An image is formed on a transfer medium comprising a hydrophilic tackifier. Any portion of the image that is dimensionally insufficient to permanently adhere the image to the receiver substrate is determined, and a colorless liquid ink comprising water is applied to cover and surround the portion of the image that is dimensionally insufficient to permanently adhere the image to the receiver substrate. When heat is applied to the image to transfer the image layer to a receiver substrate, water in the image layer swells the image layer and the hydrophilic tackifier becomes sufficiently tacky to permanently adhere the image to the receiver substrate.

An image is formed on a transfer medium comprising a hydrophilic tackifier. Any portion of the image that is dimensionally insufficient to permanently adhere the image to the receiver substrate is determined, and a colorless liquid ink comprising water is applied to cover and surround the portion of the image that is dimensionally insufficient to permanently adhere the image to the receiver substrate. When heat is applied to the image to transfer the image layer to a receiver substrate, water in the image layer swells the image layer and the hydrophilic tackifier becomes sufficiently tacky to permanently adhere the image to the receiver substrate.

It is the object of the present invention to provide a new polymer coating for low temperature plastics and plastic foams that allows for the application of disperse dyes in a sublimation process that preserves the original properties of the underlying plastic substrate. The composition includes an optically clear synthetic organic polymer base holding two layers, a first reflective layer supported by the low temperature plastic substrate that includes IR radiation reflecting additives, and a second layer supported by the first layer having light scattering particulate additives. The disperse dyes utilized in the invention may include additives to absorb IR radiation provided by an external IR source positioned above the disperse dyes causing the dyes to sublimate and diffuse quickly into the light scattering layer. The combination of these layers allows for diffusion of the disperse dye ink into the light scattering layer while protecting the low temperature plastic below.

In an illustrative embodiment, a processor determines an ink coverage for a portion of an image and retrieves one or more input parameters for the portion. The processor may adjust the height of the print head (i.e., the distance between the print head and a paper where the image is to be printed) based upon the ink coverage and the one or more input parameters. In particular, the processor may optimize the height of the print head for image clarity while preventing head strikes. In some embodiments, the processor for may maintain the same height for an image. In other embodiments, the processor may dynamically adjust the height while printing for different portions of the image.

In an illustrative embodiment, a processor determines an ink coverage for a portion of an image and retrieves one or more input parameters for the portion. The processor may adjust the height of the print head (i.e., the distance between the print head and a paper where the image is to be printed) based upon the ink coverage and the one or more input parameters. In particular, the processor may optimize the height of the print head for image clarity while preventing head strikes. In some embodiments, the processor for may maintain the same height for an image. In other embodiments, the processor may dynamically adjust the height while printing for different portions of the image.

An apparatus for texturing a plastic substrate, while forming a dye sublimation image in the plastic substrate, wherein the plastic substrate has a first side and a second side, is provided. A textured cover is on a side of a platen, wherein the platen is on a first, untextured side of the textured cover. A first side of the dye carrier is on a second, textured side of the textured cover, and wherein the plastic substrate is supported on a second side of the dye carrier, wherein a first side of the plastic substrate is supported by the dye carrier, wherein the textured side of the textured cover has a texture to be transferred to the plastic substrate. A membrane is on the second side of the plastic substrate. A vacuum pump provides a vacuum between the membrane and the platen. A heater is positioned to heat the plastic substrate.

An apparatus for texturing a plastic substrate, while forming a dye sublimation image in the plastic substrate, wherein the plastic substrate has a first side and a second side, is provided. A textured cover is on a side of a platen, wherein the platen is on a first, untextured side of the textured cover. A first side of the dye carrier is on a second, textured side of the textured cover, and wherein the plastic substrate is supported on a second side of the dye carrier, wherein a first side of the plastic substrate is supported by the dye carrier, wherein the textured side of the textured cover has a texture to be transferred to the plastic substrate. A membrane is on the second side of the plastic substrate. A vacuum pump provides a vacuum between the membrane and the platen. A heater is positioned to heat the plastic substrate.

Provided are a combination of a thermal transfer sheet and an intermediate transfer medium which is capable of accurately transferring only a transfer layer of the intermediate transfer medium desired to be transferred onto a transfer receiving article in the production of a print, and a thermal transfer sheet which is used in combination with an intermediate transfer medium. Also provided are a method for producing a print, comprising accurately transferring only a transfer layer of an intermediate transfer medium desired to be transferred onto a transfer receiving article, and a thermal transfer printer which is used in this method for producing a print. In the thermal transfer sheet which is used in combination with an intermediate transfer medium, inhibit layer 2 is disposed on substrate 1, and the inhibit layer 2 contains a carnauba wax.

An illustrative dye sublimation apparatus may include a heating surface that may have multiple zones. Each zone may include a single individually controlled heater. A controller may control the heater to generate a range of heat and not merely turn the heater ON and OFF. Therefore, one or more controllers may individually regulate heat from corresponding heaters in the zones thereby maintaining a constant and nearly constant temperature throughout the bed of the dye sublimation apparatus in the heating surface. Furthermore, one or more controllers may maintain a first range of temperature during a first state of a dye sublimation process and a second range of temperature during a second stage of the dye sublimation process.

A stratified support item for printing on a surface with sublimation inks is disclosed. The surface may include, for example, clothing items, such as T-shirts, sweatshirts or the like. The stratified support item includes a thermo-adhesive layer configured to adhere to the surface and at least one finish layer configured to receive said sublimation inks. The finish layer includes a powder, which is comprised of at least one from the group of (i) a polyester powder, and (ii) a polyamide powder, incorporated in a matrix of polymeric material.