Abstract:
A device and method that employs prints produced by video color system thermal printers as transfers for creating personalized ceramic mugs, tiles or the like articles. The method comprises creating a mirror image print by means of a color video system with printer, applying that print to the surface of the mug or the like which has been treated with a sublimable dye absorbing compound, and applying heat (200 to 400° F.) and pressure exerted by a force of 200 to 400 pounds for period of time of about three to six minutes, to sublimate the limited dye in the print whereby it is absorbed by the coated surface of the mug or the like. The device for applying the heat and pressure is a heated press that has removable heated slidable platens which conform to the shape of the article to which the print is being transferred.

Description:
RELATED APPLICATIONS 
     This is a Continuation of application Ser. No. 07/892,490, filed Jun. 3, 1992, now abandoned, which is a Continuation of application Ser. No. 07/403,339, filed Sep. 6, 1989, now abandoned, which is a Continuation-In-Part of application Ser. No. 07/240,507, filed Sep. 6, 1988, now abandoned. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of Invention 
     The present invention relates in general to print transfers using sublimation dyes, and in particular to a pressing apparatus and method of making sublimation dye transfers from color video system prints and effectively applying such prints to coated ceramic mugs, tiles or coated metal articles, or like articles. 
     2. State of the Art 
     Methods and various types of Apparatus for producing photographic-like images on hard surfaces such as ceramic mugs and tiles are commercially available to fulfill an existing need evident from the large number of decorated mugs and tiles sold and on sale in a wide variety of consumer retail outlets. These products are currently manufactured by utilizing pre-print transfers, such as decals, in most, if not all, cases which are produced by employing one of the following methods: silk screen printing, offset printing, gravure printing or mimeograph, the inks being used in these processes containing sublimable dyes. These methods require color separation and, in view of economic considerations, relatively long production runs. Another known process uses transfers produced on a xerographic type copy machine, but these transfers are limited to monotones, that is, a single color or black on white. These known transfer systems are not used, as a practical matter, for producing single, one-of-a-kind full color transfers or at least are not economically so used, and currently, other than the instant invention, the only commercially viable method for producing such one-of-a-kind colored ceramic mugs is by hand painting individual pieces. 
     Today&#39;s color video print systems employ primary thermal printing of sublimable dyes that have previously been applied on webs by known techniques. These webs contain successive blocks of yellow, magenta and cyan dyes which are thermally transferred onto print papers specially treated to accept and absorb the sublimable dyes. Information on such printing techniques is disclosed in U.S. Pat. No. 4,650,494, issued Mar. 17, 1987, to Kutsukake et al and U.S. Pat. No. 4,731,091, issued Mar. 15, 1988, to Majima. For the sublimable dyes to be absorbed and provide an image on the reception medium, which is resistent both to wear and fading or color distortion on exposure to daylight or artificial lighting, that medium is provided with a coating of, or is a composition of, or has mixed within its body materials of the types disclosed by Davis, U.S. Pat. No. 4,395,263 of Jul. 26, 1983; Hi et al, U.S. Pat. No. 4,354,851 of Oct. 19, 1982, and Krajec, U.S. Pat. No. 4,664,672 of May 12, 1987. 
     The art is redundant with patents disclosing methods and apparatus for primary transfer printing wherein sublimation dyes are affixed by known printing techniques, such as off-set, gavure and silkscreen, to carrier webs or sheets, which, in turn, are applied at various temperatures and onto surfaces of varying compositions. For the most part, this primary printing, using carriers or transfers with the prints thereon, is accomplished by heating the elements of the process to the sublimation temperatures of the dyes at near normal atmospheric pressures. The printed side of the carrier or transfer is placed in contact with the object onto which the image is to be printed while heat is applied to either the transfer, or the material to be printed, or both for relatively short durations, normally from one to ten seconds. With exceptions such as disclosed in U.S. Pat. No. 4,395,263 of Davis which relates to printing on various laminates, U.S. Pat. No. 4,411,667 of Meredith et al of Oct. 25, 1983, and U.S. Pat. No. 4,462,852 of Custor, issued Jul. 31, 1984, addressed to printing on materials passing between rollers, the application of significant pressure has not been considered a crucial factor in the transfer process. However, these latter patents are for primary print transfers. As described in the Meredith et al and Custor patents, pressure is provided to compensate for the extremely short contact period between the carrier web and the surface to receive the image. Davis teaches that a small amount of pressure may be used to control the transfer. 
     SUMMARY OF THE INVENTION 
     An important object of the present invention is to provide a method to transfer a full color one-of-a-kind image to a hard surface and do it economically and rapidly. It is also an object of this invention to provide a device for applying these one-of-a-kind images to ceramic mugs. 
     It has been discovered that the foregoing objects can be effectively accomplished by using a color video thermal printing device which produces the image to be transferred to a selected object such as a mug or tile. It has thus been discovered that prints produced using these printers, that is, products of known video printers&#39; primary print processes, can be effectively transferred to surfaces which have a coating adapted to absorb the sublimable dyes therein. When the proper heat and pressure are applied, using the thermal transfer press of the instant invention, the image on the print is transferred to the mug surface as a crisp and faithful copy. This secondary print process, making such use of a print from a primary print process product, previously unknown, provides a relatively rapid and economical vehicle for producing one-of-a-kind mugs or other articles. 
     The invention is illustrated in preferred embodiments in the accompanying figures, in which: 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic illustrating a method for producing image on surfaces using the color sublimation transfer process in accordance with the present invention; 
     FIG. 2 is a further schematic of a further method of a color sublimation transfer process which utilizes a mechanism or program that produces mirror images which is also in accordance with the present invention; 
     FIG. 3 is a plan view of the thermal transfer press in accordance with the invention; 
     FIG. 4 is a side elevation of the thermal transfer press shown in FIG. 3; 
     FIG. 5 is a side detail view showing the pressure handle employed in the press; 
     FIG. 6 is a view of a mug having a video print attached; and showing also a teflon coated wrap; 
     FIG. 7 is a wiring diagram in accordance with the invention; 
     FIG. 8 is a plan view that shows a second embodiment of a heat transfer press; 
     FIG. 9 is a plan view of a relatively stationary press block or metal platen that incorporates compression springs which can be substituted for the corresponding press block in the embodiment of FIG. 3 or FIG. 8; and 
     FIG. 10 is a perspective view of one of the removable and replaceable press blocks. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention involves a novel use of normal prints produced by a color video printing system which employs a sublimable dye thermal transfer printer  12 , such as the Kodak SV 6500 color video printer using the Kodak SV 100 color video print materials. Color video printers were developed to produce high resolution prints in full color of anything that can be viewed on a television screen, freezing the motion, and recording the resulting image. The color video system thus functions to record images for future reference and for producing prints thereof. This invention is directed to a novel use of such prints customarily produced by these color video printing systems. The images to be used in the inventive process are preferably converted by a logic means, such as provided in the Hitachi Color Video Printer VY-55A or by a computer  22  as seen in FIG. 2 with appropriate graphics capability, to produce a print  17  which is a mirror image of that which would be otherwise transmitted by the video camera  11 . Video printer  12  uses a known primary, sublimable dye heat transfer printing apparatus and method to create a print, direct (by the process illustrated in FIG. 1) or preferably mirror image (by the process illustrated in FIG.  2 ), of a composition received by camera  11  as viewed on monitor  13 . The image produced on print  17  is then transferred to specially coated ceramic mug  14  to create a one-of-a-kind product. When print  17 , produced by color video printer  12 , is placed in thermal transfer press  16  for a ceramic mug, where temperatures of 320°-480° F., preferably about 400° F, are applied under high pressure for three to six minutes, the dyes in the print are absorbed into coating  18  of mug  14  from print  17 . Because the quantities of sublimable dyes in print  17 , which are available therefrom for transfer, are limited, it is critical to provide an essentially perfect continuous, heated and substantially high pressure contact between print  17  and the surface to receive the image therefrom. 
     Referring in particular to FIGS. 3 and 4, thermal transfer press  16  is mounted on hollow base  90 . Fixed on the upper surface of base  90  is guide platform  91 . This guide platform  91  is slightly narrower than the width of base  90  and, at the end where pressure handle assembly  56  is mounted, platform  91  extends a short distance beyond the end of base  90 . To the left of guide platform  91  as seen in FIGS. 3 and 4, base  90  provides a seat for attaching the bottom of cover assembly  65 . A further cover assembly  66  is mounted to straddle guide platform  91  and is secured on its right as seen in the figures to a right angle adjustment piece  75  which is received in part in a corresponding depression formed in cover assembly  66 . A slide plate  92 , made of a heat resistant material, is affixed to the top of platform  91  between assemblies  65  and  66 , extending partially under the latter assembly. Cover assembly  65  houses the electrical circuitry, (shown in FIG.  7 ), to power and control the device. Power cord  2  feeds 115 volt alternating current into housing cover assembly  65 . Mounted on top of housing cover assembly  65  are a circuit breaker  60 , an on/off switch  63  and temperature indicator lights  62   a  and  62   b . Cover assembly  65  is open on its center facing side. 
     Mounted on slide plate  92 , so as to be partially covered by cover assembly  65 , is platen assembly  50   a  which comprises base block  57  and metal platen  52 . Base block  57  is fixedly secured to slide plate  92 . Metal platen  52  is removably affixed to transverse, vertically extending base block  57  by recessed bolts or screws  59 , only one being shown in FIG. 3, which pass through wing extensions to stationary block  57  into an offset extended portion of metal platen  52 . Immediately opposite metal platen  52 , and spaced apart therefrom, is a corresponding metal platen  51 . Metal platen  51  may be removably attached by means of recessed bolts or screws  59  to a sliding block  58  to form a sliding platen assembly  50   b . Sliding block  58  is partially housed inside cover assembly  66 . 
     Metal platens  51  and  52  are configured for use with mugs of the same dimensions. Differently configured sets of metal platens are provided for different sizes of mugs, beer steins or the like. 
     Metal platens  51  and  52  are each heated by two conventional electric resistance heaters  53 , each having a rating of 300 watts, removably seated in receptacles  53   a . Each metal platen,  51  and  52 , also has a thermostat  55  removably seated in a complimentary receptacle. The inner surfaces of metal platens  51  and  52  are concave and subscribe an equal radii arc of approximately 160°. Mounted to their inner surface is a silicone rubber gasket  54 . The concave surface of metal platens  51  and  52  and the silicone rubber gaskets  54  combine to ensure total contact of the concave surface of metal platens  51  and  52  with print  17 , mounted on the outer surface of mug  14 , when the device is in operation. 
     Rigidly attached to sliding block  58 , approximately in the center thereof and extending perpendicular to the rear surface of sliding block  58  is rod  80 . Rod  80  passes through an aperture in upwardly extending part  75  of right angle adjustment piece  74 . As seen in FIG. 5, attached to an upwardly extending part  75 , and providing an extension to the aperture through which rod  80  passes, is support block  81 . Movably connected to support block  81  and the outwardly extending end of rod  80  is pressure handle assembly  56  which attaches to support block  81  by means of a parallel pair of links  82 . As can be viewed in FIGS. 3 and 5, these links  82  extend from each side of support block  81  to an outer side of bell crank part  83 . Extending rigidly between links  82  is a cross piece which is integral with or welded to links  82 . The lower ends of links  82  are pivotally mounted to support block  81  by means of studs  86 . The opposite upper ends of the links  82  are pivotally attached by a horizontal pin  85  to bell crank part  83 . Lower arm extension  83   b  of part  83  is split to be received on each side of rod  80  to which it is pivotally mounted by pivot pin  84 . Handle  87  is threadably received in the upper head portion  83   a  of bell crank part  83 . Although pressure assembly  56  has been described as a mechanical device, it will be appreciated by those skilled in the art that a hydraulic or pneumatic pressure assembly as would occur to one skilled in the art could be substituted as an equivalent thereof. 
     Pressure adjustment is provided by adjustment member  78 . A bracket  71  is fixedly attached to base  90  and guide plate  91 . A threaded aperture through an upward extension of bracket  71  receives a threaded pressure adjustment screw  70 . The threaded end of adjustment screw  70  bears against right angle adjustment piece  74 . Mounted on the upper surface of the horizontal portion of right angle adjustment piece  74  are three locking bolts  72  which are received in associated slots  73  in guide plate  91  and base  90  in a known arrangement so that upon being tightened they firmly secure right angle adjustment piece  74  in position relative to guide plate  91 . 
     To use mug heat press  16 , a camera  11  is focused on the desired subject matter (which might be a photograph) and conveys the image it receives onto monitor  13 . Either through incorporation of a graphics computer  22  or by means internal to a color video printer  12 , a mirror image of the recorded image as selected on, and as may be adjusted by, monitor  13  is recorded and printed by video printer  12 . The resulting print  17  is then placed with the print side against a ceramic mug  14  (see FIG. 6) which has been previously permanently coated with a material known to be receptive to absorption of sublimable dyes. Print  17  is held against surface  15  of mug  14  by means of tape  19 . Tape  19  is of a type, such as duct tape, which will be unaffected by the temperatures to which it will be subjected and does not affect the finish of surface  15 . Mug  14  and print  17  are then wrapped with a thin layer of teflon coated material  20  and placed in the gap between metal platens  51  and  52 . Mug  14  is placed so that the open portion is down and the lip rests on slide plate  92 . The handle protrudes from the gap between platens  51  and  52 . Pressure assembly  56  is closed by pulling down handle  87  to force platen  51  toward metal platen  52  thereby clamping mug  14  between the two platens. Metal platen  51  is then adjusted incrementally by means of adjustment screw  70  to apply increased pressure on mug  14 . In so doing, silicone rubber gaskets  54  are compressed. When maximum or, in any event, substantial compression of silicone rubber gaskets  54  is obtained, pressure adjustment screws  72  are tightened thereby locking right angle adjustment piece  74  in place. Handle  87  is lifted withdrawing platen  51  and allowing cup  14  to be removed. Electric heating elements  53  are turned on by means of on/off switch  63 . When they reach the temperature for which thermostats  55  are set, thermostats  55  open and the corresponding indicator lights  62   a  and  62   b  are energized signalling that metal platens  52  and  51  have reached transfer temperature. Cup  14  is then placed between platens  51  and  52  and pressure assembly  56  closed by means of handle  87 . 
     The cup is held under the applied force squeezed between platens  51  and  52  of about 200 to 400 pounds for a period of three to six minutes at a platen temperature of 400° F. plus or minus eighty degrees. In the instant embodiments, a high pressure is essential and the force applied is near to, but of course, less than that which would break the mug. At the end of the period, pressure assembly  56  is opened by lifting handle  87 , mug  14  taken from the press, teflon cover  20  removed, and print  17  is pulled from mug  14 . Mug surface  15  has embedded therein a clear, crisp image with good color qualities, that replicates the composition imaged by color video camera  11  on monitor  13 . 
     A second embodiment of mug press is shown in FIG.  8 . In this embodiment, pressure adjustment is provided by rod and spring assemblies. Shown only for adjustable platen assembly  50   b  in FIG. 8, the same arrangement can be employed with platen assembly  50   a  as shown in FIG.  9 . These platen assemblies  50   a  or  50   b  or both are slidably affixed to a base plate such as shown by upward extending part  75 . For platen assembly  50   a , three compression assemblies, each comprising a rod  100  and compression spring  101  are placed between a fixed receiving plate  76  and sliding block  57 . Platen assembly  50   b , on the other hand, is attached to upward extending part  75  by means of rods  80  attached to pressure handle assembly  56  and the back of sliding block  58  and by rods  100  attached threadably or by welding or other suitable means to the back of sliding block  58  and passing through openings in upward extending part  75 . Surrounding rods  100  and  80  between sliding block  58  and upward extending part  75  are compression springs  101 . Thus, pressure handle assembly  56  allows pressure to be relieved and the cup removed as well as providing the principal component of pressure to the cup during the transfer process. The rod and spring assemblies provide the pressure to the back of sliding platen  57  and  58  wherein a tight, continuous seal is obtained over the entire surface of the print against the cup. Block  57  of assembly  50   a  has a central rod  100  rather than rod  80  attached thereto. The rods  80  and  100  are slidably received through bores in part  75 . Fully compressed, each spring  101  exerts about  75  pounds of force. 
     Transfer prints made from this system can also be printed onto a flat surface such as specially treated ceramic tiles and metal as well as fabrics containing at least 50% polyester. In all cases it is important to have the temperature in preferably a 325°-450° F. range and to apply the necessary high pressure. Most flat heat presses which can produce the desired high pressure and high temperature should operate successfully in applying the transfer to flat surfaces. 
     Platens  51  and  52  can be readily removed, one such platen  52  being shown by itself in FIG.  10 . Their electrical connections to electric heaters  53  and thermostat  55  are easily connected and disconnected. A variety of different sizes and shapes of platens  51  and  52  may be used interchangeably. For example, the diameters may be different for different sizes of mugs. They may be provided with flat faces for tiles and the like. 
     The foregoing description of the preferred embodiments of this invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms and mechanisms disclosed. The scope of the invention should not, therefore, be considered as limited to the embodiments this detailed description, but rather by claims appended hereto.