design on the transfer sheet to the substrate. After the press time has elapsed, the heated platen is lifted and the transfer sheet is manually removed while still hot, leaving the design on the substrate.

[0005] While this conventional heat transfer process can be effective in transferring a design onto a substrate, it is very time consuming and requires a lot of manual labor, resulting in room for error in the positioning of the design relative to the substrate, the required temperature of the heated press, the required pressure of the heated press, the required pressing time of the heated press, and the subsequent removal of the transfer sheet, each of which can result in a defective final product. The manual labor involved in conventional heat transfer processes also exposes the user to potential injury given their close proximity to extremely hot surfaces.

[0006] Thus, there remains a need for improved thermal transfer devices that can reduce production time while also eliminating many of the manual steps required in conventional thermal transfer techniques. Aspects of the present invention fulfill these needs and provide further related advantages, which are described in the Summary below.

[0007] It should be noted that the above background description includes information that may be useful in understanding aspects of the present invention. The background description is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art. Summary of the Invention

[0008] Aspects of the present invention teach particular advantages in construction and use that provide exemplary benefits described below.

[0009] The present invention solves the above-mentioned problems by providing a thermal transfer roller apparatus and associated method of use for more safely and effectively transferring a design onto a substrate. In at least one embodiment, a printer is configured to print at least one design onto a thermal transfer compatible transfer sheet using a thermal transfer compatible transfer ink. A thermal transfer assembly is positioned and configured to receive the transfer sheet as it exits the printer. The thermal transfer assembly includes a support base positioned and configured to support the substrate and a support frame positioned and configured to selectively sandwich the substrate substantially between the support base, the support frame defining a frame boundary that leaves a portion of the substrate onto which the at least one design is thermally transferred substantially unobstructed. An articulating carrier is configured to removably engage a leading edge of the transfer sheet and position the transfer sheet in contact with the substrate at a location within the frame boundary, prevent the transfer sheet from unintentionally shifting relative to the substrate as the design is transferred onto the substrate, and separate the transfer sheet from the substrate after the design is transferred onto the substrate. At least one heated roller is positioned and configured to selectively roll into contact with the transfer sheet as the transfer sheet is positioned on the substrate within the frame boundary. The controller is configured to automatically control each of the carrier and the at least one heated roller. During use of the apparatus, with a substrate sandwiched between the support frame and the support base and a transfer sheet positioned on the substrate within the frame boundaries, the at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined temperature, pressure, and traverse time set by the controller to adhere at least one design on the transfer sheet to the substrate, after which the carrier separates the transfer sheet from the substrate while the transfer sheet is still hot.

[0010] Other features and advantages of aspects of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of aspects of the present invention.

[0011] The accompanying drawings illustrate aspects of the present invention. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of an exemplary thermal transfer roller apparatus according to at least one embodiment. [Diagram 2] FIG. 1 is a perspective view of an exemplary thermal transfer roller apparatus according to at least one embodiment. [Diagram 3] FIG. 2 illustrates a roller of the device according to at least one embodiment. [Figure 4] FIG. 2 is a partial perspective view of an exemplary support base of a device according to at least one embodiment. [Diagram 5] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 6] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 7] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 8] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 9] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 10] 1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. [Figure 11]1 is a further partial perspective view of an exemplary thermal transfer roller apparatus illustrating an exemplary method for transferring at least one design from a thermally compatible transfer sheet onto a substrate. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The above-mentioned drawings illustrate aspects of the present invention in at least one of the exemplary embodiments defined in more detail in the following description. Features, elements, and aspects of the present invention designated with the same numerals in different figures are intended to represent the same, equivalent, or similar features, elements, or aspects according to one or more embodiments.

[0014] 1 and 2, there are shown perspective views of an exemplary embodiment of a thermal transfer roller apparatus 20. It should be noted at the outset that the respective sizes, shapes, dimensions, and relative positions of the various components of the apparatus 20 shown in the drawings (and described herein) are by way of example only and are shown for illustrative purposes. Thus, in further embodiments, each of the components of the apparatus 20 may take on any other size, shape, dimension, and / or relative position now known or later developed, so long as the apparatus 20 is capable of substantially performing the functions described herein.

[0015] With continued reference to Figures 1 and 2, in at least one embodiment, the apparatus 20 includes a printer 22 and a thermal transfer assembly 24. In at least one embodiment, the printer 22 is configured to print at least one design 26 onto a thermal transfer compatible transfer sheet 28 using a thermal transfer compatible transfer ink 30. In at least one embodiment, the transfer sheet 28 is a sheet of paper or plastic coated with a wax and pigment polymer film, while in further embodiments, the transfer sheet 28 may be composed of any other thermal transfer compatible material (or combination of materials) now known or later developed. In at least one embodiment, the transfer ink 30 is an inkjet ink, a pigment ink, or a sublimation ink, while in further embodiments, the transfer ink 30 may be any other type of thermal transfer compatible ink now known or later developed. In at least one embodiment, the printer 22 is an inkjet printer or a laser printer, but in further embodiments, the printer 22 may be any other type of printer now known or later developed that is capable of printing at least one design 26 onto a thermal transfer compatible transfer sheet 28 using a thermal transfer compatible transfer ink 30.

[0016] In at least one embodiment, the thermal transfer assembly 24 is positioned and configured to receive the transfer sheet 28 as it exits the printer 22, i.e., after the printer 22 has printed the at least one design 26 on the transfer sheet 28. In at least one embodiment, the thermal transfer assembly 24 comprises a loading ramp 32 extending between a paper exit 34 of the printer 22 and an articulated carrier 36 of the thermal transfer assembly 24, the loading ramp 32 configured to assist in moving the transfer sheet 28 from the paper exit 34 of the printer 22 to the thermal transfer assembly 24. In at least one such embodiment, the carrier 36 is configured to releasably engage a leading edge 40 of the transfer sheet 28 such that the transfer sheet 28 does not contact the at least one design 26 on the transfer sheet 28 when the transfer sheet 28 reaches the carrier 36. In at least one embodiment, the carrier 36 comprises at least one clamp 38 configured to selectively engage a leading edge 40 of the transfer sheet 28. In at least one such embodiment, the clamp 38 is actuated via a cam, although in further embodiments, the clamp 38 may be actuated via any other mechanical, hydraulic, or pneumatic mechanism (or combination of mechanisms) now known or later developed. In at least one alternative embodiment, the carrier 36 may comprise any other type of mechanism or technique now known or later developed that may selectively engage the transfer sheet 28 either on the leading edge 40 of the transfer sheet 28 or elsewhere on the transfer sheet 28. In at least one alternative embodiment, the loading ramp 32 is omitted and the carrier 36 is configured to selectively and automatically move between the paper exit 34 of the printer 22 and the thermal transfer assembly 24 such that the carrier 36 may releasably engage the leading edge 40 of the transfer sheet 28 as the transfer sheet 28 exits the paper exit 34 of the printer 22 and thereafter transport the transfer sheet 28 to the thermal transfer assembly 24. In further alternative embodiments, the apparatus 20 may utilize any other mechanism or technology, now known or later developed, capable of assisting in the movement of the transfer sheet 28 from the paper exit 34 of the printer 22 to the thermal transfer assembly 24.

[0017] In at least one embodiment, as best illustrated in FIGS. 4-6 , the thermal transfer assembly 24 further comprises a support base 42 positioned and configured to support a substrate 44, the substrate 44 being a material or object (e.g., a shirt, etc.) to which the at least one design 26 is to be thermally transferred. In this regard, it is noted that the substrate 44 may be any material or object now known or hereafter developed that is compatible with thermal transfer. Furthermore, the substrate 44 may be of any size, shape or dimension now known or hereafter developed, depending at least in part on the size of the apparatus 20. In at least one embodiment, the thermal transfer assembly 24 further comprises a support frame 46 positioned and configured to selectively sandwich the substrate 44 between the support base 42. The support frame 46 defines a frame boundary 66 that leaves a portion of the substrate 44 to which the at least one design 26 is to be thermally transferred substantially unobstructed. In at least one embodiment, as illustrated in Figures 5 and 6, each of the first end 58 of the support frame 46 and the opposing second end 60 of the support frame 46 are configured as pivotable arms configured to selectively rotate between a disengaged position (Figure 5) in which each of the first end 58 and the second end 60 are rotated away from the support base 42, and an engaged position (Figure 6) in which each of the first end 58 and the second end 60 are rotated into contact with the support base 42 to sandwich the substrate 44 between the first end 58 and the second end 60 of the support frame 46 and the support base 42. Thus, in such an embodiment, the support frame 46 and the support base 42 cooperate to prevent unintentional movement of the substrate 44 during the thermal transfer process. In at least one alternative embodiment, the support frame 46 extends around the entire perimeter of the support base 42 (and thus the frame boundary 66). In yet other embodiments, support frame 46 may take on any other size, shape, dimension and / or configuration now known or later developed, so long as support frame 46 is capable of substantially performing the functions described herein.In at least one embodiment, carrier 36 is configured to automatically position transfer sheet 28 in contact with substrate 44 at a desired location within frame boundary 66, as described further below.

[0018] In at least one embodiment, the support base 42 is constructed of a heat resistant material, such as, for example, foam or silicone rubber. Further, in at least one embodiment, the support base 42 has a thickness T of approximately 5-10 millimeters. However, in further embodiments, the support base 42 may have any other thickness T now known or later developed that depends, at least in part, on the size of one or more of the apparatus 20, the substrate 44, and the transfer sheet 28. In at least one embodiment in which the substrate 44 is manually positionable on the support base 42 by a user, the support base 42 and the support frame 46 are slidably or pivotally engaged with the thermal transfer assembly 24 such that the support base 42 and the support frame 46 can be selectively slid or pivoted away from the thermal transfer assembly 24 to allow the user to more easily access the support base 42 and the support frame 46, thereby facilitating manual positioning of the substrate 44. In at least one such embodiment, as best illustrated in FIG. 4 , the thermal transfer assembly 24 includes at least one positioning indicator 48 configured to assist a user in manually positioning the substrate 44 on the support base 42 to better ensure proper placement of the substrate 44 responsive to a desired location to which the at least one design 26 is to be transferred. In at least one such embodiment, the at least one positioning indicator 48 is a set of printed indicia positioned on the top surface 50 of the support base 42. In at least one alternative such embodiment, the at least one positioning indicator 48 is a light-based or laser-based signage system configured to project indicia onto the top surface 50 of the support base 42. In further such embodiments, the at least one positioning indicator 48 can be any other type of positioning indicator 48 now known or later developed that can assist a user in manually positioning the substrate 44 on the support base 42.In at least one alternative embodiment, thermal transfer assembly 24 is configured to automatically position substrate 44 on support base 42 via a computerized controller 52 provided by apparatus 20 .

[0019] In at least one embodiment, the thermal transfer assembly 24 further comprises at least one heated roller 54 positioned and configured for selective rolling contact with the transfer sheet 28 when the transfer sheet 28 is positioned on the substrate 44 within the frame boundary 66 to adhere the at least one design 26 on the transfer sheet 28 to the substrate 44, as described further below. In at least one embodiment, the at least one heated roller 54 is substantially cylindrical in shape with a heat source 56 concentrically positioned within the heated roller 54, the heat source 56 configured to selectively heat the heated roller 54 to a desired temperature during use of the apparatus 20. In at least one embodiment, the heat source 56 is manually controlled by a user of the apparatus 20, while in at least one alternative embodiment, the heat source 56 is automatically controlled by the controller 52. Further, in at least one embodiment, the at least one heated roller 54 has a substantially circular cross-section as illustrated in FIG. 3, however, in further embodiments, the at least one heated roller 54 may have other cross-sectional shapes now known or later developed, such as, for example, hexagonal or octagonal, so long as the apparatus 20 is capable of substantially performing the functions described herein. In at least one embodiment, the at least one heated roller 54 has a diameter D of approximately 1-3 inches. However, in further embodiments, the at least one heated roller 54 may have any other diameter D now known or later developed, depending at least in part on one or more of the size of the apparatus 20, the substrate 44, and the transfer sheet 28. In at least one embodiment, the outer surface of the at least one heated roller 54 is coated with or composed of a non-stick material, such as, for example, polytetrafluoroethylene (PTFE).

[0020] As discussed above, the at least one heated roller 54 is configured to selectively roll and contact the transfer sheet 28 between the support frame 46 and the support base 42 when the transfer sheet 28 is positioned on the substrate 44. In at least one embodiment, the transfer sheet 28, substrate 44, support frame 46, and support base 42 remain substantially stationary, while the at least one heated roller 54 is configured to selectively traverse the transfer sheet 28 within the frame boundary 66 from a first end 58 of the support frame 46 to an opposing second end 60 of the support frame 46. In at least one alternative embodiment, the at least one heated roller 54 remains substantially stationary within the frame boundary 66, while the support frame 46 and support base 42 are configured to selectively move the transfer sheet 28 and substrate 44 relative to the at least one heated roller 54. In any event, in at least one embodiment, the movement of these components is automatically controlled by the controller 52, and the movement is performed by at least one motor 62 in mechanical communication with the above-mentioned components.

[0021] The use of the at least one heated roller 54 has many advantages over the flat heated platens of the prior art. Because the at least one heated roller 54 is configured to selectively roll into contact with the transfer sheet 28, it does not have to contact the entire transfer sheet 28 at once, which means that the at least one heated roller 54 can be relatively smaller and more compact than the flat heated platens of the prior art. In turn, the entire apparatus 20 can also be relatively smaller and more compact. The relatively small size of the at least one heated roller 54 also reduces the amount of energy required to selectively heat the at least one heated roller 54, while also reducing the time it takes for the at least one heated roller 54 to reach a desired temperature. In at least one embodiment, the size and configuration of the at least one heated roller 54 allows the apparatus 20 to maintain the at least one heated roller 54 at a desired "pre-heat" temperature when the apparatus 20 is not in use (i.e., when the apparatus 20 is not being used to transfer the design 26 onto the substrate 44), thereby allowing the at least one heated roller 54 to reach a desired temperature relatively quickly when the apparatus 20 is subsequently used. Furthermore, because the at least one heated roller 54 is configured to selectively make rolling contact with the transfer sheet 28, contact between the at least one heated roller 54 and the transfer sheet 28 is tangential (as illustrated in FIG. 3 ), which significantly reduces the amount of pressure between the at least one heated roller 54 and the transfer sheet 28 required to successfully transfer the at least one design 26 onto the substrate 44. For example, in at least one embodiment, the thermal transfer assembly 24 exerts approximately 2-10 pounds per square inch of force against the at least one heated roller 54 during use of the apparatus 20, as compared to prior art flat heated platens that typically require hundreds (if not thousands) of pounds of force.In at least one such embodiment, the tangential contact of the at least one heated roller 54 with the transfer sheet 28 also allows for deformation of the transfer sheet 28 and substrate 44, which better ensures that the at least one design 26 is properly transferred onto the substrate 44 (particularly where the substrate 44 is a fabric or other flexible material). Thus, in such an embodiment, the at least one heated roller 54 can better penetrate the substrate 44 compared to a flat prior art heated platen, resulting in a relatively more effective transfer of the at least one design 26 onto the substrate 44 using a relatively smaller footprint, relatively less thermal energy, and relatively less pressure.

[0022] As noted above, in at least one embodiment, the carrier 36 is configured to removably engage the leading edge 40 of the transfer sheet 28 and position the transfer sheet 28 in contact with the substrate 44 at a desired location within the frame boundary 66. In such an embodiment, the carrier 36 is further configured to prevent the transfer sheet 28 from unintentionally shifting position relative to the substrate 44 while the at least one heated roller 54 traverses the transfer sheet 28. In at least one such embodiment, the transfer sheet 28, substrate 44, support frame 46, and support base 42 remain substantially stationary, whereas the carrier 36 is further configured to remain substantially stationary relative to the transfer sheet 28, substrate 44, support frame 46, and support base 42 when the at least one heated roller 54 selectively traverses the transfer sheet 28. In at least one alternative such embodiment, the at least one heated roller 54 remains substantially stationary within the frame boundary 66, but the carrier 36 is configured to move in unison with the support frame 46 and support base 42 when the support frame 46 and support base 42 are configured to selectively move the transfer sheet 28 and the substrate 44 relative to the at least one heated roller 54. In at least one embodiment, the carrier 36 is further configured to automatically separate the transfer sheet 28 from the substrate 44 after the at least one heated roller 54 has passed over the transfer sheet 28 while the transfer sheet 28 is still hot, leaving at least one design 26 on the substrate 44. In at least one such embodiment, the carrier 36 separates the transfer sheet 28 from the substrate 44 after the at least one heated roller 54 has passed over the entire transfer sheet 28. In at least one alternative such embodiment, as the at least one heated roller 54 passes over the transfer sheet 28, the carrier 36 gradually separates the transfer sheet 28 from the substrate 44, such that the at least one heated roller 54 can stabilize the substrate 44 while the transfer sheet 28 is separated from the substrate 44.

[0023] In at least one embodiment, the thermal transfer assembly 24 further comprises at least one sheet collection bin 64 positioned and configured to receive waste transfer sheet 28 after the transfer sheet 28 has been completely separated from the substrate 44. In at least one such embodiment, the sheet collection bin 64 is removably positioned within the thermal transfer assembly 24. In at least one further such embodiment, the sheet collection bin 64 is permanently positioned within the thermal transfer assembly 24, and the thermal transfer assembly 24 comprises an access door positioned and configured to allow access to and selective emptying of the sheet collection bin 64. In at least one further embodiment, the sheet collection bin 64 is positioned external to the thermal transfer assembly 24. It should also be noted that the size, shape, dimensions, quantity, and relative location of the at least one sheet collection container 64 shown in the drawings (and described herein) are merely examples, and thus, in further embodiments, the at least one sheet collection container 64 can be of any other size, shape, dimension, and / or quantity now known or later developed, and positioned and / or disposed elsewhere on or within the thermal transfer assembly 24 so long as the apparatus 20 is capable of substantially performing the functions described herein. In at least one embodiment, as best illustrated in Figures 1 and 10, the thermal transfer assembly 24 includes a waste ramp 68 extending between the carrier 36 and the sheet collection container 64, the waste ramp 68 configured to aid in the movement of the transfer sheets 28 from the carrier 36 to the sheet collection container 64.

[0024] During use of the apparatus 20, in at least one embodiment, as illustrated in Figures 5-11, the substrate 44 is initially positioned on the support base 42 (Figure 5), and the support frame 46 is moved into contact with the substrate 44 such that the substrate 44 is sandwiched between the support frame 46 and the support base 42, but the portion of the substrate 44 onto which the at least one design 26 is to be thermally transferred remains substantially unobstructed (Figure 6). The combination of the support base 42, substrate 44, and support frame 46 is moved into position within the thermal transfer assembly 24 such that the at least one heated roller 54 is positioned within the frame boundary 66 (i.e., over the portion of the substrate 44 onto which the at least one design 26 is to be thermally transferred) (Figure 7). In at least one embodiment, once the controller 52 determines that the at least one heated roller 54 has reached a desired temperature (which in at least one embodiment is approximately 300° F., but ultimately depends at least in part on the properties of the transfer sheet 28 and / or the substrate 44), the at least one heated roller 54 traverses the substrate 44 at least once from a first end 58 of the support frame 46 to an opposing second end 60 of the support frame 46 to dry and preheat the substrate 44. In at least one such embodiment, once the controller 52 determines that the substrate 44 has reached the desired preheat temperature, the printer 22 prints the at least one design 26 onto the transfer sheet 28, which is moved from the paper exit 34 of the printer 22 to a carrier 36 of the thermal transfer assembly 24 ( FIG. 7 ). The carrier 36 positions the transfer sheet 28 in contact with the substrate 44 at a desired location within the frame boundary 66 and maintains the position of the transfer sheet 28 relative to the substrate 44.The at least one heated roller 54 traverses the transfer sheet 28 at least once from a first end 58 of the support frame 46 to an opposing second end 60 of the support frame 46 (FIG. 8) with a predetermined pressure (depending at least in part on the characteristics of the transfer sheet 28 and / or the substrate 44) and traverse time (in at least one embodiment, approximately 30-60 seconds, etc., but ultimately depending at least in part on the characteristics of the transfer sheet 28 and / or the substrate 44) set by the controller 52 to adhere the at least one design 26 on the transfer sheet 28 to the substrate 44. In at least one embodiment, the at least one heated roller 54 traverses the transfer sheet 28 twice to enhance adhesion between the at least one design 26 and the substrate 44. As the at least one heated roller 54 passes over the transfer sheet 28, the carrier 36 separates the transfer sheet 28 from the substrate 44 (FIG. 9) while the transfer sheet 28 is still hot, leaving the at least one design 26 on the substrate 44. The carrier 36 discards the transfer sheet 28 in a sheet collection bin 64 (FIG. 10). In at least one embodiment, the at least one heated roller 54 traverses the substrate 44 at least one more time to enhance durability of the design 26 on the substrate 44. In at least one such embodiment, the carrier 36 is configured to position a protective sheet (not shown) over the design 26 before the at least one heated roller 54 traverses the substrate 44 to prevent the design 26 from separating from the substrate 44 as the at least one heated roller 54 traverses the substrate 44. After the design 26 is transferred onto the substrate 44 (FIG. 11), the support frame 46 is disengaged from the support base 42 and the substrate 44 may be removed from the thermal transfer assembly 24. Again, as noted above, in at least one embodiment, each of the above steps may be performed automatically by the apparatus 20 (via the controller 52).

[0025] The aspects of the present specification can also be described as the following embodiments.

[0026] 1. A thermal transfer roller apparatus configured to transfer at least one design onto a substrate, the apparatus comprising: a printer configured to print at least one design onto a thermal transfer compatible transfer sheet using a thermal transfer compatible transfer ink; and a thermal transfer assembly positioned and configured to receive the transfer sheet as it exits the printer, the thermal transfer assembly including a support base positioned and configured to support the substrate, and a support frame positioned and configured to selectively sandwich the substrate substantially between the support base, the support frame defining a frame boundary that leaves a portion of the substrate onto which the at least one design is thermally transferred substantially unobstructed, the support frame removably engaging a leading edge of the transfer sheet and positioning the transfer sheet in contact with the substrate at a location within the frame boundary to prevent unintentional displacement of the transfer sheet relative to the substrate as the design is transferred onto the substrate, and a thermal transfer assembly configured to receive the transfer sheet as it exits the printer, the thermal transfer assembly including a support base positioned and configured to support the substrate, the support frame defining a frame boundary that leaves a portion of the substrate onto which the at least one design is thermally transferred substantially unobstructed, the support frame removably engaging a leading edge of the transfer sheet and positioning the transfer sheet in contact with the substrate at a location within the frame boundary to prevent unintentional displacement of the transfer sheet relative to the substrate as the design is transferred onto the substrate. and a thermal transfer assembly comprising an articulated carrier configured to separate the transfer sheet from the substrate after the transfer sheet is positioned on the substrate within the frame boundary; at least one heated roller positioned and configured to selectively roll into contact with the transfer sheet when the transfer sheet is positioned on the substrate within the frame boundary; and a controller configured to automatically control each of the carrier and the at least one heated roller, so that during use of the apparatus, with the substrate sandwiched between the support frame and the support base and the transfer sheet positioned on the substrate within the frame boundary, the at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposite second end of the support frame at a predetermined temperature, pressure, and traverse time set by the controller to adhere at least one design on the transfer sheet to the substrate, and thereafter the carrier separates the transfer sheet from the substrate while the transfer sheet is still hot.

[0027] 2. A thermal transfer roller apparatus as described in embodiment 1, wherein the transfer sheet is a sheet of paper or plastic coated with a wax and pigment polymer film.

[0028] 3. The thermal transfer roller device according to embodiment 1 or 2, wherein the printer is an inkjet printer or a laser printer.

[0029] 4. The thermal transfer roller device according to any one of embodiments 1 to 3, wherein the transfer ink is an inkjet ink, a pigment ink, or a sublimation ink.

[0030] 5. The thermal transfer roller device according to any one of embodiments 1 to 4, wherein the support base is made of a heat-resistant material.

[0031] 6. The thermal transfer roller device according to any one of embodiments 1 to 5, wherein the support base has a thickness of approximately 5 to 10 millimeters.

[0032] 7. A thermal transfer roller device as described in embodiments 1-6, wherein at least one heated roller is substantially cylindrical in shape and includes a heat source positioned concentrically within said heated roller, the heat source configured to selectively heat said heated roller to a desired temperature during use of the device.

[0033] 8. The thermal transfer roller device according to any one of embodiments 1 to 7, wherein at least one heated roller has a substantially circular cross section.

[0034] 9. The thermal transfer roller apparatus of any one of embodiments 1 to 8, wherein at least one heated roller has a diameter of approximately 1 to 3 inches.

[0035] 10. A thermal transfer roller device as described in any one of embodiments 1 to 9, wherein the thermal transfer assembly includes a loading ramp extending between a paper exit of the printer and a carrier of the thermal transfer assembly, the loading ramp being configured to assist in moving a transfer sheet from the paper exit of the printer to the thermal transfer assembly.

[0036] 11. A thermal transfer roller apparatus as described in any one of embodiments 1-10, wherein the carrier includes at least one clamp configured to selectively engage a leading edge of the transfer sheet.

[0037] 12. A thermal transfer roller device as described in embodiments 1 to 11, wherein the carrier is further configured to selectively and automatically move between the paper exit of the printer and the thermal transfer assembly, such that the carrier can releasably engage a leading edge of the transfer sheet as it exits the paper exit of the printer and then transport the transfer sheet to the thermal transfer assembly.

[0038] 13. The thermal transfer roller device of any one of embodiments 1-12, wherein the carrier is further configured to automatically position the transfer sheet in contact with the substrate at a desired location within the frame boundary.

[0039] 14. A thermal transfer roller device as described in embodiments 1-13, wherein the support base and support frame are slidably or pivotally engaged with the thermal transfer assembly such that the support base and support frame can be selectively slidably or pivotably moved away from the thermal transfer assembly to assist in manual positioning of the substrate on the support base.

[0040] 15. A thermal transfer roller apparatus as described in any one of the preceding embodiments, wherein the thermal transfer assembly includes at least one positioning indicator configured to assist in manual positioning of the substrate on the support base.

[0041] 16. A thermal transfer roller device as described in any one of embodiments 1 to 15, wherein at least one positioning indicator is a set of printed markings positioned on the upper surface of the support base.

[0042] 17. A thermal transfer roller device as described in embodiments 1-16, wherein at least one positioning indicator is a light-based or laser-based marking system configured to project a marking onto the upper surface of the support base.

[0043] 18. A thermal transfer roller device as described in embodiments 1-17, wherein the thermal transfer assembly further comprises at least one sheet collection container positioned and configured to receive the transfer sheet after it has been completely separated from the substrate by the carrier.

[0044] 19. A thermal transfer roller device as described in any one of embodiments 1 to 18, wherein the thermal transfer assembly includes a waste ramp that can extend between the carrier of the thermal transfer assembly and the at least one sheet collection container, the waste ramp being configured to assist in moving the transfer sheet from the carrier to the at least one sheet collection container.

[0045] 20. A thermal transfer roller device according to any one of the preceding embodiments, wherein the support frame extends around the entire periphery of the support base.

[0046] 21. A thermal transfer roller device as described in embodiments 1 to 20, wherein the first end and the second end of the support frame are configured to selectively rotate between a disengaged position in which each of the first end and the second end are rotated away from the support base, and an engaged position in which each of the first end and the second end are rotated into contact with the support base substantially to sandwich the substrate between the first end and the second end of the support frame and the support base.

[0047] 22. A thermal transfer roller apparatus configured to transfer at least one design onto a substrate, the apparatus comprising: a thermal transfer assembly positioned and configured to receive a thermal transfer compatible transfer sheet as it exits a printer, the printer configured to print at least one design onto the thermal transfer compatible transfer sheet using a thermal transfer compatible transfer ink; the thermal transfer assembly comprising: a support base positioned and configured to support the substrate; and a support frame positioned and configured to selectively sandwich the substrate substantially between the support base, the support frame defining a frame boundary that leaves a portion of the substrate onto which the at least one design is thermally transferred substantially unobstructed; and a support frame removably engaging a leading edge of the transfer sheet and positioning the transfer sheet in contact with the substrate at a location within the frame boundary to prevent unintentional displacement of the transfer sheet relative to the substrate as the design is transferred onto the substrate. a thermal transfer assembly comprising an articulated carrier configured to stop the transfer sheet from the substrate after the design has been transferred onto the substrate, at least one heated roller positioned and configured to make selective rolling contact with the transfer sheet when the transfer sheet is positioned on the substrate within the frame boundary, and a controller configured to automatically control each of the carrier and the at least one heated roller, so that during use of the apparatus, with the substrate sandwiched between the support frame and the support base and the transfer sheet positioned on the substrate within the frame boundary, the at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposite second end of the support frame at a predetermined temperature, pressure and traverse time set by the controller to adhere at least one design on the transfer sheet to the substrate, and thereafter the carrier separates the transfer sheet from the substrate while the transfer sheet is still hot.

[0048] 23. A method of transferring at least one design from a thermal transfer compatible transfer sheet onto a substrate using the thermal transfer roller apparatus of claim 1, comprising the steps of: positioning the substrate on a support base; moving the support frame into contact with the substrate such that the substrate is sandwiched between the support frame and the support base but the portion of the substrate onto which the at least one design is to be thermally transferred is substantially unobstructed; printing the at least one design onto the transfer sheet using a printer; moving the transfer sheet from a paper exit of the printer to a carrier of a thermal transfer assembly; and transferring the transfer sheet to a position within the frame boundary of the support frame. positioning a transfer sheet in contact with the substrate via a carrier at a desired location; moving the at least one heated roller into rolling contact with the transfer sheet at a predetermined pressure when a controller determines that the at least one heated roller has reached a desired temperature; rolling the at least one heated roller across the transfer sheet from a first end of a support frame to an opposing second end of the support frame in a predetermined traverse time to adhere at least one design on the transfer sheet to the substrate; and separating the transfer sheet from the substrate via the carrier while the transfer sheet is still hot.

[0049] 24. The method of embodiment 23, further comprising the steps of moving at least one heated roller into rolling contact with the substrate before the transfer sheet is positioned on the substrate, and rolling the at least one heated roller across the substrate from a first end of the support frame to an opposing second end of the support frame to dry and preheat the substrate before the transfer sheet is positioned on the substrate.

[0050] 25. The method of any one of claims 23-24, further comprising rolling at least one heated roller again across the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined traverse time to enhance adhesion of the at least one design to the substrate.

[0051] 26. The method of any one of embodiments 23 to 25, further comprising the steps of moving at least one heated roller into rolling contact with the substrate after the at least one design is adhered to the substrate and the transfer sheet is separated from the substrate, and rolling the at least one heated roller across the substrate from a first end of the support frame to an opposing second end of the support frame to increase durability of the at least one design on the substrate.

[0052] 27. The method of any one of embodiments 23-26, comprising disengaging the support frame from the support base and removing the substrate from the thermal transfer assembly.

[0053] Finally, with respect to the exemplary embodiments of the present invention shown and described herein, it will be understood that a thermal transfer roller apparatus and associated method are disclosed and configured to more safely and effectively transfer designs onto a substrate. It will be understood that the principles of the present invention can be embodied in many configurations other than those shown and described, and therefore the present invention is in no way limited to the exemplary embodiments, but is directed generally to thermal transfer roller apparatus, which can take many forms to do so without departing from the spirit and scope of the present invention. Those skilled in the art will appreciate that the present invention is not limited to the specific shapes and materials of structure disclosed, but can instead include other functionally equivalent structures or materials, known or later developed, without departing from the spirit and scope of the present invention.

[0054] Certain embodiments of the present invention are described herein, including the best mode known to the inventor(s) for carrying out the invention. Of course, variations of these described embodiments will become apparent to those skilled in the art upon reading the above description. The inventor(s) expect those skilled in the art to adopt such variations as necessary, and the inventor(s) intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, the present invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, the present invention encompasses any combination of the above-described embodiments in all possible variations thereof unless otherwise indicated herein or clearly contradicted by context.

[0055] Grouping of alternative embodiments, elements, or steps of the invention should not be construed as limiting. Each group member may be referred to and claimed individually or in any combination with other group members disclosed herein. It is anticipated that one or more members of a group may be included in or deleted from the group for convenience and / or patentability. When any such inclusion or deletion occurs, the specification includes the group as modified and is thus deemed to embody the recitation of all Markush groups used in the appended claims.

[0056] Unless otherwise indicated, all numbers expressing features, items, amounts, parameters, characteristics, periods, etc. used in the specification and claims should be understood to be modified in all instances by the terms "about" and "approximately". As used herein, the terms "about" and "approximately" mean that the feature, item, amount, parameter, characteristic, or period so qualified encompasses a range of plus or minus 10 percent of the value of the stated feature, item, amount, parameter, characteristic, or period. Thus, unless otherwise indicated, the numerical parameters set forth in the specification and the appended claims are approximations that may vary. At the very least, and without intending to limit the application of the doctrine of equivalents to the scope of the claims, each numerical indication should be construed at least in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and values ​​setting forth the broad scope of the invention are approximations, the numerical ranges and values ​​set forth in the specific examples are reported as precisely as possible. However, any numerical range or value inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. The recitation of numerical ranges of values ​​herein is merely intended to serve as a shorthand method of referring to each individual numerical value within the range.Unless otherwise indicated herein, each value of the numerical range is incorporated herein as if it were individually recited herein.Similarly, as used herein, unless otherwise indicated, the term "substantially" is a degree term for indicating the approximation of the characteristic, item, amount, parameter, property, or period so limited, encompassing the range that can be understood and interpreted by those skilled in the art.

[0057] The use of the term "may" or "can" with respect to an embodiment or an aspect of an embodiment also carries the alternative meaning of "may not" or "cannot". Thus, if the specification discloses that an embodiment or an aspect of an embodiment may or may not be included as part of the subject matter of the present invention, a negative limitation or exclusive condition is also expressly expressed, meaning that an embodiment or an aspect of an embodiment may or may not be included as part of the subject matter of the present invention. Similarly, the use of the term "optionally" with respect to an embodiment or an aspect of an embodiment means that such an embodiment or an aspect of such an embodiment may or may not be included as part of the subject matter of the present invention. Whether such a negative limitation or exclusive condition applies is based on whether the negative limitation or exclusive condition is recited in the claimed subject matter.

[0058] The terms "a," "an," "the," and similar references used in the context of describing the present invention (particularly in the context of the claims that follow) should be construed to encompass both the singular and the plural, unless otherwise indicated herein or clearly contradicted by the context. Furthermore, ordinal labels such as "first," "second," "third," and the like of identified elements are used to distinguish elements, and do not indicate or imply a required or limited number of such elements, nor do they indicate a particular location or order of such elements, unless otherwise indicated. All methods described herein may be performed in any suitable order, unless otherwise indicated herein or clearly contradicted by the context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein is intended merely to better illuminate the invention, and does not otherwise limit the scope of the invention as claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0059] When used in the claims, whether as filed or added per amendment, the open-ended transitional term "comprising" (along with equivalent open-ended transitional phrases such as "including," "containing," and "having") includes all of the explicitly recited elements, limitations, steps, and / or features, either alone or in combination with unrecited subject matter, where the specified elements, limitations, and / or features are essential, but other unspecified elements, limitations, and / or features may be added to still form the construct within the scope of the claim. Certain embodiments disclosed herein may be further limited in the claims using the open-ended transitional phrases "consisting of" or "consisting essentially of" in place of or as an amendment to "comprising." When used in the claims, whether as filed or added per amendment, the open-ended transitional phrase "comprising" excludes any element, limitation, step, or feature not explicitly recited in the claim. The closed transitional phrase "consisting essentially of" limits the scope of the claim to those elements, limitations, steps, and / or features that are expressly recited, and any other elements, limitations, steps, and / or features that do not materially affect the basic and novel characteristic(s) of the claimed subject matter. Thus, the meaning of the open transitional phrase "comprising" is defined to include all of the specifically recited elements, limitations, steps, and / or features, as well as optional additional unspecified ones. The meaning of the closed transitional phrase "consisting of" is defined to include only those elements, limitations, steps, and / or features that are specifically recited in the claim, while the meaning of the closed transitional phrase "consisting essentially of" is defined to include only those elements, limitations, steps, and / or features that are specifically recited in the claim, and those elements, limitations, steps, and / or features that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.Thus, the open-ended transitional phrase "comprising" (and equivalent open-ended transitional phrases) includes, in its extreme sense, the claimed subject matter identified by the open-ended transitional phrase "consisting of" or "consisting essentially of." Thus, embodiments described or claimed herein with the phrase "comprising" are expressly or inherently clearly described, enabled, and supported herein in opposition to the phrases "consisting essentially of" and "consisting of."

[0060] Although any claim intended to be treated under 35 U.S.C. 112(f) will begin with the words "means for," use of the word "for" in any other context is not intended to invoke treatment under 35 U.S.C. 112(f). Accordingly, applicants reserve the right to pursue additional claims after filing this application, either in this application or in any continuing application.

[0061] It should be understood that the methods disclosed herein are merely examples, along with the order in which the respective elements of any such methods are performed. Depending on the implementation, they may be performed in any order or in parallel, unless otherwise indicated in the disclosure.

[0062] All patents, patent publications, and other publications referenced and identified in this specification are individually and expressly incorporated herein by reference in their entirety, for example, to describe and disclose the compositions and methodologies described in such publications that may be used in connection with the present invention. These publications are provided solely for their disclosure prior to the filing date of this application. Nothing in this regard should be construed as an admission that the inventors are not entitled to antedate such disclosure by reason of prior invention or for any other reason. All statements as to the date or representation as to the content of these documents are based on the information available to the applicant and are not an admission as to the accuracy of the date or content of these documents.

[0063] While aspects of the present invention have been described with reference to at least one exemplary embodiment, it should be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the present invention should be interpreted only in conjunction with the appended claims, which now disclose what the inventor(s) believe to be the invention as claimed subject matter.

Claims

1. 1. A thermal transfer roller apparatus configured to transfer at least one design onto a substrate, the apparatus comprising: a printer configured to print the at least one design onto a thermal transfer compatible transfer sheet using a thermal transfer compatible transfer ink; a thermal transfer assembly positioned and configured to receive the transfer sheet as it exits the printer, the thermal transfer assembly comprising: a support base positioned and configured to support the substrate; a support frame positioned and configured to selectively sandwich the substrate substantially between the support base and the support frame, the support frame defining a frame boundary that leaves a portion of the substrate substantially unobstructed onto which the at least one design is thermally transferred; an articulating carrier configured to releasably engage a leading edge of the transfer sheet, position the transfer sheet in contact with the substrate at a location within the frame boundary, prevent unintentional displacement of the transfer sheet relative to the substrate as the design is transferred onto the substrate, and separate the transfer sheet from the substrate after the design has been transferred onto the substrate; at least one heated roller positioned and configured to selectively roll contact the transfer sheet when the transfer sheet is positioned on a substrate within the frame boundary; a controller configured to automatically control each of the carrier and the at least one heated roller; a thermal transfer assembly comprising: Equipped with A thermal transfer roller device whereby, during use of the device, with the substrate sandwiched between the support frame and the support base and the transfer sheet positioned on the substrate within the frame boundaries, the at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined temperature, pressure and traverse time set by the controller to adhere at least one design on the transfer sheet to the substrate, and thereafter the carrier separates the transfer sheet from the substrate while the transfer sheet is still hot.

2. 2. The thermal transfer roller apparatus of claim 1, wherein the support base is constructed from a heat resistant material.

3. 2. The thermal transfer roller apparatus of claim 1, wherein the support base has a thickness of approximately 5 to 10 millimeters.

4. the at least one heated roller is substantially cylindrical; the at least one heated roller comprises a heat source positioned concentrically within the heated roller, the heat source configured to selectively heat the heated roller to a desired temperature during use of the apparatus; 2. The thermal transfer roller device according to claim 1.

5. The thermal transfer roller apparatus of claim 4 , wherein the at least one heated roller has a substantially circular cross section.

6. 5. The thermal transfer roller apparatus of claim 4, wherein said at least one heated roller has a diameter of approximately 1 to 3 inches.

7. 2. The thermal transfer roller apparatus of claim 1, wherein the thermal transfer assembly includes a loading ramp extending between a paper exit of the printer and a carrier of the thermal transfer assembly, the loading ramp configured to assist in moving the transfer sheet from a paper exit of the printer to the thermal transfer assembly.

8. The thermal transfer roller apparatus of claim 1 , wherein the carrier comprises at least one clamp configured to selectively engage a leading edge of the transfer sheet.

9. 2. The thermal transfer roller device of claim 1, wherein the carrier is further configured to selectively and automatically move between a paper exit of the printer and the thermal transfer assembly, such that the carrier can releasably engage a leading edge of the transfer sheet as it exits the paper exit of the printer and thereafter transport the transfer sheet to the thermal transfer assembly.

10. The thermal transfer roller apparatus of claim 1 , wherein the carrier is further configured to automatically position the transfer sheet in contact with the substrate at a desired location within the frame boundary.

11. 2. The thermal transfer roller apparatus of claim 1, wherein the support base and the support frame are slidably or pivotally engaged with the thermal transfer assembly such that the support base and the support frame can be selectively slidably or pivotably moved away from the thermal transfer assembly to assist in manual positioning of the substrate on the support base.

12. The thermal transfer roller apparatus of claim 1 , wherein the thermal transfer assembly comprises at least one positioning indicator configured to assist in manual positioning of a substrate on the support base.

13. 10. The thermal transfer roller apparatus of claim 1, wherein the thermal transfer assembly further comprises at least one sheet collection bin positioned and configured to receive the transfer sheet after it has been completely separated from the substrate by the carrier.

14. 14. The thermal transfer roller apparatus of claim 13, wherein the thermal transfer assembly includes a waste ramp that can extend between a carrier of the thermal transfer assembly and the at least one sheet collection container, the waste ramp configured to assist in moving the transfer sheet from the carrier to the at least one sheet collection container.

15. 2. The thermal transfer roller apparatus of claim 1, wherein the first and second ends of the support frame are configured to selectively rotate between a disengaged position in which the first and second ends are each rotated away from the support base, and an engaged position in which the first and second ends are each rotated into contact with the support base to substantially sandwich the substrate between the first and second ends of the support frame and the support base.

16. 1. A thermal transfer roller apparatus configured to transfer at least one design onto a substrate, the apparatus comprising: a thermal transfer assembly positioned and configured to receive a thermal transfer compatible transfer sheet as it exits a printer, the printer configured to print the at least one design onto the transfer sheet using a thermal transfer compatible transfer ink, the thermal transfer assembly comprising: a support base positioned and configured to support the substrate; a support frame positioned and configured to selectively sandwich the substrate substantially between the support base and the support frame, the support frame defining a frame boundary that leaves a portion of the substrate substantially unobstructed onto which the at least one design is thermally transferred; an articulating carrier configured to releasably engage a leading edge of the transfer sheet, position the transfer sheet in contact with the substrate at a location within the frame boundary, prevent unintentional displacement of the transfer sheet relative to the substrate as the design is transferred onto the substrate, and separate the transfer sheet from the substrate after the design has been transferred onto the substrate; at least one heated roller positioned and configured to selectively roll contact the transfer sheet when the transfer sheet is positioned on a substrate within the frame boundary; a controller configured to automatically control each of the carrier and the at least one heated roller; A thermal transfer assembly comprising: Equipped with A thermal transfer roller device whereby, during use of the device, with the substrate sandwiched between the support frame and the support base and the transfer sheet positioned on the substrate within the frame boundaries, the at least one heated roller traverses the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined temperature, pressure and traverse time set by the controller to adhere at least one design on the transfer sheet to the substrate, and thereafter the carrier separates the transfer sheet from the substrate while the transfer sheet is still hot.

17. 10. A method for transferring at least one design from a thermal transfer compatible transfer sheet onto a substrate using the thermal transfer roller apparatus of claim 1, said method comprising: positioning the substrate on the support base; moving the support frame into contact with the substrate such that the substrate is sandwiched between the support frame and the support base, but a portion of the substrate onto which the at least one design is thermally transferred is substantially unobstructed; printing said at least one design onto said transfer sheet using said printer; moving the transfer sheet from a paper exit of the printer to a carrier of the thermal transfer assembly; positioning the transfer sheet via the carrier in contact with the substrate at a desired location within a frame boundary of the support frame; when the controller determines that the at least one heated roller has reached a desired temperature, moving the at least one heated roller into rolling contact with the transfer sheet at a predetermined pressure; rolling the at least one heated roller across the transfer sheet from a first end of the support frame to an opposing second end of the support frame in a predetermined traverse time to adhere at least one design on the transfer sheet to the substrate; Separating the transfer sheet from the substrate via the carrier while the transfer sheet is still hot. Steps and A method comprising:

18. moving the at least one heated roller into rolling contact with the substrate before the transfer sheet is positioned on the substrate; rolling the at least one heated roller across the substrate from a first end of the support frame to an opposing second end of the support frame to dry and preheat the substrate before the transfer sheet is positioned on the substrate; 20. The method of claim 17, further comprising:

19. 20. The method of claim 17, further comprising the step of rolling the at least one heated roller again across the transfer sheet from a first end of the support frame to an opposing second end of the support frame at a predetermined traverse time to enhance adhesion of the at least one design to the substrate.

20. after the at least one design is adhered to the substrate and the transfer sheet is separated from the substrate, moving the at least one heated roller into rolling contact with the substrate; rolling the at least one heated roller across the substrate from a first end of the support frame to an opposing second end of the support frame to enhance durability of at least one design on the substrate; 20. The method of claim 17, further comprising:

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