Method of fabricating a thermal transfer image

Abstract

A method of fabricating a thermal transfer image (100) by utilizing a Thermoplastic Polyurethane (TPU) (161) colored in white as the white pigment of the thermal transfer image. Various colored inks (122, 124, 126, 128) are applied to a substrate (110) in accordance with their respective layers of colors (122, 124, 126, 128) of the desired artwork image design (120). The process leaves voids where white is desired for the artwork image (120). The process applies a clear ink (141) over the image, including locations of the artwork image (120) where white is the desired visible color. Thermoplastic Polyurethane (TPU) (161) is applied in a powder form to an area covering the applied clear ink (141) while the applied clear ink (141) remains wet. Excess TPU (163) is removed from the substrate (110) in areas of the image (120) void of any wet ink (122, 124, 126, 128, 141). The TPU (162) residing on the wet ink (122, 124, 126, 128, 141) is annealed using any heat applying process (199).

Description

Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 METHOD OF FABRICATING A THERMAL TRANSFER IMAGE CROSS-REFERENCE TO RELATED APPLICATION

[0001] This International Patent Application filed under the Patent Cooperation Treaty (PCT) claims the benefit of co-pending United States Non-Provisional Patent Application Serial Number 18 / 820,887 filed on August 30, 2024, wherein United States Non-Provisional Patent Application Serial Number 18 / 820,887 claims the benefit of United States Provisional Patent Application Serial Number 63 / 558,632 filed on February 27, 2024. FIELD OF THE INVENTION

[0002] The present invention relates to the field of printing. In particular, the present invention relates to a method of fabricating a thermal transfer image. BACKGROUND OF THE INVENTION

[0003] Thermal transfer images are generated by applying colors, including white, to a substrate, than applying TPU (Thermoplastic Polyurethane) to the wet ink. Colored ink tends to conceal imperfections, contaminants, or other defects in the ink. Conversely, white ink tends to embellish imperfections, contaminants, or other defects in the ink.

[0004] The process for fabricating a thermal transfer image applies a TPU (Thermoplastic Polyurethane) to the wet ink applied to a substrate. Imperfections introduced by the TPU (Thermoplastic Polyurethane) tend to be embellished in the white ink.

[0005] Thus, there presently exists a need for providing a method of fabricating thermal transfer images that are free from any visible imperfections in the artwork, more specifically in the portions of the artwork presenting white color.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 BRIEF SUMMARY OF THE INVENTION

[0006] The present invention provides a method for fabricating thermal transfer images that are free from any visible imperfections in the artwork, more specifically, free from any visible imperfections in the portions of the artwork displaying white.

[0007] The present invention provides a method of applying a clear ink in at least areas where the image presents white pigments and applying a Thermoplastic Polyurethane (TPU) in a white pigment over the entire printed image, wherein the white coloration of the Thermoplastic Polyurethane (TPU) provides the white pigment in the respective white areas of the image.

[0008] In one aspect, the present invention is directed towards a method of generating a thermal transfer image in accordance with the present invention includes steps of: applying a clear ink onto a substrate wherein the clear ink is applied following an outline of an artwork image carried by the substrate, wherein areas of the artwork having a color of a Thermoplastic Polyurethane (TPU) remain void; applying the Thermoplastic Polyurethane (TPU) in a powder form to an area covering the applied clear ink while the applied clear ink remains wet; removing any excess Thermoplastic Polyurethane (TPU) from the substrate in areas of the image void of the wet ink; curing (annealing) the Thermoplastic Polyurethane (TPU) residing on the wet ink.

[0009] In a second aspect, the process further comprising a step of applying colored ink to the image.

[0010] In yet another aspect, the Thermoplastic Polyurethane (TPU) is white in color.

[0011] In yet another aspect, the process further comprising a step of: applying at least one colored ink in accordance with a layer of the imageApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 designed to receive the at least one respective colored ink onto a substrate, wherein the step of applying the at least one colored ink onto the substrate creates the artwork image, wherein the step of applying the at least one colored ink onto the substrate occurs prior to the step of applying the clear ink onto the substrate.

[0012] In yet another aspect, the substrate is optionally referred to as Direct To Film (DTF) film.

[0013] In yet another aspect, the substrate can be fabricated of multiple layers, wherein each layer provides a function.

[0014] In yet another aspect, the substrate can be fabricated of multiple layers, wherein each layer provides a distinct function.

[0015] In yet another aspect, the substrate can be fabricated of multiple layers, including a base layer and a release layer.

[0016] In yet another aspect, the substrate can be fabricated of multiple layers, including a base layer, a release layer, and an ink receptive layer.

[0017] In yet another aspect, the substrate can be fabricated of multiple layers, including an antistatic layer, a base layer, and a release layer.

[0018] In yet another aspect, the substrate can be fabricated of multiple layers, including an antistatic layer, a base layer, a release layer, and at least one ink receptive layer.

[0019] In yet another aspect, the substrate can be fabricated of multiple layers, including a base layer, a release layer, a matt coating, and an ink receptive layer.

[0020] In yet another aspect, the substrate can be fabricated of multiple layers, including an antistatic layer, a base layer, , a matt coating, and a release layer.

[0021] In yet another aspect, the substrate can be fabricated of multiple layers, including an antistatic layer, a base layer, , a matt coating, a release layer, and at least one ink receptive layer.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002

[0022] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, a base layer, a release layer, and an ink receptive layer.

[0023] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, an antistatic layer, a base layer, and a release layer.

[0024] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, an antistatic layer, a base layer, a release layer, and at least one ink receptive layer.

[0025] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, a base layer, a release layer, a matt coating, and an ink receptive layer.

[0026] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, an antistatic layer, a base layer, a matt coating, and a release layer.

[0027] In yet another aspect, the substrate can be fabricated of multiple layers, including an antiblocking treatment, an antistatic layer, a base layer, a matt coating, a release layer, and at least one ink receptive layer.

[0028] In yet another aspect, the base layer of the substrate can be fabricated of a Polyethylene terephthalate (PET) base layer.

[0029] In yet another aspect, the release layer of the substrate is arranged between the print and backing that helps the film peel off after heat pressing.

[0030] In yet another aspect, the at least one ink receptive layer is provided to aid in absorption of the applied ink.

[0031] In yet another aspect, the at least one ink receptive layer is provided to aid in maintaining placement of the applied ink.

[0032] In yet another aspect, the at least one ink receptive layer is provided as multiple ink receptive layers to aid in maintaining placement of the applied ink.

[0033] In yet another aspect, the at least one ink receptive layer is provided as multipleApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 ink receptive layers to aid in maintaining placement of the applied ink, wherein the ink receptive layers can be of the same material.

[0034] In yet another aspect, the at least one ink receptive layer is provided as multiple ink receptive layers to aid in maintaining placement of the applied ink, wherein the ink receptive layers can be of at least two distinct materials.

[0035] In yet another aspect, the antistatic layer helps prevent static electricity.

[0036] In yet another aspect, the ink receptive layer can be designed for oil based ink.

[0037] In yet another aspect, the ink receptive layer can be designed for oil based ink, wherein the ink receptive layer includes a lipophilic, oil-based adhesion.

[0038] In yet another aspect, the ink receptive layer can be designed for oil based ink, wherein the ink receptive layer includes a lipophilic, oil-based adhesion for high color reproduction.

[0039] In yet another aspect, the ink receptive layer can be designed for water based ink.

[0040] In yet another aspect, the process further comprising a step of applying colored ink to the image, wherein the image remains void of colored ink in areas designed to display white pigment.

[0041] In yet another aspect, the process further comprising a step of determining which colored ink / inks is / are to be applied to the substrate to create the image.

[0042] In yet another aspect, the at least one colored ink is at least one of an organic ink, an inorganic ink, a pigmented ink, and a sublimation ink.

[0043] In yet another aspect, the at least one colored ink is selected from a group of inks, the group of inks consisting of: cyan colored ink, magenta colored ink, yellow colored ink, key colored ink, yellow colored ink, light cyan colored ink, light magenta colored ink, gray colored ink, red colored ink, green colored ink, blue colored ink, an ink composition comprising a metallic component, an ink composition comprising a metallic copper component, an ink composition comprising a metallic bronze component, an ink composition comprising a metallic zinc component, an ink composition comprising a metallic aluminumApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 component, an ink composition comprising a metallic silver component, an ink composition comprising a metallic gold component, and an ink composition comprising a glow in the dark element.

[0044] In yet another aspect, the process utilizes combination of colored inks including Cyan, Magenta, and Yellow.

[0045] In yet another aspect, the process utilizes combination of colored inks including Cyan, Magenta, Yellow, and Black.

[0046] In yet another aspect, the process utilizes combination of colored inks including Cyan, Magenta, Yellow, Light Cyan, Light Magenta, and Gray.

[0047] In yet another aspect, the process utilizes combination of colored inks including Cyan, Magenta, Yellow, Light Cyan, Light Magenta, Gray, and Black.

[0048] In yet another aspect, the process utilizes combination of colored inks including Cyan, Magenta, Yellow, Light Cyan, Light Magenta, and Black.

[0049] In yet another aspect, the process utilizes combination of colored inks including Red, Green, and Blue.

[0050] In yet another aspect, the process utilizes combination of colored inks including Red, Green, and Blue, and Black.

[0051] In yet another aspect, the process utilizes as least one metallic ink.

[0052] In yet another aspect, the ink composition includes a metallic component.

[0053] In yet another aspect, the ink composition includes a metallic component, wherein the metallic component is at least one of copper, bronze, zinc, aluminum, silver and gold.

[0054] In yet another aspect, the ink composition includes a glow in the dark element.

[0055] In yet another aspect, a layer of a foil material can be applied to the layer of wet ink.

[0056] In yet another aspect, a layer of a foil material can be applied to the layer of wetApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 ink, wherein foil material not secured to any wet ink is considered excess and is removed.

[0057] In yet another aspect, a layer of a foil material can be applied to the layer of wet ink, wherein foil material not secured to any wet ink is considered excess and is removed using any suitable excess foil removal process.

[0058] In yet another aspect, a layer of a foil material can be applied to the layer of wet ink, wherein foil material not secured to any wet ink is considered excess and is removed using any suitable excess foil removal process, including using airflow, mechanically removing the excess foil material, mechanically removing the excess foil material using a brush, removing the excess foil material using a sponge, removing the excess foil material using a burnishing tool, and any other suitable removal process.

[0059] In yet another aspect, the foil material can be a metallic material.

[0060] In yet another aspect, the layer of the foil material can be applied to the layer of wet ink.

[0061] In yet another aspect, a foil layer can be applied to the layer of wet clear ink.

[0062] In yet another aspect, a foil layer can be applied to the layer of wet color ink and wet clear ink.

[0063] In yet another aspect, the layer of the foil material can be applied to the layer of wet clear ink, wherein the wet clear ink is placed over the color ink layer and over areas that are desirous of displaying the foil material.

[0064] In yet another aspect, the layer of the foil material can be applied following an application of a layer of color ink, a drying of the color ink, and an application of a layer of clear ink upon the substrate in areas that are desirous of displaying the foil material.

[0065] In yet another aspect, the Thermoplastic Polyurethane (TPU) can be applied to an exposed surface of the layer of the foil material.

[0066] In yet another aspect, the Thermoplastic Polyurethane (TPU) is applied manually to the wet ink.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002

[0067] In yet another aspect, the Thermoplastic Polyurethane (TPU) is spatially arranged from at least one of the release layer and the base layer of the substrate.

[0068] In yet another aspect, the Thermoplastic Polyurethane (TPU) is spatially arranged from at least one of the release layer and the base layer of the substrate by at least one of the color ink layer and the clear ink layer.

[0069] In yet another aspect, the Thermoplastic Polyurethane (TPU) is applied to the wet ink using a dispensing process.

[0070] In yet another aspect, the color ink remains wet during the process of applying the Thermoplastic Polyurethane (TPU).

[0071] In yet another aspect, the color ink and the clear ink remain wet during the process of applying the Thermoplastic Polyurethane (TPU).

[0072] In yet another aspect, the color ink is warmed slightly (80-100 F) prior to the process of applying the Thermoplastic Polyurethane (TPU).

[0073] In yet another aspect, the color ink and the clear ink is warmed slightly (80-100 F) prior to the process of applying the Thermoplastic Polyurethane (TPU).

[0074] In yet another aspect, the color ink is at least partially cured while the clear ink remains wet prior to the process of applying the Thermoplastic Polyurethane (TPU).

[0075] In yet another aspect, the color ink is at least partially cured while the clear ink remains wet and is slightly warmed (80-100 F) during the process of applying the Thermoplastic Polyurethane (TPU).

[0076] In yet another aspect, the Thermoplastic Polyurethane (TPU) is applied to the wet ink using a rolling process.

[0077] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a negative pressure process.

[0078] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using an airflow process.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002

[0079] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate by subjecting the excess Thermoplastic Polyurethane (TPU) to a light airflow.

[0080] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate by subjecting the excess Thermoplastic Polyurethane (TPU) to a light positive airflow.

[0081] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate by subjecting the excess Thermoplastic Polyurethane (TPU) to a light negative airflow.

[0082] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a volume application process, wherein the volume application process orients the substrate in a generally u-shaped configuration, wherein the Thermoplastic Polyurethane (TPU) is applied at the lowest portion of the u-shaped configuration and excess Thermoplastic Polyurethane (TPU) is removed using gravity when the respective segment of the filing is oriented in a substantially vertical orientation.

[0083] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a volume application process, wherein the volume application process orients the substrate in a generally u-shaped configuration, wherein a volume of the Thermoplastic Polyurethane (TPU) is maintained in a roll and applied at the lowest portion of the u-shaped configuration as the printed film proceeds forward. The u-shaped configuration of the printed film maintains the volume of Thermoplastic Polyurethane (TPU) at the lowest location of the passing film, allowing continuous exposure to the applied ink as the printed film proceeds forward.

[0084] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process.

[0085] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process, wherein the shaker process orients the substrate in a generally vertical orientation and applies a vibration to the substrate.

[0086] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process, wherein the shaker process orients the substrate in aApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 generally u-shaped configuration, wherein the Thermoplastic Polyurethane (TPU) is applied at the base of the u-shaped configuration and excess Thermoplastic Polyurethane (TPU) is removed along the vertically oriented segment.

[0087] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process, wherein the excess Thermoplastic Polyurethane (TPU) is returned to an applying volume of the Thermoplastic Polyurethane (TPU).

[0088] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process, wherein the shaker process orients the substrate in a generally vertical orientation and applies a vibration to the substrate, wherein a combination of the substantially vertical orientation of the substrate and the applied vibrations efficiently removes the excess Thermoplastic Polyurethane (TPU) from the substrate.

[0089] In yet another aspect, excess Thermoplastic Polyurethane (TPU) is removed from the substrate using a shaker process, wherein the shaker process orients the substrate in a generally vertical orientation and applies a vibration to the substrate, wherein a combination of the substantially vertical orientation of the substrate and the applied vibrations efficiently removes the excess Thermoplastic Polyurethane (TPU) from the substrate, wherein the wetting properties of the applied ink retains the desired Thermoplastic Polyurethane (TPU).

[0090] In yet another aspect, the step of curing (annealing) the TPU residing on the wet ink is accomplished using at least one of a heating element, an ultraviolet light source, and a laser.

[0091] In yet another aspect, the step of curing (annealing) the TPU residing on the wet ink is accomplished by applying heat to the TPU.

[0092] In yet another aspect, the step of curing (annealing) the TPU residing on the wet ink is accomplished by exposing the TPU to ultraviolet light.

[0093] In yet another aspect, the step of curing (annealing) the TPU residing on the wet ink is accomplished by laser sintering the TPU.

[0094] In yet another aspect, at least one of the following steps is accomplished using an ink jet printer:Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 (a) a step of applying at least one colored ink in accordance with a layer of the image designed to receive the at least one respective colored ink onto a substrate, (b) the step of applying the clear ink onto the substrate, and (c) the step of applying Thermoplastic Polyurethane (TPU) in the powder form to the area covering the applied clear ink while the applied clear ink remains wet.

[0095] In yet another aspect, a single machine accomplishes each of the following steps: applying the clear ink onto the substrate wherein the clear ink is applied following the outline of an artwork image carried by the substrate, wherein portions of the artwork image that are of a color of a Thermoplastic Polyurethane (TPU) remain unprinted; applying the Thermoplastic Polyurethane (TPU) in the powder form to the area covering the applied clear ink while the applied clear ink remains wet; removing any excess Thermoplastic Polyurethane (TPU) from the substrate in areas of the image void of the wet ink; and annealing the Thermoplastic Polyurethane (TPU) residing on the wet ink.

[0096] In yet another aspect, the printed and cured image is distributed to an image applying party.

[0097] In yet another aspect, the method further comprising steps of: locating the artwork image onto a desired location on an object; and applying heat to the thermal transfer image to transfer the thermal transfer image onto the object.

[0098] In yet another aspect, the process is accomplished by conveying a continuous roll of film.

[0099] In yet another aspect, the process is accomplished by conveying a continuous roll of DTF film.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002

[0100] In yet another aspect, the process is accomplished by conveying a continuous roll of DTF film through an ink color printing process, a Thermoplastic Polyurethane (TPU) application process, an excess Thermoplastic Polyurethane (TPU) removal process and a Thermoplastic Polyurethane (TPU) curing process.

[0101] These and other aspects, features, and advantages of the present invention will become more readily apparent from the attached drawings and the detailed description of the preferred embodiments, which follow. BRIEF DESCRIPTION OF THE DRAWINGS

[0102] The preferred embodiments of the invention will hereinafter be described in conjunction with the appended drawings provided to illustrate and not to limit the invention, in which:

[0103] FIG. 1 presents an isometric top view of a first exemplary step of a method of fabricating a thermal transfer image, the first step providing a process of applying non-white colored ink onto a substrate;

[0104] FIG. 2 presents an isometric top view of a partially completed thermal transfer image following the first exemplary step of the method of fabricating a thermal transfer image wherein the non-white colored ink has been applied to the substrate;

[0105] FIG. 3 presents an isometric top view of a second exemplary step of the method of fabricating the thermal transfer image, the second step providing a process of applying a clear ink onto the substrate in locations where white is the designed pigment;

[0106] FIG. 4 presents an isometric top view of a partially completed thermal transfer image following the second exemplary step of the method of fabricating a thermal transfer image wherein the clear colored ink has been applied onto the substrate at least in locations where white is the designed pigment with the exemplary illustration presenting an application of the clear colored ink has been applied onto the substrate covering the entire colored image and additional locations where white is the designed pigment;

[0107] FIG. 5 presents an isometric top view of a third exemplary step of the method ofApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 fabricating the thermal transfer image, the third step providing a process of applying a Thermoplastic Polyurethane (TPU) in a fine powdered form over an area encompassing the entire application of the wet ink;

[0108] FIG. 6 presents an isometric top view of a partially completed thermal transfer image following the third exemplary step of the method of fabricating a thermal transfer image wherein the fine powdered form of the Thermoplastic Polyurethane (TPU) has been applied onto the substrate covering an area encompassing the entire application of the wet ink;

[0109] FIG. 7 presents an isometric top view of a fourth exemplary step of the method of fabricating the thermal transfer image, the fourth step providing a process of removing excessive Thermoplastic Polyurethane (TPU) material from the substrate not covered by wet ink and annealing the remaining TPU retained covering the entire image by the wet ink; and

[0110] FIG. 8 presents a sectioned elevation view of an exemplary Thermoplastic Polyurethane (TPU) shaker application process representative of the fourth exemplary step of the method of fabricating the thermal transfer image, the fourth step providing a process of removing excessive Thermoplastic Polyurethane (TPU) material from the substrate not covered by wet ink;

[0111] FIG. 9 presents an exemplary thermal transfer image fabrication flow diagram detailing steps for fabricating the thermal transfer image.

[0112] Like reference numerals refer to like parts throughout the several views of the drawings. DETAILED DESCRIPTION OF THE INVENTION

[0113] The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word "exemplary" or "illustrative" means "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" or "illustrative" is not necessarily to be construed as preferred or advantageous over otherApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. In other implementations, well- known features and methods have not been described in detail so as not to obscure the invention. For purposes of description herein, the terms "upper", "lower", "left", "right", "front", "back", "vertical", "horizontal", and derivatives thereof shall relate to the invention as oriented in FIG. 1. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments that may be disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

[0114] The present invention describes an improved process for fabricating a thermally transferred image, wherein the improved process resolves a long standing issue where imperfections, contaminants, or other defects in the ink are visible in the printed image. More specifically, where imperfections, contaminants, or other defects in the ink are embellished in the white portions of the printed image.

[0115] The process is summarized in an exemplary thermal transfer image generation process flow diagram 200 presented in FIG. 9. Each of the steps described in the thermal transfer image generation process flow diagram 200 are diagrammatically exemplified in drawings illustrated in FIGS. 1 through 6. The thermal transfer image generation process flow diagram 200 initiates with a step of selecting a desired image 120 for printing (block 210). A colored ink set 121 is determined based upon the various colors and desired features of the artwork used for the desired image 120. The artwork is separated into the layers for each of the respective colors associated with the ink set 121 and additionally with considerations for a layer for a white pigment. Each of the respective separated color layers is associated with a respective ink color in the digital format. This includes a layer that is established for the white pigment. The layer identifying the white pigment can be limited to the areas where the white pigment is applied to the artwork or, for the used in the present invention; the layer identifying the white pigment can be modified to include an outlineApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 containing the entire desired image 120.

[0116] The digital artwork associated with the desired image 120 is uploaded to a printer (not shown but exemplified by a color ink print applicator 192, a clear ink print applicator 194, a Thermoplastic Polyurethane (TPU) applicator 196 and a thermal applicator 199). The color ink set (colors, formulations, etc.) 121 required to generate the colored portion of the desired image are selected and installed into the printer (block 212). The most common color ink set 121 is referred to as CMYK, which refers to cyan, magenta, yellow, and key (black). The exemplary illustrations present CMYK as the selected color ink set 121 for the exemplary desired image 120.

[0117] A reverse image of the desired image 120 is applied to a thermal transfer print substrate image receiving surface 112 of a thermal transfer print substrate 110, as illustrated in FIGS. 1 and 2 (block 220). The exemplary thermal transfer print substrate 110, sometimes referred to as Direct To Film (DTF) film, commonly includes a plurality of layers. The exemplary thermal transfer print substrate 110 includes a release layer 116 carried by a base layer 114. An optional ink control layer 118 may be applied to an exposed surface of the release layer 116. The thermal transfer print substrate 110 can additionally include an antistatic treatment (commonly applied to the non-print side of the thermal transfer print substrate 110), and a matt coating sandwiched between the antistatic treatment and the base layer 114. The optional ink control layer 118 can include one or more layers of like or different coatings to increase control of the color ink (122, 124, 126, 128) and the clear ink (140). The thermal transfer print substrate 110 is designed to enable at least one of warm peel off and cold peel off.

[0118] The exemplary illustration presents a color ink print applicator 192 of an ink jet printer applying the color ink set 121 in accordance with the digital layout of the desired image 120 onto the thermal transfer print substrate image receiving surface 112 of the thermal transfer print substrate 110. In the exemplary illustration, the color ink set 121 is applying four colors: an exemplary first ink color deposit (cyan) 122 in accordance with an exemplary first color image layer (cyan) 132, an exemplary second ink color deposit (magenta) 124 in accordance with an exemplary second color image layer (magenta) 134, an exemplary third ink color deposit (yellow) 126 in accordance with an exemplary third color image layer (yellow) 136, and an exemplary fourth ink color deposit (key / black) 128 inApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 accordance with an exemplary fourth color image layer (key / black) 138, as illustrated in FIG. 1. The resulting color image 120 is illustrated in FIG. 2. It is noted that areas designed to present white pigment remains unprinted (block 222). The ink can be at least one of organic, inorganic, an ink pigment and sublimation.

[0119] Clear ink 141 is applied using a clear ink print applicator 194 of the ink jet printer creating an exemplary clear ink deposit 140 in accordance with an exemplary clear ink image layer 150, as illustrated in FIGS. 3 and 4 (block 224). The clear ink 141 can be applied only where the white pigment is desired or over the exposed areas where the white pigment is desired and over the applied color ink 123, 125, 127, 129, as illustrated in FIGS. 3 and 4. The shading of exemplary first ink color deposit (cyan) 122, exemplary second ink color deposit (magenta) 124, exemplary third ink color deposit (yellow) 126, and exemplary fourth ink color deposit (key / black) 128 as illustrated in FIGS. 1 and 2 indicates exposed color ink, wherein the differing shading of exemplary first clear covered ink color deposit (cyan) 123, exemplary second clear covered ink color deposit (magenta) 125, exemplary third clear covered ink color deposit (yellow) 127, and exemplary fourth clear covered ink color deposit (key / black) 129 as illustrated in FIGS. 3 and 4 indicates color ink covered by the clear ink as described.

[0120] An optional layer of a foil material can be applied to the artwork in areas that are desirous to display the foil material. A layer of clear ink can be applied to the substrate for adhesion of the foil material. Excess foil material can be removed using any suitable foil removal process, including but not limited to exposure to airflow, mechanically removing the excess foil material, mechanically removing the excess foil material using a brush, removing the excess foil material using a sponge, removing the excess foil material using a burnishing tool, and any other suitable removal process.

[0121] A Thermoplastic Polyurethane (TPU) applicator 196 applies Thermoplastic Polyurethane (TPU) 161 having a white coloration in a powdered form covering the desired image 120. While the applied clear ink is still wet, Thermoplastic Polyurethane (TPU) 161 is applied to the thermal transfer print substrate image receiving surface 112 by the Thermoplastic Polyurethane (TPU) applicator 196 of the ink jet printer over a Thermoplastic Polyurethane (TPU) target coverage area 160 depositing a Thermoplastic Polyurethane (TPU) applied powder 162 to cover (and preferably an area larger than) the entire printed image 120Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 (block 230) as illustrated in FIG. 5. In the exemplary illustration, the Thermoplastic Polyurethane (TPU) applied powder 162 is applied over the entire area of the Thermoplastic Polyurethane (TPU) target coverage area 160. This includes both areas having wet ink (exemplary clear ink deposit 140 in the exemplary illustration) and areas of the thermal transfer print substrate image receiving surface 112 that are void of any wet ink. Excess Thermoplastic Polyurethane (TPU) applied powder 162 not retained by any wet ink is removed using any suitable process, leaving Thermoplastic Polyurethane (TPU) applied powder 162 that is retained by the wet ink, as illustrated in FIG. 7 (block 232). The removal process can be accomplished using any of: a shaking process, an airflow process, or any other suitable removal process.

[0122] The Thermoplastic Polyurethane (TPU) applied powder 162 retained by the wet ink (defining an annealed Thermoplastic Polyurethane (TPU) material outline 166) is annealed (cured) forming an annealed Thermoplastic Polyurethane (TPU) material 164 by any suitable process, such as a thermal applicator 199, as illustrated in FIG. 7 (block 234). The annealing process can be accomplished by applying heat to the Thermoplastic Polyurethane (TPU) applied powder 162, using a heating element, Ultra-violet, a laser, or any other suitable process for elevating the temperature of the Thermoplastic Polyurethane (TPU) applied powder 162 to melt the particles of the Thermoplastic Polyurethane (TPU) applied powder 162 together forming the annealed Thermoplastic Polyurethane (TPU) material 164, as illustrated in FIG. 7. The annealed Thermoplastic Polyurethane (TPU) material 164 provides the white coloring for all areas of the image 120 that are void of colored ink 121 and having clear ink 141. The use of the white pigmented Thermoplastic Polyurethane (TPU) material 161 avoids any imperfections, contaminants, or other defects in the ink, more specifically, the white colored ink. By using clear ink 141, the white pigmented Thermoplastic Polyurethane (TPU) material 161 provides the consistent coloring for the white portions of the image 120, thus avoiding any imperfections, contaminants, or other defects in the white portion of the image 120.

[0123] The illustration presented in FIG. 7 is first exemplary method of applying the Thermoplastic Polyurethane (TPU) 161 onto the exposed wet ink. A second exemplary method of applying the Thermoplastic Polyurethane (TPU) 161 onto the exposed wet ink 121, 141 is presented in FIG. 8. A vibrating Thermoplastic Polyurethane (TPU) powder application / removal system 102 is introduced in FIG. 8, wherein the vibrating ThermoplasticApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 Polyurethane (TPU) powder application / removal system 102 provides a system for applying the Thermoplastic Polyurethane (TPU) 161 to the exposed wet ink 122, 123, 124, 125, 126, 127, 128, 129, 140. The exemplary vibrating Thermoplastic Polyurethane (TPU) powder application / removal system 102 illustrates a system that employs a substrate transfer system for advancing a substantially elongated roll of the thermal transfer print substrate 110. The system may continuously advance the thermal transfer print substrate 110 or advance the thermal transfer print substrate 110 in accordance with a timing during printing. The ink 121 is applied to the thermal transfer print substrate 110 forming the desired image 120 in a combination of colored inks and optionally a clear ink as the thermal transfer print substrate 110 is advanced using an initial substrate feed system 190. The base ink creating the desired image 120 can remain wet allowing the Thermoplastic Polyurethane (TPU) 161 to be adhered directly to the wet ink forming the desired image 120. In a condition where the artwork includes a white coloring, a clear ink deposit 140 can be applied over the region designed to present as white in color or the entire desired image 120, and where applicable including over the region designed to present as white in color. When using the clear ink 140, the applied color ink 122, 124, 126, 128 can either remain wet, be heated to place the ink into a gel state, or be partially or completely cured. When using the clear ink 140 for only areas that present a white color in the desired image 120, the applied color ink 122, 124, 126, 128 remains wet or may be heated to place the applied color ink 122, 124, 126, 128 in a gel state.

[0124] The vibrating Thermoplastic Polyurethane (TPU) powder application / removal system 102 is arranged where the initial substrate feed system 190 and the Thermoplastic Polyurethane (TPU) curing feed system 191 are above a bottom of the thermal transfer print substrate 110, placing the thermal transfer print substrate 110 in a u-shape. The thermal transfer print substrate 110 is effectively continuous, where a portion of the thermal transfer print substrate 110 exiting the initial substrate feed system 190 drops in a generally vertical orientation, creates an arch, and returns in a generally vertical orientation to continue processing and being advanced via a Thermoplastic Polyurethane (TPU) curing feed system 191. As illustrated, the wet ink layer 120, 140 is fed into the base of the u-shape of the thermal transfer print substrate 110, as illustrated on a left side of u-shaped feature of the thermal transfer print substrate 110 in the illustration presented in FIG. 8. The u-shape of the thermal transfer print substrate 110 provides a distinct opportunity, where a volume of Thermoplastic Polyurethane (TPU) 161 in powder form rolls over the width of the thermalApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 transfer print substrate 110. A thin layer of the Thermoplastic Polyurethane (TPU) powder 161 employs surface tension to be temporarily retained by the exposed wet ink, creating the Thermoplastic Polyurethane (TPU) applied powder 162, as illustrated on a right side of u- shaped feature of the thermal transfer print substrate 110 in the illustration presented in FIG. 8.

[0125] A vibration application system 197 applies a vibration 198 to the upward extending portion (right side of the u-shaped formation) of the thermal transfer print substrate 110. The vibration application system 197 can be any suitable device to create a vibration onto the upward directed segment of the thermal transfer print substrate 110. In the exemplary illustration, the vibration application system 197 is a generally vertically oriented vibrating panel. Any suitable vibration generating mechanism can be employed to create and transfer the vibrating energy to the upward directed segment of the thermal transfer print substrate 110. The combination of the vibrations 198 and the use of gravity respective to the upward orientation of the segment of the thermal transfer print substrate 110 loosen any excess, un-wet or minimally wetting particles of the Thermoplastic Polyurethane (TPU) applied powder 162. The loosened Thermoplastic Polyurethane (TPU) applied powder 162 is returned to the volume of Thermoplastic Polyurethane (TPU) 161 located at the base of the u- shaped formation; the returned Thermoplastic Polyurethane (TPU) applied powder 162 is identified as removed Thermoplastic Polyurethane (TPU) powder 163. In an alternative arrangement, a vibration 198 can be applied to the Thermoplastic Polyurethane (TPU) curing feed system 191, where the vibrations of the Thermoplastic Polyurethane (TPU) curing feed system 191 would perpetuate down the upward directed segment of the thermal transfer print substrate 110. A thermal applicator 199 if preferably integrated into the vibrating Thermoplastic Polyurethane (TPU) powder application / removal system 102 at a location proximate the Thermoplastic Polyurethane (TPU) curing feed system 191. The thermal applicator 199 would anneal the Thermoplastic Polyurethane (TPU) applied powder 162.

[0126] Once the Thermoplastic Polyurethane (TPU) applied powder 162 is annealed into the annealed Thermoplastic Polyurethane (TPU) material 164, the desired image 120 of the thermal transfer printed assembly 100 is ready for transfer onto an object. The thermal transfer print substrate 110 can be provided as individual sheets or on a continuous roll. Each thermal transfer printed assembly 100 is prepared for distribution. In a condition where the thermal transfer print substrate 110 is provided as a continuous roll, each of the thermalApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 transfer printed assemblies 100 can be singulated for packaging and distribution. The completed thermal transfer printed assemblies 100 are optionally packaged and distributed from the printing location to an application location (block 240). The receiving object is placed upon an anvil of a thermal image transfer application apparatus. The thermal transfer printed assembly 100 is placed upon the receiving object orienting the desired image 120 at the desired location on the receiving object. The thermal transfer printed assembly 100 is orientated with the annealed Thermoplastic Polyurethane (TPU) material 164 side contacting the image receiving surface of the receiving object (block 250). Heat is applied to the thermal transfer printed assembly 100, transitioning a state of the annealed Thermoplastic Polyurethane (TPU) material 164 from a solid into an adhesive, and using the annealed Thermoplastic Polyurethane (TPU) material 164 to bond the desired image 120 to the image receiving surface of the receiving object (block 252).

[0127] The object can be a textile, a solid object, a planar object, or with advancements to the anvil and the heating source, the object can be a three-dimensional object.

[0128] The processes described herein can be modified while maintaining the spirit and intent of the present invention. For example, as described above, the clear ink 141 can be applied to the areas where white is displayed in the image 120 or, in an alternative, can be applied to the entire image 120, including the voids where the white is displayed and the colored ink. The process for applying the ink can vary, wherein the ink can be applied using any suitable known ink application processes. The colors and compositions of the ink can vary based upon the desired final image. The equipment for accomplishing each of the steps for creating the thermal transfer printed assembly 100, including the color ink print applicator 192, the clear ink print applicator 194, the Thermoplastic Polyurethane (TPU) applicator 196, and the thermal applicator 199, can be integrated into a single machine.

[0129] Having thus described at least illustrative embodiments of the invention, various modifications and improvements will readily occur to those skilled in the art and are intended to be within the scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto. REFERENCE ELEMENT DESCRIPTIONSApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 Ref. No. Description 100 thermal transfer printed assembly 102 vibrating Thermoplastic Polyurethane (TPU) powder application / removal system 110 thermal transfer print substrate 112 thermal transfer print substrate image receiving surface 114 base layer 116 release layer 118 ink control layer 120 desired image 121 color ink set 122 exemplary first ink color deposit (cyan) 123 exemplary first clear covered ink color deposit (cyan) 124 exemplary second ink color deposit (magenta) 125 exemplary second clear covered ink color deposit (magenta) 126 exemplary third ink color deposit (yellow) 127 exemplary third clear covered ink color deposit (yellow) 128 exemplary fourth ink color deposit (key / black) 129 exemplary fourth clear covered ink color deposit (key / black) 132 exemplary first color image layer (cyan) 134 exemplary second color image layer (magenta) 136 exemplary third color image layer (yellow) 138 exemplary fourth color image layer (key / black) 140 exemplary clear ink deposit 141 clear ink application 150 exemplary clear ink image layer 160 Thermoplastic Polyurethane (TPU) target coverage area 161 Thermoplastic Polyurethane (TPU) 162 Thermoplastic Polyurethane (TPU) applied powder 163 removed Thermoplastic Polyurethane (TPU) powder 164 annealed Thermoplastic Polyurethane (TPU) material 166 annealed Thermoplastic Polyurethane (TPU) material outline 190 initial substrate feed systemApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 Thermoplastic Polyurethane (TPU) curing feed system color ink print applicator clear ink print applicator Thermoplastic Polyurethane (TPU) applicator vibration application system vibration thermal applicator thermal transfer image generation process flow diagram select image for printing step select ink type for printing step print color ink on color portion of reverse image onto substrate white layer is excluded from printing step print clear ink onto / over image apply TPU over wet ink of printed area remove excess TPU from non printed area thermally set TPU on wet ink area of image optional print distribution step locate image on object apply heat to thermally transfer image to object

Claims

Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 Claims What is claimed is:

1. A method of fabricating a thermal transfer image (100), the method comprising steps of: applying a clear ink (141) onto a substrate (110) wherein the clear ink (141) is applied following at least a portion of an artwork image (120) desired to be applied onto the substrate (110), wherein the clear ink is applied to at least portions of the artwork image having a color of a Thermoplastic Polyurethane (TPU) (161); applying the Thermoplastic Polyurethane (TPU) (161) in a powder form to an area covering at least the applied clear ink (140) while the applied clear ink (140) remains wet; removing any excess Thermoplastic Polyurethane (TPU) (163) from the substrate (110) in areas of the image void of the wet clear ink (140); and annealing the Thermoplastic Polyurethane (TPU) (164) residing on the wet clear ink (140).

2. The method of fabricating a thermal transfer image (100) as recited in claim 1, the method further comprising a step of: applying at least one colored ink (122, 124, 126, 128) in accordance with a layer of the image (120) designed to receive the at least one respective colored ink (122, 124, 126, 128) onto a substrate (110), wherein the step of applying the at least one colored ink (122, 124, 126, 128) onto the substrate at least partially creates the artwork image (120).

3. The method of fabricating a thermal transfer image (100) as recited in claim 2, wherein the Thermoplastic Polyurethane (TPU) (161) is white in color.Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 4. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the step of applying the at least one colored ink (122, 124, 126, 128) onto the substrate (110) occurs prior to the step of applying the clear ink (141) onto the substrate.

5. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the at least one colored ink (122, 124, 126, 128) is at least one of an organic ink, an inorganic ink, a pigmented ink, and a sublimation ink.

6. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the step of applying the at least one colored ink (122, 124, 126, 128) onto the substrate (110) occurs prior to the step of applying the clear ink (141) onto the substrate (110).

7. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the clear ink (141) is applied only to portions of the artwork image having a color of a Thermoplastic Polyurethane (TPU) (161), wherein the step of applying the Thermoplastic Polyurethane (TPU) (161) in the powder form to the area covering the at least the applied clear ink (140) while the applied clear ink (140) remains wet includes applying the Thermoplastic Polyurethane (TPU) (161) in the powder form to an area covering both the applied color ink (122, 124, 126, 128) and the applied clear ink (140) while the applied color ink (122, 124, 126, 128) and the applied clear ink (140) remain wet.

8. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the clear ink (141) is applied to portions of the artwork image havingApplicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 a color of a Thermoplastic Polyurethane (TPU) (161) and to the at least one colored ink (122, 124, 126, 128).

9. The method of fabricating a thermal transfer image (100) as recited in any one of claims 2 or 3, wherein the at least one colored ink (122, 124, 126, 128) is selected from a group of inks, the group of inks consisting of: cyan colored ink (122), magenta colored ink (124), yellow colored ink (126), key colored ink (128), light cyan colored ink, light magenta colored ink, gray colored ink, red colored ink, green colored ink, blue colored ink, an ink composition comprising a metallic component, an ink composition comprising a metallic copper component, an ink composition comprising a metallic bronze component, an ink composition comprising a metallic zinc component, an ink composition comprising a metallic aluminum component, an ink composition comprising a metallic silver component, an ink composition comprising a metallic gold component, and an ink composition comprising a glow in the dark element.

10. The method of fabricating a thermal transfer image as recited in any one of claims 1, 2, or 3, wherein the step of removing any excess Thermoplastic Polyurethane TPU (163) from the substrate (110) in areas of the image (120) void of the wet ink (122, 124, 126, 128, 140) is accomplished using at least one of: gravity (102), a shaking process (102), and an airflow process.

11. The method of fabricating a thermal transfer image as recited in any one of claims 1, 2, or 3, wherein the step of annealing the Thermoplastic Polyurethane (TPU) residing on the wet ink (122, 124, 126, 128, 140) is accomplished using at least one of a heating element (199), an ultraviolet light source (199), and a laser (199).

12. The method of fabricating a thermal transfer image (100) as recited in any one of claims 1, 2, or 3, the method further comprising steps of:Applicant: TURGEMAN, Shahar First Named Inventor: TURGEMAN, Shahar Atty. Docket No.: TUR-PCT-24-002 locating the artwork image (120) onto a desired location on an object, and applying heat to the thermal transfer image (100) to transfer the thermal transfer image (100) onto the object.

13. The method of fabricating a thermal transfer image as recited in any one of claims 1, 2, or 3, wherein the clear ink (141) is applied using an ink jet process.

14. The method of fabricating a thermal transfer image as recited in any one of claims 1, 2, or 3, further comprising a step of applying a layer of a foil material to at least one of the applied clear ink (140) and the substrate (110).

15. The method of fabricating a thermal transfer image as recited in any one of claims 1, 2, or 3, further comprising a step of applying heat to the clear ink (140) to set the clear ink (140) into a gel state.

16. A thermal transfer image (100) fabricated using the method of fabricating a thermal transfer image (100) as recited in any one of claims 1, 2, or 3.

Images