Method of manufacturing a transfer sheet and method of transfer printing
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Solution Overview
Problem
Existing methods for transfer printing on fabrics require multiple thermal press processes and separation steps, leading to inefficiencies and inadequate masking properties, especially when trying to print white images using conventional electronic image forming apparatuses that lack white toner or ink.
Innovation Solution
A method using two sheets, A and B, where a sheet A with a substrate, release, and porous resin layers is combined with a sheet B having a substrate, release, and adhesive layers, with the sheets being heated and pressed to adhere and separate, allowing for a single-step transfer of a clear and robust ink/resin toner layer onto a fabric surface without medium separation, utilizing transparent resin toner for improved masking and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional thermal transfer methods using PVA layer as medium are used, then transfer printing can be performed, but the process requires double separation steps and has inferior rubbing resistance
Solution Approach 1:
The invention extracts and eliminates the PVA medium layer from the transfer printing process. Instead of using a separate PVA layer as an intermediary medium that requires separation, the adhesive layer is directly transferred to the substrate along with the toner image in a single thermal press step, removing the need for subsequent separation operations.
Solution Approach 2:
The invention merges the adhesive layer and the toner image layer into a single transferable unit. By applying heat and pressure simultaneously, the adhesive layer bonds the toner image directly to the substrate in one step, combining multiple functions (adhesion and image transfer) into a single integrated process.
2Adaptability or versatility
If electronic image forming apparatus is used for printing on fabric, then individualization and variety production is enabled, but white color printing is not possible due to lack of white toner
Solution Approach 1:
The invention introduces a transparent or white adhesive layer as an intermediary between the electronic image forming apparatus and the fabric substrate. This adhesive layer serves as a masking medium that provides white color coverage, allowing the electronic printer to deposit toner that appears white or brightly colored against the light-reflecting adhesive background.
Solution Approach 2:
The invention changes the optical parameters of the transfer medium by using a transparent or white adhesive layer with specific light reflection properties. This parameter change enables the electronic image forming apparatus to produce white or high-visibility prints on dark fabrics by altering how light interacts with the printed surface.
3Manufacturing precision
If multiple thermal press steps are used for transfer printing, then image quality can be improved, but production time and cost increase
Solution Approach 1:
The invention performs preliminary preparation by designing the adhesive layer with specific thermal and adhesive properties before the transfer process. The adhesive layer is formulated to activate and bond at the thermal press conditions used in electronic image forming apparatus, enabling single-step transfer without requiring multiple sequential pressing operations.
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 simplifies the transfer printing process, reduces costs, and enhances the quality and durability of printed images by eliminating the need for double thermal press steps and improving washing resistance, enabling quick and cost-effective transfer printing of clear, robust images on fabrics.
Implementation Method 1
both of the sheets A and B are superimposed on one another and brought into adhesion with heat
Implementation Method 2
the adhesive layer is separated from the release layer and is adhered to the sheet A side only on the ink/resin toner layer
Implementation Method 3
the sheets are heated to a temperature in a range from 110°C to 140°C and pressed
Data Source
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AI summary
Provided is a transfer sheet whereby a T-shirt or the like can be printed in few steps by means of an electronic image forming device that uses powdered toner, liquid ink, or the like containing a plastic resin. By means of mirror-image printing a picture pattern, which is an electronic image, onto sheet A, aligning sheet A and sheet B, and heat-pressing, there is spread coating over the portion of the picture pattern printed to sheet A. Sheet A has a structure layering a mold release layer, a resin layer, and a porous resin layer in a substrate, and sheet B layers a mold release layer, a resin layer, an adhesive layer, and a colored porous resin layer in a substrate.