Source: http://www.google.fr/patents/US7810538
Timestamp: 2013-05-18 21:39:54
Document Index: 412902471

Matched Legal Cases: ['Application No. 06', 'Application No. 06', 'Application No. 2', 'Application No. 200610074147', 'Application No. 200610074147', 'Application No. 02725420', 'Application No. 02', 'Application No. 2', 'Application No. 1147', 'Application No. 2002', 'Application No. 2002', 'Application No. 2002', 'Application No. 2008', 'Application No. 2007249071', 'Application No. 10', 'Application No. 08']

Brevet US7810538 - Method and apparatus for forming dye sublimation images in solid plastic - Google�BrevetsRecherche Images Maps Play YouTube Actualit�s Gmail Drive Plus » Recherche avanc�e dans les brevets | Historique Web | Connexion Recherche avanc�e dans les brevets BrevetsMethod for forming a dye sublimation image in a substrate, particularly a plastic substrate, and apparatus to perform the method. According to the method taught by the present invention, a substrate is disposed on a perforated platen and a dye carrier having an image formed thereon of a dye sublimation...http://www.google.fr/patents/US7810538?utm_source=gb-gplus-shareBrevet US7810538 - Method and apparatus for forming dye sublimation images in solid plastic Num�ro de publicationUS7810538 B2Type de publicationOctroi Num�ro de demande11/204,830 Date de publication12 oct. 2010 Date de d�p�t15 ao�t 2005 Date de priorit�29 mars 2001Autre r�f�rence de publicationCN1847022ACN1847022BUS6814831US6998005US20020148054US20030192136US20060028531 InventeursJonathan C. DrakeRick EssertTed N. MageeRobert W. Shaw Cessionnaire d'origineFresco Plastics Llc Classification aux �tats-Unis156/498156/583.1156/583.5 Classification internationaleB41M5/035B41M5/025B44C1/17B32B37/00B29C45/14D06P5/28 Classification coop�rativeD06P5/004B41M5/0256B44C1/1712B29C2045/14737B41M5/035B29C45/14688 Classification europ�enneD06P 5/00T2B41M 5/025NB44C 1/17FR�f�rencesCitations de brevets (53)Citations hors brevets (34)Liens externesUSPTO Cession USPTO EspacenetMethod and apparatus for forming dye sublimation images in solid plasticUS 7810538 B2 R�sum� Method for forming a dye sublimation image in a substrate, particularly a plastic substrate, and apparatus to perform the method. According to the method taught by the present invention, a substrate is disposed on a perforated platen and a dye carrier having an image formed thereon of a dye sublimation ink is disposed on the substrate such that the image is in contact with the substrate. The substrate, dye carrier and at least a portion of the perforated platen are then covered with a flexible membrane. A clamping pressure is then applied to the substrate and the dye carrier through the membrane. Once the clamping pressure is attained, the substrate and dye carrier are first heated, then cooled.
a heater for heating the dye carrier to a sublimation temperature, wherein the heater is able to provide sustained temperatures of 600� F.;
RELATED APPLICATIONS This is a Divisional application of prior U.S. application Ser. No. 09/823,290 , entitled �METHOD AND APPARATUS FOR FORMING DYE SUBLIMATION IMAGES IN SOLID PLASTIC�, filed on Mar. 29, 2001, now U.S. Pat. No. 6,998,005, which is incorporated herein by reference and from which priority under 35 U.S.C. �120 is claimed.
FIELD OF THE INVENTION The present invention relates to the formation of images within solid sheets of plastic. More particularly, the present invention relates to a methodology for forming dye sublimation, or dye transfer, images within solid sheets of plastic and to an apparatus for performing the methodology.
BACKGROUND OF THE INVENTION From the advent of plastics, users and manufacturers thereof have sought a workable means for imprinting or forming images thereon. Prior imaging technologies suitable for use on other materials, for instance metals, wood, and the like, have not generally met with success when used to perform permanent imaging on plastics. Examples of such prior imaging technologies include but are not limited to paints, decals, lacquers, and dyes. In general the problems associated with utilizing prior imaging or marking technologies center on certain chemical and physical properties of plastics in general.
In searching for a methodology for forming permanent, abrasion-resistant images in sheet plastics workers in this field have noted that plastics tend to be molecularly similar to certain fabrics which are imaged utilizing a dyeing process known as �dye sublimation�. According to known dye sublimation processes, an image, for instance a decorative design, is formed of sublimation printing inks on a dye carrier, sometimes also referred to as a transfer paper or auxiliary carrier. Dye carriers are often, but not exclusively, formed of paper. Printing the image on the dye carrier is carried out by any of several known printing methods including, but specifically not limited to offset or rotary printing methods. The print images formed on the dye carrier are transferred by sublimation, also called transfer printing, from the dye carrier to the textile or fabric which is to be decorated with the design.
There are several known dyestuffs suitable for use with dye sublimation printing techniques. The actual dyestuff or dye carrier utilized is not essential to the principles of the present invention, provided that the dyestuff is capable of sublimation. This is to say that the dyestuff sublimates directly to the vapor state from the solid state upon the application of heat. One type of printing ink suitable for sublimation printing is prepared from sublimable dyestuffs utilizing binders and oxidation additives. The term �sublimable� is defined herein to mean capable of sublimation.
U.S. Pat. No. 5,308,426 to Claveau teaches a process for forming sublimation images on objects, evidently irregular non-planar objects, by forming an �ink support� from a material which is both extensible and air permeable and which will conform to the shape of the object. This ink support is used to envelop the object, which is then placed in a vacuum machine. The vacuum machine, with the ink support inside, is then introduced into a heated space, causing transfer of the decoration over the whole surface of the object be decorated. Examples of extensible air-permeable materials suitable as ink carriers for utilization in the '426 invention include woven fabrics, knitted fabrics, and sheets of non-woven material.
U.S. Pat. No. 5,997,677 to Zaher teaches a methodology for applying a colored decorative designed on a plastic substrate by heating the carrier and then placing the carrier in contact with the substrate by air suction, such that a sub-pressure results between the carrier and the substrate. Thereafter an inhomogeneous exposure of infrared radiation is directed to the carrier in correspondence with the prevalent color portion of the dyestuff to which the radiation is applied. The dye carriers taught by '677 � . . . above all are sheets of paper which, on the one hand, are good at accepting the images of sublimable dyes to be transferred and, on the other hand, are sufficiently permeable so that air can be sucked through the dye carrier . . . during sublimation transfer printing.� Many of the known dye sublimation printing methodologies applied to solid plastics are so sensitive to variations in pressure, temperature, dye lot, substrate lot, and other manufacturing variables, that at least one inventor has directed his inventive efforts solely to the task of pre-conditioning a plastic substrate for dye sublimation printing. This pre-conditioning is taught and explained in U.S. Pat. No. 5,580,410 to Johnston.
SUMMARY OF THE INVENTION The present invention provides a methodology for forming a dye sublimation image in a solid sheet of plastic. The methodology completely obviates the unwanted adhesion of dye carriers to substrates. The imaging methodology taught herein routinely produces a durable, clear, sharp image in a flat plastic sheet, which sheet is un-shrunken, un-warped, and distortion-free and which retains all of its original technical performance specifications.
DETAILED DESCRIPTION OF THE INVENTION The succeeding discussion centers on one or more preferred embodiments of the present invention, implemented by a number of components. Those having skill in the art will understand that where the embodiments enumerated herein specify certain commercially available components, these are by way of example. The principles of the present invention are capable of implementation in a wide variety of configurations and these principles specifically contemplate all such embodiments.
Moreover, in order to smoothly mold and flow over the several elements of the cooling device-substrate-dye carrier stack, as well as to platen 10, it is desirable that membrane 16 be formed of a flexible material. When used on dye carrier-substrate-cooling device stacks having significant vertical extent, for instance greater than about one inch in thickness, it further desirable that the membrane be formed of an elastomeric material to more smoothly mold and flow over these several elements. As the imaging process taught herein utilizes rapid temperature changes, as well as sustained periods of temperatures up to 600� F., is also required of the membrane that it be not only heat-resistant, but that it be capable of withstanding repeated thermal cycles between higher and lower temperatures without hardening, cracking, loss of structural integrity or loss of any of the previously discussed properties.
Referring now to FIG. 1C, the clamping step of one embodiment of the present invention is explained. Membrane 16 having previously been positioned over the dye carrier-substrate-cooling device stack, as well as at least a portion of platen 10 including at least one and preferably a plurality of vacuum orifices 14, now exerts an atmospheric clamping pressure, as shown at 20. As used herein, the term �atmospheric clamping pressure� denotes the use of a pressure differential between the ambient atmosphere and the atmosphere beneath the membrane to effect the clamping of the substrate and dye carrier. This atmospheric clamping pressure may be effected by means of vacuum, air pressure, or a combination of the two.
Referring now to FIGS. 1F-1H, at the completion of the second, cooling thermal event, vacuum is released at 26 and membrane 16 removed from the dye carrier�substrate stack at 28. Thereafter, dye carrier 3 and substrate 1 are lifted from passive cooling device 12. At this point the image carried by dye carrier 3 has been formed within substrate 1. The degree of dye penetration within the plastic is dependent upon several factors. These include sublimation temperature, clamping pressure, and duration of application of thermal energy and clamping pressure.
Referring now to FIG. 2B, details of thermal imaging unit 206 and platen assembly 204 are shown. Platen assembly 204 comprises a perforated aluminum platen 10, atop which is placed a passive cooling device 12. A frame, sometimes referred to herein as a �spectacle frame�, 216 is hingedly attached at one side to platen 10 by means of hinges 208. Frame 216 has mounted thereto a sheet of elastomeric membrane 16, previously discussed, which membrane covers the aperture formed by the frame. In this embodiment of the present invention membrane 16 takes the form of the textured sheet of DuPont Viton�.
In one application of this embodiment of the present invention an 80 mil acrylic sheet was utilized as substrate 1. The acrylic sheet was imaged by positioning it on passive cooling device 12, and then superposing a dye carrier 3 thereover, as shown. Spectacle frame 216 was then lowered over the acrylic sheet and dye carrier 3, covering them with membrane 16. In this embodiment, a silicone rubber sheet was implemented as membrane 16. After evacuation of the space under membrane 16, processing proceeds in previously discussed for this embodiment. In this case the acrylic sheet was processed for 10 minutes at a temperature 350� F. After this first thermal event, cooling proceeded as previously discussed.
In one application of this embodiment of the present invention an 80 mil Sintra� sheet was utilized as substrate 1. The Sintra� sheet was imaged by positioning it on passive cooling device 12, and then superposing a dye carrier 3 thereover, as shown. Spectacle frame 216 is then lowered over the Sintra� sheet and dye carrier 3, covering them with membrane 16. In this embodiment, a Viton� fluoroelastomer sheet was implemented as membrane 16. After evacuation of the space under membrane 16, processing proceeds as previously discussed for this embodiment. In this case the Sintra� sheet was processed for 5-7 minutes at a temperature of 285� F. Following this first thermal event, cooling proceeded as previously discussed.
Yet another alternative is presented having reference to FIG. 8. This embodiment is similar to the embodiment depicted in FIG. 7, but with this difference: active cooling plate 550 is not utilized in the present environment, but both heating and active cooling are performed by means of a thermal plate 802. Thermal plate 802 is similar to conductive heating plate 502 shown in FIG. 7 with the exception that it provides both heating and active cooling to substrate 1 and dye carrier 3 through membrane 16. This is accomplished in the following manner: to effect the heating of thermal plate 802 there is introduced into an internal cavity 803 thereof a controlled flow of heated fluid, for instance a 50 percent mixture of ethylene glycol and water, this mixture sometimes hereafter referred to as �water�, by means of hot water piping 804 controlled by hot water valve 806.
In one application of this embodiment of the present invention a 60 mil Kydex� sheet was utilized as substrate 1. The Kydex� sheet was imaged by positioning it on platen 10, and then superposing a dye carrier 3 thereover, as shown. Spectacle frame 216 is then lowered over the Kydex� sheet and dye carrier 3, covering them with membrane 16. In this embodiment, a butyl rubber-covered canvas sheet was implemented as membrane 16. After evacuation of the space under membrane 16, processing proceeds in previously discussed for this embodiment. In this case the Kydex� sheet was processed for 5 to 10 minutes at temperatures from 370� F. to 335� F. Following the first thermal event, a flow of chilled fluid was introduced into the interior, 803 of thermal plate 802 to cool the Kydex� sheet, substantially to room temperature.
A plurality of ABS sheets were imaged by superposing a dye carrier 3 and a dye stop layer 1003 atop each sheet. The plurality of ABS sheets were then positioned atop passive cooling device 12. Frame 1010 was then lowered, covering the several substrate-dye carrier-dye stop stacks with membrane 16. In this embodiment, a silicone rubber sheet was implemented as membrane 16. After evacuation of the space under membrane 16, processing proceeds in previously discussed for this embodiment. In this case the ABS sheets were processed for 3 hours at a temperature of 300� F. After this first thermal event, cooling proceeded as previously discussed.
In one application of this embodiment of the present invention a plurality of 40 mil polycarbonate sheets, 30 inches by 60 inches, were imaged by forming imaging body 650 as discussed. Imaging package 670 was formed by evacuating vacuum bag 600 to a substantially complete vacuum. Thereafter, imaging package 670 was inserted into oven 700 and heated at 265� F. for a period of three hours. Following imaging, imaging package 670 was removed from oven 700 and allowed to cool utilizing natural air circulation. Once cooling was effected, vacuum was released and imaging body 650 separated into its component substrates, as discussed.
From the preceding discussion of imaging times, clamping pressures, imaging temperatures, and cooling times, it will be appreciated that the principles enumerated herein are applicable over a wide range of these variables. While the specifics of any given imaging regime are both highly specific and empirically determinable, in general terms, the present invention contemplates imaging temperatures for most plastic substrates at temperatures between 200� F.-600� F.; more particularly between 225� F. and 400� F., and more particularly still at temperatures between 250� F. and 300� F.
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