SYSTEMS AND METHODS FOR APPLYING A SUBLIMABLE DYE TO A SUBSTRATE

Abstract

Systems and methods for applying a sublimable dye to a substrate are described herein. While such systems and methods can include any suitable component, in some cases, they include a sublimable dye transfer medium that includes a transfer sheet, a sublimable dye, a dye-permeable adhesive, and a release liner. While the various components of the transfer medium can be arranged in any suitable manner, in some cases, the dye is disposed on a first surface of the transfer sheet, the adhesive is disposed over the dye, and the liner is releasably attached to the adhesive. Thus, in some cases, a user can peel the liner from the adhesive, stick the transfer sheet to a substrate, and heat the transfer sheet to transfer dye from the sheet to the substrate. In some cases, dye is transferred from the transfer sheet to the substrate at an ambient pressure. Other implementations are described.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to dye sublimation. In particular, the present invention relates to systems and methods for applying a sublimable dye to a substrate. In some implementations, the described systems and methods include a sublimable dye transfer medium that includes a transfer sheet, a sublimable dye, a dye-permeable adhesive, and an optional release liner. While the various components of the transfer medium can be arranged in any suitable manner, in some cases, the dye is disposed on a first surface of the transfer sheet, the adhesive is also disposed on the transfer sheet's first surface, and the liner is releasably attached to the adhesive. Thus, in some cases, a user can peel the liner from the adhesive, stick the transfer sheet to a substrate, and heat the transfer sheet to transfer dye from the sheet to the substrate. In some cases, the adhesive portion of the transfer medium is configured in such a manner that the adhesive can intimately attach the transfer sheet and the substrate with each other such that the dye is able to transfer from the transfer sheet to the substrate when the dye is heated, even under an ambient pressure.

2. Background and Related Art

One popular method for placing a pattern, text, image, design, or other decoration on an object is that of sublimable dye transfer. In some cases, this method is accomplished as one or more sublimable dyes are placed on a first side of a dye-donor element. In some such cases, the dye-donor element is then placed on an object (such as a mug, a shirt, or another object having a surface that is capable of receiving the dye), so that the dye on the donor element is in contact with a surface of the object. In many cases, the dye-donor element is then pressed firmly against the object and heated to a temperature that allows the dye to sublime (or to change from a solid to a gaseous state, without passing through the liquid state) and to diffuse and/or to otherwise transfer and solidify on or into a surface of the object. In this manner, the pattern from the donor element (or a mirror image thereof) can be affixed to the object.

While the dye-donor element can be pressed onto the object in a variety of manners, in some cases, the donor element is forced against the object with a heat press platen, a dye sublimation vacuum press, a 3D vacuum sublimation machine, a dye sublimation mug printing machine, and/or a similar heat press that increases pressure between the donor element and the object as the element is heated. In any case, by using pressure to force the donor element onto the desired object and heating the dye, the dye can be forced to diffuse directly onto the object.

Although many conventional methods for decorating objects through the use of a dye sublimation transfer technique may be very effective, such techniques are not necessarily without their shortcomings. Indeed, many conventional dye sublimation transfer techniques require relatively expensive heat presses, are relatively limited in the shape and size of objects with which they can be used, and are relatively difficult to perform in a manner that ensures that the final decoration that is transferred to a desired object is clear and crisp.

Thus, while techniques currently exist that are used to transfer sublimable dyes to an object, challenges still exist, including those mentioned above. Accordingly, it would be an improvement in the art to augment or even replace current techniques with other techniques.

SUMMARY OF THE INVENTION

The present invention relates to dye sublimation. In particular, the present invention relates to systems and methods for applying a sublimable dye to a substrate. In some implementations, the described systems and methods include a sublimable dye transfer medium that includes a transfer sheet, a sublimable dye, a dye-permeable adhesive, and an optional release liner. While the various components of the transfer medium can be arranged in any suitable manner, in some cases, the dye is disposed on a first surface of the transfer sheet, the adhesive is also disposed on the transfer sheet's first surface, and the liner is releasably attached to the adhesive. Thus, in some cases, a user can peel the liner from the adhesive, stick the transfer sheet to a substrate, and heat the transfer sheet to transfer dye from the sheet to the substrate. In some cases, the transfer medium is configured in such a manner that dye is able to be transferred from the transfer sheet to the substrate at an ambient pressure.

With respect to the transfer sheet, the transfer sheet can include any suitable material that is capable of receiving sublimable dye and an adhesive in a manner that allows the transfer sheet to be adhered to a substrate and heated to cause a portion of the dye to transfer from the transfer sheet to the substrate. Some examples of such materials include, but are not limited to, one or more tissue papers, plastic films, and/or metal foils.

The sublimation dye can be any suitable dye that is configured to pass from the transfer sheet to the receiving object when heated. Some examples of such dyes include any known or novel water-based and/or solvent-based sublimation dyes that are suitable for use with the described transfer medium.

The adhesive can comprise any suitable adhesive that allows it to adhere the transfer sheet to a receiving object, and that allows dye on the transfer sheet to be transferred to the receiving object when the dye is heated sufficiently. Some examples of suitable adhesives include one or more pressure-sensitive adhesives, such as one or more suitable: emulsion polymers, elastomers (e.g., acrylics, butyl rubbers, nitriles, etc.) compounded with a tackifier (e.g., a rosin ester), and/or any other suitable adhesives.

The release liner can have any suitable characteristic that allows it to be releasably adhered to the adhesive. In some cases, the liner has a first and a second side, and the adhesive is applied to the first side of the liner. In some such cases, the first side of the liner has a lower affinity for the bonding with the adhesive than does the first surface of the transfer sheet. Thus, when the adhesive is sandwiched between the liner and the transfer sheet, and the liner is peeled from the transfer sheet, the adhesive is retained on the transfer sheet, while being released from the liner.

The described transfer medium can be made in any suitable manner. Indeed, in some instances, the dye is placed on the transfer sheet in any suitable manner (e.g., via inkjet printing, laser printing, etc.). Moreover, while the adhesive can be disposed directly on the transfer sheet (e.g., on a first surface of the transfer sheet, over and/or under the dye), in some instances, the adhesive is first added to the release liner (e.g., via rotogravure, a roll coater, etc.) and then allowed to at least partially dry. Once the adhesive has at least partially dried, the release liner and the transfer sheet are joined together, with the adhesive being disposed between the two.

The transfer medium can further be used in any suitable manner that allows the transfer sheet to be adhered to a receiving object and that allows dye to transfer from the receiving transfer sheet to the receiving object when the dye is heated sufficiently (e.g., to a temperature between about 300 and about 450 degrees Fahrenheit). In one example, once the release liner is peeled from the transfer paper, the transfer paper is adhered to a desired receiving object (e.g., a piece of furniture, a railing, an appliance, a computer case, a safe, a car part, a piece of fabric, a mug, a wall, a floor, ID card, etc.). In some instances, the transfer sheet is then pressed against the object and heated with a heated platen, a mug press, a vacuum press, a vacuum bag, or similar heat press that is configured to increase pressure between the transfer sheet and the receiving object when the transfer sheet and dye are heated. In some other instances, however, once the transfer sheet is adhered to the receiving object, the transfer sheet is heated under ambient pressures. Thus, in such instances, the described transfer medium can effectively transfer dyes to a receiving object, without the need for an expensive heat press.

While the methods and processes of the present invention have proven to be particularly useful in the area of applying sublimable dyes to powder-coated metals, those skilled in the art can appreciate that the described methods and processes can be used in a variety of different applications and in a variety of different areas of manufacture. For instance, the described systems and methods can be used to apply a sublimation dye to virtually any suitable material that is capable receiving the dye, including, without limitation, any suitable fabric (e.g., polyester), acrylic material, vinyl material, epoxy, polymeric material, polymer coating (e.g., polyester coating, polyurethane coating, etc.), tile, cement, and/or any other material comprising a substance and/or surface that is configured to receive the dye.

These and other features and advantages of the present invention will be set forth or will become more fully apparent in the description that follows and in the appended claims. The features and advantages may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Furthermore, the features and advantages of the invention may be learned by the practice of the invention or will be obvious from the description, as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the manner in which the above-recited and other features and advantages of the present invention are obtained, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. Understanding that the drawings are not necessarily drawn to scale or in proper proportion, and that the drawings depict only typical embodiments of the present invention and are not, therefore, to be considered as limiting the scope of the invention, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

FIG. 1 illustrates a cross-sectional, side view of a representative embodiment of a transfer medium;

FIG. 2 depicts a flow chart showing a representative embodiment of a method for making the transfer medium;

FIGS. 3-4 each depict a flow chart showing a different representative embodiment of a method for using the transfer medium;

FIG. 5A illustrates a cross-sectional, side view of a representative embodiment of a transfer sheet having a sublimable dye disposed on a first surface of the transfer sheet;

FIG. 5B illustrates a cross-sectional, side view of a representative embodiment of a release liner having an adhesive disposed on a first side of the liner;

FIG. 5C illustrates a cross-sectional, side view of a representative embodiment of an adhesive sandwiched between a first and a second release liner; and

FIG. 6 illustrates a cross-sectional, side view of a representative embodiment of the transfer medium, adhered to a receiving object.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to dye sublimation. In particular, the present invention relates to systems and methods for applying a sublimable dye to a substrate. In some implementations, the described systems and methods include a sublimable dye transfer medium that includes a transfer sheet, a sublimable dye, a dye-permeable adhesive, and an optional release liner. While the various components of the transfer medium can be arranged in any suitable manner, in some cases, the dye is disposed on a first surface of the transfer sheet, the adhesive is disposed over the dye, and the liner is releasably attached to the adhesive. Thus, in some cases, a user can peel the liner from the adhesive, stick the transfer sheet to a substrate, and heat the transfer sheet to transfer dye from the sheet to the substrate. In some cases, the dye is transferred from the transfer sheet to the substrate under an ambient pressure.

In the disclosure and in the claims the term ambient pressure, and variations thereof, may be used to refer to a pressure that is provided by a transfer sheet/transfer medium adhered to a substrate, without requiring that any pressure be applied to the transfer sheet/medium by a heat press platen, an inflatable bladder, a vacuum bladder, a vacuum bag, constriction of the transfer sheet/medium about the object, and/or any other heat press or force, besides the adhesive on the transfer sheet, pressures of sublimed gases trapped by the adhesive between the transfer sheet and the substrate, and/or the weight of the transfer sheet, the adhesive, and/or the dye.

As used herein, the term receiving object, object, and variations thereof may refer to any suitable item, material, and/or other suitable substrate to which the described sublimable dye transfer medium can be adhered such that a dye from the transfer medium is able to transfer to the object when the dye is heated sufficiently. Some non-limiting examples of such objects include any suitable type of: fabric (e.g., a fabric comprising polyester, a cotton polyester blend, etc.), powder-coated material (e.g., a powder-coated metal, powder-coated wood, powder-coated ceramic, powder-coated glass, etc.), polymer (e.g., polyurethane, polyester, acrylic, vinyl, epoxy, etc.), polymer coating (e.g., a coating comprising at least one of a polyurethane, polyester, acrylic, vinyl, epoxy, etc.), plastic, cement, stone, natural material, synthetic material, hand railing, furniture (e.g., desk, table, chair, filing cabinet, credenza, bookshelf, bench, safe, lamp, cabinet, entertainment center, etc.), computer case, light, garage door, automotive part, heating/cooling register, exercise equipment, playground equipment, picture frame, poster, door, metal ceiling tile, partition, window frame, metal (e.g., aluminum) extrusion, appliance (e.g., dishwasher, washing machine, dryer, fridge, freezer, toaster, range hood, etc.), luggage, toilet, partition, elevator door, elevator interior, dressing room locker, ceramic (e.g., tile, mug, vase, dinner ware, light sconce, pot, dish, soap dish, ceramic shelf, etc.) with a dye-receptive coating, wood (e.g., cabinet door, interior door, shelf, head board, dresser, furniture top, shade, millwork, ballast, column, beam, ceiling fan, etc.) with a dye-receptive coating, trailer, building cover, car cover, floor, and/or any other suitable material or item.

As mentioned above, the described systems and methods relate generally to a sublimable dye transfer medium that is configured to stick to an object, such that one or more dyes can transfer from the transfer medium to the object when the transfer medium is heated—even under ambient pressures. While the transfer medium can have any suitable component that allows it to function as described herein, FIG. 1 shows a representative embodiment in which the sublimable dye transfer medium 10 comprises a transfer sheet 15 having a first surface 20 and a second surface 25, a sublimable dye 30 disposed on the first surface, an adhesive 35 that is also attached to the first surface, and an optional release liner 40 that is attached to the adhesive.

With respect to the transfer sheet 15, the transfer sheet can comprise any suitable material that: is heat resistant, allows it to retain the dye 30 and the adhesive 35 on its first surface 20 (at least until it is properly heated), and to be adhered to an object such that a portion of the dye transfers from the transfer sheet to the object when the dye is heated. Some examples of such materials include, but are not limited to, one or more sheets, films, ribbons, or other substrates comprising one or more pieces of: paper (e.g., cellulosic paper, tissue paper, condenser paper, glassine paper, paraffin paper, capacitor paper, fine paper, art paper, coated paper, cast-coated paper, backing paper, synthetic-resin-intercalated paper, synthetic-rubber-latex-impregnated paper, wall paper, emulsion-impregnated paper, combinations thereof, etc.), paperboard, a heat-resistant plastic or polymer (e.g., a polyester, polyamide, polytetrafluoroethylene, polyolefin, polyvinyl chloride, polyethylene terephthalate, polystyrene, polymethacrylate, polycarbonate, combinations thereof, etc.), metal (e.g., tin foil, aluminum foil, foiled films (e.g., bi-axially-oriented polyethylene terephthalate), etc.), and/or any other suitable material that is capable of functioning as the transfer sheet. In some embodiments, however, the transfer sheet comprises one or more pieces of tissue paper (e.g., PROTEX™ Protection Tissue and TEXTPRINT™ paper, produced by Beaver Paper & Graphic Media, Inc. of Lawrenceville, Ga., USA; INTELICOAT™ paper, produced by InteliCoat Technologies, of South Hadley Mass., USA; HD 15# tissue paper and/or XHD 20# tissue paper, produced by S. Walter Packaging Corp., of Philadelphia, Pa., USA. In still other embodiments, the transfer sheet comprises a piece of metal foil, which is capable of being heated with an open flame—thus allowing for rapid transfer of dye from the transfer sheet to a receiving object.

In some embodiments, the transfer sheet 15 further comprises a material that is impermeable (or at least semi-impermeable) to sublimed dye 30 gases. While such a transfer sheet can perform any suitable function, it is theorized that, in some cases, when the adhesive 35 attaches the transfer sheet to an object, the transfer sheet and the object each form a barrier that prevents dye gases from escaping to atmosphere, and that helps force sublimed dye gases onto the object.

In some other embodiments, the transfer sheet 15 comprises a material that is permeable or semi-permeable to air. While this permeability/semi-permeability of the transfer sheet can serve a variety of purposes, in some embodiments, it allows one or more air bubbles between the transfer sheet and the object to escape during the application of the transfer sheet to the object—thus allowing for intimate contact between the transfer sheet (with the dye 30 and adhesive 35 disposed thereon) and the surface of the object to which the transfer medium 10 is attached. In this regard, the transfer sheet can be made permeable or semi-permeable to air in any suitable manner. Indeed, in one example, the transfer sheet comprises a material or fabric that is permeable or semi-permeable to air. In another example, the transfer sheet defines any suitable number of perforations (and/or other suitable air holes), of any suitable size, that allow air to escape from between the transfer sheet and the receiving object. In this example, while air can escape from the transfer sheet, in some embodiments, the perforations are small enough and/or far enough apart, and the adhesive is strong enough that sublimed dyes readily transfer from the transfer sheet to the object to which the sheet is adhered.

Although, in some embodiments, the transfer sheet 15 comprises a single sheet of material, in other embodiments, the transfer sheet comprises 2, 3, 4, or more layers of a single type of material or of two or more materials. In this regard, the transfer sheet can comprise any suitable combination of materials, which may vary from one application to another. In one non-limiting example, the transfer sheet includes a first layer of cellulose fiber paper and a second layer of a synthetic paper or a plastic film. In this example, the cellulose fiber paper would be exposed at the first surface 15 of the transfer sheet, while the synthetic paper/plastic film would be exposed at the second surface 25 of the transfer sheet. In still another example, the second surface 25 of the transfer sheet comprises a release coating (e.g., polytetrafluoroethylene, etc.) that is configured to allow the adhesive to releasably bind to the second surface of the transfer sheet when the transfer sheet is rolled on itself (e.g., without the liner 40).

The transfer sheet 15 can further be any suitable size that allows it to be used to transfer dye 35 to an object. Indeed, some embodiments of the transfer sheet have a width and length that is greater than about 0.1 inches and less than about 100 feet (though much longer lengths are possible). In other embodiments, the width, length, and/or diameter of the transfer sheet fall in any sub-range of the aforementioned range (e.g., between about 0.5 inches and about 50 feet). In any case, the transfer sheet can be used to cover objects of virtually any size, even if such objects are too large to fit in (or otherwise be used with) a conventional or novel heat press.

With reference to the sublimable dye 30, the dye can include any suitable number (e.g., 1, 2, 3, 4, or more) of dyes, of any suitable color (e.g., cyan, magenta, yellow, black (or key), etc.), and of any suitable type that is configured to, at least partially, transfer (e.g., via sublimation, diffusion, etc.) from the transfer sheet 15 to the receiving object when the transfer sheet is adhered to the object and heated sufficiently (e.g., to between about 300 and about 450 degrees Fahrenheit, and/or any other suitable temperature). In some embodiments, the dye comprises a sublimable dye (e.g., a dye that is configured to change, when heated sufficiently, from a solid to a gas, without passing through the liquid phase). In other embodiments, however, the dye comprises a dye that transfers from the transfer sheet to the object when heated, even if the dye does not necessarily sublime. In any case, some examples of suitable dyes include one or more solvent-based sublimable dyes, water-based sublimable dyes, and/or any other suitable type of known or novel dye or ink. In some embodiments, however, the dye comprises SENSIENT™ ink, produced by Sensient Imaging Technologies, of Escondido, Calif., USA.

In addition to the dye 30 itself, the dye can comprise any other suitable ingredient. Some examples of such ingredients include, but are not limited to, one or more UV protectants, UV absorbers, dye binders (e.g., unsaturated aliphatic hydrocarbons, acrylic acid esters, methacrylic acids esters, compounds derived from vinyl halide, etc.), thickeners (e.g., polyacrylates, cellulose ethers, etc.), and/or any other suitable ingredients, at any suitable concentration.

With reference now to the adhesive 35, the adhesive can comprise any suitable adhesive that is configured to releasably adhere the transfer sheet 15 to a desired object, and to allow the dye 30 to transfer from the transfer sheet 15 to the object when the dye is heated sufficiently. Indeed, in some embodiments in which the dye is applied directly to the first surface 20 of the transfer sheet (as opposed to embodiments in which the adhesive that is applied directly to the transfer sheet's first surface, and the dye is then added to the adhesive), the adhesive is permeable (at least partially) to the dye so as to allow the dye to transfer from the transfer sheet, through the adhesive, and to the object. In some other embodiments, however, in which the adhesive is used to help provide an object with a desired decoration, the adhesive is impermeable (or semi-impermeable) to the dye—thus allowing the adhesive to serve as a mask that prevents at least some dye from being transferred to the object at the location of such adhesive.

While the adhesive 35 can comprise any suitable glue, paste, epoxy, and/or other adhesive, in some embodiments, the adhesive comprises one or more pressure-sensitive adhesives. In such embodiments, the adhesive can comprise any suitable pressure-sensitive adhesive, such as an emulsion polymer, an elastomer (such as one or more acrylics, butyl rubbers, natural rubbers, silicon rubbers, styrene block copolymers, nitriles, styrene-butadiene-styrene, styrene-ethylene/butylene-styrene, styrene-ethylene/propylene, styrene-isoprene-styrene, vinyl ethers, etc.), an elastomer compounded with a tackifier (e.g., a rosin ester), combinations thereof, and/or any other suitable adhesive. In some embodiments, however, the adhesive comprises a pressure-sensitive, dye-permeable acrylic copolymer (e.g., Covinax 377-02, produced by Franklin International, of Columbus, Ohio USA). Moreover, where the adhesive comprises a pressure-sensitive adhesive, the adhesive can further comprise any other suitable ingredient, including, without limitation, water, alcohol, and/or another suitable material.

Turning now to the liner 40, the liner can comprise any suitable material and characteristic that allows it to be removed from the adhesive 35, such that the transfer sheet 15 can be adhered to a desired receiving object and such that dye 30 on the transfer sheet can be transferred to the receiving object when the dye is heated sufficiently. In this regard, some examples of suitable materials for the liner include, but are not limited to, one or more sheets, films, ribbons, or other substrates comprising one or more pieces of: a silicone release liner; a tin-solvent, silicone-coated material (e.g., paper, foil, etc.); a platinum-solvent, silicone-coated material; a polytetrafluoroethylene-coated material; a silicon-coated material; a wax-coated material; and/or any other suitable material. Indeed, in some embodiments, the liner comprises a platinum-solvent, silicone-coated paper or foil.

Although, in some embodiments, the release liner 40 comprises a single sheet of material, in other embodiments, the liner comprises 2, 3, 4, or more layers of a single type of material or of two or more materials. In this regard, the liner can comprise any suitable combination of materials, which can vary from one application to another. In one non-limiting example, the liner includes a first layer of a tin-solvent silicone coating, a second layer of paper, and a third layer of a platinum-solvent silicone-coating, wherein the second layer is sandwiched between the first and third layers.

As shown in FIG. 1, the liner 40 comprises a first side 45 (to which the adhesive 35 releasably attaches) and a second side 50. In this regard, the first and second sides of the liner can have any suitable affinity for bonding with the adhesive. Indeed, in some embodiments, the first side of the liner comprises a surface having a lower affinity for bonding with the adhesive than does the first surface 25 of the transfer sheet 15. In such embodiments, when the adhesive 35 is sandwiched between the first surface 25 of the transfer sheet 15 and the first side 45 of the liner 40 (e.g., as shown in FIG. 1), the liner can be separated (e.g., peeled) from the transfer sheet, such that adhesive is released from the liner and remains attached to the transfer sheet.

In some embodiments, the first 45 and second 50 sides of the liner 40 have substantially the same affinity for bonding with the adhesive 35. In other embodiments, however, the first side has a higher affinity for bonding with the adhesive than does the second side. In some such embodiments, the adhesive can be applied to the liner (e.g., before it is applied to the transfer sheet 15 and/or a receiving object) and the liner can then be rolled up, such that when the liner is unrolled the adhesive is released from the liner's second side while remaining attached to the liner's first side.

The described transfer medium 10 can be made in any suitable manner. In this regard, FIG. 2 shows a representative embodiment of a method 100 for making the medium. While the various portions of the method of FIG. 2 (as well as all other methods described herein) can be rearranged, shortened, added to, and otherwise modified in any suitable manner, FIG. 2 (at step 105) shows that, in some embodiments, the method 100 for making the transfer medium includes applying the dye 30 to the first surface 20 of the transfer sheet 15.

While the dye 30 can be applied to the transfer sheet 15 in any suitable manner, in some embodiments, one or more dyes are applied to the transfer sheet by being printed on the transfer sheet with one or more inkjet printers, laser printers, dot matrix printers, 3D printers, digital printers, dye-sublimation printers, and/or any other suitable type of printer; and/or by being applied through a known or novel silk-screening process, rotogravure process, offset-printing process, lithographic-printing process, electrophotography process, xerography process, cyanotype process, flexography process, and/or other suitable process. In some embodiments, however, the dye is simply printed on the transfer sheet through the use of a printer (e.g., an inkjet or laser printer). In other embodiments, however, the dye is applied through a method (e.g., silk-screening, rotogravure, etc.) that allows thicker dyes (e.g., dyes comprising UV absorbers or other suitable ingredients) to be applied to the transfer sheet than could otherwise be applied by a conventional inkjet printer.

Although, in some embodiments, the adhesive 35 is applied to the transfer sheet's first surface 20 before being applied to the liner 40, step 110 of FIG. 2 shows that, in some preferred embodiments, the adhesive is first applied to the liner's first side 45. In either case, the adhesive can be applied to the appropriate portion of the transfer medium 10 in any suitable manner, including, without limitation, via rotogravure, a mayer rod, a roll coater, a curtain coat, and/or any other suitable method.

Where the adhesive 35 is applied to a portion of the transfer medium 15 (e.g., to the liner's first side 45), the adhesive can be applied at any suitable thickness. Indeed, in some embodiments, the adhesive is applied to a portion of the transfer medium at varying thickness and/or at a uniform thickness to provide the transfer medium with one or more desired characteristics. In some embodiments, however, the adhesive is applied at a substantially uniform thickness, thus allowing dye 30 to transfer from the transfer sheet and through the adhesive at a relatively uniform rate. In this regard, in some embodiments, the adhesive is applied to the transfer medium (e.g., the liner) at a substantially uniform thickness that is between about 0.01 mils and about 2 mils, or within any suitable sub-range thereof (e.g., between about 0.2 mils and about 0.8 mils, or even between about 0.4 mils and 0.6 mils).

The adhesive 35 can also be applied to the transfer medium (e.g., the liner 40) so when the transfer medium 10 is applied to an object, the adhesive will cover any suitable amount of the dye 30 that is to be applied to object. Indeed, in some embodiments, the adhesive is configured to be applied to the transfer sheet 15 so that it does not cover any of the dye that is to be transferred to the object. In other embodiments, the adhesive is applied to the transfer medium in such a manner that it helps provide a desired decoration on the object (e.g., the adhesive is applied in some spots to provide a strong transfer of the dye and a crisp image in such spots, the adhesive is not applied in some spots so as to provide a more diffuse transfer of the dye in such spots, a dye-impermeable adhesive is used to mask a portion of the object from receiving dye, etc.). In other embodiments, however, the adhesive is configured to be applied to the transfer sheet so as to substantially cover most, if not all, of the dye that is to be transferred to the object. In such embodiments, the adhesive can help hold the transfer sheet in close proximity to the object to ensure that the dyes pass directly from the transfer sheet to the object during heating.

Continuing with FIG. 2, step 115 shows that, in at least some embodiments, the method 100 optionally continues as the adhesive 35 is allowed to at least partially dry (e.g., on the liner 40). This drying process can provide the adhesive with one or more beneficial characteristics. Indeed, in some cases in which the adhesive has been dried, the adhesive can be heated (e.g., when the dye 30 is sublimed) with limited, or no, shrinkage—thus allowing the transfer medium 10 to transfer dyes to an object (i.e., a concave part of an object) without undue distortion. In any case, this drying process can be accomplished in any suitable manner, including, without limitation, by allowing the adhesive to dry at ambient temperature, by heating the adhesive (e.g., via convection heating, conventional heating, infrared heating, etc.), by blowing air on the adhesive, and/or through any other suitable technique.

At step 120, FIG. 2 shows that some embodiments of the method 100 continue as the first surface 20 of the transfer sheet 15 (e.g., the surface comprising the dye 30) is contacted with the adhesive 35 on the first side 45 of the liner 40. In such embodiments, the transfer sheet, adhesive, and liner can be contacted with each other in any suitable manner, including, without limitation, via a pinch roller, a hot laminator, and/or another suitable device that is configured to apply heat and pressure to the transfer sheet and the adhesive covered liner as the sheet and liner are attached to each other with the adhesive sandwiched in between the two. In some such embodiments (as mentioned above), the bond between the dried adhesive and the transfer sheet is stronger than the bond between the adhesive and the release liner, thus allowing the liner to be peeled from the adhesive and the transfer sheet. Additionally, in some such embodiments, the bond between the dried adhesive and the transfer sheet is configured to be stronger than the bond between the adhesive and the object to which the adhesive and the transfer sheet are adhered—thus allowing the adhesive to be peeled from the object as the transfer sheet is removed from the object.

While the transfer medium 10 can be used in any suitable manner, FIG. 3 shows an embodiment of a method 200 that begins at step 205 as the described transfer medium is obtained. At step 210, FIG. 3 shows the method 200 continues as the liner 40 is peeled (or otherwise removed) from the transfer sheet 15.

Next, at step 215, FIG. 3 shows the transfer medium 10 is stuck on a desired receiving object. While this step can be accomplished in any suitable manner, in some embodiments, the transfer sheet 15 is smoothed out (e.g., by hand, with a brush, with wall-paper laying tools, a vacuum bag, a vacuum jig, and/or in any other suitable method) to ensure that the pattern on the transfer sheet is transferred to the object without undesired or unnecessary blemishes.

At step 215, FIG. 3 shows the method 200 continues as the transfer medium 10 (e.g., the transfer sheet, the dye, etc.), the object, and/or any other item that allows the dye to sublime (or otherwise transfer) when heated sufficiently is heated on the object so as to transfer dye 30 from the transfer sheet 15 to the object. In this regard, the transfer medium can be heated to any suitable temperature, including, without limitation, to a temperature between about 300 and about 450 degrees Fahrenheit (or to any other suitable temperature).

When the transfer medium 10 is heated, it can be heated in any suitable manner that allows it to function as intended. Indeed, in some embodiments, the transfer medium is heated through the use of a heat press, such as heat press platen, a dye sublimation vacuum press, a 3D vacuum sublimation machine, a vacuum bag, a dye sublimation mug printing machine, and/or any other device that is configured to increase pressure between the transfer sheet 15 and the object as the transfer sheet and dye are heated.

In other embodiments, however, the adhesive 35 allows the transfer sheet 15 to be held to the object and to transfer dye 30 from the transfer sheet to the object without the use of a heat press or other device that forces the transfer sheet against the object during heating. Indeed, in some embodiments, the adhesive allows the transfer sheet to simply be stuck to an object and then be heated at ambient pressures to transfer the dye to the object. As a result, some embodiments of the described transfer medium 10 can be used without a relatively expensive heat press. Moreover, such embodiments can also be used to decorate objects that would be difficult to use with a vacuum bag process, a heated platen, and/or another heat press (e.g., large objects, such as floors, murals, billboard covers, etc.; concave objects; objects that have an inside return; convex objects; irregularly shaped objects; objects with a complicated design; etc.). Additionally, in some embodiments, the transfer medium is applied to a portion of an object, but is not required to envelop, extend around, and/or constrict down on the object to increase pressure between the transfer sheet and the object to properly transfer dye to the object.

Where the transfer medium 10 is adhered to a desired object and heated (without a heat press) to transfer dye to the object, the transfer medium can be heated in any suitable manner, including, without limitation, through the use of a heat gun, a blow dryer, an oven, a heated wand, a heater, a heating element, a stove, an infrared heater, an open flame, and/or any other suitable heating device. In one non-limiting example, once a large sheet of the transfer medium is applied to a floor that is configured to receive the dye (e.g., a floor having a polymeric coating), the transfer medium is heated through the use of a heater that is rolled (or otherwise) passed (at least partially) over the transfer medium.

Once the transfer medium 10 has been heated and the dye 30 has been transferred to the object, step 225 in FIG. 3 shows that the used transfer medium 10 (e.g., transfer sheet 15 and adhesive 30) can be removed from the object. In this regard, the transfer medium can be removed from the object in any suitable manner, including, without limitation, be being peeled off of the object. Additionally, while most, if not all, of the adhesive is removed from the object as the transfer sheet is peeled from the object, in some embodiments, residual adhesive is washed (e.g., with water, a solvent, soap, and/or any other suitable wash) from the object as and/or after the transfer sheet has been removed.

As previously mentioned, the various steps of the described methods can be modified in any suitable manner. In one example, instead of applying the adhesive 35 to the liner 40 first, the adhesive is applied to the transfer sheet 15 before the adhesive is contacted with the liner. In this example, the adhesive can be applied to the transfer sheet at any suitable time, including before and/or after the dye 30 is added to the transfer sheet—though, in some embodiments, the adhesive is placed on the transfer sheet after the dye.

In another example of a suitable modification, FIG. 4 shows a method 300 in which (at step 305) the adhesive 35 is applied to the object and then (at step 310) the transfer sheet 15 (with the dye 35) is contacted with the adhesive before being heated (as shown at step 315). In this method, the adhesive can be applied to the object by being dried on the liner 40, being applied to the object, and then having the be liner removed from the adhesive. In this regard, FIG. 5A shows an embodiment in which the transfer sheet 15 and dye 30 are produced without the adhesive 35 and without the liner 40. In contrast, FIG. 5B shows an embodiment in which the adhesive 35 is applied to a liner 40 that can be rolled on itself (e.g., a liner with a first side 45 that has a greater bonding affinity for the adhesive than does the liner's second side 50). Similarly, FIG. 5C shows an embodiment in which the adhesive 35 is sandwiched between the first side 45 of a first liner 40 and a first side 60 of a second liner 55, wherein the first side of the first line has a higher bonding affinity for the adhesive than does the first side of the second liner (thus allowing the second liner to be peeled from the adhesive and the first liner).

Once the adhesive 35 has been applied to the object 70, and the transfer sheet 15 with the dye 30 has been applied to the adhesive (as shown in FIG. 6), FIG. 4 (at step 315) shows the transfer sheet and dye are heated to transfer the dye to the object. FIG. 4 then shows that the method 300 continues as the transfer sheet and adhesive are removed from the object.

In addition to the aforementioned characteristics, the described transfer medium 10 can have a variety of other features. Indeed, as some embodiments of the medium can be used without a heat press, such embodiments can save time and money, as well as greatly expand the types and sizes of objects that can be decorated by the transfer medium. Moreover, in some such embodiments, the transfer medium allows production speeds to be increased due to the ability to automate the process by applying the transfer media to the object and allowing the object and transfer medium to run down an oven line, without the aid of any additional means of transfer (e.g., a heat press)—thus allowing production rates to be far superior to some current production methods.

In another example of a feature of the described transfer medium 10, some embodiments of the transfer medium are able to securely hold the transfer sheet to the object during heating, thus ensuring that the object receives a crisp and un-blurred reproduction of the pattern on the transfer sheet. In still another example, some embodiments of the transfer medium and its adhesive 35 layer are capable of simultaneously producing a print on the external surface of an object as well on an internal surface of that object. Indeed, in one example, a gun safe that has a surface external to the safe's cabinet and an internal surface that is inside of the gun cabinet, can be decorated by placing the transfer medium on both surfaces and then heating the medium.

Thus, as discussed herein, embodiments of the present invention embrace dye sublimation. In particular, the present invention relates to systems and methods for applying a sublimable dye to a substrate. In some embodiments, the described systems and methods include a sublimable dye transfer medium that includes a transfer sheet, a sublimable dye, a dye-permeable adhesive, and an optional release liner. While the various components of the transfer medium can be arranged in any suitable manner, in some cases, the dye is disposed on a first surface of the transfer sheet, the adhesive is disposed over the dye, and the liner is releasably attached to the adhesive. Thus, in some cases, a user can peel the liner from the adhesive, stick the transfer sheet to a substrate, and heat the transfer sheet to transfer dye from the sheet to the substrate. In some cases, the dye is transferred from the transfer sheet to the substrate at an ambient pressure.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. In addition, as the terms on, disposed on, attached to, connected to, coupled to, etc. are used herein, one object (e.g., a material, element, structure, member, etc.) can be on, disposed on, attached to, connected to, or coupled to another object—regardless of whether the one object is directly on, attached, connected, or coupled to the other object, or whether there are one or more intervening objects between the one object and the other object. Also, directions (e.g., on top of, below, above, top, bottom, side, up, down, under, over, upper, lower, lateral, orbital, horizontal, etc.), if provided, are relative and provided solely by way of example and for ease of illustration and discussion and not by way of limitation. Where reference is made to a list of elements (e.g., elements a, b, c), such reference is intended to include any one of the listed elements by itself, any combination of less than all of the listed elements, and/or a combination of all of the listed elements. Moreover, the term step is not used herein to signify any starting or ending point of a portion of a method. Furthermore, as used herein, the terms a, an, and one may each be interchangeable with the terms at least one and one or more.

Claims

1. A dye transfer medium comprising:

a transfer sheet;

a dye that is disposed on the transfer sheet;

an adhesive; and

a release liner,

wherein the adhesive is disposed between, and is attached to, the transfer sheet and the release liner,

wherein the release liner is configured to be removed from the adhesive and the transfer sheet, and

wherein the adhesive is configured to adhere the transfer sheet to a substrate when the liner is removed from the adhesive such that a portion of the dye is configured to transfer to the substrate under ambient pressure when the dye is heated.

2. The transfer medium of claim 1, wherein the adhesive comprises a pressure-sensitive adhesive.

3. The transfer medium of claim 1, wherein the adhesive comprises a water-based acrylic adhesive.

4. The transfer medium of claim 1, wherein the adhesive is present on the transfer sheet at a thickness between about 0.1 mils and about 1 mil.

5. The transfer medium of claim 1, wherein the adhesive substantially covers a portion of the transfer sheet that is configured to transfer the dye to the substrate.

6. The transfer medium of claim 1, wherein the transfer sheet comprises a metal foil.

7. The transfer medium of claim 1, wherein the adhesive is disposed over the dye on the transfer sheet such that the dye is disposed between the transfer sheet and the adhesive, and wherein the adhesive comprises a dye-permeable adhesive.

8. A sublimable dye transfer medium comprising:

a transfer sheet having a first surface and a second surface;

a sublimable dye that is disposed on the first surface of the transfer sheet;

an adhesive disposed on the first surface of the transfer sheet, over the sublimable dye; and

a release liner having a first side and a second side,

wherein the adhesive is permeable to the dye and substantially covers a portion of the transfer sheet that is configured to transfer the dye to the substrate,

wherein the first side of the liner is removably attached to the adhesive, and

wherein the adhesive is configured to adhere the transfer sheet to a substrate and to transfer a portion of the dye to the substrate when the dye is heated under ambient pressure.

9. The transfer medium of claim 8, wherein the adhesive was applied to and at least partially dried on the liner before being applied to the first surface of the transfer sheet.

10. The transfer medium of claim 8, wherein the adhesive comprises a pressure-sensitive adhesive.

11. The transfer medium of claim 8, wherein the release liner comprises a material selected from a tin-solvent, silicone-coated material; a platinum-solvent, silicone-coated material; and a polytetrafluoroethylene-coated material.

12. The transfer medium of claim 8, wherein the dye has been disposed on the first surface of the transfer sheet through a method selected from silk-screening, rotogravure, offset printing, electrophotography, and flexography.

13. A method for using a sublimable dye transfer medium, the method comprising:

obtaining a transfer sheet having a first surface with a sublimable dye disposed thereon;

obtaining a first release liner having a first side with a dye-permeable adhesive disposed thereon;

removing the first release liner from the adhesive; and

attaching the adhesive to the first surface of the transfer sheet and to a substrate such that the transfer sheet is configured to transfer a portion of the sublimable dye to the substrate when the sublimable dye is heated under ambient pressure.

14. The method of claim 13, wherein the adhesive is applied to the first side of the first release liner and allowed to at least partially dry before the adhesive and the first release liner are attached to the first surface of the transfer sheet.

15. The method of claim 13, wherein the adhesive is applied to the first side of the first release liner and allowed to at least partially dry before the adhesive and the first release liner are attached to the substrate; and then, after attaching the adhesive and the first release liner to the substrate and the removing of the first release liner from the adhesive, the first surface of the transfer sheet is attached to the adhesive.

16. The method of claim 13, wherein prior to applying the adhesive to the substrate, the adhesive is disposed between the first side of the first release liner and a first side of a second release liner.

17. The method of claim 16, wherein the first side of the first liner has a higher bonding affinity for the adhesive than does the first side of the second liner such that the adhesive is configured to remain on the first side of the first liner and separate from the first side of the second liner when the first and second liners are separated from each other.

18. The method of claim 13, wherein the first release liner further comprises a second side, wherein the first side of the first release liner has a higher bonding affinity for the adhesive than does the second side of the first release liner, and wherein prior to attaching the adhesive to the substrate, the first release liner was rolled upon itself, such that a portion of the adhesive was in contact with both the first side and the second side of the first release liner.

19. The method of claim 13, wherein the adhesive and the first release liner are attached to the first surface of the transfer sheet before the first release liner is removed from the adhesive and the transfer sheet, and before the transfer sheet with the dye disposed thereon is adhered to the substrate.

20. A sublimable dye transfer medium comprising:

a transfer sheet having a first surface and a second surface;

a sublimable dye that is disposed on the first surface of the transfer sheet; and

a dye-permeable adhesive disposed on the first surface of the transfer sheet, over the sublimable dye, wherein the dye transfer medium is configured to adhere to a substrate and to transfer a portion of the sublimable dye to the substrate under ambient pressure.

21. The transfer medium of claim 20, further comprising a first side and a second side, wherein the first side of the release liner is removably attached to the adhesive, and wherein the adhesive is sandwiched in between, and attached to, the first surface of the transfer sheet and the first side of the release liner.