Abstract: Methods are generally disclosed for forming and using a casting paper. In one embodiment, the casting paper can be made by coating a first surface of a base sheet with a release coating such that the release coating covers the entire first surface of the base sheet. A printed release coating is then applied on a portion of the first release coating, and is dried or cured as needed to form the casting paper having a textured surface defined by elevated areas corresponding to the printed release coating and valley areas corresponding to exposed areas of the printed release coating. In another embodiment, the casting paper can be made by first printing a base sheet with a patterned, structured coating, then coating over the patterned, structured coating with a release coating such that the release coating covers at least the unprinted areas of the base sheet. The casting paper can be used to form a texturized surface in a substrate.

Abstract: Methods are generally disclosed for forming and using a release sheet. To form the release sheet, a release coating is applied over a first surface of a base sheet. Generally, the release coating includes a fatty alcohol ester of acrylic acid and a curable monomer, and can also include a curable polymeric resin. Then, the release coating can be cured. In one particular embodiment, the release coating can be substantially free from siloxanes. The release sheet formed according to this method is also generally provided, along with methods of forming a casting sheet using the release sheet are also generally provided.

Abstract: A heat transfer material kit is disclosed that includes a first image transfer material that includes a printable non-porous surface, and a second image transfer material that includes an outer layer having a film forming binder and thermoplastic particles. The film forming binder is polar. A method of using the kit is disclosed that includes the steps of a) imaging the substantially non-porous printable surface to form an imaged surface having printed and un-printed areas; b) positioning the outer layer adjacent the imaged surface; c) transferring a portion of the outer layer to the printed area while transferring a lesser portion of the outer layer to the non-printed area to form a coated imaged surface having a non-printed area with less coating than the printed area; and d) thereafter transferring the coated image to a substrate. Alternate methods of using the kit and applying images to substrates that provide good image appearance and durability are also disclosed.

Abstract: A heat transfer material kit is disclosed that includes a first image transfer material that includes a printable non-porous surface, and a second image transfer material that includes an outer layer having a film forming binder and thermoplastic particles. A method of using the kit is disclosed that includes the steps of a) imaging the substantially non-porous printable surface to form an imaged surface having printed and un-printed areas; b) positioning the outer layer adjacent the imaged surface; c) transferring a portion of the outer layer to the printed area while transferring a lesser portion of the outer layer to the non-printed area to form a coated imaged surface having a non-printed area with less coating than the printed area; and d) thereafter transferring the coated image to a substrate. Alternate methods of using the kit and applying images to substrates that provide good image appearance and durability are also disclosed.

Abstract: A heat transfer paper configured to reduce the amount of stray toner on a heat transfer material, especially when the image is formed via a laser printer or laser copier, is generally disclosed. The heat transfer material includes an image-receptive coating overlying a splittable layer and a base sheet. The image-receptive coating includes thermoplastic polyolefin wax microparticles, a thermoplastic binder, and a humectant. The thermoplastic polyolefin wax microparticles have an average particle size of from about 30 microns to about 50 microns and melt at temperatures between about 130° C. and about 200° C.

Abstract: A method of forming an opaque image on a substrate is generally provided. The method generally includes the use of three papers: a toner printable sheet, a coating transfer sheet, and an opaque transfer sheet. Toner printing can be utilized to print an image on the toner printable sheet, and then the toner ink can be utilized to remove a portion of a melt coating layer from the coating transfer sheet to form an intermediate imaged coated transfer sheet. This intermediate imaged coated transfer sheet and the opaque transfer sheet can then be utilized to form an image, defined by the opaque areas, on a substrate.

Abstract: Method of making a heat transfer materials are generally provided, along with the materials and the methods of using the materials. A splittable layer can be formed to overlie a base sheet, and an image-receptive coating can be formed to overlie the splittable layer. The image-receptive coating can include thermoplastic microparticles, a thermoplastic binder, and a humectant. The thermoplastic microparticles can be styrene particles having an average particle size of from about 5 microns to about 80 microns and melt at temperatures between about 90° C. and about 115° C. A second thermoplastic microparticle can also be included in the image-receptive coating. Alternatively, a combination of thermoplastic polyester microparticles and thermoplastic polyamide microparticles can be included in the image-receptive coating. The heat transfer material can then be dried. The humectant is configured to draw moisture back into the heat transfer sheet after drying.

Abstract: 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.

Abstract: Methods of making a stenciled screen for use in screen printing an image onto a substrate are generally disclosed. The method involves removing a portion of a transfer coating from a transfer sheet via heat transfer with a printable sheet defining a printable surface. The portion of the transfer coating removed from the transfer sheet corresponds to areas where an ink is present on the printable surface of the printable sheet. The transfer coating can then be transferred to a screen to form a stenciled screen having closed mesh areas corresponding to where the transfer coating is present. The stenciled screen can then be used to screen print an image onto any of a variety of fibrous substrates.

Abstract: Method of making a heat transfer materials are generally provided, along with the materials and the methods of using the materials. A splittable layer can be formed to overlie a base sheet, and an image-receptive coating can be formed to overlie the splittable layer. The image-receptive coating can include thermoplastic microparticles, a thermoplastic binder, and a humectant. The thermoplastic microparticles can be styrene particles having an average particle size of from about 5 microns to about 80 microns and melt at temperatures between about 90° C. and about 115° C. A second thermoplastic microparticle can also be included in the image-receptive coating. Alternatively, a combination of thermoplastic polyester microparticles and thermoplastic polyamide microparticles can be included in the image-receptive coating. The heat transfer material can then be dried. The humectant is configured to draw moisture back into the heat transfer sheet after drying.

Abstract: Methods of transferring an image to a substrate are generally provided. A heat transfer material can be partially cut to define a shape with cuts made into the heat transfer material (i.e., into its thickness). The heat transfer material includes a transferable portion overlying a release layer overlying a base sheet such that the cuts are made into the heat transfer material through the transferable portion while leaving the release layer and base sheet uncut. The transferable portion of the heat transfer material can be removed from the base sheet in an area surrounding the shape. Then, the heat transfer material can be positioned adjacent the substrate such that the transferable portion defined by the shape contacts the substrate. Heat and pressure can be applied to the heat transfer material. Thereafter, the base sheet can be removed.

Abstract: Laminates and methods of making them are generally provided. The methods of making a laminate for use as a clothing tag can include laminating a first fibrous web to a second fibrous web. Both the first and second fibrous webs can include cellulosic fibers and a binder composition present in the respective fibrous web from about 10% by weight to about 100% by weight of the dry weight of the fibrous web. Both the first and second binder composition can include a curable latex polymer and a crosslinker. The second fibrous web can be creped and can have a thickness less than 10 mils. The laminate can be aged for at least about 1 hour at an aging temperature of greater than about 150° F. The resulting laminated and their use in clothing are also provided.

Abstract: Method of making a heat transfer materials are generally provided, along with the materials and the methods of using the materials. A splittable layer can be formed to overlie a base sheet, and an image-receptive coating can be formed to overlie the splittable layer. The image-receptive coating can include thermoplastic microparticles, a thermoplastic binder, and a humectant. The thermoplastic microparticles can be styrene particles having an average particle size of from about 5 microns to about 80 microns and melt at temperatures between about 90° C. and about 115° C. A second thermoplastic microparticle can also be included in the image-receptive coating. Alternatively, a combination of thermoplastic polyester microparticles and thermoplastic polyamide microparticles can be included in the image-receptive coating. The heat transfer material can then be dried. The humectant is configured to draw moisture back into the heat transfer sheet after drying.

Abstract: A heat transfer paper configured to reduce the amount of stray toner on a heat transfer material, especially when the image is formed via a laser printer or laser copier, is generally disclosed. The heat transfer material includes an image-receptive coating overlying a splittable layer and a base sheet. The image-receptive coating includes thermoplastic polyolefin wax microparticles, a thermoplastic binder, and a humectant. The thermoplastic polyolefin wax microparticles have an average particle size of from about 30 microns to about 50 microns and melt at temperatures between about 130° C. and about 200° C.

Abstract: A heat transfer paper configured to reduce the amount of stray toner on a heat transfer material, especially when the image is formed via a laser printer or laser copier, is generally disclosed. The heat transfer material includes an image-receptive coating overlying a splittable layer and a base sheet. The image-receptive coating includes thermoplastic polyolefin wax microparticles, a thermoplastic binder, and a humectant. The thermoplastic polyolefin wax microparticles have an average particle size of from about 30 microns to about 50 microns and melt at temperatures between about 130° C. and about 200° C.

Abstract: Methods of making fibrous webs having a visible transparency variation image and products constructed from such methods are generally disclosed. The variation in transparency creates a transparency variation image in the fibrous substrate in the form of a false watermark and/or a false shadow mark. In the method disclosed, a transfer sheet having a transfer coating is utilized. A portion of the transfer coating is removed from the transfer sheet by heat transfer with a printable sheet having a toner image applied thereon. The transfer coating of the transfer sheet includes a powdered thermoplastic polymer and a film-forming binder. The film-forming binder can have a melting point that is less than that of the powdered thermoplastic polymer. In the final step of the method, the remaining transfer coating is transferred to a fibrous substrate to form the transparency variation image in the fibrous substrate.

Abstract: A coated label substrate including a label substrate, a printable coating, and a connector (e.g., an adhesive layer) is generally provided. The printable coating overlies one surface of the label substrate. The printable coating includes an organic polymer covalently bonded to a plurality of inorganic nanoparticles (e.g., metal oxide nanoparticles such as SiO2), and is configured to not melt during printing at temperatures up to about 350° F. Other materials, such as an opacifier, may also be present in the printable coating. An ink composition (e.g., toner ink, resin ribbon composition, etc.

Abstract: A method of forming an opaque image on a substrate is generally provided. The method generally includes the use of three papers: a toner printable sheet, a coating transfer sheet, and an opaque transfer sheet. Toner printing can be utilized to print an image on the toner printable sheet, and then the toner ink can be utilized to remove a portion of a melt coating layer from the coating transfer sheet to form an intermediate imaged coated transfer sheet. This intermediate intermediate imaged coated transfer sheet and the opaque transfer sheet can then be utilized to form an image, defined by the opaque areas, on a substrate.

Abstract: A heat transfer paper configured to reduce the amount of stray toner on a heat transfer material, especially when the image is formed via a laser printer or laser copier, is generally disclosed. The heat transfer material includes an image-receptive coating overlying a splittable layer and a base sheet. The image-receptive coating includes thermoplastic polyolefin wax microparticles, a thermoplastic binder, and a humectant. The thermoplastic polyolefin wax microparticles have an average particle size of from about 30 microns to about 50 microns and melt at temperatures between about 130° C. and about 200° C.

Abstract: The present invention is directed to a unique heat transfer material for use in transferring a discontinuous coating onto a substrate, such as an article of clothing. The heat transfer material of the present invention may be used cold peel transfer processes, resulting in an image-bearing coating having superior crack resistance, washability, and breathability compared to conventional image-bearing coatings. Additionally, the materials may be used on dark colored fabrics without washed-out appearance typically associated with printing on darker fabrics. The heat transfer material of the present invention produces superior results due to the use of discontinuous coatings.