Systems and devices for transferring images onto white and light-colored articles

Abstract

Transfer assemblies, sheets, and processes for manufacturing them are provided for transferring images onto articles such as textiles and fabrics. The transfer sheet comprises a support layer, such as backing paper, and an image transfer layer containing a binder and an ink acceptor. The image transfer layer further includes a release layer between the support layer and the image transfer layer. The release layer contains a crosslinking agent and is configured to allow the image transfer layer to be peeled off the backing paper before transferring the image to the substrate or article. This allows the use of thin parchment paper as a protective cover for the image layer instead of backing paper during the transfer process, resulting in improved and enhanced heat transfer to the image transfer layer and the article, and deeper ink penetration.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application No. 63 / 492,001, filed on March 24, 2023, the entire disclosure of which is incorporated herein by reference for all purposes. This description generally relates to transfer assemblies and transfer sheets for transferring messages, designs, pictures or other images onto articles such as textiles and other fabrics, and to processes for manufacturing these transfer sheets and articles.

Background Art

[0002] In recent years, an important industry has developed for applying designs, letters, numbers, messages, illustrations, etc. (hereinafter collectively referred to as "images") selected by customers onto articles such as T - shirts, sweatshirts, leather products, etc. These images are either commercially available products printed on the surface of release paper or transfer paper customized for a specific use, or in some cases, the customer generates an image on heat - transfer paper for white or light - colored substrates. When the transfer sheet is brought into contact with the article and heat and pressure are applied to the backing layer or backing paper, the image transfer layer peels off and transfers to the article together with the printed image. One drawback associated with current transfer sheets is that after the image is transferred onto an article such as a fabric, the backing paper must be peeled off from this article. Since heat and pressure are applied to the transfer sheet and the article during the transfer process, a large peeling force is required to remove the backing paper. This peeling force generated by this peeling often causes tearing and destruction of the image after the image has been transferred to the fabric. This has an adverse effect on the appearance of the image and may look different from the printed image.

[0003] Another drawback of current transfer sheets is that the backing paper reduces overall heat transfer to the image layer and the article, thereby decreasing the penetration depth of the ink and layer into the article. This reduced penetration depth reduces the overall durability and washability of the article, leading to fading of the image over time and an increase in defects such as cracking or bursting of the image layer. Therefore, there is a need for improvements in systems and processes for transferring images onto white and light-colored articles such as fabrics or textiles. In particular, it is desirable to provide systems and processes that can overcome the limitations of standard backing paper and transfer brighter, sharper images onto articles that can withstand numerous washing and drying cycles over a long period of time. [Overview of the project]

[0004] The following is a simplified summary of the claimed subject matter to provide a basic understanding of some aspects of the claimed subject matter. This summary is not a comprehensive overview of the claimed subject matter. It is not intended to identify essential elements of the claimed subject matter or to describe its scope. Its sole purpose is to present some concepts of the claimed subject matter in a simplified form as a prelude to the more detailed explanations that will follow. Various embodiments provide transfer assemblies, transfer sheets, release layers and backing paper or support paper for transferring images to articles such as textiles and fabrics, as well as improved processes for manufacturing transfer sheets and other articles. Such transfer sheets can be used to transfer messages, designs, pictures or other images to any article or substrate, and are particularly useful for transferring images to white or light-colored fabrics such as T-shirts, hats, and sweatshirts.

[0005] In one embodiment, a transfer sheet for transferring an image onto a substrate includes a support layer such as backing paper and an image transfer layer disposed on the support layer. The image transfer layer includes a first layer containing a binder and a second layer containing an ink acceptor. The second layer further comprises the first and second components, each containing an ethylene acrylic acid (EAA) copolymer. The second component contains less than 20% acrylic acid by mass of the EAA copolymer. In the embodiment, the first layer constitutes a tie coat layer, and the second layer constitutes at least a print coat layer containing an ink acceptor. The applicant has found that reducing the amount of acrylic acid in the binder of the print coat improves the melt flow of the image onto an article, such as a fabric. This improves the washability of the fabric, and especially in the case of light-colored fabrics, the image transferred to the fabric remains more robust and clear even after multiple washes of the fabric.

[0006] In the embodiment, the first layer, or tie coat, contains at least about 20% acrylic acid by mass of the EAA copolymer. Since the tie coat is typically located on the outer surface of the image after the image has been transferred to the article, this layer is subject to most of the abrasion and pilling that occurs as the fabric swells and shrinks during the wash and dry cycle. Maintaining a higher level of acid in the tie coat reduces wear and improves the retention of ink color in the article. In embodiments, the second layer, or print coating layer, comprises a first EAA material containing about 20% acrylic acid and a second EAA material containing less than 20%, preferably about 15%, acrylic acid. The first and second materials may have a mass ratio of about 90 / 10 to about 50 / 50, preferably about 80 / 20 to about 70 / 30. In exemplary embodiments, the second material is about 25% by mass of the second component. This reduces the overall acid content of the print coating layer and improves the image melt flow without substantially increasing abrasion and pilling during washing and drying of the fabric.

[0007] In the embodiment, the transfer sheet further includes a third layer, i.e., a base coat, which is either positioned between the print coat and the tie coat, or mixed with the print coat to form a single layer containing both the print coat and the base coat. The third layer may be mixed with one or both of the first and second layers, or these layers may be formed as individual layers positioned in contact with or joined to each other. In certain embodiments, the white base coat layer comprises a first material containing about 20% acrylic acid and a second material containing less than 20%, preferably about 15%, acrylic acid. The first and second materials may have a mass ratio of about 90 / 10 to about 50 / 50, preferably about 80 / 20 to about 70 / 30. In exemplary embodiments, the second material is about 25% by mass of the second component.

[0008] In the embodiment, the transfer sheet further includes a release layer between the support layer and the image transfer layer. The release layer may include any suitable material that allows the release layer to be removably attached to the support layer. The release layer can function as a hot peel, warm peel, or cold peel. In embodiments, the support layer includes backing paper. Suitable backing papers include woven or knitted textile sheets made from nonwoven webs, synthetic polymer sheets, metallized films, natural or synthetic fibers, or combinations thereof, or laminates consisting of two or more materials from the above categories. In one embodiment, the backing paper contains a certain proportion of used fibers. The backing paper may be opaque, translucent, or transparent. The thickness of the backing layer may be in the range of about 1 mil (0.0254 mm) to about 10 mils, particularly 2 mils to about 6 mils. This thickness is desirable to allow sufficient heat to pass through the backing paper during image transfer. The image may be transferred to the article by using a transfer sheet to bring a support layer or backing paper into contact with the article and applying heat and pressure to transfer the ink composition, thereby reproducing the image on the article. The substrate or article may include any suitable white or light-colored article on which the image is to be printed. In certain embodiments, the article includes a white or light-colored textile. The textile may include 100% cotton, less than 100% cotton, or a cotton / polyester blend.

[0009] In another embodiment, a transfer sheet for transferring an image to an article includes a support layer and an image transfer layer located on the support layer. The image transfer layer includes a first layer containing a binder and a second layer containing an ink acceptor. The image transfer layer further includes a release layer between the support layer and the image transfer layer. The release layer contains a crosslinking agent and is configured to be attached to the support layer, and the release layer may include any suitable backing paper until the image is transferred to the substrate or article. When parchment paper is used instead of backing paper to cover the transfer sheet, peeling the backing paper from the transfer sheet before transferring the image to the article can promote and improve heat transfer between the image transfer layer and the article. This allows the ink to penetrate more deeply into the article, thereby improving the brightness, sharpness, and saturation of the image. Furthermore, deeper ink penetration improves the overall durability and washability of the image on the article surface.

[0010] In the embodiment, the support layer is configured to peel off from the image layer with a peeling force of less than approximately 30 N / 25 mm, preferably between approximately 10 N / 25 mm and approximately 20 N / 25 mm. A reduced peeling force minimizes tearing and damage of the image after it has been transferred to the fabric. In the embodiment, the first layer constitutes a tie-coat layer or film-forming layer containing an EAA copolymer. Normally, when the film-forming layer and the release layer are combined, cracking increases after the image is transferred onto the article, reducing the article's washability. However, the applicant has found that when the film-forming layer and the release layer having a crosslinking agent are combined, the penetration of the image into the fabric increases, thereby improving the article's washability and durability, especially when the image transfer layer is peeled from the support layer before the image is transferred to the article, and making it possible to use thin parchment paper instead of relatively thick backing paper for the transfer process. The crosslinking agent may include any suitable agent such as epoxy resins and isocyanates. In one embodiment, the crosslinking agent includes a polyfunctional aziridine.

[0011] In this embodiment, the release layer is substantially cured before being applied to or mixed with the image transfer layer. This allows the image transfer layer to be easily peeled off from the release layer. In particular, this reduces the peeling force required to peel off the support layer, minimizing tearing and breakage of the image transfer layer when transferring it to an article. In the embodiment, the degree of curing of the release layer is at least about 80%, preferably at least about 90%, before applying the release layer to the first layer. In the preferred embodiment, the release layer is cured in less than about 10 minutes, preferably less than about 4 minutes. This also facilitates the peeling of the image transfer layer from the support layer. In this embodiment, the release layer is approximately 3 pounds (approximately 1.36 kg) / 1300 ft² (approximately 121 m 2 The mass is less than 1 lb / 1300 ft² to about 1.5 lb / 1300 ft². Providing a lightweight release layer further reduces the release force required to separate the image transfer layer and / or release layer from the support layer.

[0012] In embodiments, the transfer sheet preferably includes a protective layer configured to be positioned on the opposite side of the image transfer layer after the backing paper has been peeled from the image transfer layer. In embodiments, the protective layer has a thickness of less than about 2.5 mils. Suitable materials for the protective layer include silicone release paper and parchment paper. In preferred embodiments, the protective layer includes parchment paper and the like.

[0013] In another embodiment, a transfer sheet for transferring an image onto a substrate is provided, manufactured by a novel process. This process includes the steps of providing a backing paper and an image transfer layer containing ink receptors attached to the backing paper, and peeling the image transfer layer from the backing paper. Next, instead of using the backing paper to cover the image layer during the heat transfer process, a material such as parchment paper may be used.

[0014] In this embodiment, a protective layer is placed on the image transfer layer, opposite the backing layer (after the backing layer has been removed). The image transfer layer is then placed on the article, and heat and pressure are applied to transfer the image to the article. This process accelerates and increases heat transfer, thereby increasing the penetration of ink from the image transfer layer to the article, resulting in a softer-feeling transfer with improved washability and durability. This process is particularly useful for low-pressure heat press transfer and / or iron transfer of the image transfer layer to an article. Furthermore, this process reduces the total peeling force required to remove the image transfer layer from the backing layer of the original model, thereby reducing cracking and breakage of the coating when it is transferred to the article. The image layer is cleanly removed at room temperature and room pressure, instead of being subjected to high temperature and high pressure. Next, a non-stick material is used as a protective layer during the heat transfer process. This improves the appearance of the image on the article surface compared to the standard process.

[0015] In embodiments, the protective layer has a thickness of less than about 2.5 mils. Suitable materials for the second support layer include parchment paper and silicone release paper. In preferred embodiments, the second support layer includes parchment paper and the like. In the embodiment, the original backing layer is peeled off from the image transfer layer with a peeling force preferably less than about 30 N / 25 mm, and preferably between about 10 N / 25 mm and about 20 N / 25 mm. In this embodiment, the temperature and pressure applied to the image transfer layer by this process are lower than those of conventional transfer sheets. In one such embodiment, the temperature of the heat applied to the image transfer layer is about 360°F to about 375°F. The pressure is preferably about 30 psi (about 0.207 MPa) to about 45 psi.

[0016] In embodiments, the process further includes the steps of applying a release layer between the backing paper and the image transfer layer, and peeling the image transfer layer from the release layer. In preferred embodiments, the release layer includes a crosslinking agent. In the embodiment, the image transfer layer comprises a binder having first and second components, each comprising an EAA copolymer, the second component comprising less than about 20% by mass of the EAA copolymer, preferably about 15% by mass of acrylic acid. In another embodiment, a transfer assembly, system, or kit for transferring an image onto a substrate is provided. The transfer assembly includes a protective layer having a thickness of less than approximately 2.5 mils, an image transfer layer containing an ink acceptor, and a release layer adhered to the image transfer layer. In this embodiment, the protective layer includes parchment paper. The parchment paper may be applied to the opposite side of the article from the image transfer layer. In the embodiment, the transfer assembly further includes a backing paper that is removably adhered to the image transfer layer. The backing paper is preferably removed from the image transfer layer with a peeling force of less than about 30 N / 25 mm, preferably between about 10 N / 25 mm and about 20 N / 25 mm.

[0017] In an embodiment, the image transfer layer includes a first layer and a second layer, the second layer includes an ink receptor, the second layer includes a binder having first and second components, each including an EAA copolymer. The second component includes less than about 20%, preferably about 15% by mass of acrylic acid based on the mass of the EAA copolymer. In an embodiment, the image transfer layer further includes a release layer. The release layer includes a crosslinking agent. In an embodiment, the substrate includes a light-colored or white textile such as cotton or a cotton / polyester blend. In an embodiment, the ink composition includes a colorant and an aqueous liquid carrier. The composition is not limited to a particular type of colorant and includes organic pigments and inorganic pigments, dyes or polymeric colorants (such as poly(oxyalkylene)), substituted chromophores incorporating such compounds (such as polyurethanes and polyesters) and polymers. As further examples, the colorant may be selected from sublimable dyes, disperse dyes, reactive dyes, acid dyes and basic dyes, and titanium dioxide, carbon black and calcium carbonate.

[0018] The ink composition can be printed on the upper surface of the transfer sheet by any of various conventional techniques. By way of example, the ink composition may be applied by inkjet printing, screen printing, lithographic printing, stamping, gravure printing, or the ink composition may be applied by hand. In an exemplary embodiment, the ink composition is applied by inkjet printing. In an embodiment, the ink receptor includes a hydrophilic organic material bonded 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 zeolites. The listing of desirable objectives satisfied by various embodiments herein is not intended to imply or suggest that any or all of these objectives are present as essential features, either individually or collectively, in either the most general embodiment of this description or a more specific embodiment thereof.

Brief Description of the Drawings

[0019] [Figure 1] It is a diagram illustrating a transfer sheet for transferring an image to a substrate or an article. [Figure 2] It is a diagram showing another embodiment of a transfer sheet for transferring an image to a substrate or an article. [Figure 3] It is a diagram showing another embodiment of a transfer sheet for transferring an image to a substrate or an article. [Figure 4] It is a diagram schematically illustrating the removal of an image transfer layer from a release layer and a backing layer of a transfer sheet. [Figure 5] It is a diagram schematically illustrating the arrangement of the first surface of an image transfer layer on an article and the arrangement of a protective layer on the opposite second surface of the image transfer layer. [Figure 6] It is a diagram illustrating a conventional transfer sheet including conventional backing paper. [Figure 7] It is a diagram illustrating that a transfer sheet is peeled off from conventional backing paper. [Figure 8] It is a diagram illustrating that a transfer sheet is applied to an article using parchment paper on the transfer sheet. [Figure 9] It is a diagram illustrating the result after performing a cleaning and drying cycle of a conventional transfer sheet 10 times after transferring an image to an article by hot pressing. [Figure 10] It is a diagram illustrating the result after performing a cleaning and drying cycle 10 times after transferring an image to an article by hot pressing using a new process. [Figure 11] It is a diagram illustrating the result after performing a cleaning and drying cycle of a conventional transfer sheet 10 times after transferring an image to an article by an iron. [Figure 12] This figure illustrates the results after transferring an image to an item using a novel process via ironing, followed by 10 wash-and-dry cycles. [Modes for carrying out the invention]

[0020] This description and accompanying drawings illustrate exemplary embodiments and should not be considered limiting, and the claims define the scope of this description, including equivalents. Various mechanical, structural, and operational modifications may be made without departing from the scope of this description and claims, including equivalents. In some examples, well-known structures and techniques are not shown or described in detail so as not to obscure this description. Similar figures in two or more figures represent the same or similar elements. Furthermore, elements and their related aspects described in detail with reference to one embodiment may, whenever practical, be included in other embodiments that are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment but not with reference to a second embodiment, it can still be argued that the element is included in the second embodiment. Furthermore, the illustrations in this specification are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or the components illustrated.

[0021] When used herein and in the appended claims, the singular forms "a," "an," and "the," and any singular use of any word, should be noted to include multiple referents unless expressly and clearly limited to one. The term "include" and its grammatical variations are intended to be non-restrictive as used herein, so that the listing of items in a list does not exclude other similar items that may replace or add to the listed items. Unless otherwise specified, all quantitative values ​​are approximate, regardless of whether the words "about" or "approximately" are explicitly stated. The materials, processes, and examples described herein are illustrative and not intended to be limiting.

[0022] Various embodiments provide systems and processes for transferring images onto articles such as textiles and fabrics. Furthermore, various embodiments demonstrate improved processes for manufacturing transfer assemblies and sheets. Such systems and processes are particularly useful for transferring images onto white or colored fabrics such as T-shirts, hats, and sweatshirts. Figure 1 illustrates one embodiment of a transfer sheet 10 for transferring an image to an article 20. The transfer sheet 10 includes a support layer, i.e., a base sheet 30, a release layer 40, and an image transfer layer 50 which includes at least a binder, an ink receptor, and, in some embodiments, a blocking agent. An ink composition, or a printed coating including an image, is applied to the upper surface of the image transfer layer 50. The ink composition may include printed and unprinted areas.

[0023] In some embodiments, heat and pressure are applied to the transfer sheet 10 to transfer the ink composition or printed coating from the image transfer sheet 50 to the article 20. In other embodiments, the base sheet 30 is removed from the image transfer sheet 50 before heat and pressure are applied (described in more detail below). The ink composition can be printed onto the upper surface of the transfer sheet by any of the various conventional techniques. For example, the ink composition may be applied by inkjet printing, screen printing, lithography, stamping, gravure printing, or it may be applied manually. The formulation of the ink composition may be adjusted to be compatible with the chosen printing method. The ink composition may have a viscosity ranging from liquid to paste. The ink composition may contain additional components known to those skilled in the art, such as binders, wetting agents, and surfactants. The aqueous carrier liquid may contain, in addition to water, trace amounts of water-miscible organic cosolvents such as lower alcohols, glycols, and glycerin. For example, the organic cosolvent may contain 20% by mass or less of the liquid carrier component of the ink composition.

[0024] In exemplary embodiments, the ink composition is a pigment ink applied by inkjet printing in a one-step process. The substrate or article may include any suitable article on which an image is desired to be printed. Suitable articles include T-shirts, sweatshirts, hats, leather goods, signs, laminates, metals, glass, wood, paper, or other cellulose materials. The article may be a woven, knitted, or nonwoven textile material consisting of natural fibers, synthetic fibers, or combinations thereof. For example, the textile may include fibers selected from cotton, wool, jute, hemp, polyester, polyamide, polyurethane, and polyolefin. The articles may include white or light-colored textiles. The textiles may include 100% cotton, less than 100% cotton, or cotton / polyester blends.

[0025] In this embodiment, the image transfer layer 50 includes three layers: (1) a print coat layer 52 containing an ink receptor and, in some embodiments, a blocking agent; (2) a base coat 54; and (3) a tie coat layer 56 containing a binder. The three layers may be formed separately, or they may be applied to each other such that the tie coat layer 56 is positioned between the other two layers and the release layer 40. Alternatively, one or more layers may be mixed together. Figure 2 illustrates an alternative embodiment of the transfer sheet 10', in which the print coat layer and the base coat layer are mixed together to form a single layer 60, which is applied to the tie coat layer 56. Figure 3 illustrates yet another embodiment of the transfer sheet 10', in which all three of these layers are mixed together to form a single layer 70, which is applied to the release layer 40. In yet another embodiment, the blocking agent and the ink acceptor may be formed in separate layers. These separate layers may or may not include a binder or a base layer.

[0026] The printed coating layer 52 contains an ink acceptor. The ink acceptor is preferably hydrophilic and can absorb the aqueous liquid carrier component of the ink composition used to print an image onto the transfer assembly. In particular, the 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. As the aqueous liquid carrier passes through the image transfer layer, the blocking agent is destroyed. Depending on the properties of the ink composition, the colorants present in the ink composition may be absorbed by ink acceptors along with the liquid carrier, or the colorants may become concentrated on the upper surface of the transfer sheet. For example, dyes soluble in aqueous liquid carriers can be easily absorbed into the image transfer layer, but pigments, disperse dyes, and polymer colorants have low mobility and low penetration into the image transfer layer.

[0027] As an example, suitable ink acceptors may be selected from hydrophilic polymers, including poly(acrylic acid), poly(vinylimidazole), poly(2-hydroxyethyl methacrylate), poly(vinylpyrrolidone), poly(vinyl)poly(pyrrolidone), and polyvinyl acetate, cationic polymers, and their salts. Other examples include 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.

[0028] The ink acceptor may be present in the printed coating layer in an amount of about 2% to about 25% by mass, or about 5% to about 15% or about 10%. In one embodiment, the ink acceptor comprises a crosslinked homopolymer of N-vinyl-2-pyrrolidone, such as Polyplasdone® INF-10 manufactured by Ashland®. The printed coating layer 52 further comprises a binder having first and second components, each comprising an ethylene acrylic acid (EAA) copolymer. The second component contains less than 20% acrylic acid by mass of the EAA copolymer. The applicant has found that reducing the amount of acid in the binder of the printed coating improves the melt flow of the image onto an article, such as a fabric. This improves the washability of the fabric, and especially in the case of light-colored fabrics, the image transferred to the fabric remains more robust and clear even after multiple washes of the fabric.

[0029] In embodiments, the print coating layer 52 comprises a first material containing about 20% acrylic acid and a second material containing less than 20%, preferably about 15%, acrylic acid. The first and second materials may have a mass ratio of about 90 / 10 to about 50 / 50, preferably about 80 / 20 to about 70 / 30. In exemplary embodiments, the second material is about 25% by mass. This reduces the overall acid content of the print coating layer and improves the image melt flow without substantially increasing abrasion and pilling during washing and drying of the fabric. In exemplary embodiments, the first material contains about 10% to about 40% of the ethylene acrylic acid dispersion by mass of the printed coating layer, and the second material contains about 2% to about 15% by mass of the printed coating layer.

[0030] The print coating layer 52 may contain materials other than ink acceptors. For example, the print coating layer 52 may contain certain silica, surfactants, waxes and / or thickeners. Suitable surfactants include, but are not limited to, nonionic, anionic, cationic and amphoteric surfactants such as sodium stearate, 4-(5-dodecyl)benzenesulfonate, sodium dodecylbenzenesulfonate wetting agent, doxate (sodium dioctyl sulfosuccinate), alkyl ether phosphate, benzalkonium chloride (BAC), and perfluorooctanesulfonate (PFOS). Examples of waxes include, but are not limited to, polyolefins, polyethylene, functionalized waxes (amines, amides, etc.), fluorinated waxes, mixed fluorinated waxes, and amide waxes (esters, quaternary amines, carboxylic acids or acrylic polymer emulsions, chlorous acid polyethylene, etc.), natural or synthetic ester waxes, carnauba wax, and paraffin. Such waxes may be fractionated or distilled to yield a specific cut that satisfies certain viscosity and / or temperature criteria. Suitable thickeners include, but are not limited to, starch, gum, pectin, and paragum.

[0031] In exemplary embodiments, the print coating layer 52 may contain a plasticizer, a wax and / or an ethylene oxide homopolymer. In exemplary embodiments, the print coating layer 52 contains about 15% to about 40% by mass of a plasticizer, about 15% to about 40% by mass of a wax composite, and about 2% to about 15% by mass of an ethylene oxide homopolymer. In certain embodiments, the base coat layer 54 comprises a first material containing about 20% acrylic acid and a second material containing less than 20%, preferably about 15%, acrylic acid. The first and second materials may have a mass ratio of about 90 / 10 to about 50 / 50, preferably about 80 / 20 to about 70 / 30. In exemplary embodiments, the second material is about 25% by mass of the second component.

[0032] In exemplary embodiments, the base coat layer 54 contains about 25% to about 50% ethylene acrylic acid dispersion by mass of the printed coat layer, and the second material contains about 2% to 10% ethylene acrylic acid dispersion by mass of the printed coat layer. The printed coating layer 52 may contain certain silica, surfactants, waxes and / or other materials such as thickeners. Suitable surfactants include, but are not limited to, nonionic, anionic, cationic and amphoteric surfactants such as sodium stearate, 4-(5-dodecyl)benzenesulfonate, sodium dodecylbenzenesulfonate wetting agent, doxate (sodium dioctyl sulfosuccinate), alkyl ether phosphate, benzalkonium chloride (BAC), and perfluorooctanesulfonate (PFOS). Examples of waxes include, but are not limited to, polyolefins, polyethylene, functionalized waxes (amines, amides, etc.), fluorinated waxes, mixed fluorinated waxes, and amide waxes (esters, quaternary amines, carboxylic acids or acrylic polymer emulsions, chlorous acid polyethylene, etc.), natural or synthetic ester waxes, carnauba wax, and paraffin.

[0033] The tie coat layer 56 contains a binder, which preferably contains a material that promotes bonding between the print coat layer 52 and the base coat layer 54, which includes the release layer 40. The binder preferably contains a material that does not swell when in contact with water, i.e., the binder absorbs water (>5% and <50% of its own mass). The binder is preferably hydrophobic. The binder may be a wax, a thermoplastic polymer, or a prepolymer, or a combination thereof. Additional reactive compounds may be used in the binder composition, including crosslinking agents, monomers, and oligomers, and these compounds can be bonded to other components in the binder composition. The components of the binder composition may be self-crosslinkable or bonded to functional groups present in the printed article to improve wash fastness. Ink compositions useful for transfer sheets include a colorant and an aqueous liquid carrier. This composition is not limited to a specific type of colorant and includes organic and inorganic pigments, dyes or polymeric molecular colorants (such as poly(oxyalkylene)), substitutional chromophores, and polymers incorporating such compounds, such as polyurethanes and polyesters. Further examples include colorants selected from sublimation dyes, dispersible dyes, reactive dyes, acid dyes, and basic dyes, as well as titanium dioxide, carbon black, and calcium carbonate.

[0034] In certain embodiments, the tie coat layer 56 comprises an EAA copolymer containing at least about 20% acrylic acid dispersion of the copolymer. Since the tie coat is typically located on the outer surface of the image after the image has been transferred to the article, this layer is subject to most of the abrasion and pilling that occurs as the fabric swells and shrinks during the wash-and-dry cycle. Maintaining a higher acid level in the tie coat reduces wear and improves the retention of ink color in the article. In exemplary embodiments, the Tiecoat layer 56 contains an EAA dispersion in an amount of about 80% to about 99% by mass. The Tiecoat layer 56 may also contain other components such as surfactants, crosslinking agents, urethanes, and polyesters. In such one embodiment, the Tiecoat layer 56 contains a silicone glycol copolymer and an aqueous surfactant.

[0035] The release layer 40 allows the image transfer layer 50 to be separated from the base sheet 30 before or after the print coating is applied to the article 20. The release layer 40 may include any suitable material that allows the release layer 40 to be removably attached to the base sheet 30. Suitable materials for the release layer 40 include hot peel, cold peel, hot split, and the like. In exemplary embodiments, the release layer 40 is a hot peel containing an acrylic polymer emulsion in an aqueous dispersion. The acrylic polymer emulsion may be present in an amount of at least about 50%, at least about 75%, or at least about 90% of the base sheet. In one exemplary embodiment, the release layer 40 may contain a crosslinking agent in the binder. The applicant has found that combining the tie coat layer 56 described above with a release layer containing a crosslinking agent improves the penetration of the image into the fabric, and in particular, improves the washability and durability of the article when the image transfer layer is peeled off from the support layer before the application of heat and pressure.

[0036] Suitable crosslinking agents include epoxy resins, isocyanates, or polyfunctional aziridines. In preferred embodiments, the crosslinking agent comprises polyfunctional aziridines in an amount of about 2% to about 10% by mass. In this embodiment, the release layer is substantially cured before the image transfer layer is applied over it. This facilitates the separation of the release layer from the support layer. In particular, this reduces the peeling force required to separate the release layer from the support layer, thereby minimizing tearing and breakage of the image transfer layer when transferring it to an article. In embodiments, the degree of curing of the release layer after application to the first layer is at least about 80%, preferably at least about 90%. “Degree of curing” is defined herein to mean the extent to which the composition is sufficiently crosslinked, resulting in the composition being substantially in its final form (i.e., no further crosslinking occurs in the composition, and / or no further substantial changes occur). The degree of curing as defined herein does not necessarily mean 100% crosslinking, such that the composition becomes a fully cured resin, but rather 100% curing that occurs before the function or appearance of the composition is substantially altered.

[0037] In a preferred embodiment, the release layer is cured in less than about 10 minutes, preferably less than about 4 minutes. This also facilitates the removal of the image transfer layer from the support layer. In the embodiment, the release layer has a mass of less than about 3 pounds / 1300 ft², preferably about 1 pound / 1300 ft² to about 1.5 pounds / 1300 ft². Providing a lightweight release layer further reduces the release force required to separate the image transfer layer and / or the release layer from the support layer. In certain embodiments, the release layer 40 may further contain a surfactant and / or an acrylic emulsion. Suitable surfactants for use with the binders disclosed herein include nonionic, anionic, cationic and amphoteric surfactants such as sodium stearate, 4-(5-dodecyl)benzenesulfonate, sodium dodecylbenzenesulfonate wetting agent, doxate (sodium dioctyl sulfosuccinate), alkyl ether phosphate, benzalkonium chloride (BAC), and perfluorooctanesulfonate (PFOS).

[0038] The base sheet, or support layer 30, may be any backing sheet selected from laminates of two or more materials from the above classification, including (i) nonwoven webs made from cellulosic fibers, such as coated and uncoated paper, parchment paper, and cardboard, and synthetic polymers such as polyethylene, polypropylene, polystyrene, and other polyolefins; (ii) synthetic polymer sheets including thermoplastic polymers such as polyester (e.g., PET and PEN), poly(vinyl chloride), polystyrene, polymethacrylate, polycarbonate, polyimide, polyurethane, ethylene-vinyl acetate, polytetrafluoroethylene, and thermosetting resins; (iii) metallized films including metallized biaxially oriented polyethylene terephthalate; (iv) woven and knitted textile sheets made from natural or synthetic fibers and combinations thereof; and (V) laminates of nonwoven webs and thermoplastic polymers.

[0039] The base sheet may be opaque, translucent, or transparent. In certain embodiments, the base sheet contains a certain proportion of used fibers. The thickness of the base sheet may be in the range of about 1 mil to about 10 mil, particularly 2 mil to about 6 mil. This thickness is desirable because it allows sufficient heat to pass through the base sheet while the image is being transferred. In one embodiment, the release layer 40 is configured to peel off from the support layer 30 before heat and pressure are applied to the transfer sheet. Peeling off the support layer 30 from the transfer sheet accelerates and increases the transfer of heat to the image transfer layer and the article. This allows the ink to penetrate more deeply into the article, thereby improving the brightness, sharpness, and saturation of the image. Furthermore, deeper ink penetration improves the overall durability and washability of the image on the article surface. In this embodiment, the support layer 30 is configured to be peeled from the release layer 40 with a peeling force of less than approximately 30 N / 25 mm, preferably between approximately 10 N / 25 mm and approximately 20 N / 25 mm. This reduction in peeling force minimizes tearing and damage of the image after it has been transferred to the fabric.

[0040] In this embodiment, the transfer sheet 10 includes a protective layer 60 (see Figure 6). The protective layer 60 is placed on the image transfer layer 50 opposite the backing layer (after the backing layer 30 has been removed). Next, the image transfer layer 50 is positioned on the article 20, and heat and pressure are applied to transfer the image to the article 20. This process promotes and enhances heat transfer, thereby increasing the penetration of ink from the image transfer layer to the article, which allows for softer heat transfer and improves washability and durability. This process is particularly useful for low-pressure heat press transfer and / or iron transfer of the image transfer layer to an article. Furthermore, this process reduces the total peeling force required to remove the image transfer layer from the backing layer of the original model, thereby reducing cracking and breakage of the coating once it is transferred to the article. This improves the appearance of the image on the article surface. In the embodiment, the protective layer 60 has a thickness of less than about 2.5 mils. Suitable materials for the second support layer 60 include silicone release paper and parchment paper. In a preferred embodiment, the protective layer includes parchment paper or the like. In this embodiment, the temperature and pressure applied to the image transfer layer by this process are lower than those of a conventional transfer sheet. In such one embodiment, the temperature of the heat applied to the image transfer layer is about 360°F to about 375°F. The pressure is preferably about 30 psi to about 45 psi.

[0041] Figures 4 and 5 illustrate a novel process for manufacturing the above-described transfer sheet. 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 brought into contact with this layer. In conventional processes, as discussed above, the image transfer layer 50 is then heated and pressurized by a hot press, iron, or other suitable machine to apply an image to the upper surface of the image transfer layer 50 using a suitable ink composition or printing coating. However, in one embodiment described herein, the image transfer layer 50 is peeled off from the release layer 40 and the base layer 30 before such heating and pressurizing processes (see Figure 4). In exemplary embodiments, the image transfer layer 50 is peeled off from the release layer 40 at room temperature and with minimal pressure. For example, the removal process may be started from one of the corners of the image transfer layer 50 (see Figure 7).

[0042] The image transfer layer 50 is placed face down on the surface of the article 20 after being completely removed from the release layer 40 (see Figure 5), and the protective layer 60 (such as parchment paper) is placed on the opposite surface from the image transfer layer 50 (see also Figure 8). The parchment paper is much thinner than the original backing paper, as discussed above. At this point, the ink in the image transfer layer 50 is transferred to the article 20, and the image is transferred to the article. This may be achieved, for example, by a heat press at high temperature and medium pressure for about 30 seconds, or by a standard iron for about 3 minutes. In exemplary embodiments, heat and pressure may be applied to the article and the transfer sheet for about 25 to 30 seconds. At the end of the transfer time, the transfer sheet is peeled from the article, with the printed area of ​​the image transfer layer bonded to the article, and in some embodiments, the non-printed area of ​​the image transfer layer bonded to the support layer of the transfer sheet. [Examples]

[0043] The applicant has conducted tests on conventional transfer sheets and the transfer sheets discussed herein. In particular, the applicant has performed parallel comparisons of articles on which images were transferred using a conventional process (i.e., backing paper) and a process according to a specific embodiment described herein (a process on which the backing paper is removed and parchment paper is replaced on the opposite side of the image transfer layer).

[0044] Figure 9 is a black and white photograph illustrating an article with an image transferred onto a backing sheet using a conventional method. The image was transferred using a relatively low-pressure heat press. After transfer, the article underwent 10 washing and drying cycles. As shown, cracks began to appear in multiple places on the image. Furthermore, the image had already begun to fade, losing some of its gloss and brightness.

[0045] Figure 10 is a black and white color photograph illustrating an article having an image transferred onto it by a process according to a particular embodiment described herein (i.e., parchment facing downwards). The image was transferred using a heat press at relatively low pressure. After transfer, the article was subjected to 10 wash-and-dry cycles. As shown, the image has not begun to crack. Furthermore, this image is brighter and sharper than the image shown in Figure 9. This illustrates that the transfer sheet and process according to the particular embodiment described herein produces an image with improved durability and washability compared to conventional transfer sheets and processes. Figure 11 is a black and white color photograph illustrating an article with an image transferred onto a backing sheet using a conventional method. The image was transferred using an iron for approximately 3 minutes. After transfer, the article underwent 10 wash-and-dry cycles. As shown, a significant defect has already formed in the image.

[0046] Figure 12 is a black and white color photograph illustrating an article having an image transferred onto it by a process according to a particular embodiment described herein (i.e., parchment facing downwards). The image was transferred by ironing for approximately 3 minutes. After transfer, the article was subjected to 10 wash-and-dry cycles. As shown, the image contains no major defects and is brighter and sharper than the image shown in Figure 11. This illustrates that the transfer sheets and processes according to the particular embodiments described herein produce images that are more durable and wash-resistant than conventional transfer sheets and processes, even when the image is transferred to the article by ironing rather than by heat pressing. While devices, systems, and processes have been described in detail in this specification with respect to their particular preferred embodiments, many modifications and changes can be made to them by those skilled in the art. Therefore, the foregoing descriptions should not be construed as limiting, but rather as being limited only by the spirit and scope of the following claims, including the obvious modifications described above.

[0047] For example, in a first embodiment, the first embodiment is a transfer sheet for transferring an image onto a substrate. The transfer sheet includes a support layer and an image transfer layer disposed on the support layer. The image transfer layer includes a first layer containing a binder and a second layer containing an ink acceptor. The second layer includes first and second components, each containing an ethylene acrylic acid (EAA) copolymer. The second component contains less than 20% acrylic acid by mass of the EAA copolymer. The transfer sheet further includes a release layer between the support layer and the first layer. The second embodiment is the same as the first embodiment, wherein the second component contains about 15% acrylic acid by mass of the EAA copolymer. The third embodiment is a combination of either of the first two embodiments, wherein the first component contains about 20% acrylic acid by mass of the EAA copolymer. The fourth embodiment is a combination of any of the first three embodiments, wherein the second layer contains the first and second components in a ratio of approximately 90 / 10 to approximately 50 / 50.

[0048] The fifth embodiment is a combination of any of the first four embodiments, where the ratio is approximately 80 / 20 to approximately 70 / 30. The sixth embodiment is a combination of any of the first five embodiments, wherein the first layer is a tie coat layer containing a binder having at least about 20% EAA copolymer by mass basis of the binder. The seventh embodiment is a combination of any of the first six embodiments, wherein the second layer includes a print coating layer and a base coating layer. The eighth embodiment is a combination of any of the first seven embodiments, wherein the first layer and the second layer are mixed with each other. The ninth embodiment is a combination of any of the first eight embodiments, wherein the support layer includes backing paper containing used fibers. The tenth embodiment is a combination of any of the first nine embodiments, wherein the release layer contains a crosslinking agent. The eleventh embodiment is any combination of the first ten embodiments, wherein the crosslinking agent comprises a polyfunctional aziridine.

[0049] In another embodiment, the first embodiment is a transfer sheet for transferring an image onto a substrate. The transfer sheet includes a support layer and an image transfer layer disposed on the support layer. The image transfer layer includes a first layer and a second layer, the second layer including an ink acceptor, the first layer including a binder and a release layer between the support layer and the first layer, the release layer including a crosslinking agent. The second embodiment is the first embodiment, wherein the crosslinking agent comprises a polyfunctional aziridine.

[0050] The third embodiment is a combination of either of the first two embodiments, wherein the binder comprises an EAA copolymer. The fourth embodiment is a combination of any of the first three embodiments, wherein the second layer comprises a print coating layer and a base coat layer, and the base coat layer comprises one or more materials that enhance the opacity of the print coating layer. The fifth embodiment is a combination of any of the first four embodiments, wherein the first and second layers are mixed together. The sixth embodiment is a combination of any of the first five embodiments, wherein the release layer is cured before the image transfer layer is applied to the release layer. The seventh embodiment is a combination of any of the first six embodiments, wherein the degree of curing of the release layer before applying the release layer to the first layer is at least 80%.

[0051] The eighth embodiment is a combination of any of the first seven embodiments, wherein the degree of curing is at least 90%. The ninth embodiment is one in which the release layer is approximately 3 pounds / 1300 ft. 2 It is a combination of any of the first eight embodiments, which is less than [a certain value]. In the tenth embodiment, the release layer is approximately 1 pound / 1300 ft 2 ~Approximately 1.5 pounds / 1300 ft 2 This is a combination of any of the first nine embodiments. The eleventh embodiment is a combination of any of the first ten embodiments, wherein the release layer is cured in less than four minutes. The twelfth embodiment is a combination of any of the first eleven embodiments, wherein the support layer includes a backing containing used fibers.

[0052] The 13th embodiment is a combination of any of the first 12 embodiments, wherein the backing paper is configured to be peeled from the image transfer layer with a peeling force of less than approximately 20 N / 25 mm. A fourteenth embodiment is a combination of any of the first thirteen embodiments, further comprising the configuration in which the protective layer is applied to the surface of the second layer. The 15th embodiment is a combination of any of the first 14 embodiments, wherein the protective layer is parchment paper. The sixteenth embodiment is a combination of any of the first fifteen embodiments, wherein the protective layer has a thickness of less than approximately 2.5 mils. The 17th embodiment is a combination of any of the first 16 embodiments, wherein the image transfer layer comprises a first layer and a second layer, the second layer comprising an ink acceptor, the second layer comprising the first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer.

[0053] In another embodiment, the first embodiment is a transfer sheet for transferring an image onto a substrate, manufactured by a process. This process includes the steps of providing a backing paper and an image transfer layer attached to the backing paper, wherein the image transfer layer includes an ink receptor; peeling the image transfer layer from the backing paper; and applying heat and pressure to the image transfer layer after the backing paper has been removed from the image transfer layer. The second embodiment is the first embodiment, in which the image transfer layer is peeled off from the backing paper. The third embodiment is a combination of either of the first two embodiments, wherein the peeling force required to peel the image transfer layer from the backing paper is less than approximately 20 N / 25 mm. The fourth embodiment is a combination of any of the first three embodiments, wherein the temperature of the heat applied to the image transfer layer is approximately 360°F to approximately 375°F. The fifth embodiment is a combination of any of the first four embodiments, with a pressure of approximately 30 psi to approximately 45 psi.

[0054] The sixth embodiment is a combination of any of the first five embodiments, further comprising positioning an image transfer layer on a substrate. The seventh embodiment is a combination of any of the first six embodiments, further comprising positioning a protective layer on the image transfer layer. The eighth embodiment is a combination of any of the first seven embodiments, wherein the protective layer has a thickness of less than 2.5 mils. The ninth embodiment is a combination of any of the first eight embodiments, wherein the protective layer is parchment paper. The tenth embodiment is a combination of any of the first nine embodiments, further comprising applying heat and pressure to the support layer and the image transfer layer to transfer the image to the substrate. The eleventh embodiment is a combination of any of the first ten embodiments, further comprising applying a release layer between the backing paper and the image transfer layer, and peeling the image transfer layer from the release layer.

[0055] The twelfth embodiment is any combination of the first eleven embodiments, wherein the release layer contains a crosslinking agent. The 13th embodiment is any combination of the first 12 embodiments, wherein the crosslinking agent comprises a polyfunctional aziridine. A fourteenth embodiment is any combination of the first thirteen embodiments, further comprising applying an ink composition to an image transfer layer. The 15th embodiment is a combination of any of the first 14 embodiments, wherein the image transfer layer comprises a binder having first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer. The sixteenth embodiment is a combination of any of the first fifteen embodiments, wherein the acrylic acid in the second component is approximately 15% by mass of the EAA copolymer. The 17th embodiment is a combination of any of the first 16 embodiments, wherein the first component contains about 20% acrylic acid by mass of the EAA copolymer. The 18th embodiment is a combination of any of the first 17 embodiments, wherein the base material includes a light-colored textile. The 19th embodiment is a combination of any of the first 18 embodiments, wherein the textile includes cotton or a cotton / polyester blend.

[0056] In another embodiment, the first embodiment is a transfer assembly for transferring an image onto a substrate, comprising a support layer having a thickness of less than about 2.5 mils, an image transfer layer containing an ink receptor, and a release layer adhered to the image transfer layer. A second embodiment is the first embodiment, wherein the protective layer is configured to be removablely attached to the image transfer layer. A third embodiment is a combination of either of the first two embodiments, wherein the protective layer is parchment paper. A fourth embodiment is a combination of any of the first three embodiments, further comprising a backing paper, wherein the release layer is removably bonded to the backing paper.

[0057] The fifth embodiment is a combination of any of the first four embodiments, wherein the image transfer layer comprises a first layer and a second layer, the second layer comprising an ink acceptor, the second layer comprising the first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer. The sixth embodiment is a combination of any of the first five embodiments, wherein the release layer contains a crosslinking agent. The seventh embodiment is a combination of any of the first six embodiments, wherein the crosslinking agent comprises a polyfunctional aziridine.

Claims

1. A transfer sheet for transferring an image onto a substrate, support layer, An image transfer layer disposed on the support layer, wherein the image transfer layer comprises a first layer containing a binder and a second layer containing an ink acceptor, the second layer comprising first and second components, each comprising an ethylene acrylic acid (EAA) copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer, and The delamination layer between the support layer and the first layer, A transfer sheet containing this.

2. The transfer sheet according to claim 1, wherein the second component contains about 15% acrylic acid by mass of the EAA copolymer.

3. The transfer sheet according to claim 1, wherein the first component contains about 20% acrylic acid by mass of the EAA copolymer.

4. The transfer sheet according to claim 1, wherein the second layer contains the first and second components in a ratio of about 90 / 10 to about 50 / 50.

5. The transfer sheet according to claim 4, wherein the ratio is approximately 80 / 20 to approximately 70 / 30.

6. The transfer sheet according to claim 1, wherein the first layer is a tie coat layer containing a binder having at least about 20% by mass of the binder in the form of an EAA copolymer.

7. The transfer sheet according to claim 1, wherein the second layer includes a print coating layer and a base coating layer.

8. The transfer sheet according to claim 1, wherein the first layer and the second layer are mixed together.

9. The transfer sheet according to claim 1, wherein the support layer includes backing paper containing used fibers.

10. The transfer sheet according to claim 1, wherein the release layer contains a crosslinking agent.

11. The transfer sheet according to claim 10, wherein the crosslinking agent comprises a polyfunctional aziridine.

12. A transfer sheet for transferring an image onto a substrate, support layer, An image transfer layer disposed on the support layer, wherein the image transfer layer comprises a first layer and a second layer, the second layer comprising an ink receptor, and the first layer comprising a binder, and A release layer between the support layer and the first layer, comprising a crosslinking agent, A transfer sheet containing this.

13. The transfer sheet according to claim 12, wherein the crosslinking agent comprises a polyfunctional aziridine.

14. The transfer sheet according to claim 12, wherein the binder comprises an EAA copolymer.

15. The transfer sheet according to claim 12, wherein the second layer comprises a print coating layer and a base coat layer, and the base coat layer comprises one or more materials that enhance the opacity of the print coating layer.

16. The transfer sheet according to claim 12, wherein the first and second layers are mixed together.

17. The transfer sheet according to claim 12, wherein the release layer is cured before the image transfer layer is applied to the release layer.

18. The transfer sheet according to claim 18, wherein the degree of hardening of the release layer before applying the release layer to the first layer is at least 80%.

19. The transfer sheet according to claim 19, wherein the degree of curing is at least 90%.

20. The aforementioned peeling layer is approximately 3 pounds / 1300 ft 2 A transfer sheet according to claim 12, which is less than [amount missing].

21. The aforementioned peeling layer is approximately 1 pound / 1300 ft 2 ~Approximately 1.5 pounds / 1300 ft 2 The transfer sheet according to claim 12.

22. The transfer sheet according to claim 18, wherein the release layer is cured in less than 4 minutes.

23. The transfer sheet according to claim 12, wherein the support layer includes a backing containing used fibers.

24. The transfer sheet according to claim 24, wherein the backing paper is configured to be peeled off from the image transfer layer with a peeling force of less than approximately 20 N / 25 mm.

25. The transfer sheet according to claim 12, further comprising the protective layer being configured to be applied to the surface of the second layer.

26. The transfer sheet according to claim 25, wherein the protective layer is parchment paper.

27. The transfer sheet according to claim 25, wherein the protective layer has a thickness of less than approximately 2.5 mils.

28. The transfer sheet according to claim 12, wherein the image transfer layer comprises a first layer and a second layer, the second layer comprising an ink acceptor, the second layer comprising first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer.

29. A transfer sheet for transferring an image onto a substrate, manufactured by the following process: A step of providing backing paper and an image transfer layer attached to the backing paper, wherein the image transfer layer includes an ink receptor. The steps of peeling the image transfer layer from the backing paper, After the backing paper is removed from the image transfer layer, heat and pressure are applied to the image transfer layer. A transfer sheet containing this.

30. The transfer sheet according to claim 30, wherein the image transfer layer is peeled off from the backing paper.

31. The transfer sheet according to claim 30, wherein the peeling force required to peel the image transfer layer from the backing paper is less than approximately 20 N / 25 mm.

32. The transfer sheet according to claim 29, wherein the temperature of the heat applied to the image transfer layer is approximately 360°F to approximately 375°F.

33. The transfer sheet according to claim 29, wherein the pressure is approximately 30 psi to approximately 45 psi.

34. The transfer sheet according to claim 29, further comprising positioning the image transfer layer on the substrate.

35. The transfer sheet according to claim 34, further comprising positioning the protective layer on the image transfer layer.

36. The transfer sheet according to claim 35, wherein the protective layer has a thickness of less than 2.5 mils.

37. The transfer sheet according to claim 35, wherein the protective layer is parchment paper.

38. The transfer sheet according to claim 35, further comprising applying heat and pressure to the support layer and the image transfer layer to transfer the image to the substrate.

39. The transfer sheet according to claim 29, further comprising applying a release layer between the backing paper and the image transfer layer, and peeling the image transfer layer from the release layer.

40. The transfer sheet according to claim 39, wherein the release layer contains a crosslinking agent.

41. The transfer sheet according to claim 40, wherein the crosslinking agent comprises a polyfunctional aziridine.

42. The transfer sheet according to claim 29, further comprising applying an ink composition to the image transfer layer.

43. The transfer sheet according to claim 29, wherein the image transfer layer comprises a binder having first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer.

44. The transfer sheet according to claim 43, wherein the acrylic acid in the second component is about 15% by mass of the EAA copolymer.

45. The transfer sheet according to claim 44, wherein the first component contains about 20% acrylic acid by mass of the EAA copolymer.

46. The transfer sheet according to claim 29, wherein the substrate includes a light-colored textile.

47. The transfer sheet according to claim 46, wherein the textile comprises cotton or a cotton / polyester blend.

48. A transfer assembly for transferring an image onto a substrate, A support layer having a thickness of less than approximately 2.5 mils, An image transfer layer containing ink receptors, and A release layer adhered to the aforementioned image transfer layer, A transfer assembly including the transfer assembly.

49. The transfer assembly according to claim 48, wherein the protective layer is configured to be removably attached to the image transfer layer.

50. The transfer assembly according to claim 49, wherein the protective layer is parchment paper.

51. The transfer assembly according to claim 48, further comprising backing paper, wherein the release layer is removably bonded to the backing paper.

52. The transfer assembly according to claim 48, wherein the image transfer layer comprises a first layer and a second layer, the second layer comprising an ink acceptor, the second layer comprising first and second components, each comprising an EAA copolymer, and the second component comprising less than 20% acrylic acid by mass of the EAA copolymer.

53. The transfer assembly according to claim 48, wherein the release layer contains a crosslinking agent.

54. The transfer assembly according to claim 53, wherein the crosslinking agent comprises a polyfunctional aziridine.

Images