Digitally printed and produced heat transfer and method of manufacture
A process for producing a digital printed heat transfer, the process comprising the steps of: 1) obtaining a substrate having a release layer; 2) applying a primer suitable for electrophotographic toner to the release layer; 3) digitally-printing electrophotographic toner to define a graphic within a defined region of a substrate inclusive of both printed and unprinted areas within that region; 4) digitally printing a tacky viscoelastic binder in registration with the printed areas of the digitally-printed graphic; 5) applying a polyurethane-based powder adhesive to the defined region of said substrate; 6) removing loose powder adhesive that does not adhere to the defined regions of said graphic; and 7) fusing and bonding the adhesive to the digital printed graphic. The binder precisely secures the adhesive powder to the printed graphical areas. The result is then cooled to set the image for use as a heat transfer.
1 . A process to create printed heat activated transfers for application to soft goods, comprising the steps of:
obtaining a substrate having a release layer pre-coated on one side;
applying a primer to the coated side of the substrate;
digitally printing a graphic onto said primer within a defined region of the substrate using a first printer configured to print electrophotographic toner and pursuant to a digital image file, the graphic comprising both printed and unprinted areas;
digitally printing a tacky viscoelastic binder having a storage modulus of less than 0.3 MPa and a shear modulus of less than 0.1 MPa within a temperature range of 60° F. to 130° F. onto and in registration with the printed areas of said graphic using a second DOD printer that is drop-on-demand (DOD) and pursuant to a copy of said digital image file, wherein the binder has a thickness of 0.2 to 0.75 microns;
forming an adhesive layer by applying powdered adhesive, whereupon some of the powdered adhesive adheres directly to the printed tacky viscoelastic binder and in registration therewith;
removing powdered adhesive applied to the unprinted areas that does not contain binder; and
thermally curing the adhering adhesive.
2 . The process of claim 1 , further comprising the step of applying a protective sheet over the adhesive layer.
3 . The process of claim 1 , further comprising the step of applying a protective coating onto the release layer.
4 . The process of claim 1 , wherein a release layer is applied to the substrate prior to the primer.
5 . The process of claim 1 , wherein the polymeric adhesive powder is cured by any one of an LED, UV, or IR lamp.
6 . The process of claim 1 , wherein the powder adhesive is cured by a heated roller.
7 . The process of claim 1 , wherein the powder adhesive is cured in an oven.
8 . The process of claim 1 , wherein the tacky viscoelastic binder has a viscosity of less than 250 cps.
9 . The process of claim 1 , wherein the tacky viscoelastic binder comprises at least 10% resin.