Process of dry adhesive-free thermal transfer of indicia

Claim 2

A dry, adhesive-free process for transferring a dry thermally-transferable ink composition from a carrier to a receptor comprising the steps of: (a) providing a receptor and a carrier bearing a dry thermally-transferable ink composition and a vacuum frame having a vacuum bed, a top capable of covering the vacuum bed, a porous material on said top for contacting said carrier, and a source of heat above said porous material; (b) placing said receptor and said carrier on said vacuum bed so that said ink composition contact said receptor to form an interface therebetween; (c) adjusting said interface so that it is free from any wrinkles and closing said top so as to form a chamber; (d) evacuating substantially all of the air from said interface by means of vacuum to create a reduced pressure in said chamber and coform said ink composition to said ink composition to said receptor; (e) mantaining said reduced pressure and heating said ink composition and said receptor to a temperature, and for a time, sufficient to soften said ink composition, fuse said ink composition to said receptor and form an intimate bond thereto and transfer said ink from said carrier to said receptor; and (f) removing said carrier from said ink, thereby leaving said ink adhered to said receptor surface.

Claim 3

A process according to claim 1 comprising the further step of cooling said ink and said receptor to a temperature sufficient to harden said ink and cause the adhesion of said ink to said receptor to be greater than the adhesion of said ink to said carrier.

Claim 4

A process according to claim 2 wherein said ink and said receptor are cooled to a temperature of less than about 65° C.

Claim 5

A process according to claim 1 wherein heating is carried on at a temperature in the range of about 75° C. to 110° C.

Claim 6

A process according to claim 4 wherein heating is carried on for from about 2 to 5 minutes.

Claim 7

A process according to claim 1 wherein said reduced pressure in said chamber is at most about 0.75 atmosphere.

Claim 8

A process of manufacturing a sign face having a thermally-transferable ink composition applied to at least a portion of a receptor in a dry, adhesive-free manner, said process comprising the steps of: (a) providing a receptor and a carrier bearing a layer of a dry thermally-transferable ink composition and a vacuum frame having a vacuum bed, a top capable of covering the vacuum bed, a porous material on said top for contacting said carrier, and a source of heat above said porous material; (b) placing said receptor and said carrier on said vacuum bed so that said ink composition contacts said receptor to form an interface therebetween; (c) adjusting said interface so that it is free from any wrinkles and closing said top so as to form a chamber; (d) evacuating substantially all of the air from said interface by means of vacuum to create a reduced pressure in said chamber and conform said ink composition to said receptor; (e) maintaining said reduced pressure and heating said ink composition and said receptor surface to a temperature, and maintaining said temperature for a time, sufficient to soften said ink composition, fuse said ink composition to said receptor surface and form an intimate bond thereto and transfer said ink composition to said receptor surface; (f) cooling said ink composition and said receptor surface to a temperature sufficient to harden said ink composition and cause the adhesion of said ink composition to said receptor surface to be greater than the adhesion of said ink composition to said carrier; and (g) removing said carrier from said ink thereby leaving said ink adhered to said receptor surface.

Claim 9

A process of manufacturing a sign face having a thermally-transferable ink composition applied to at least a portion of a receptor in a dry, adhesive-free manner, said process comprising the steps of: (a) providing a receptor and a carrier bearing a layer of a dry thermally-transferable ink composition and a vacuum frame having a vacuum bed, a top capable of covering the vacuum bed, a porous material on said top for contacting said carrier, and a source of heat above said porous material; (b) placing said receptor and said carrier on said vacuum bed so that said ink composition contacts said receptor to form an interface therebetween; (c) adjusting said interface so that it is free from any wrinkles and closing said top so as to form a chamber; (d) evacuating substantially all of the air from said interface by means of vacuum to create a reduced pressure in said chamber and conform said ink composition to said receptor; (e) maintaining said reduced pressure and heating said ink composition and said receptor surface to a temperature, and maintaining said temperature for a time, sufficient to soften said ink composition, fuse said ink composition to said receptor surface and form an intimate bond thereto and transfer said ink composition to said receptor surface; (f) cooling said ink composition and said receptor surface to a temperature sufficient to harden said ink composition and cause the adhesion of said ink composition to said receptor surface to be greater than the adhesion of said ink composition to said carrier; and (g) removing said carrier from said ink thereby leaving said ink adhered to said receptor surface.

Claim 10

A process according to claim 7 wherein said receptor is polymeric.

Claim 11

A process according to claim 8 wherein said receptor is rigid.

Claim 12

A process according to claim 8 wherein said receptor is flexible.

Claim 13

A process according to claim 8 wherein said receptor comprises polyvinyl chloride sheeting.

Claim 14

A process according to claim 11 wherein said receptor is fiber reinforced.

Claim 15

A process according to claim 12 wherein said fiber is thermoplastic.

Claim 16

A process according to claim 13 wherein said receptor has a three dimensional surface.

Claim 17

A process according to claim 7 wherein said receptor has a smooth surface.

Claim 18

A process according to claim 7 wherein said receptor has a three dimensional surface.

Claim 19

A process according to claim 1 wherein said thermally-transferable ink composition comprises (a) from about 50 to 95% by weight of a thermoplastic polymer selected from the group consisting of polyvinyl chloride and copolymers thereof; (b) from about 50 to 5% by weight of a flexibilizer for said thermoplastic polymer that is compatible with said thermoplastic polymer; and (c) up to about 40% by weight of a colorant; wherein said composition has a 20% elongation temperature of less than 85° C. and an elongation at break of at least about 15%.

Claim 20

A process according to claim 17 wherein said thermoplastic polymer is selected from the group consisting of polyvinyl chloride and polyvinyl chloride-polyvinyl acetate copolymers.

Claim 21

A process according to claim 17 wherein said flexiblilizer is selected from the group consisting of synthetic resins free from vinyl chloride units having a 20% elongation temperature of less than about 85° C., and plasticizers for polyvinyl chloride.

Claim 22

A process according to claim 19 wherein said flexiblilizer is selected from the group consisting of ethyl, methyl, and butyl methacrylate homopolymers, and copolymers of said homopolymers with methyl, ethyl, and butyl acrylate, polyester-functional aromatic urethanes, polyester and polyether-functional aliphatic urethanes, linear polyester resins, acrylonitrile-butadine-styrene resins, polycaprolactam polymers, sucrose acetate isobutyrate, ethylene vinyl acetate resin, ethyl methacrylate, butyl methacrylate, alcohol phthalates, polymeric polyesters, aromatic phthalates, mixed lower alkyl benzyl phthalates, epoxidized vegtable oils, phosphoric acid derivatives, and tricresyl phosphate.

Claim 23

A process according to claim 17 wherein said colorant is a pigment.

Claim 24

A process according to claim 7 or 17 wherein said heating is carried out at a temperature in the range of about 75° C. to 110° C.