Abstract:
The present invention claims and discloses a method of transferring an image to a generally non-absorbent fabric having at least one fiber. The method comprises the steps of providing an image on a transfer sheet or a medium, placing the transfer sheet or the medium against the generally non-absorbent fabric, applying a predetermined amount of heat in a predetermined amount of time to the transfer sheet or the medium, subliming the solid state ink or dye on the transfer sheet or the medium from a solid state to a gaseous state, binding the gaseous ink or dye with the fiber of the generally non-absorbent fabric and condensing the gaseous ink or dye to a sold state, thereby binding the dyes or ink into the fiber of the generally non-absorbent fabric. The fabric may be in the form of a pillow or a clothing article or any item of desire.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    Polyester, nylon, fleece and other fabrics have been around for quite some time. The dyeing of these fabrics has also taken place so that various colors, routine patterns and the like are available for use to form a number of objects such as pillows, jackets, shirts, pants and the like. However, because polyester, nylon or fleece material is formed of a man-made fiber, the material is typically non-absorbent of liquids, and is therefore difficult to print on with any great accuracy and detail. While the use of standard dyes and printing in a repeating pattern or single color may be sufficient because great detail is not required, the printing of more precise and detail-oriented images such as photographs has proven difficult.  
         SUMMARY OF THE INVENTION  
         [0002]    In accordance with the invention, a desired colorful design, such as a photographic image, is first printed on a sheet of transfer paper. This image is printed on the transfer paper using a dispersion, scattering of dissipation of oil dye onto a pretreated paper to form the transfer image paper. Thus, the image is not printed directly onto the fabric, thereby allowing for additional detail to be shown as will be discussed below. While this type of transfer paper is used for printing many types of products, it is the method for transfer of this transfer paper image to the polyester-type fabric and the makeup of the inks, dyes and additives adhered to the transfer paper that comprises the core of the invention.  
           [0003]    The dyes or inks utilized in accordance with the invention have “sublime” characteristics. Thus, these inks or dyes would sublime directly from solid state to gaseous state upon the application of heat, and condense from gas back to solid state upon removal of the heat source, bypassing the liquid state in both directions. Therefore, when heated under pressure, the solid dye from the transfer paper is vaporized, and spreads through the polyester fibers to create a depth of overlapping or overlaying colors that adhere directly to the polyester fleece. Thus, rather than simply printing with ink on a surface of the polyester fabric, the dye is infused into the fabric, condensing back to a solid form and binding with the fibers on multiple layers, thereby ensuring a vivid depth of color and resiliency. This process is termed a heat-transfer printing.  
           [0004]    Therefore, this invention addresses the problem of fleece or other polyester fabrics that are not very absorbent and have a high-fiber density. Commonly used screen-printing would not be able to show the detailed design of an image. Furthermore, this screen-printing process would not provide a three-dimensional expression with various color depth as is shown and desirable in the reprinting of a photograph.  
           [0005]    Therefore, in accordance with the invention, a detailed image or photograph may be transferred to a polyester fleece-type material, providing three-dimensional depth of color such as in a photograph in a manner and with a result not previously obtainable.  
           [0006]    Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification and the drawings.  
           [0007]    The invention accordingly comprises the several steps and the relation of one or more of such steps with respect to each of the others, and the apparatus embodying features of construction, combinations of elements and arrangement of parts that are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]    For a more complete understanding of the invention, reference is made to the following description and accompanying drawings, in which:  
         [0009]    [0009]FIG. 1 is a flow chart diagram depicting the steps for heat transfer printing to a polyester or fleece fabric in accordance with the invention;  
         [0010]    [0010]FIG. 2 is a chart depicting the solvent composition for solvents employed in accordance with the invention; and  
         [0011]    [0011]FIG. 3 is a further chart depicting the features of the solvents in accordance with the invention.  
         [0012]    These and other embodiments will be described and/or will be obvious from the following detailed description. 
     
    
     DETAILED DESCRIPTION  
       [0013]    The following detailed description, given by way of example, is not intended to limit the invention to any specific embodiments described. The detailed description may be understood in conjunction with the accompanying figures, incorporated herein by reference. Without wishing to unnecessarily limit the foregoing, the following shall disclose the present invention with respect to certain preferred embodiments.  
         [0014]    As is shown in FIG. 1, a flow chart for depicting a procedure in accordance with the invention is disclosed for printing an image to a generally non-absorbent fabric. While this fabric may be used to produce a pillow or the like, and use for the fabric, such as jackets, clothing household goods, or any other fabric product may be produced. As is shown in FIG. 1, first an image is designed at step  102 . Thereafter, a color separation process as is well known in the art is performed at step  104 . Once the color separation process at step  104  has been completed, the inks or dyes are sprayed and mixed at step  106 , and the various colors are set at step  108 . Thus, in accordance with the mixing, the colors that are required for the proper printing have been determined in the color separation process of step  104 , and these colors are generated at steps  106  and  108 .  
         [0015]    Thereafter, at step  110 , the colors are confirmed, and at step  112 , the actual printing boards are produced. These boards will receive the inks, and will print the transfer paper as is noted below. Thus, at step  112 , after production of the board, the inks are transferred to the board, and the image from the boards are printed to the transfer paper at step  114 . After including the image on transfer paper at step  114 , the image is printed to fabric, at step  116  (as will be described in greater detail below) and the final product is produced at step  118 .  
         [0016]    When producing the various products in the production procedure, the following raw materials and equipment may be employed. First, the dyes in accordance with the invention comprise dispersed dye material, adhesive powder and various solvents. The proper mixture of these three products will allow for the appropriate printing procedure, employing sublimation, as well as appropriate other characteristics for a printing process. The transfer paper that is to receive the image and then transfer the image to a fabric may include a typical tracing or transfer paper, or other waxed paper as appropriate. This paper may also include newspaper, copper-plated paper or the like. Additionally, in order to receive the ink printed onto it, and to appropriately transfer the image under pressure, the paper must be resilient enough to receive heat and a predetermined pressure thereon so that the dyes may be transferred, while the paper will remain intact and not melt into the fleece fabric, or otherwise affect the transfer of ink.  
         [0017]    As noted above, the boards that are used for printing are typical offset lithographical printing boards, or other printing boards that are appropriate for printing ink images to a transfer paper. These boards may be generated using electrical engraving, laser engraving or various etching (erosion) and engraving.  
         [0018]    The equipment required for the printing procedure may include the following: a printing machine for printing on paper, such as a concave board printing machine, a printing machine for printing on fabrics such as a heat-transfer printing machine, an electronic board machine, an automatic conveyor machine to supply materials, a rowing machine for paper, a rowing machine for fabric, a multi-rowing machine, a machine to prepare the design and drawings, and also specific for colors to perform the color separation process, a mixing machine for mixing of adhesives, and an infiltration apparatus. In accordance with the invention, the step of transferring the printing image to the fabric is a critical step. The sublimation of the inks and dyes is required so that a three-dimensional effect such as in a picture image may be provided, to ensure that a proper depth of color is produced, and to ensure that inks will properly bond to, and not be washed off of, the polyester fleece fabric. This process allows for the printing to take place through the image, and not simply on the surface thereof.  
         [0019]    While this sublimation process is well understood by the inventor, the control of the precise transfer of ink from the transfer paper to the polyester fleece fabric is difficult. It requires precise application of heat and for specific periods of time in order to achieve appropriate and/or optimal transfer. Therefore, in accordance with the invention, when transferring the images from the transfer paper to the fabric, such as a polyester fleece, the temperature for transferring the image is in the range of from about 180° C. to 280° C., preferably from 200° C. to 240° C. applied for the range of between 10 to 30 seconds and preferably between 15 and 20 seconds. This application will cause the dye to separate, vaporize, adhere to the fleece and thereafter, upon removal of the heat, condense and transform back into a solid, properly bonded with the fleece. Preferably, the procedure for this printing is performed in a very high volume printing environment, for example, about 20,000 meters of fabric per day, and therefore can be performed on a roll such as printing on a roll-fed stock so that the fleece is pulled through a machine, and appropriate heat and pressure are applied for precise periods of time to insure proper transfer of the image. However, the process is equally applicable to sheet fed, low volume applications.  
         [0020]    Through the proper application of these inks to the fabric, the dye imported to the fabric in accordance with the invention does not fade after repeated washing because the inks have been bonded to the fibers throughout the entire depth of the fabric, and are not merely placed on the surface thereof. Rather they have infused in a three-dimensional effect into various levels of the fabric. While certain fading may appear, such as with the blue dye, generally, the colors are quite colorfast and uneven discoloration is not a problem.  
         [0021]    In the heat transfer process, dyes are first transferred from transfer paper and vaporized by the application of heat as noted above. Thereafter, the fiber surface and various fibers in the three-dimensional layers absorb the gaseous dyes. The gaseous dyes infiltrate into the core of the fibers at all levels of the fabric, thereby bonding therewith. Thus, the gaseous dyes are permanently adhered to the internal portion of the fiber, and upon removal of the heat source, these colors condense are bonded and set in their location. While printing on fleece has taken place in the past, the procedure has been less than satisfactory, and indeed has been more complicated, requiring more machinery and manpower than the present invention. Indeed, the apparatus in accordance with the present invention is easier to operate, requires less machinery, thus saving space, requires less steps and therefore less labor. Furthermore, electricity and heat treatment are utilized without boiling pots, washing machines, steam machines, dryers and therefore does not create harmful chemicals and/or gasses to pollute the environment. The product can be produced in a shorter amount of time, and can be printed on any wrinkle-free or waterproof material. Finally, the transfer paper that the original design has been placed upon can be recycled.  
         [0022]    As is noted above, the composition of the inks, dyes and solvents is of utmost importance in order to generate proper sublimation. The dyes are generated by placing an appropriate solvent in a container and slowly adding in adhesive materials while stirring. Once all the adhesive materials have been added to the solvent, a high-speed mixer is employed to mix the solvent and adhesive materials for three to four hours. The solution then preferably sits for at least 8 hours or until it reaches a desired saturation. The solvents are preferably non-toxic, do not have an unpleasant odor or fragrance, and must contain less than about 3% of water to guarantee appropriate purity. Finally, the solvents, after mixing, must be filtered to make sure there are no contaminations in the chemicals. As is shown in FIG. 2, the combination of solvents may be adjusted based upon ambient temperature and humidity in the air. Therefore, an IBA solvent is utilized more in the summer and less in the winter, while an MeOH solvent is utilized more in the winter and less in the summer.  
         [0023]    [0023]FIG. 3 shows the specific gravity and boiling temperature of various chemicals that may be employed for solvents, such as methyl alcohol or methanol, ethanol, and isobutyl alcohol or isopropylcarbinol. The specific characteristics of each of these solvents will determine the precise combination and percentages of uses for the appropriate desired results and appropriate ambient conditions.  
         [0024]    Therefore, in accordance with the invention, by the appropriate application of heat for a particular period of time, a proper and desirable sublimation of inks, solvents and adhesive material can be obtained. Therefore, in accordance with the invention, the sublimated inks are transferred to a thick layer of fleece or other polyester material, and saturates into the fibers on all of the various interweaved layers of material. This insures a deep, rich color and allows for a more precise transfer of an image to a polyester, fleece or other generally non-absorbent fabric.  
         [0025]    In accordance with the invention, a more detailed image can be transferred, reducing bleeding, and improving durability, as opposed to the transfer methods previously employed.  
         [0026]    It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, because certain changes may be made in carrying out the above method and in the construction(s) set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.  
         [0027]    It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.