Patent ID: 12202289

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

Implementations of the present disclosure relate generally to sublimation printing components, apparatuses, systems and methods. In some examples, the present disclosure describes configurations of layup sheets including sublimation ink.

For example, some aspects described herein are configured for ink sublimation projects that are easily created and highly customizable before and after printing and/or cutting the material with, for example processing equipment (see, e.g., sheet processing device100inFIGS.1and3-7).

In some instances, layup sheets may be processed (e.g., cut, worked with, or the like) and stored at a user's residence or home without the need for utilizing expensive and complex industrial equipment, machines, or storage facilities.

In at least one aspect of the present disclosure, cut materials minimizes the risk of damage to customized sublimation prints and minimizes unwanted alterations thereto during handling and use.

In some implementations, the disclosure describes configurations of layup sheets that may include a plurality of layers (e.g., two or more of a sublimation material layer, a laminated layer, and a backing layer) to provide a more robust material for improved handling, transportation, and storage.

In some instances, the disclosure describes exemplary layup sheets that, once processed (e.g., cut) by processing equipment100, provides for easy “weedability” (i.e., the ability to remove unwanted portions of cut material from a backing layer of the layup sheet) such that design elements of a sublimation print of the layup sheet are maintained in position during handling and sublimation but also easily re-arrangeable as desired).

In other implementations, the disclosure describes exemplary layup sheets that are less susceptible to curling during or at least excessively curling during handling, transportation, and storage.

With reference toFIGS.1-2, a layup sheet is shown generally at10. As seen atFIG.2, the layup sheet10may include a plurality of distinct layers (see, e.g., layers16,18,20,22, and24inFIG.2) disposed together to form a single layup. The term “layup,” as used herein, may define multiple layers that are disposed together or adjacent one another. Two or more layers of the plurality of layers16,18,20,22, and24forming the layup sheet10may be separable or separated (see, e.g.,FIG.2′). Furthermore, when two or more layers of plurality of layers16,18,20,22, and24of the layup sheet10are acted upon (e.g., by heat or mechanical force), the two or more layers of plurality of layers16,18,20,22, and24of the layup sheet10generally remain together to form a single functional sheet of material when handled or used.

With continued reference toFIG.1, a system including a plurality of components associated with the layup sheet10for performing a method (see, e.g.,32atFIG.13) are also shown. For example, in addition to the layup sheet10, the system may also include, for example: a workpiece28(e.g., a cloth article, a ceramic article, or the like) that is also seen at, for example,FIGS.3and10-12D; and a heating device150(see also, e.g.,FIGS.3and10-12D). In other implementations, the system may further include, for example, a processing device100(e.g., a home cutting machine); and a cutting mat102(see also, e.g.,FIGS.3-9). In yet other implementations, the system may further include, for example, a support surface or table200. The components of the system and how they are interfaced with or work upon the layup sheet10will be described in greater detail in the following disclosure.

With reference toFIG.2, in some configurations, the layup sheet10may include a plurality of layers of material defined by five distinct layers of material16,18,20,22,24. The plurality of layers of material16,18,20,22,24are stacked upon or disposed adjacent one another for defining a thickness T of the layup sheet10. A length L (see, e.g.,FIG.1) and a width W (see, e.g.,FIG.1) of the layup sheet10may be, for example, 8.5″×11″, 12″×12″, or the like, while the thickness T of the layup sheet10may be on the order of less than a millimeter or a few millimeters.

With reference toFIGS.2-8and11-11′, each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10are illustrated to have an approximately equal thickness; each layer of the plurality of layers of material16,18,20,22,24, however, may be defined by a different thickness.

As seen atFIG.2, the several layers16,18,20,22,24of the layup sheet10may be grouped into separate layups12,14. For example, the layers16,18of the plurality of layers of material16,18,20,22,24may be define a sublimation layup12, and, the layers of material20,22,24of the plurality of layers of material16,18,20,22,24may be define a support layup14. In general, the ink sublimation layup12provides a sublimation ink (see, e.g., layer of material16) and a sublimation ink carrier material (see, e.g., layer of material18) to enable the sublimation of a design or artwork into an article (see, e.g., workpiece layer of material28atFIGS.11-11′, which may be, for example, a cloth article or ceramic article) when acted upon by heat (see, e.g., arrows30atFIGS.11and12B) and/or pressure from a heating device (see, e.g., heating device150atFIG.11). The transfer, by sublimation, of sublimation ink16from sublimation layup12into an article (see, e.g., workpiece layer of material28atFIGS.11-11′) will be described in more detail below.

The support layup14is configured to provide the layup sheet10with rigidity for handling the sublimation layup12. The support layup14may include a carrier material or backing material (see, e.g., layer of material24), a barrier material or laminate material (see, e.g., layer of material20). The support layup14may improve/enable: (1) a user to successfully perform cutting of the sublimation layup12with a processing device100; and (2) sublimation processes of the sublimation layup12conducted by the heating device150

In some configurations, with reference toFIG.2, the sublimation layup12includes: (1) sublimation material layer16; and (2) a sublimation material carrier layer18. In some instances, the support layup14may include: (1) a laminate layer20; (2) an adhesive layer22; and (3) a backing layer24. As seen atFIG.2, the sublimation material carrier layer18disposed between sublimation material layer16and the laminate layer20. The laminate layer20is disposed between the sublimation material carrier layer18and the adhesive layer22. The adhesive layer22is disposed between laminate layer20and the backing layer24.

In some configurations, the sublimation material carrier layer18may include, for example, a paper-based material. The sublimation material layer16that is carried by the sublimation material carrier layer18may include, for example, an ink, such as a sublimation ink.

With respect to the sublimation material layer16, an act of “sublimation” (see, e.g.,FIGS.12A-12D) may be defined as a chemical process where a solid material (defining the sublimation material layer16) as seen atFIG.12Aturns into a gas (see, e.g.,FIG.12B) without going through a liquid stage. “Sublimation printing,” which may also be referred to as “dye sublimation printing,” may be utilized for transferring images onto suitable materials. Upon arranging the sublimation material carrier layer18(including the sublimation material layer16disposed thereon) proximate the heating device150that produces heat30(see, e.g.,FIGS.11and12B), the sublimation material layer16changes from: (1) a solid state disposed upon the sublimation material carrier layer18as seen atFIG.12A; and then to (2) a gaseous state as seen atFIG.12Bthat permeates into, for example, fibers of the workpiece28(see, e.g.,FIGS.11′ and12C-12D).

When the heat30is removed from the sublimation material carrier layer18and the workpiece28, the sublimation material layer16that transitioned from a solid state (as seen at, e.g.,FIG.12A) to a gaseous state (as seen at, e.g.,FIG.12B) that permeated into the workpiece28(as seen at, e.g.,FIGS.12C-12D) is permanently set into place by within the workpiece28(as seen atFIG.12D). Furthermore, with reference toFIGS.12A-12B, not only does the heat30release change the state of the sublimation material layer16, but it may also open, for example, pores of the material defining the workpiece28that receives the sublimation material layer16(as seen at, e.g.,FIG.12C) that changed from a solid state to a gaseous state. Once the heat30and pressure is released, the sublimation material layer16that is “gassed” into the workpiece28returns to the solid state, and, as seen atFIGS.12C-12D, the pores of the workpiece28transitions from the open state back to the closed state, thereby trapping the sublimation material layer16within the workpiece28as seen atFIG.12D.

The thicknesses and specific material compositions of each layer of the plurality of layers of material16,18,20,22,24of implementations of the layup sheet10in combination with thicknesses and materials of other layers (such as, e.g., the thickness and/or material of the workpiece28, achieve a number of advantages are achieved. For example, the selected materials and/or thicknesses of each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10enable proper heat transfer there-through to effectuate a successful sublimation of the sublimation material layer16into the workpiece28, such as a cloth article or ceramic article.

Also, in some instances, the thickness and/or selected material of each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10affects the rigidity of the layup sheet10, which may provide a user with advantageous handling and storage options discussed herein. Furthermore, in some examples, the selected material and/or thickness of each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10affects the permeability of certain barrier layers so that the sublimation material layer16sublimates into the workpiece28successfully during use and does not damage heat press surfaces of the heating device150or other equipment used during sublimation processes. Yet even further, in some implementations, the selected material and/or thickness of each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10affects the peel force and/or adhesion force of, for example, the adhesive layer22). Thus, the selected material and/or thicknesses of each layer of the plurality of layers of material16,18,20,22,24of the layup sheet10described herein may be chosen to provide an optimal solution for provided a modified workpiece28with a design including at least a portion of the sublimation material layer16of the sublimation layup12of the layup sheet10.

With reference toFIG.2, the sublimation material layer16of the sublimation layup12may include one or more sublimation inks, dye particles, or the like. For example, in some configurations, the sublimation material layer16includes sublimation ink comprising diglycol, glycerol, and water. In other configurations, the sublimation material layer16may also include dye particles. In yet other configurations, the sublimation material layer16may include other ingredients, which may include those mentioned above, that act to stabilize the dye particles in a solution defining the sublimation material layer16.

In some examples, the composition of the materials forming the sublimation material layer16may include a diglycol component of ranging between about 0.15%-1.65% by weight of the layup sheet10. In other implementations, the composition of the material forming the sublimation material layer16may include a diglycol component ranging between about 0.3%-1.5% by weight of the layup sheet10.

In other examples, the composition of the materials forming the sublimation material16may include a glycerol component ranging between about 0.99%-2.31% by weight of the layup sheet10. In other implementations, the composition of the material forming the sublimation material layer16may include a glycerol component ranging between about 1.2%-2.1% by weight of the layup sheet10.

In yet other examples, the composition of the materials forming the sublimation material16may include a water component ranging between about 0.84%-3.96% by weight of the layup sheet10. In other implementations, the composition of the material forming the sublimation material layer16may include a water component ranging between about 1.2%-3.6% by weight of the layup sheet10.

According to the exemplary implementations of the sublimation material layer16described above, in some configurations, the composition of the materials forming the sublimation material layer16may be range between about 1.98%-7.92% by weight of the layup sheet10. In other configurations, the composition of the materials forming the sublimation material layer16may range between about 2.7%-7.2% by weight of the layup sheet10. The described sublimation material layer16and its component compounds are given as examples of suitable types of compositions for forming sublimation inks of the sublimation material layer16that may be incorporated into the design of the layup sheet10.

In some examples, the sublimation material carrier layer18may include one or a combination of a woody fiber, a pigment, and a binder. In some configurations, a woody fiber may include carbon and oxygen that ranges between about 26.7%-37.3% by weight of the layup sheet10. In other configurations, the woody fiber including carbon and oxygen may range between about 30.1%-33.9% by weight of the layup sheet10.

In some examples, the pigment may include silicone that ranges between about 0.8%-3.3% by weight of the layup sheet10. In other examples, the pigment including silicone that ranges between about 1.1%-3.0% by weight of the layup sheet10.

In some implementations, the binder may include polyvinyl alcohol, or the like, and range between about 0.8%-3.3% by weight of the layup sheet10. In other implementations, the binder including polyvinyl alcohol may range between about 1.1%-3.0% by weight of the layup sheet10.

According to the exemplary implementations of the sublimation material carrier layer18described above, the sublimation material carrier layer18may range between about 28.3%-43.9% by weight of the layup sheet10. In other configurations, the sublimation material carrier layer18may range between about 32.3%-39.9% by weight of the layup sheet10. The described sublimation material carrier layer18and its component compounds are given as exemplary types of sublimation paper of the sublimation material carrier layer18that may be used in the design of the layup sheet10. Other material compositions defining other types of sublimation papers may also be utilized of the design of the sublimation material carrier layer18.

During formation of the sublimation layup12, the sublimation material layer16may be printed onto (and is therefore disposed upon) an outer surface of the sublimation material carrier layer18. In other implementations, however, some or all of the sublimation material layer16may be impregnated or disposed within at least a portion of the thickness of the sublimation material carrier layer18such that sublimation material carrier layer18and sublimation material layer16form one layer of material defined by the thickness of the sublimation material carrier layer18.

In at least one embodiment, the sublimation layup12is between about 80-120 grams-per-meter squared (g/m2). In some implementations, the sublimation layup12may be between about 90-110 grams-per-meter squared (g/m2). In other implementations, the sublimation layup12may be between about 97-103 g/m2. In yet other implementations, the sublimation layup12may be between about 100 g/m2. As such, in some configurations, the sublimation layup12may be between about 30.3%-51.5% by weight of the layup sheet10. In other configurations, the sublimation layup12may be between about 35%-47.1% by weight of the layup sheet10.

With reference toFIG.2, in some implementations, the layup sheet10, the laminate layer20is disposed between the sublimation material carrier layer18and the adhesive layer22. The laminate layer20provides a barrier between the sublimation layup12and other layers, such as, for example, the adhesive layer22and the backing layer24. In this exemplary configuration, the laminate layer20may mitigate or reduce the likelihood of the sublimation material layer16from sublimating or otherwise transferring to other layers of the layup sheet10, such as, for example, the backing layer24, and, furthermore onto other devices, such as, for example the heating device150or other equipment, which may come into contact with the layup sheet10during the sublimation of the sublimation material layer16into the workpiece28. In some examples, as will be described in more detail below, during the sublimation process, a heat plate of the heating device150may come into contact with the backing layer24of the layup sheet10to heat30(see, e.g.,FIGS.11and12B) the sublimation layup12and cause the sublimation material layer16to sublimate into the workpiece28. During contact of the heat plate of the heating device150with the layup sheet10, the laminate layer20functions as a barrier to prevent or reduce the heated sublimation material layer16from transferring or sublimating onto the heat plate of the heating device150; the heat plate is thereby insulated and protected from damage by the laminate layer20. Accordingly, the sublimation ink of sublimation material layer16will be pressed into and directed to sublimate into the workpiece28.

In addition to the aforementioned functionality provided by the laminate layer20, the laminate layer20also provides weeding capabilities. For example, during the process of transferring an image or design from the sublimation layer16of the layup sheet10to the workpiece28, the layup sheet10may be interfaced with the processing device100and undergo a cutting operation in order to cut26(see, e.g.,FIGS.6-7) and then selectively remove (see, e.g.,FIGS.8-9) one or more layers or portions of the sublimation layup12from the layup sheet10. Accordingly, the laminate layer20enables a user to easily and quickly remove (see, e.g.,FIGS.8-9) one or more layers or portions of the sublimation layup12from the layup sheet10.

With reference toFIG.2′, an exemplary removal of the laminate layer20from the backing layer24is illustrated. In some configurations, the laminate layer20may be removably secured to the backing layer24with an adhesive layer22.

As shown atFIG.2′, the laminate layer20can be peeled from the adhesive layer22, which, in some implementations, may result in in one or more portions or layers of the sublimation layup12that is secured to the laminate layer20also being removed as the laminate layer20is peeled from the adhesive layer22. In some implementations, a permanent glue (not shown), that, in some configurations may define a relatively smaller thickness (compared to other layers of the layup sheet10) may be disposed between the laminate layer20and the sublimation material carrier layer18(or the sublimation layup12in general) so that any removal of the laminate layer20also results in removal of one or more portions or layers of the sublimation layup12.

Accordingly, in some instances, the laminate layer20may define or form a layer or coating on the sublimation material carrier layer18that interfaces with adhesive layer22. As stated above, the material defining the laminate layer20allows the laminate layer20to be easily separated from the adhesive layer22after, for example, a cutting operation has been performed on the layup sheet10by the processing device100. For example, portions of the laminate layer20may be removed as uniform, complete portions of material from the adhesive layer22along with corresponding portions of the sublimation layup12that is secured to the removed laminate layer20, which may be carried out without tearing or otherwise damaging any remaining portion of the sublimation layup12that has not been removed. Thus, the laminate layer20of the layup sheet10is configured in a manner to permit a user to cleanly and easily remove certain portions of the sublimation layer12from the layup sheet10(i.e., “weed” the layup sheet10) after the layup sheet10has been subjected to a cutting operation (e.g., that was performed by the processing device100) in order to form customized designs for sublimation into articles.

Although some configurations of the layup sheet10may include the laminate layer20, some configurations could be practiced without the laminate layer20(e.g., the laminate layer20could be optional). In such configurations, however, separating the sublimation material carrier layer18from backing layer24and the adhesive layer22without the presence of the laminate layer20may, in some but not all instances, introduce inconsistent results, such as, for example, torn portions or partial portions of the sublimation material carrier layer18remaining with the layup sheet10after weeding. Accordingly, in some configurations, the material defining the sublimation material carrier layer18may not otherwise cleanly peel away from the adhesive layer22if it was to be arranged in direct contact with the adhesive layer22; when such exemplary configuration are provided, a portion of the thickness of the sublimation material carrier layer18may undesirably remain upon the adhesive layer22when the sublimation layup12is peeled away from the backing layer24(i.e., in the absence of providing the laminate layer20), thereby leaving residual portions of the sublimation layup12upon the adhesive layer22.

After the cut26(see, e.g.,FIG.7) layup sheet10is weeded, the laminate layer20of remaining portions of the cut26layup sheet10, which may be part of the desired design to be sublimated into the workpiece28, can be removed and reapplied to adhesive layer22so that such portions of a user's design can be rearranged and reoriented as desired. In this way, a user can alter custom designs as needed and maintain those portions of the design, whether rearranged or not, in relative positions on cut material during handling and sublimation processes.

Furthermore, in configurations of the layup sheet10including the laminate layer20, such configurations may improve the quality of one or more cuts26defined by the layup sheet10when the layup sheet10is operated on by the processing device100. In some instances, the blade101(FIGS.5and7) of the processing device100may be set to cut into the thickness of the layup sheet10at a depth or distance that extends all the way through, for example, the sublimation layup12, which may include the thickness of the sublimation material carrier layer18and the thickness of the laminate layer20. In this way, and because of the material properties of, for example: silicone; pulp; and/or calcium carbonate, which may define materials that are selected for forming the laminate layer20, some configurations of the layup sheet10may provide one or more layers that may be cut cleanly without tearing (even when intricate, small shapes are being cut). In some configurations of the layup sheet10that does not include the laminate layer20, the sublimation material carrier layer18may, but not always, tear when impinged upon by the blade101of the processing device100.

Some configurations of the laminate layer20may be defined by one or more materials that comprise, for example: pulp; and calcium carbonate. In other configurations, the laminate layer20may be defined by one or more materials that comprise, for example: pulp, calcium carbonate; and silicone; in such configurations, the silicone material component may be in the form of a silicone coating that faces or is arranged opposite or adjacent the backing layer24, or, alternatively, between and in adjacent contact with both of the laminate layer20and the adhesive layer22as seen at, for example,FIG.2. Inclusion of the silicone coating material in the design of the laminate layer20may improves the releaseability of the laminate layer20from the adhesive layer22during weeding.

In some implementations, the laminate layer20may be between about 20%-26% by weight of the layup sheet10. In other implementations, the laminate layer20may be about 23% by weight of the layup sheet10. In some examples, the laminate layer20may be between about 40 g/m2−60 g/m2. In other examples, the laminate layer20may be between about 45 g/m2−55 g/m2. In yet other examples, the laminate layer20may be about, for example, 50 g/m2.

In some configurations, a combined thickness of the laminate layer20and the sublimation layup12may be between about 0.17 mm-0.25 mm. In other configurations, the combined thickness of the laminate layer20and the sublimation layup12may be between about 0.23 mm-0.19 mm. In yet other configurations, the combined thickness of the laminate layer20and the sublimation layup12may be about, for example, 0.21 mm.

In some configurations, the layup sheet10may optionally include at least one adhesive layer22. The adhesive layer22may be disposed between and connect the laminate layer20to the backing layer24. The adhesive layer22removably-secures the laminate layer20to the backing layer24so that the layup sheet10may be handled and stored as a single sheet of material. However, in some examples, during the sublimation process, a user may peel away the laminate layer20from the adhesive layer22to separate one or more portions of the sublimation layup12from one or more other layers defining the layup sheet10. In some implementations, the adhesive layer22may be defined by a pressure sensitive adhesive.

In order to provide the layup sheet10with weeding, peeling, and holding power (of adjacent layers) functionality described above, the materials that define the adhesive layer22may be quantified by one or more exemplary a “peel forces” (e.g., a force that results in the laminate layer20separating from the adhesive layer22), as follows. In some configurations, the material that defines the adhesive layer22may be defined by a peel force between about 15 gram-force/25-millimeters (gf/25 mm)-60 gf/25 mm. In other configurations, the material that defines the adhesive layer22may be defined by a peel force between about 20 gf/25 mm-55 gf/25 mm. In yet other configurations, the material that defined the adhesive layer22may be defined by a peel force between about 25 gf/25 mm-50 gf/25 mm.

In some implementations, the adhesive layer22may be defined by an acrylic polymer adhesive. In some configurations, the adhesive layer22may be between about 12%-16% by weight of the layup sheet10. In other configurations, the adhesive layer22may be between about 13%-15% by weight of the layup sheet10. In yet other configurations, the adhesive layer22may be about 14% by weight of the layup sheet10. Furthermore, in some examples, the adhesive layer22may be between about 12 μm 18 μm. In other examples, the adhesive layer22may be between about 13.5 μm-16.5 μm. In yet other examples, the adhesive layer22may be about 15 μm.

With reference toFIG.2, some configurations of the layup sheet10may also include the backing layer24, which may be alternatively referred to as: a support layer; a release layer; or a layer portion that is disposed on a first surface of the adhesive layer22that opposite a second surface of the adhesive layer22that is disposed on the laminate layer20. In some instances, the backing layer24provides structural rigidity that promotes, for example, handling or cutting operations when, for example, the layup sheet10is interfaced with a home-use cutting machine, such as, for example, the processing device100. In other instances, the backing layer24may also provide a base portion layer from which the laminate layer22can be separated after, for example, a cutting operation has been performed by the processing device100on the layup sheet10, thus providing the weeding capability of the layup sheet10as discussed above.

Furthermore, the backing layer24may also provide a base portion layer having a mat-interfacing surface25(see, e.g.,FIGS.2-2′ and4-9) that may be configured for placement onto an upper surface of a cutting mat102(see, e.g.,FIGS.13-9), such as, for example, a cutting mat with a pressure-sensitive adhesive104disposed upon some or all of an upper surface of the cutting mat102, such that the layup sheet10may be held in place while being interfaced with and cut26by the processing device100. Accordingly, one or more materials that are chosen for defining the backing layer24may define functional the properties of backing layer24that, for example, allow the mat-interfacing surface25of the backing layer24to stick in place adjacent the pressure-sensitive adhesive102of the cutting mat102and thereafter be removed, as needed, before or after cutting26the layup sheet10, without damaging the sublimation layup12of the layup sheet10.

Furthermore, the backing layer24may also be defined by one or more materials that permit heat30(see, e.g.,FIGS.11and12B) from a heating device150, a heat plate, or another heat source to travel for sublimating sublimation material layer16. As such, the material and thickness defining the backing layer24may be selected in order to provide a desired structural rigidity of the layup sheet10without impeding heat transfer of the heat30through the thickness of the layup sheet10. Also, the material defining the backing layer24may functionally provide resiliency of the layup sheet10in order to prevent, for example, a blade101of the processing device100(e.g., a home cutting machine) to not pass there-through when the processing device100is, for example, set to a cutting pressure or cutting force that desirably results in the cutting blade101cutting through upper layers of the layup sheet10, such as, for example, the layers defining the sublimation layup12, and, for example the laminate layer20. In this way, the backing layer24provides a carrier portion of the layup sheet10that allows one or more first portions of the sublimation layup12to be cut by, for example, the processing device100(e.g., a home cutting machine) and one or more second portions of the sublimation layup12to remain in a position that is supported by the backing layer24remain after weeding in order for a user to selectively arranged and customize a design before sublimation. Accordingly, one or more materials that are selected for forming the backing layer24may be formed to define a thickness that will withstand cutting blades101while also providing the handling and weeding advantages as discussed above.

In some instances, the backing layer24may be formed from polyethylene terephthalate (PET) or the like; such materials may be defined by a heat resistant characteristic. In some configurations, a thickness of the backing layer24may be between about 40 μm-60 μm. In other configurations, the backing layer24may be between about 45 μm-55 μm. In yet other configurations, the backing layer24may be about 50 μm. In some examples, the backing layer24may be between about 16%-24% by weight of the layup sheet10. In other examples, the backing layer24may be between 18%-22% by weight of the layup sheet10. In yet other examples, the backing layer24may be about 19.8% by weight of the layup sheet10.

Accordingly, in some configurations, a total thickness of the layup sheet10shown at, for example,FIG.2may be between about 0.21 mm-0.31 mm. In other configurations, a total thickness of the layup sheet10may between about 0.23 mm-0.29 mm. In yet other configurations, a total thickness of the layup sheet10may be about 0.26 mm. In some configurations, an overall thickness and materials defined by all layers of the layup sheet10that may include, for example, the backing layer24, the adhesive layer22, the laminate layer20, and the sublimation material carrier layer18may also include one or more silicone oil coatings or one or more adhesive layers between, for example, the sublimation material carrier layer18and the laminate layer20.

In some instances, the selected number of layers as well as material compositions defining the layers of the layup sheet10are selected in order to permit a transfer of heat30arising from contact of the layup sheet10with the heating device150plate. In some implementations, the layup sheet10may be configured to be heated with the heat30that results in the layup sheet10being heated to a temperature at about 400° F. for about 240-seconds in order to sublimate the sublimation material layer16onto, for example, a workpiece28defined by, for example, a ceramic material so that a vivid, clear design may be transferred from the layup sheet10into the ceramic workpiece28. Alternatively, the layup sheet10may be configured to be heated with the heat30that results in the layup sheet10being heated to a temperature at about 385° F. for about 40 seconds in order to sublimate the sublimation material layer16onto, for example, a workpiece28defined by, for example, a cloth material that defines, for example, a T-shirt28(see, e.g.,FIG.1). Accordingly, workpieces28that may be defined by materials other than, for example, cloth and ceramics may have to be subjected to heat30at a variety of temperatures and time durations in order to sublimate the sublimation material layer16onto a particular workpiece28.

In some instances, a variety of temperature settings and time durations may be selected in order to sublimate the sublimation material layer16of the layup sheet10into a workpiece28. In some implementations, a selected temperature may be in a range between about 350° F.-450° F. and a selected time duration may be in a range between about 25 second-300-seconds. Such exemplary temperatures and time durations may be sufficient for utilization with, for example, a “home” heating device150configured for utilization by a user that may be, for example, a novice or home crafter.

In some instances, the layup sheet10may be manufactured by firstly disposing or layering (e.g., printing) the sublimation material layer16upon the sublimation material carrier layer18in order to form the sublimation layup12. Thereafter, the laminate layer20may be disposed or layered upon the sublimation material carrier layer18of the sublimation layup12. Then, the backing layer24and the adhesive layer22may be applied to the laminate layer20. In some instances, the adhesive layer22may be firstly applied to backing layer24to define a multilayer subassembly of the support layup14before the adhesive layer22of the multilayer subassembly of the support layup14is disposed upon or layered over the laminate layer20. Additionally, in the course of manufacturing the layup sheet10, the manufacturing process may optionally include coating the laminate layer20with a silicone oil after the laminate layer20is disposed or layered over the sublimation material carrier layer18and before the adhesive layer22of the multilayer subassembly of the support layup14(defined by the adhesive layer and the backing layer24) is disposed or layered over the laminate layer20.

With reference toFIGS.3-12D, a sublimating methodology, which is shown generally at32inFIG.13is described. Although the methodology includes several steps seen generally at34,36,38,40, and42, one or more of the steps34,36,38,40, and42may be optional. For example, one or more of the components of the system (e.g., the processing device100and the cutting mat102) may be optional; in some instances, the layup sheet may be pre-processed or pre-cut, and, as such, steps36and38that are related to processing or cutting the layup sheet10may be omitted from the methodology32. Furthermore, althoughFIGS.3-12Dillustrate a method32of utilizing the layup sheet10as shown and described atFIGS.1-2′, the methodology32associated withFIGS.3-12Dare equally applicable to other layup sheets such as, for example, exemplary layup sheets10a,10b,10c,10d, and10ethat are seen at, respectively,FIGS.14,15,16,17, and18.

Firstly, as shown atFIGS.1-2′, a layup sheet10is provided 34 (see, e.g.,FIG.13). Furthermore, as also seen atFIG.1, the layup sheet10may be included as a component of a system that includes one or more other components (e.g., a workpiece28, a processing device100, a cutting mat102, a heating device150, and a table200) for performing the methodology32.

Then, as shown atFIGS.3-7, the method32may optionally include performing a cutting operation36on the layup sheet10. For example, in some configurations, the layup sheet10may be cut26(see, e.g.,FIGS.4-7) with a processing device100, such as, for example, an electronic cutting machine with a cutting blade101that impinges downwardly into the layup sheet10. With reference toFIGS.3and4-5, prior to performing the cutting operation36, the layup sheet10may be positioned upon the cutting mat102. After positioning the layup sheet10upon, for example, the pressure-sensitive adhesive104disposed upon some or all of an upper surface of the cutting mat102such that the layup sheet10is removably-secured to the pressure-sensitive adhesive104disposed upon some or all of an upper surface of the cutting mat102, the cutting mat102and the layup sheet10are then disposed within the processing device100(with the sublimation material layer16of the layup sheet10opposingly-facing the blade101that is arranged within the processing device100. As noted above, the backing layer24provides a surface that can be placed onto the pressure-sensitive adhesive104that defines an upper surface of the cutting mat102. The material defining the backing layer24allows the rear surface of the backing layer24to be adhesively secured upon the upper surface of the cutting mat102and be selectively-removed, as needed, before or after cutting26, without impairing the integrity of the sublimation layup12.

Referring toFIGS.6-7, the one or more cuts26defined by the layup sheet10are formed by, for example, the blade101of the processing device100. In other instances, the one or more cuts26may be pre-formed, and, as such, step36, which may, in some implementations, be performed by a home cutting machine (e.g., the processing device100, may be optional, and, as such, omitted from the methodology32.

In some implementations, the one or more cuts26may extend through the upper layers of layup sheet10that may define at least, for example, the layers defining the sublimation layup12. In some instance, the one or more cuts26may extend through: (1) the sublimation material layer16; (2) the sublimation material carrier layer18; and (3) the laminate layer20. In other instances, the one or more cuts26may be further extend partially or entirely through the adhesive layer22. Furthermore, although the backing layer24may be configured to withstand the pressure setting of the cutting blade101of the processing device100, the one or more cuts26formed by the blade101of the processing device100may also pass partially or entirely through the thickness of the backing layer24. In some instances, the processing device100may be calibrated to impart a force to the blade101of the processing device100such that the blade101cuts through the laminate layer20without cutting through the adhesive layer22or the backing layer24as seen at, for example,FIG.7. In one or more implementations, the one or more cuts26may pass entirely through or partially through the adhesive layer22but into or through the backing layer24. Even if the blade101forms the one or more cuts26that extend into one or both of the adhesive layer22and the backing layer24, the layup sheet10may still function properly during the act of performing sublimation42(see, e.g.,FIG.13)

With reference toFIG.6, the one or more cuts26may define a cut perimeter that forms or creates enclosed portions or regions of the layup sheet10. Next, as shown inFIGS.8-9, the one or more enclosed portions or regions of the layup sheet10can be peeled away and removed38(see, e.g.,FIG.13); in some instances, the one or more enclosed portions or regions of the layup sheet10can be peeled away and removed38before or after the layup sheet10is removably-separated from the pressure-sensitive adhesive104disposed upon some or all of an upper surface of the cutting mat102, the cutting mat102and the layup sheet10.

As seen atFIG.8, in some examples, some, but not all of the layers defining the layup sheet10may be peeled away and then removed38while some of remaining layers of the layup sheet10are not peeled away for sequent removal38. In some instances, the layers of the layup sheet that are peeled away for subsequent removal38may include, for example: (1) the sublimation material layer16; (2) the sublimation material carrier layer18; and (3) the laminate layer20. The portions of sublimation material layer16and sublimation material carrier layer18(i.e., the sublimation layup12) corresponding in position with, and removably secured to, the portion of laminate layer20being removed38from the adhesive layer22and backing layer24, is thus removed38as well. The above-described process of removing38portions of the layup sheet10after the cutting operation36is performed may be referred to as “weeding,” as noted above. Weeding may be performed by hand and/or with the use of one or more weeding tools (not shown).

During weeding, the laminate layer20is peeled off adhesive layer22and thus the backing layer24. As such, the holding power of the adhesive layer22is greater against the backing layer24than it is against the laminate layer20, which, as noted above, may optionally include a silicone oil coating. Even if the one or more cuts26penetrate the adhesive layer22and/or the backing layer24, as discussed above, the laminate layer20will still separate from the adhesive layer22.FIG.9illustrates a perspective view of a portion of the layup sheet10being peeled off during weeding. Additionally, once the layup sheet10is weeded, the laminate layer20of remaining portions of layup sheet10, which may be part of the desired design to be sublimated42into a workpiece28, can enjoy these advantages while being removed and reapplied to the adhesive layer22so that such portions of a user's design can be rearranged and reoriented as desired. In this way, a user can alter custom designs as needed and maintain those portions of the design, whether rearranged or not, in relative positions on the layup sheet10during sublimation42.

Referring toFIGS.10,11, and12A, after the layup sheet10has been cut36and weeded38as desired, the layup sheet10can be placed40(see, e.g.,FIG.13) against a workpiece28that may be formed from any desirable material, such as, for example, a cloth material, a ceramic material, or other material. In some instances, the workpiece28may be arranged upon a support surface or table200prior to arranging the cut36and weeded38layup sheet10upon the workpiece28. After being placed over or adjacent the workpiece28, the heating device150may be activated (see, e.g.,FIGS.11and12B) such that heat30can be passed through the layup sheet10in order to sublimate42(see, e.g.,FIGS.12A-12D) the sublimation material layer16into the workpiece28as seen atFIGS.11′ and12D.

With reference toFIG.10, the workpiece28may define an article of clothing, such as, for example, a cloth T-shirt including a plurality of fibers. As described above, the heat30generated by the heating device150not only changes the state of the sublimation material layer16but also may, for example, open pores of the fibers defining the workpiece28as seen atFIGS.12A-12B. Furthermore, as seen atFIGS.12A-12C, as a result of application of the heat30to the layup sheet10, the sublimation material layer16changes from a solid state (as seen atFIG.12A) that is secured to the sublimation material carrier layer18and separates therefrom (as seen atFIG.12B) in the form of as gas that permeates into (as seen atFIG.12C) open-pore fibers defining the workpiece28. After the heating device150is deactivated, thereby ceasing application of the heat30as seen atFIGS.11′ and12D, the sublimation material layer16has been effectively “gassed” into the fibers defining workpiece28, as a result of the pores of the fibers defining the workpiece28transitioning back to the closed state from the open state as a result of the heat30being removed from the workpiece28.

In some instances, the heating device150may be, for example, a heat press or iron, which may be designed for home use at temperatures discussed above, can be pressed against the backing layer24as seen atFIG.11. The heat30from such a heating device150passes through the various layers of layup sheet10in order to heat30and therefore sublimates42the sublimation material layer16into the workpiece28.

As noted above, during contact between the heating device150and the layup sheet10, the laminate layer20forms a barrier to prevent or reduce heated sublimation material layer16from transferring or sublimating onto the heating device150. The heating device150thus is prohibited from being in direct contact with the sublimation material layer16; accordingly, a sublimation ink that may define the sublimation material layer16would only be permitted to sublimate into the workpiece28that is arranged adjacent the opposite side of the layup sheet10with respect to the heating device150. In this way, inclusion of the laminate layer20in the design of the layup sheet10may contribute to consistent preparation of a resulting image or design formed by the sublimation material layer16that is sublimated into the workpiece28as seen atFIGS.11′ and12D. Furthermore, the backing layer24may provide a layer to which the design portions of sublimation layup12are secured so the design that is transferred to the workpiece28does not shift or stretch during sublimation42.

As noted above, the materials and thicknesses of each layer of the layup sheet10may affect the heat transfer properties of the layup sheet10and are thus tuned to optimize heat transfer into the sublimation material layer16. Also, as noted above, the laminate layer20may also function as a barrier layer such that gases from the sublimated sublimation material layer16do not pass through the laminate layer20and other layers above the laminate layer20during sublimation, such as, for example, the adhesive layer22and the backing layer24. In this way, the sublimated sublimation material layer16gases cannot escape through the layup sheet10, and, as a result, are predominantly directed toward for forced entry into the workpiece28that results in more consistent design transfers from the layup sheet10into the workpiece28.

A user may customize the design transferred into the workpiece28by customizing the portions of the layup sheet10that are cut and weeded. For example, a portion of the layup sheet10shown atFIG.11may be void of the sublimation material layer16such that no sublimation ink will sublimate into the workpiece28at that portion. Also, as noted above, the remaining portions of the layup sheet10that include the sublimation material layer16can be peeled away, by separating the laminate layer20from the adhesive layer22and then reapplied to the adhesive layer22in different positions. In this way, a user can rearrange and customize a design even after the one or more cuts26are formed in the layup sheet10by, for example, a blade101of a processing device100. Thus, implementations of the layup sheet10described herein enable a high level of customization right up to the time the sublimation material layer16of the layup sheet10is transferred into the workpiece28.

With reference toFIG.11, after the heat30(see, e.g.,FIGS.11and12B) has been applied for an appropriate duration and the sublimation material layer16has partially or totally sublimated into the workpiece28, the layup sheet10can be lifted from the workpiece28. In this step, the portion of the sublimation material layer16that has sublimated into the workpiece28remains in the workpiece28and then the sublimation material carrier layer18is separated therefrom when the layup sheet10is peeled away. The result of the described method32is the transfer, by sublimation, of the cut26design of the layup sheet10being transferred into the workpiece28.

In addition to the foregoing steps of method32described above, some implementations of the method32may further include the steps of: (1) removing the cut material from the workpiece28after sublimating42the sublimation material layer16into the workpiece28; and (2) leaving portions of the sublimated sublimation material layer16, which may be defined by sublimation ink, in the workpiece28(see, e.g.,FIGS.11′ and12D). Furthermore, other implementations of the method32may include the step of rearranging portions of the layup sheet10after the layup sheet10has been cut36and before the sublimation material layer16is sublimated42into the workpiece28; for example, such a step may include removing portions of the sublimation layup12removed with a corresponding portion of the laminate layer20and then reapplying said portions back onto the backing layer24via the adhesive layer22in one or more different positions.

In other implementations, the method32of transferring one or more sublimated portions of the sublimation material layer16into the workpiece28can also be reversed such that, for example, heat30from the heating device150is firstly applied to the workpiece28instead of the backing layer24of layup sheet10; for example, with reference toFIG.11, a reverse stack up where the workpiece28comprises ceramic materials, would include heat30applied to the workpiece28, with the workpiece28disposed between the heat30and sublimated sublimation material layer16of the layup sheet10. This reverse-stack-up method step may be advantageous when using home heating devices150; in such circumstances, users may find it more difficult to apply even pressure with the heating device150across the workpiece28, especially against rigid materials like ceramics. The reverse-stack up step allows for the various layers of the layup sheet10to be situated between the workpiece28and the sublimated sublimation material layer16to disperse pressure more evenly to the workpiece28in order to compensate for uneven pressure from users manually pressing the heating device150against the workpiece28.

In addition to layup sheet10described above and shown atFIGS.1-12D, other exemplary layup sheets10a,10b,10c,10d, and10eare also described in the present disclosure at, respectively,FIGS.14,15,16,17, and18. Accordingly, in view of the substantial similarity in structure and function of the components associated with the layup sheets10a,10b,10c,10d,10ewith respect to the layup sheet10, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions (e.g., “a”, “b”, “c”, “d”, and “e”) are used to identify those components that have been modified.

With reference toFIG.14, an additional printed layer44ais printed on the backing layer24asuch that the backing layer24ais disposed between adhesive layer22aand the printed layer44a. In such an embodiment, the printed layer44amay comprise ink that is not defined by sublimation ink (i.e., the ink defining the printed layer44amay be, e.g., standard printer ink or other non-sublimation ink).

In some implementations, the printed layer44amay include, for example: logos; gridlines; fiducials; alignment assisting markings; or other marks or combinations thereof. Such marks may provide information regarding appropriate temperatures and durations for sublimation with a heating device150or iron as well as other instructions for utilizing the layup sheet10a. In other implementations, the printed layer44amay include marks that assist the user in aligning the layup sheet10aonto a workpiece28or otherwise guiding the placement of layup sheet10aon the workpiece28for performing a subsequent sublimation step42.

Alternatively or additionally, in some configurations not shown in the Figures, the layup sheet10amay also include an addition backing layer similar to backing layer24adescribed herein on the print layer44athat is shown atFIG.14. In such implementations, the print layer44ais disposed between the two backing layers24a; in this way, the additional backing layer24awould prevent the ink defining the print layer44afrom transferring onto the surface of the heating device150during sublimation42.

Referring toFIG.15, some configurations an exemplary layup sheet10bmay include a printed layer44bdisposed between the adhesive layer22band the backing layer24b. In such implementations, ink defining the printed layer44bmay be shielded from a heat-generating surface of the heating device150that is pressed into and disposed adjacent the layup sheet10bduring sublimation42by the backing layer24b; such an arrangement of layers defining the layup sheet10bmay prevent ink defining the print layer44bfrom transferring onto the heating surface of the heating device150during sublimation42.

Additionally, the layup sheets10a,10bmay also include other layers. In some instances, the other layers may include a silicone oil coating of the laminate layer20a,20band/or one or more other adhesive layers arranged between the laminate layer20a,20band the sublimation material carrier layer18a,18b.

With reference toFIG.16, an exemplary layup sheet10cmay include two separate sheets of material that can be removably secured together. For example, any of the layup sheet10cmay include a first sheet46cand a separate second sheet48c. The first sheet46cmay include the laminate layer20cbelow other layers, such as, for example, the sublimation material carrier layer18cand the sublimation material layer16cand other layers such as, for example, any adhesive layers between the laminate layer20cand the sublimation material carrier layer18cdiscussed above as well as, for example, a silicone coating on the laminate layer20c. The second sheet48cmay include the adhesive layer22c, the backing layer24c, and any other layers discussed herein, such as, for example, the print layer44c.

If the layup sheet10cis utilized, is utilized the method32may include an additional step of pressing the first sheet46cand the second sheet48together before performing the cutting step36. Additionally, the layup sheet10cmay also include a removable layer50cthat may be disposed upon the adhesive layer22cof the second sheet48cin order to protect the adhesive layer22cbefore the first sheet46cis pressed onto the adhesive layer22c. The user would remove the removable layer50cbefore pressing the first sheet46and the second sheet48together in order to form a single sheet defining the layup sheet10c.

As seen atFIG.17, another exemplary layup sheet10dmay include two separate sheets46dand48d; however the sheets46d,48dmay not include a laminate layer. In such configurations, the sublimation material carrier layer18dmay be applied directly to the adhesive layer22dwhen the first sheet46dand the second sheet48are pressed together. Additionally, the layup sheet10dmay include a removable layer50dthat protects the adhesive layer22duntil the first sheet46dand the second sheet48are pressed together.

Referring toFIG.18, another exemplary layup sheet is shown generally at10e. The layup sheet10eincludes a second backing layer52edisposed between the print layer44eand the adhesive layer22e. In this way, the print layer44eis sandwiched between the two backing layers24e,52e, which may further prevent print layer44efrom traveling through layers of the layup sheet10efor subsequent transfer to the workpiece28or the heating surface of the heating device150during sublimation42.

In some configurations, the second backing layer52emay comprise similar or dissimilar materials and characteristics of the backing layer24e. For example, in some implementations, the second backing layer52emay comprise PET or other similar materials, such as, for example, other heat resistant materials and films. Furthermore, in some examples, the sum of the thicknesses of the backing layer24eand the second backing layer52emay be between about 40 μm-60 μm and preferably 45 μm-55 μm. In some configurations, the sum of the thicknesses of the backing layer24eand the second backing layer52emay be about, for example, 50 μm. In other examples, the thickness of the second backing layer52eis about the same as the thickness of the backing layer24e. In yet other examples, the thickness of the second backing layer52eis different than the thickness of the backing layer24e.

In some configurations the backing layer24eand the second backing layer52etogether may define between about 16%-24% by weight of the layup sheet10e. In other configurations, the backing layer24eand the second backing layer52emay define between about 18%-22% by weight of the layup sheet10e. In yet other configurations, the backing layer24eand the second backing layer52emay define between about, for example, 19.8% by weight of the layup sheet10e.

Alternatively, or in addition to the various implementations of layup sheets10,10a,10b,10c,10d,10edescribed herein, one or more implementations may include a perforated backing layer (not shown). A perforated backing layer may include a plurality of holes extending through the thickness of the perforated backing layer. Such a perforated backing layer may increase ventilation, and, as such, allow gases, such as, for example, moisture from ambient air or any other gases in the surrounding environment to pass through the backing layer24,24a,24b,24c,24d,24eduring sublimation42. One effect of this ventilation of gases through the backing layer24,24a,24b,24c,24d,24emay include cooling of the backing layer24,24a,24b,24c,24d,24eduring sublimation42.

In some instances, due to the cooling advantages of a perforated backing layer, the thickness of a perforated backing layer may be less than those thicknesses described above with reference to other backing layers24,24a,24b,24c,24d,24e, without negatively affecting the layup sheet10,10a,10b,10c,10d,10e. That is, the thicknesses described for the backing layer24,24a,24b,24c,24d,24e, or any layer for that matter, is in part based on the melting point and thickness of the material used. For example, a backing layer2424a,24b,24c,24d,24edescribed above comprising, for example PET and having a thickness of between about 40 μm-60 μm will withstand the temperature ranges of between about 350° F.-450° F. for a duration of between about 25 seconds-300 seconds without melting or negatively affecting the sublimation of the layup sheet10,10a,10b,10c,10d,10e. However, a perforated backing layer of less than 40 μm may be able to withstand temperatures above 450° F. as well as heat application durations of more than 300 seconds. Alternatively, or additionally, perforated backing layers may comprise materials that are less heat resistant than PET but may be less expensive or lighter.

In addition to the foregoing, because sublimation inks are typically sensitive to humidity, some configurations of the layup sheet10,10a,10b,10c,10d,10emay include a dry-environment packaging (not shown). Dry-environment packaging reduces exposure of sublimation material layer16,16a,16b,16c,16d,16eto humidity from the air or a user's hands, either of which can cause the sublimation material layer16,16a,16b,16c,16d,16eto smear. For example, in some instances, the layup sheet10,10a,10b,10c,10d,10emay be preferably packaged in an airtight, sealed package and may include a silicone packet or other moisture absorbing material to maintain dryness within the package. The layup sheet10,10a,10b,10c,10d,10emay be packaged in a dry environment, and the packaging maintains the appropriate level of humidity during transport and storage to preserve the quality of sublimation material layer16,16a,16b,16c,16d,16e. Such packaging is advantageous for retailers and distributors as well as users because it allows them to store layup sheet10,10a,10b,10c,10d,10efor longer periods of time before sale or use. By using the dry-environment packaging described herein, the layup sheet10,10a,10b,10c,10d,10ecan be placed on store shelves, in transport trucks or ships, and user's storage places for a prolonged period of time, such as, for example, a week or more.

As noted above, each of the implementations described in the detailed description above may include any of the features, options, and possibilities set out in the present disclosure, including those under the other independent implementations, and may also include any combination of any of the features, options, and possibilities set out in the present disclosure and figures. Further examples consistent with the present teachings described herein are set out in the following numbered clauses:

Clause 1: A cut material, comprising: an infusible ink layup; a backing layer; and a laminate layer disposed between the infusible ink layup and the backing layer.

Clause 2: The cut material of clause 1, wherein the infusible ink layup comprises an infusible sublimation material layer and a sublimation material carrier layer.

Clause 3: The cut layer of clause 2, wherein the laminate layer is disposed against the sublimation material carrier layer.

Clause 4: The cut material of any of clauses 1 through 3, further comprising an adhesive layer disposed between the backing layer and the laminate layer, wherein the adhesive layer removably secures the backing layer to the laminate layer.

Clause 5: The cut material of any of clauses 1 through 3, further comprising a print layer disposed between the backing layer and the laminate layer.

Clause 6: The cut material of clause 5, further comprising a print layer, wherein the backing layer is disposed between the print layer and the laminate layer.

Clause 7: The cut material of any of clauses 1 through 3, further comprising a print layer, wherein the backing layer is disposed between the print layer and the laminate layer.

Clause 8: The cut material of clause 7, further comprising an adhesive layer disposed between the backing layer and the laminate layer, wherein the adhesive layer removably secures the backing layer to the laminate layer.

Clause 9: A cut material, comprising: an infusible sublimation material layer; a sublimation material carrier layer; a laminate layer; and a backing layer. The sublimation material carrier layer is disposed between the infusible sublimation material layer and the laminate layer and the laminate layer is disposed between the sublimation material carrier layer and the backing layer.

Clause 10: The cut material of clause 9, the laminate layer comprising pulp and calcium carbonate.

Clause 11: The cut material of clauses 9 or 10, wherein the laminate layer is between about 40-60 g/m{circumflex over ( )}2.

Clause 12: The cut material of any of clauses 9 through 11, the laminate layer further comprising a silicone oil coating, the silicone oil coating disposed between the laminate layer and the backing layer.

Clause 13: The cut material of any of clauses 9 through 12, wherein the backing layer comprises PET.

Clause 14: The cut material of any of clauses 9 through 13, wherein a thickness of the backing layer is between about 40-60 μm.

Clause 15: The cut material of any of clauses 9 through 14, further comprising an adhesive layer disposed between the laminate layer and the backing layer.

Clause 16: The cut material of clause 15, wherein the adhesive layer comprises a pressure sensitive adhesive.

Clause 17: A method of infusing ink into an article, comprising: providing a cut material comprising an ink sublimation layup and a backing layer, the ink sublimation layup comprising sublimation ink; performing a cutting operation on the cut material; removing a portion of the ink sublimation layup from the backing layer of the cut material; placing the ink sublimation layup against an article; and sublimating the sublimation ink into the article.

Clause 18: The method of clause 17, wherein the cut material further comprises a laminate layer disposed between the ink sublimation layup and the backing layer.

Clause 19: The method of clause 17 or 18, wherein performing a cutting operation on the cut material comprises cutting through the ink sublimation layup but not the backing layer.

Clause 20: The method of claim 18 or 19, further comprising removing a portion of the laminate layer from the backing layer after performing the cutting operation, the portion of the laminate layer being removed from the backing layer corresponding in position with, and removably secured to, the portion of the ink sublimation layup being removed from the backing layer.

The articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements in the preceding descriptions. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Additionally, it should be understood that references to “one embodiment” or “an embodiment” of the present disclosure are not intended to be interpreted as excluding the existence of additional implementations that also incorporate the recited features. Numbers, percentages, ratios, or other values stated herein are intended to include that value, and also other values that are “about” or “approximately” the stated value, as would be appreciated by one of ordinary skill in the art encompassed by implementations of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable manufacturing or production process, and may include values that are within 5%, within 1%, within 0.1%, or within 0.01% of a stated value.

A person having ordinary skill in the art should realize in view of the present disclosure that equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations may be made to implementations disclosed herein without departing from the spirit and scope of the present disclosure. Equivalent constructions, including functional “means-plus-function” clauses are intended to cover the structures described herein as performing the recited function, including both structural equivalents that operate in the same manner, and equivalent structures that provide the same function. It is the express intention of the applicant not to invoke means-plus-function or other functional claiming for any claim except for those in which the words ‘means for’ appear together with an associated function. Each addition, deletion, and modification to the implementations that falls within the meaning and scope of the claims is to be embraced by the claims.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of a stated amount. Further, it should be understood that any directions or reference frames in the preceding description are merely relative directions or movements. For example, any references to “up” and “down” or “above” or “below” are merely descriptive of the relative position or movement of the related elements.

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.