Selective Heat Transfer Coating for Weed-Free Image Application
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Solution Overview
Problem
Current heat transfer papers require excessive transfer coatings that stiffen and non-porous substrates, making them less absorbent, and existing weeding processes are difficult, especially around intricate designs, necessitating improved weedable heat transfer papers and methods for better image appearance and durability.
Innovation Solution
A method involving a printable transfer sheet with a transfer coating layer and a toner printable sheet where a negative mirror image is printed, allowing the transfer coating to be selectively transferred only to imaged areas, enabling the image to be coated on a substrate without coating unimaged areas, using different temperatures for each transfer step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transfer coating is applied to the entire substrate area, then the image colorants can be carried into the porous substrate and adhered, but the substrate becomes stiffened, less porous, and less able to absorb moisture
Solution Approach 1:
The transfer coating is applied selectively only to the imaged areas of the substrate rather than the entire surface. This is achieved by transferring the coating from a transfer sheet that has been printed with the image, so the coating adheres only where image content exists. This local application maintains substrate flexibility and porosity in unimaged areas while providing adequate adhesion where needed.
2Reliability
If a heavy transfer coating is used for coarse fabrics, then better image adhesion is achieved, but the substrate flexibility and moisture absorption are reduced
Solution Approach 1:
The coating is applied locally only to imaged areas, so even when using sufficient coating weight for coarse fabric adhesion, the total coated area is minimized. This preserves flexibility and moisture absorption in the larger uncoated portions of the substrate.
Solution Approach 2:
The transfer process uses controlled temperature and pressure parameters to optimize coating transfer efficiency. By adjusting these parameters, adequate coating transfer is achieved in imaged areas without requiring excessive coating material, thus maintaining substrate properties.
3Object-affected harmful factors
If traditional weeding processes are used to remove coating from non-printed areas, then unimaged areas remain uncoated, but the process is difficult especially around intricate graphic designs
Solution Approach 1:
Instead of applying coating to the entire substrate and then removing it from unimaged areas (traditional weeding), the invention inverts the process by applying coating only to imaged areas from the beginning. The transfer sheet is printed with the image, and coating is transferred only where ink or toner exists, eliminating the need for difficult weeding operations.
Solution Approach 2:
The image is printed on the transfer sheet before the coating transfer process. This preliminary imaging step creates a pattern that guides selective coating transfer, so the coating is deposited only in areas that will become the final image, avoiding the need for post-application removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for easy production of customized images on substrates without cutting around printed areas, ensuring the substrate remains uncoated in non-image areas, maintaining substrate porosity and flexibility, and enhancing image durability and appearance.
Implementation Method 1
The images are transferred to the article by means of heat and pressure
Implementation Method 2
A portion of the transfer coating layer of the printable transfer sheet is transferred to the toner printable sheet
Implementation Method 3
a negative mirror image is printed with toners on a toner printable sheet. The negative mirror image on the toner printable sheet defines imaged areas having toner ink
Data Source
AI summary
Methods and products for forming a coated image on a substrate are generally disclosed. The methods can include forming an image on a printable surface of a transfer coating layer of a printable transfer sheet. In a separate step, the negative mirror image of that same image is printed with toners on a toner printable sheet. After registering the sheets together, a portion of the transfer coating layer of the printable transfer sheet is transferred to the toner printable sheet, such that the portion of the transfer coating layer transferred to the toner printable sheet corresponds to the imaged areas on the toner printable sheet. However, the image formed on the printable surface of the transfer coating layer and the underlying transfer coating substantially remain on the printable transfer sheet. Thereafter, the image and the transfer coating layer remaining on the printable transfer sheet are transferred to a substrate.