Apparatus and method for image transfer processing and application

Abstract

An image transfer system for handling a substrate includes an image processing location and an object conveyor to convey an object to the image processing location. The image processing location includes a printer to form an image on a target surface of the substrate, a separator mechanism to separate a section of the substrate with the image formed thereon, a platform configured to receive the section, a particulate material dispenser to dispense particulate material on the target surface to form an adhesive, and a treatment apparatus to direct heat to the section to heat the ink and the particulate material. The platform is further configured to hold the section and to selectively reorient the section wherein the target surface of the substrate faces the object and to deposit the section on the object while supported by the object conveyor at the image processing location.

Description

BRO07 FP-102A (WO)APPARATUS AND METHOD FOR IMAGE TRANSFER PROCESSING AND APPLICATION BACKGROUND

[0001] The present disclosure pertains to an image transfer system, substrate handling apparatus, and method for preparing and applying an image formed from a fluid or paste on a substrate to transfer the image onto a target surface of an object, such as clothing and accessories, including T-shirts, hats, bags, jackets, aprons, socks, backpacks, and other wearable items or fabric-based products.SUMMARY

[0002] The present disclosure is directed to an image transfer system with a substrate handling apparatus and a method to provide a process of transferring an image to an object through use of a substrate to reduce production time and waste. The preparation capabilities and positioning precision that this disclosure describes is not only beneficial to digital film printing but is adaptable to all applications requiring process accuracy.

[0003] An image transfer system and method for image application on an object are described using an intermediary substrate, such as a film substrate that is used as an image transfer substrate. The image transfer system may consist of a conveyor, at least one printer, at least one substrate handling apparatus, at least one heat and / or pressure apparatus, and at least one apparatus to handle the transfer substrate.

[0004] The printer may comprise a standard printer that can print ink onto a substrate for later transfer to the object. The substrate handling apparatus is configured to receive the printed substrate directly from the printer, with the printed section of the substrate separated from the balance of substrate either in the printer or after being output from the printer, to apply particulate material to the ink on the substrate to form an adhesive layer, and then to position the substrate onto the object to allow for later transfer of the ink from the substrate to the object.

[0005] Further, the substrate handling apparatus may include a treatment apparatus that may be used to bond the particulate material to the image. A suitable treatment apparatus may include a curing device with the technology disclosed in U.S. Patent No. 10,011,136, which is incorporated by reference herein in its entirety.

[0006] In some examples, the substrate handling apparatus may contain multiple transportation apparatuses. The transportation apparatuses may have the same or different configurations toaccommodate various substrate preparation processes, allowing each transportation apparatus to be optimized for a specific function.

[0007] In some examples, as noted, the image transfer system may have more than one heat and / or pressure apparatuses. For example, a heat and / or pressure apparatus may be provided to apply heat and / or pressure to the object before it is conveyed to the image transfer location. One advantage of this optional heat and / or pressure apparatus may be to smooth the target surface of the object prior to transferable substrate positioning. Another additional heat and / or pressure apparatus may be used to apply heat and / or pressure to the object after the substrate is removed to further enhance the adhesion. When heat is applied to the object before being conveyed to the image transfer location, this may reduce the time needed to apply heat after the substrate is deposited onto the object and / or reduce the time heat is applied to the object after the substrate is removed.

[0008] The present disclosure is also directed to a method involving a combination of the preparation steps used to transform a substrate into a substrate with a transferable image and the application steps, as more fully described below. The method starts with object data being uploaded to a control system and an object being loaded onto a conveyor.

[0009] The printer begins outputting the image associated with the object data onto the substrate.During this time, the object is conveyed to the substrate handling apparatus. Once the image is printed onto the substrate, the printed substrate is fed (e.g., pushed) onto a transportation apparatus, which includes a movable substrate support surface, such as a platform.

[0010] Optionally, in one example, while being fed to the transportation apparatus, particulate material, such as an adhesive powder, is dispensed onto the printed substrate via a particulate material applicator, such as a hopper. The particulate material creates an adhesive for the ink, ensuring that the image will adhere to the object after it is transferred. Upon completion of substrate transfer onto the transportation apparatus, the substrate is retained on the substrate support surface, such as by clamps, suction, or another retention device or devices. For example, suction may be applied to the substrate through the substrate support surface to hold the substrate thereon. The portion of the substrate with the image printed thereon, as noted, is separated from the balance of the substrate by a separator mechanism, such as a cutter, to reduce the amount of wasted substrate, which may be located in the printer or near or adjacent to the output of the printer.

[0011] Optionally, the transportation apparatus may pass through a particulate material, such as an adhesive powder, which is dispensed onto the printed substrate via a particulate material applicator, for example, a hopper. The particulate material forms an adhesive on the ink, thereby ensuring that the image adheres to the object upon transfer. Excess particulate material may then be removed by the substrate handling apparatus using one or more of the following: a tilting motion, mechanical excitation (e.g., vibration), or an air-moving device, such as a fan, blower, or vacuum.

[0012] After application of the particulate material, the substrate is heated using the treatment apparatus that applies heat to bond the particulate material to the ink and enhance adhesion of the printed image.

[0013] In one example, the transportation apparatus may selectively adjust the position or orientation of the substrate to ensure that the particulate material is properly exposed to the heat, further facilitating bonding of the particulate material to the ink and enhancing adhesion of the printed image.

[0014] After the particulate material is bonded to the ink, the transferable substrate is then positioned on the object. In one example, the substrate is supported on a substrate support surface, such as a platform, that is movable, for example is rotatable from a substrate receiving position, where the substrate is received from the printer, to a substrate transfer position, where the substrate is transferred to the object. For example, the platform may be configured to apply suction to or clamp the substrate to hold the substrate on the platform and then reorient the platform substrate and then to release the suction or clamping to allow the substrate to detach from the platform under the influence of gravity and be positioned on the object.

[0015] The image transfer system may then convey the object to at least one heat and / or pressure apparatus. The control system may control the time, temperature, and / or pressure at which heat is applied to the object. The object is then conveyed to a substrate removal apparatus before returning to a conveyor unloading location. There may be an optional heat and / or pressure apparatus on the output of the substrate removal apparatus before the object is returned to the unloading location. The additional heat and / or pressure apparatuses may enhance adhesion of the print to the object and print quality.

[0016] Upon the object being returned to the unloading location, the control system monitors and notifies whether the image transfer onto the object is completed or that additional processing isrequired for the object. For example, additional processing could involve a second print transfer location on the object.

[0017] The present method can result in increased production speeds by removing manual intervention during intermediate steps. It can also reduce waste from not only the substrate, but also from rejected objects due to incorrect positioning of the ink and mismatched prints to objects. This apparatus and method ultimately expand the market for object customizations by allowing more printing locations that are systematically tracked.BRIEF DESCRIPTION OF DRAWINGS

[0018] FIG. 1 is a simplified schematic plan view of the system and method based on an example of the disclosure;

[0019] FIG. 2 is a top elevation view of the substrate handling apparatus illustrating the particulate material applicator and transportation apparatus with a transportation platform connected to a conveyor;

[0020] FIG. 3 is a side elevation view of the substrate handling apparatus additionally illustrating the separator mechanism;

[0021] FIG. 4 is an alternative side elevation view of the substrate handling apparatus;

[0022] FIG. 5A is a schematic plan view of a substrate handling apparatus and method depicting the start of the process sequence, for example, with the inked substrate exiting a printer, passing a particulate material applicator, and transferring onto a transportation platform;

[0023] FIG. 5B is a schematic plan view of the separator mechanism cutting the substrate;

[0024] FIG. 5C is a schematic elevation view of the substrate handling apparatus and method depicting the third step, for example, with the transportation platform tilting to remove excess particulate material;

[0025] FIG. 5D is a schematic elevation view of the substrate handling apparatus and method depicting the fourth step, for example, with the transportation platform adjusting position for a later step;

[0026] FIG. 5E is a schematic elevation view of the substrate handling apparatus and method depicting the fifth step, for example, with the treatment apparatus applying heat to the particulate material on the inked substrate;

[0027] FIG. 5F is a schematic elevation view of the substrate handling apparatus and method depicting the sixth step, for example, with the transportation platform being conveyed over the object and the substrate being positioned for transfer to the object;

[0028] FIG. 6 is a perspective view of the pallet depicting the platform, tray, and support structure;

[0029] FIG. 7 is a perspective view of the heat and / or pressure apparatus;

[0030] FIG. 8 is a perspective cutaway view of the heat and / or pressure apparatus depicting the heating element, pneumatically controlled cylinder, sheathing, and internal frame;

[0031] FIG. 9 is a perspective view of a mechanical stop assembly in a retracted state;

[0032] FIG. 10 is a perspective view of the mechanical stop assembly of FIG. 9 in an extended state;

[0033] FIG. 11 is a simplified schematic plan view of another example of an image transfer system;

[0034] FIG. 12 is a top plan view of a substrate handling apparatus of the image transfer system of FIG. 11 illustrating the particulate material applicator, a treatment apparatus, and a transportation apparatus, including one or more movable transportation platforms supported by a frame that extends over an object support platform connected to a conveyor;

[0035] FIG. 13 is a side elevation view of the substrate handling apparatus of FIG. 12, with the object support platform and conveyor shown below the transportation platform;

[0036] FIG. 14 is an elevation view of the input end of the substrate handling apparatus;

[0037] FIG. 15A is a schematic plan view of a substrate handling apparatus and method, depicting an optional start of the process sequence for example, when the inked substrate exits a printer and slides onto a transportation platform;

[0038] FIG. 15B is a schematic plan view of the substrate handling apparatus and method, depicting an optional second step, for example, the inked substrate being cut by a separator mechanism;

[0039] FIG. 15C is a schematic plan view of the substrate handling apparatus and method, illustrating an example third step, for example, where the transportation platform passes under a particulate material applicator;

[0040] FIG. 15D is a schematic elevation view of the substrate handling apparatus and method, depicting an optional fourth step, for example with the transportation platform tilting to remove excess particulate material;

[0041] FIG. 15E is a schematic elevation view of the substrate handling apparatus and method, depicting an optional fifth step, for example, where the transportation platform is repositioned;

[0042] FIG. 15F is a schematic elevation view of the substrate handling apparatus and method, illustrating an optional sixth step, for example where the treatment apparatus cures the particulate material on the inked substrate before being transferred onto the object;

[0043] FIG. 15G is a schematic elevation view of the substrate handling apparatus and method, illustrating an optional seventh step, for example, the transportation platform ready for rotating to re-orient the substrate for transfer to the object;

[0044] FIG. 15H is a schematic elevation view of the substrate handling apparatus and method, depicting an optional eighth step, for example, where the transportation platform is conveyed over the object and the substrate re-oriented to be transferred onto the object;

[0045] FIG. 16 is similar perspective view to FIG. 6 of a pallet depicting the object support platform, tray, and support structure;

[0046] FIG. 17 is a similar perspective view to FIG. 7 of the heat and / or pressure apparatus;

[0047] FIG. 18 is a similar perspective cutaway view to FIG. 8 of the heat and / or pressure apparatus depicting the heating element, pneumatically controlled cylinder, sheathing, and internal frame;

[0048] FIG. 19A is a similar perspective view to FIG. 9 of a mechanical stop assembly in a retracted state;

[0049] FIG. 19B is a similar perspective view to FIG. 10 of the mechanical stop assembly in an extended state;

[0050] FIG. 20 is a side elevation view of a substrate removal apparatus showing a removal apparatus configured with a removal tool with an engagement member and a pressure applicator, positioned over the conveyor;

[0051] FIG. 21 A is a schematic elevation view of a substrate handling apparatus and method, depicting an example first step in the transfer of the substrate between two platforms;

[0052] FIG. 21B is a schematic elevation view of the substrate handling apparatus and method, depicting an example second step in the transfer of the substrate between two platforms;

[0053] FIG. 21C is a schematic elevation view of the substrate handling apparatus and method, illustrating an example third step in the transfer of the substrate between two platforms;

[0054] FIG. 21D is a schematic elevation view of the substrate handling apparatus and method, illustrating an example fourth step in the transfer of the substrate between two platforms;

[0055] FIG. 21E is a schematic elevation view of the substrate handling apparatus and method, depicting an optional sixth step in the transfer of the substrate between two platforms;

[0056] FIG. 22 is an enlarged fragmentary perspective view of the first and second platform configuration illustrating the platforms in their home positions; and

[0057] FIG. 23 is an enlarged fragmentary perspective view of the first and second platform configuration illustrating the first platform in its transfer position and the second platform is in its home positions where the substrate is transferred from the first platform to the second platform.DETAILED DESCRIPTION

[0058] Referring to FIG. 1, the numeral 10 designates an image transfer system that is configured to transfer an image onto an object. The image transfer system 10 may include at least one image processing location, with the object conveyed to the image processing location by a conveyor 11, where one or more images are transferred onto the object. For ease of reference, the description hereafter will refer to a conveyor with the understanding that the term conveyor is used broadly to mean one or more conveyor sections that cooperate together to convey the object or objects being processed and which may include roller conveyors, belt conveyors, chain conveyors etc. As will be more fully described below, image transfer system 10 may include at least one processing location(e.g., at 14, 16, and / or 17), including an image processing location, resulting in object enhancement, such as an image being attached to the object, which includes a printer 15, a substrate handling apparatus 14, and a heat and / or pressure apparatus 16. Objects handled by this system may include textiles, ceramics, wood, and plastics.

[0059] As noted above, the conveyor 11 may include a roller conveyor, a belt conveyor, a chain conveyor, or the like, and may be driven by at least one motor and gearbox, for example, located under the conveyor or in a housing 12 of the system.

[0060] Image transfer system 10 also includes a main control system that controls conveyor 11 and the various components of the substrate handling apparatus 14, printer 15, heat and / or pressure apparatus 16, and substrate removal apparatus 17. It should be understood that theconveyor 11 may have a dedicated, local control system, which monitors the speed, direction, and positioning of the conveyor 11 , which is in communication with the main control system allowing for independent or synchronized operations as required. Similarly, each of the substrate handling apparatus 14, printer 15, heat and / or pressure apparatus 16, and substrate removal apparatus 17 may have a local control system, which are in communication with the main control system. Additionally, the main control system is configured to manage and control the movement of a plurality of objects through the image transfer system 10, using a combination of sensors, actuators, and / or control algorithms, as will be more fully described below. For ease of description reference will be made to “control system” to refer to the main control system and the local control systems collectively.

[0061] The control system may be a microprocessor-based control system with one or more controllers that control necessary data modifications and further routes the data to at least one printer. The controller or controllers may be implemented as hardware, software, firmware, and / or any combination of hardware, software, and / or firmware. The controller or controllers may include one or more devices, such as programmable processors (e.g., field programmable gate arrays, programmable logic controllers), microprocessors (e.g., central processing units, multi-core processors, crypto processors, digital signal processors, graphics processing units), microcomputers (e.g., electronic control units, microcontrollers, state machines), and / or circuits (e.g., analog circuits, logic circuits, crypto circuits, application-specific integrated circuits).

[0062] To support the object on the conveyor 11, image transfer system 10 includes a pallet 27 as shown in FIG. 6, which may be supported on conveyor 11 to enhance the efficient and seamless conveyance of the objects processed by the system. The pallet 27 may include a tray 29 and an object support platform 28, which is connected to the tray 29 via a support structure 30 designed to maintain a gap between the object support platform 28 and the tray 29. The support structure 30 may be configured to be releasable connected to the platform and / or tray, for example via couplers, such as releasable fasteners (including screws, bolts, or manipulable spring biased detent mechanisms) to allow for a detachable coupling, enabling the platform to be removed from the tray and / or support structure.

[0063] The area between the object support platform 28 and the tray 29 may be used to protect object overflow, such as excess garment material that may drape over the object support platform 28, from getting entangled in the processing apparatuses of the system 10. The object supportplatform 28 may contain a cushion that is heat-resistant and has a compressible structure to allow the cushion to conform to the object shape when pressure is applied. The cushion may be attached to the platform using an adhesive, such as a silicone sealant. The pallet 27 may be engineered with heat-resistant, moisture-resistant, and chemically inert properties, ensuring its suitability for deployment across a wide array of industrial environments. The pallet 27 may be configured with a modular design, enabling the object support platform 28 to be replaced to accommodate varying sizes of objects. The tray 29 may contain flanges around the perimeter to allow for pallet alignment and tracking during transport. Additionally, the pallet 27 may contain an RFID tag to further allow for object identification and tracking by the control system.

[0064] To initiate the processing of an object, the object is loaded onto the conveyor 11, which as noted may utilize a pallet 27 to support the object as it is transported. The conveyor 11 then moves the object along the conveyor 11, directing it to the image processing location at substrate handling apparatus 14 for the image transfer process. As noted above, a printer 15 is located at the image processing location adjacent to substrate handling apparatus 14. A suitable printer may be chosen from available technology for screen printing, digital printing, heat transfer, sublimation and the like. The printer 15 is responsible for depositing or placement of the ink onto a substrate, which is then prepared as follows.

[0065] In one example, the printed substrate is formed from a roll of substrate (FIG. 1). The roll is fed to each printer 15 to print the desired image on a section of the substrate. After printing the substrate, the printed substrate is fed to substrate handling apparatus 14 from the printer 15, and specifically onto a transportation platform 20 of the substrate handling apparatus 14, such a plate, including a foraminous plate (as more fully described below). For example, guide rails may be incorporated along the output path of the printer 15 to direct the printed substrate onto the transportation platform 20 of the substrate handling apparatus 14, ensuring accurate positioning and smooth movement of the printed substrate for subsequent processing.

[0066] Referring to FIG. 3, substrate handling apparatus 14 may include a frame that straddles conveyor 11 and supports the transportation platform 20 and supports its various components described below. As will be more fully described below in reference to another example, depending on the configuration of the substrate handling apparatus 14, the substrate may be transported through the substrate handling apparatus 14 by a single transportation platform 20 or more than one, including by a series of transportation platforms.

[0067] In one example, the portion of the substrate that is printed is separated, such as by cutting, from the balance or remainder of the substrate by a separator mechanism 23. The separator mechanism 23 is designed to interact with the substrate, facilitating a precise break of the substrate along the designated path. It may achieve substrate division using technology such as blades, lasers, or heat. The separator mechanism 23 may be driven by an actuator, such as a motor, and may be initiated and controlled by the control system based on sensor feedback. It should be understood that the separator mechanism 23 may be a component of or a separate component from the substrate handling apparatus 14, and further may be part of the printer, as described below

[0068] The substrate handling apparatus 14 may also include a particulate material applicator 19, which is supported by the frame optionally downstream of the separator mechanism 23 and designed to dispense particulate material, such as powder, onto the target surface of the substrate in a controlled manner.

[0069] In one example, the target surface is the inked portion of the substrate. The particulate material applicator 19 may be designed with a tapered structure (e.g., a hopper) to promote the even dispersion of particulate material onto the inked portion of the substrate. It may feature a motor-driven roller, for example, positioned at the output of the tapered end of the tapered structure, which regulates the flow of particulate material onto the target surface. The motor is in communication with the control system and is controlled by the control system to provide precise dispensing, thereby allowing uniform coverage of the target surface. The image transfer system 10 may be equipped with sensors and / or additional control systems to adjust particulate material flow for specified requirements.

[0070] To remove excess particulate materials, the transportation platform 20 may be configured to tilt to reorient the substrate so that the excess particulate material falls off the substrate under the force of gravity. For example, the transportation platform 20 may be coupled to one or more actuators configured to impart angular movements to the transportation platform 20, thereby causing the transportation platform 20 to tilt relative to a horizontal reference plane. The degree, direction, and duration of the tilt may be selectively controlled to reorient the substrate and encourage particulate material to migrate toward an edge of the transportation platform 20. In addition to tilting, the transportation platform 20 may be configured to impart vibratory motion to the substrate. Such vibratory motion may be generated by mechanical, electromechanical,pneumatic, or other suitable means for imparting oscillatory movement. The vibratory motion may be continuous, intermittent, or pulsed.

[0071] The transportation platform 20 may further be configured to retain the printed substrate on the transportation platform 20 using one or more retention systems or devices, including a vacuum-based retention system, mechanical retention device, or other suitable devices and systems, to permit precise manipulation or reorientation of the platform and substrate supported thereon. An example of a mechanical retention device may comprise a clamp that is actuated using at least one pneumatically controlled cylinder that is configured to operate the clamp to engage the substrate, again which may be controlled by the control system.

[0072] In the illustrated example, a motor rotates the transportation platform 20, which facilitates reorientation of the transportation platform 20 and the substrate so that gravity can cause excess particulate material to fall off the substrate. To hold the substrate, as noted, the transportation platform 20 may include a retention device, such as a suction surface formed by a foraminous plate (a plate with a plurality of openings) to apply negative pressure to the substrate to create a seal (i.e., suction force) between the substrate and the suction surface of the transportation platform 20, thus allowing for precise manipulation or reorientation of the substrate.

[0073] Additional methods to assist in removal of excess particulate material may be incorporated into the substrate handling apparatus 14. These methods may rely on airflow dynamics, either through vacuum suction or direct fan-based air movement, to remove unwanted particulate material from the surface of a printed substrate.

[0074] The substrate handling apparatus 14 may include a designated collection area 24 (FIG.5C), such as a receptacle, configured to facilitate collection, disposal, and / or recycling of the particulate material removed from the substrate. The designated collection area 24 may be mounted to the substrate handling apparatus 14, connected to the transportation platform 20 or other component of the apparatus, or provided as a separate receptacle positioned beneath the substrate. In some examples, the designated collection area 24 may further include a unit for returning collected particulate material to the particulate material applicator 19 for reuse, which may, for example, comprise a vacuum, auger, conveyor, or other suitable systems or mechanisms.

[0075] To move the transportation platform 20 and substrate supported thereon, substrate handling apparatus 14 may include a transportation apparatus 21, which is supported by theframe of the substrate handling apparatus 14 and moved by a conveyor 22, such as a belt or chain conveyor, which is driven by a motor and controlled by the control system. Transport apparatus 21 may include a pair of brackets that are coupled to the conveyor 22 and, further, which may be guided along guides parallel to the conveyor 22.

[0076] Conveyor 22 is configured to transport the transportation apparatus 21 and transportation platform 20 (and printed substrate supported thereon before being transferred to the object) along a defined path between the printer and the object, which is supported on the pallet 27 on conveyor 11. In other words, when operated, the conveyor 22 moves the transportation apparatus 21 between a substrate receiving position at or adjacent to the inlet of the substrate handling apparatus 14, where the transportation platform 20 receives the substrate, and a substrate transfer location above the object. The transportation apparatus 21 may be indexed between several intermediate positions, such as a separation position where the inked substrate is separated and / or where the particulate matter is deposited on the inked substrate, and a treatment position where the substrate may be heated, as described below. The conveyor 22 is in communication with the control system and is controlled using feedback from at least one sensing device. For example, the at least one sensing device may detect rotational movement of the transportation platform 20 through optical, magnetic, or capacitive sensing technologies. Additionally, at least one proximity sensing device may be incorporated into the conveyor 22 to track the position of the transportation apparatus 21 along conveyor 22. The transportation apparatus 21 may also incorporate at least one pneumatically controlled cylinder 26 (FIG. 3) to adjust the position, such as height, of the transportation platform 20 relative to the transportation apparatus 21 and object to enable accurate elevation adjustments when depositing or positioning the printed substrate onto the object.

[0077] In one example, described below, where the substrate handling apparatus 14 includes multiple transportation platforms, each potentially having a different configuration, the transportation apparatus 21 may itself be implemented in various configurations.

[0078] Before depositing the printed substrate onto the object, the ink may be subject to heat to activate the particulate material layer on the ink by a treatment apparatus 25 (FIG. 5E), which may be integrated into the substrate handling apparatus 14. The treatment apparatus 25 may include at least one heating element, at least one imaging sensor with shield, a cooling device, and the necessary controls, such as disclosed in U.S. Patent No. 10,011,136.

[0079] Referring now to FIGS. 1, 7, and 8, as noted, image transfer system 10 may include one or more heat and / or pressure apparatuses 16 that are used to bond the ink to the object. After the object has been processed by substrate handling apparatus 14 and the inked substrate has been deposited on the object, conveyor 11 conveys the object to heat and / or pressure apparatus 16. Optionally, as illustrated, when image transfer system 10 includes multiple image processing locations, image transfer system 10 may include a heat and / or pressure apparatus 16 for each substrate handling apparatus 14 to increase the speed or throughput of the image transfer system 10.

[0080] Additionally, image transfer system 10 may include a heat and / or pressure apparatus 16 to apply heat and / or pressure to the object before it is conveyed to the image transfer location. One advantage of this optional heat and / or pressure apparatus may be to smooth the target surface of the object prior to transferable substrate positioning. Another additional heat and / or pressure apparatus 16 may be used to apply heat and / or pressure to the object after the substrate is removed to further enhance the adhesion, as noted below. When heat is applied to the object before being conveyed to the image transfer location, this may reduce the time needed to apply heat after the substrate is deposited onto the object and / or reduce the time heat is applied to the object after the substrate is removed.

[0081] Each heat and / or pressure apparatus 16 may apply heat and / or pressure. For example, each heat and / or pressure apparatus 16 may contain a heating element 34, which comprises a flat, metal surface directed toward the object to allow even heat distribution to the object. The heating element 34 may be enclosed in a housing 31 and includes an internal frame 33. The heating element 34 may be supplied with an insulated case allowing it to be mounted to the internal frame 33. There may be at least one mechanical device, such as a spring, mounted between the heating element 34 and the internal frame 33 that allows the heating element 34 to flex in response to applied pressure. Also integrated into the internal frame 33, may be a pneumatically controlled cylinder 35 responsible for the vertical movement that allows for uniform contact between the heating element 34 and the object when the object is conveyed on object support platform 28 into the heat and / or pressure apparatus 16. The temperature of the heating element 34 is maintained by the control system using at least one temperature controller. It is configured to allow for the application of controlled heat and / or pressure for a specified duration.

[0082] There may be a sheathing 36 located between the heating element 34 and the object to protect both the heating element and the object. The sheathing 36 may act as a non-stick barrier that prevents the object from coming into direct contact with the heating element 34 and it also protects the heating element 34 from contamination by preventing unwanted debris, residues, or substances from directly touching and sticking to the heating element 34. The sheathing 36 may be of a material with low friction, chemically inert, and high thermal stability properties. The sheathing 36 may be supplied as a continuous loop positioned around the heating element 34 to allow for restored sections of the sheathing to make contact with the ink and object.

[0083] In the illustrated example, an apparatus may be incorporated to hold the position of the sheathing and may include a plurality of cylindrical components that allow for rotation along an axis to form a continuous loop. One of the cylindrical components may have a motor that determines the position of the sheathing 36 based on sensor feedback. The housing 31 may also include a movable barrier 32 allowing access to the sheathing 36.

[0084] A suitable heat and / or pressure apparatus may include the heat and / or pressure apparatuses disclosed in U.S. Patent Publication No. 2021 / 0197604, which is incorporated by reference herein in its entirety.

[0085] After heat and / or pressure has been applied to the substrate and object, the substrate is removed from the object. To remove the substrate, image transfer system 10 may include at least one substrate removal apparatus 17. The substrate removal apparatus 17 may include at least one removal tool to remove the substrate upon the completion of ink bonding to the target object via heat and / or pressure apparatus 16. The removal tool may incorporate technologies such as robotics, vacuum suction, or mechanical guide. Additionally, the substrate removal apparatus 17 may include a mechanical device, such as a clamp, used to hold the position of the object during substrate removal. The at least one removal tool used for substrate removal is systematically controlled by the control system and may incorporate the feedback from sensors to verify precision when the object is ready to have the substrate removed. For further details of an exemplary substrate removal apparatus, reference is made to FIG. 20 and the description that follows below.

[0086] An additional heat and / or pressure apparatus 16 may also be provided to apply heat and / or pressure to the object after the substrate is removed, as noted above.

[0087] The image transfer process starts in a loading location 13 where an operator can load an object onto a pallet 27, which may be positioned on the conveyor 11. At least one mechanical stop assembly 37 may be provided to prevent unintentional movement of the object in the loading location 13. As shown in FIGS. 9 and 10, the mechanical stop assembly 37 may include a stop 38 that can be raised using an actuator, such as a pneumatic cylinder, to form a stop in the path of the object on the conveyor. Additionally, the stop 38 helps to align the object and may contain a sensor to detect object presence. The operator inputs object enhancement data into the control system through manual entry, a primary key or unique identifier used to store object data, or through Radio Frequency Identification technology. After the object is positioned on the pallet 27 and the object data is loaded into the control system, the operator uses a control input to the control system, such as a button or touch screen, to trigger the initiation of the image transfer process. In response, the control system processes the object data and converts it into a format compatible with the printer’s technology, then transmits it to a plurality of printers through a communication link, such as an ethernet or router. A printer 15 is selected according to a system algorithm, which is based on the availability of printers and / or substrate handling apparatuses. The selected printer 15 begins transferring the image based on the object data onto a substrate. During this time, the object is conveyed to the image processing location at the selected substrate handling apparatus 14. There is an optional process sequence where the object may be routed through a heat and / or pressure apparatus 16 before being conveyed to a substrate handling apparatus 14. The purpose of this optional heat and / or pressure apparatus 16, as noted, is to smooth the target surface of the object prior to transferable substrate positioning.

[0088] To control conveyor 11, the control system may use the feedback from a plurality of sensors to track the object. For example, the sensors may emit a signal using a wireless format, such as electromagnetic fields, infrared light, or sound waves. When the sensors detect the presence or absence of an object within a specific range, they may send a corresponding output signal to the control system. The sensors may be located around the perimeter of the image transfer system 10, for example, in the housing 12, and in the aforementioned mechanical stops 37. When the object reaches the selected substrate handling apparatus 14, it may be aligned for printed substrate transfer using at least one mechanical stop assembly 37.

[0089] It should be understood that within the selected substrate handling apparatus 14, the printed substrate is processed into a transferable form.

[0090] One sequence of steps that the object data may include, as illustrated in FIGS. 5A-5F, which are provided by way of example. It should be understood that one or more steps may be performed in a different order, omitted, repeated, or otherwise modified in various examples of the system. Further, as described below in reference to FIGS. 15A-15H, additional steps may be performed.

[0091] With reference to FIG. 5A, after the printed substrate is generated by the printer 15, it may be conveyed, such as by pushing, onto the transportation platform 20. In one example, particulate material may be dispensed on the ink and substrate as the substrate passes under the particulate material applicator 19 (FIG. 5A), which may be located near or adjacent to the output of the printer. In the illustrated example, the particulate material applicator 19 is mounted to and, hence, formed as part of the substrate handling apparatus 14, though it should be understood that it can be separately mounted. Once the printed portion of the substrate is fully positioned on the transportation platform 20, and the printed portion is retained on the platform, for example by suction , the control system enables the motor driving the separator mechanism 23 (FIG. 5B) to separate the printed substrate from the balance of or remaining portion of the substrate. The separator mechanism 23 may be incorporated as part of the substrate handling apparatus 14 or integrated into or part of the printer 15. Its location may be varied. For example, the separator mechanism 23 may be located near or at the inlet of the treatment apparatus 25 or at or near the outlet of the printer 15. The control system may then command the motor driving the conveyor 22 to reposition the transportation apparatus 21 to avoid obstruction and may tilt the transportation platform 20 to a predefined angle (FIG. 5C). This movement, as noted, allows for dislodgement of loosely adhered or surplus particulate material into a designated collection area 24. As previously described, additional methods may be employed, including air flow, which utilize the airflow dynamics to assist in dislodging excess particulate material.

[0092] Following the removal of excess particulate material from the substrate, the printed substrate may be repositioned to ensure controlled exposure of the adhered particulate material to the treatment apparatus 25 (FIGS. 5D and 5E). The control system may then enable the conveyor 22 again to transport the transportation apparatus 21 over the target object where the transportation platform 20 is rotated and oriented towards the object by initiating the transportation platform 20 motor (FIG. 5F). The at least one pneumatically controlled cylinder 26 on the transportation apparatus 21 is initiated resulting in the printed substrate contacting thetarget surface of the object. The transportation platform 20 removes suction and may instead apply pressurized air to urge the substrate to separate or detach from the transportation platform 20 so that it can be deposited or positioned on the object. The at least one pneumatically controlled cylinder 26 is commanded to retract and the transportation apparatus 21 may be commanded to return to a base position.

[0093] The at least one mechanical stop assembly 37, which aligns the object with the substrate handling apparatus 14, may be commanded to retract and the object may then be conveyed on the conveyor 11 to at least one heat and / or pressure apparatus 16. Using the aforementioned mechanical stop assembly 37, the object may be aligned with the heating element 34. The control system enables the pneumatically controlled cylinder 35 causing the object to contact the heating element 34. The amount of time, temperature of the heating element, and / or pressure at which the object is held into the heating element are configured into the system as part of the object data. The configuration of these settings is dependent on object, substrate, and ink properties. The object is released from the heating element 34 and the pneumatically controlled cylinder 35 is returned to the initial position. The applied heat and / or pressure activates the particulate material embedded in the ink, leading to ink adhesion to the object.

[0094] After the ink has been bonded to the object, the object may then be conveyed on the conveyor 11 to at least one substrate removal apparatus 17. Once object alignment is confirmed, the control system may initiate at least one removal tool to remove the substrate. The perimeter of the substrate does not contain bonded ink, thus the removal tool may engage and utilize these sections for the removal process. The substrate is carefully and progressively separated from the object, ensuring a controlled detachment to avoid disruption to the bonded ink. Upon removal, the control system may instruct the removal tool to dispose of the substrate waste into a designated collection area.

[0095] As noted above, the object containing the bonded ink may be moved through an optional heat and / or pressure apparatus 16 succeeding the substrate removal apparatus 17. The objective of this subsequent heat and / or pressure apparatus may be to further complete adhesion of the ink to the target object and to enhance the finish quality of the print, creating a more consistent, smooth, and visually appealing result.

[0096] The object may then be conveyed on the conveyor 11 to an unloading location 18 to allow for inspection and safe removal of the enhanced object. Similar to the loading location 13,at least one mechanical stop assembly 37 is provided in this location to prevent unintentional movement of the object. Alternatively, inspection and removal of the object may also be completed at the loading location 13. If additional processing is necessary for the object, a control system notification will appear on the loading location 13 control. The operator may adjust object position in accordance with the requirements, and the activator may be triggered to reinitiate the process.

[0097] Referring to FIG. 11, the numeral 110 designates another example of an image transfer system that is configured to transfer an image onto an object, which may be supported on and conveyed by a conveyor or conveyors 111 to an image processing location where one or more images are transferred onto the object. As noted above, the term conveyor is used broadly to mean one or more conveyor sections that cooperate to convey the object or objects being processed and which may include roller conveyors, belt conveyors, chain conveyors, and the like. Similar to the first example, image transfer system 110 may include one or more processing locations resulting in object enhancement, such as an image being transferred to the object, which each include a printer 115, a substrate handling apparatus 114, and heat and / or pressure apparatus 116. Objects handled by this system may also include textiles, ceramics, wood, and plastics. For further details of conveyor 111 (and its housing 112), printer 115, and heat and / or pressure apparatus 116 reference is made to the corresponding components described in reference to the image transfer system 10 described above.

[0098] Image transfer system 110 also includes a control system that monitors the speed, direction, and positioning of the conveyor 111, allowing for independent or synchronized operations as required. Additionally, similar to the first example of image transfer system 10, the control system is capable of managing and controlling the movement of a plurality of objects through combined use of sensors, actuators, and control algorithms. For further exemplary details of the control system, reference is made to the above description.

[0099] Similar to image transfer system 10 described above, image transfer system 10 may also include a pallet 127 as shown in FIG. 16 to enhance the efficient and seamless conveyance of the objects processed by the system. The pallet 127 may similarly contain an object support platform 128 connected to a tray 129 with a support structure 130 designed to maintain a gap between the object support platform 128 and the tray 129. The area between the object support platform 128 and the tray 129 may be used to protect object overflow, such as excess garment material thatmay drape over the platform, from getting entangled in the processing apparatuses of the system 10. For further details of pallet 127, reference is made to the pallet 27.

[0100] An object is loaded onto the conveyor 111, which may utilize a pallet 127 to support the object as it is transported. The conveyor then moves the object along the conveyor, directing it to the printer 115 for further processing. The printer 115 is responsible for depositing or placement of the ink onto a substrate, which is then prepared as follows.

[0101] In the illustrated example, the printed substrate may also be formed from a roll of substrate (FIG. 10). A roll is fed to each printer to print the desired image on a section of the substrate. After printing the substrate, the printed substrate is fed onto substrate handling apparatus 114, and specifically onto a transportation platform 120 of the substrate handling apparatus 114. For example, guide rails may be incorporated along the output path of the printer to direct the printed substrate onto the transportation platform 120, ensuring accurate positioning and smooth movement for subsequent processing. Depending on the configuration of the substrate handling apparatus 114, the substrate may be transported through the subsequent processes by a single transportation platform 120 or by a series of multiple transportation platforms 120 and 120A. In the following description, reference is made to a single transportation platform 120 for clarity, although the substrate handling apparatus 114 may include one or more transportation platforms 120 and 120A, which may be the same or each differently configured.

[0102] In one example, the portion of the substrate that is printed may be separated, such as by cutting, from the balance or remainder of the substrate by a separator mechanism 123. The separator mechanism 123 is designed to interact with the substrate, facilitating a precise break of the substrate along the designated path. It may achieve substrate division using technology such as blades, lasers, or heat. The separator mechanism 123 may be driven by an actuator, such as a motor, and may be initiated and controlled by the control system based on sensor feedback. It should be understood that the separator mechanism 123 may be located at one of several locations — either in or at the outlet of the printer 115, at or near the inlet of the treatment apparatus 125, or at or near the outlet of the treatment apparatus 125 and further may be a component of or a separate component from the printer 115, treatment apparatus 125, or substrate handling apparatus 114.

[0103] The substrate handling apparatus 114 may also include a particulate material applicator 119, which is designed to dispense particulate material, such as powder, onto the target surface (the target surface is the inked portion of the substrate) in a controlled manner prior to being conveyed into the treatment apparatus 125.

[0104] Similar to particulate material applicator 19, particulate material applicator 119 may be designed with a tapered structure (e.g., a hopper) to promote the even dispersion of particulate material onto the inked portion of the substrate. For further details of a suitable particulate material applicator, reference is made to particulate material applicator 19.

[0105] To remove excess particulate materials, similar to transportation platform 20, the transportation platform 120 may be coupled to one or more actuators configured to impart angular movements to the transportation platform 120, thereby causing the transportation platform 120 to tilt relative to a horizontal reference plane. The degree, direction, and duration of the tilt may be selectively controlled to reorient the substrate and encourage particulate material to migrate toward an edge of the transportation platform 120. In addition to tilting, the transportation platform 120 may be configured to impart vibratory motion to the substrate. Such vibratory motion may be generated by mechanical, electromechanical, pneumatic, or other suitable means for imparting oscillatory movement. The vibratory motion may be continuous, intermittent, or pulsed. The transportation platform 120 may further be configured to retain the printed substrate thereon using one or more retention techniques, including vacuum-based retention, mechanical retention, or other suitable methods, to permit precise manipulation or reorientation of the substrate. An example of a mechanical retention configuration may include a clamp that is actuated using at least one pneumatically controlled cylinder.

[0106] Additional methods to assist in removal of excess particulate material may be incorporated into the substrate handling apparatus 114. These methods may rely on airflow dynamics, either through vacuum suction or direct fan-based air movement, to remove unwanted particulate material from the surface of the printed substrate.

[0107] The substrate handling apparatus 114 may include a designated collection area 124 configured to facilitate collection, disposal, and / or recycling of the particulate material removed from the substrate. The designated collection area 124 may be mounted to the substrate handling apparatus 114, connected to the transportation platform 120 or other component of the apparatus, or provided as a separate receptacle positioned beneath the substrate. In some examples, thedesignated collection area 124 may further include a unit for returning collected particulate material to the particulate material applicator 119 for reuse, which may, for example, comprise a vacuum, auger, conveyor, or other suitable mechanism or system.

[0108] To move the transportation platform 120 and the substrate supported thereon, substrate handling apparatus 14 may include a transportation apparatus 121. Transportation apparatus 121 include a pair of brackets Bl, which support platform 120. Brackets Bl are in turn supported by and moved along guides G1 (e.g., by tabs or angle brackets) and are coupled to a conveyor 122 (FIGS. 13, 14, 22, and 23), such as a belt conveyor or a chain conveyor, which is driven by a motor M 1 and is responsible for transport of the printed substrate along a defined path between the printer and the object, which is supported on the pallet 127.

[0109] In versions where the substrate handling apparatus 114 includes multiple transportation platforms 120 and 120A, each potentially having the same or a different configuration, the transportation apparatuses 121 and 121A may be implemented in various configurations. For example, platform 120 may comprise a frame F that is mounted on its opposed sides to brackets Bl, which includes clamps Cl to releasably hold the substrate.

[0110] Referring again to FIG. 22, the frame F may include two transverse rods or bars R1 connected between two opposed L-shaped plates Pl that are coupled to brackets Bl. Each L- shaped plate Pl has a lower flange, which may be used to form part of the clamps Cl. For example, each clamp C 1 may be formed by a bar supported above the lower flange of the L- shaped plate Pl and a pair of actuators Al, such as air cylinders, that raise or lower the bar to clamp on the opposed edges of the substrate between the bar and the lower flange.

[0111] In the illustrated example, conveyor 122 includes a pair of looped belts or chains (only one shown) that are driven by gears and motor M 1 , with each bracket B 1 coupled to a respective belt or chain belt via a bracket bl, such as a ladder bracket (see e.g., bracket b2), which couples to a respective bracket B 1.

[0112] As best seen in FIG. 22, platform 120A may be formed from a plate P2, such as a foraminous plate, and a base that is supported by two brackets B2 on a opposed guides G2. Similar to platform 120, brackets B2 are coupled to conveyor 122A, which is driven by a motor (not shown, see e.g., Ml for an example) to move the platform 120A between its home position, for example, where it is aligned under platform 120, and a transfer position where it aligned over the object and can then deposit the substrate onto the object.

[0113] In the illustrated example, conveyor 122A includes a pair of looped belts or chains that are driven by gears and the motor, with each bracket B2 coupled to a respective belt or chain belt via a bracket b2, such as a ladder bracket.

[0114] In one example, platform 120 may be elevated relative to platform 120A so that the substrate can be transferred from platform 120 to platform 120A by releasing the clamps on platform 120.

[0115] As illustrated in FIGS. 21 A-21E, platform 120 is moved from its home position (where it receives the substrate from the printer) to its transfer position (where it is aligned and above platform 120A) (FIG. 21A). When aligned, platform 120A may be raised by an actuator 126, such as an air cylinder, to bring the suction holes of platform 120A closer to the substrate (FIG.21B). After being raised, the vacuum system of platform 120A is actuated to apply a suction force (FIG. 21C) on the substrate to pull the substrate onto platform 120A (FIG. 21E).Thereafter, the pneumatically controlled cylinders on clamps C 1 are actuated (by the control system) to release the substrate. Thereafter, the platform 120A is lowered by the actuator 126 with the substrate attached.

[0116] Alternatively, each platform may be configured to hold the substrate thereon using the same holding mechanism, such as a vacuum or a clamp or the like, such as described above in reference to platform 20. The platforms may, therefore, incorporate the same holding mechanisms or different holding mechanisms, as illustrated.

[0117] As described, therefore, in the case of serial platforms, each platform may have a designated conveyor, which may be in parallel. Alternately, the conveyors may be in series, with the platforms at the same level, in which case the transfer of a section of the substrate from one platform to the other platform may be achieved using engagement devices, such as clamps, which are guided along tracks from the first platform to the second platform, and which are similarly controlled by the control system.

[0118] Thus, as described, the conveyors may be parallel and in a stacked relationship or they may be arranged in a series, with each platform being indexed back and forth between a home or receiving position and a transfer position. Alternately, the platforms may share a conveyor, which has a configuration that extends in a closed loop so that the platforms may be circulated in a loop between the receiving position adjacent to the printer output, the treatment position, and then the placement location, with the platforms being in series.

[0119] Again, each conveyor 122 and 122A is in communication with the control system and is controlled using feedback from at least one sensing device. For example, the at least one sensing device may detect rotational movement of the transportation platform 120 and 120 A through optical, magnetic, or capacitive sensing technologies. Additionally, at least one proximity sensing device may be incorporated into the conveyor 122 and 122A to track the position of the transportation apparatus 121 and 121A, respectively, along their corresponding conveyors.

[0120] In the illustrated example, vertical alignment between the transportation platform 120A and the object is achieved using at least one pneumatically controlled cylinder 126. The at least one pneumatically controlled cylinder 126 may be coupled to the transportation platform 120A, the transportation apparatus 121A, and / or the object support and configured to vary a distance therebetween. In certain implementations, the pneumatically controlled cylinder 126 causes the transportation platform 120A to move toward the object for placement of the printed substrate. In alternative implementations, the pneumatically controlled cylinder 126 causes the object to move toward the transportation platform 120 A. Accordingly, the desired positioning may be obtained by movement of either or both components, depending on the configuration.

[0121] Before positioning the printed substrate onto the object, the ink may be subject to heat to activate the particulate material layer on the ink by a treatment apparatus 125 (FIG. 15F). The treatment apparatus 125 may utilize at least one heating element, at least one imaging sensor with shield, a cooling device, and the necessary controls such as disclosed in U.S. Patent No. 10,011,136.

[0122] Referring now to FIG. 17 and FIG. 18, image transfer system 110 may include at least one heat and / or pressure apparatus 116 that is used to bond the ink to the object. For example, the heat and / or pressure apparatus 116 may apply heat and / or pressure to the object. In one example, the heat and / or pressure apparatus 116 includes a heating element 134, which may comprise a flat, metal surface directed toward the object to allow even heat distribution to the object. The heating element 134 may be enclosed in a housing 131 and includes an internal frame 133. The heating element 134 may be supplied with an insulated case allowing it to be mounted to the internal frame 133. There may be at least one mechanical device, such as a spring, mounted between the heating element 134 and the internal frame 133 that allows the heating element 134 to flex in response to applied pressure. Also mounted in the internal frame 133 may be a pneumatically controlled cylinder 135 (which is in communication with the controlsystem) that is configured to impart vertical movement to the heating element 134 to provide for uniform contact between the heating element 134 and the object when the object is conveyed on object support platform 128 into the heat and / or pressure apparatus 116. The temperature of the heating element 134 is maintained by the control system using at least one temperature controller. It is configured to allow for the application of controlled heat and / or pressure for a specified duration.

[0123] There may be a sheathing 136 located between the heating element 134 and the object to protect both the heating element and the object. The sheathing 136 may act as a non-stick barrier that prevents the object from coming into direct contact with the heating element 134 and it also protects the heating element 134 from contamination by preventing unwanted debris, residues, or substances from directly touching and sticking to the heating element 134. The sheathing 136 may be of a material with low friction, chemically inert, and high thermal stability properties. The sheathing 136 may be supplied as a continuous loop positioned around the heating element 134 to allow for restored sections of the sheathing to make contact with the ink and object.

[0124] In the illustrated example, an apparatus may be incorporated to hold the position of the sheathing and may include a plurality of cylindrical components that allow for rotation along an axis to form a continuous loop. One of the cylindrical components may have a motor that determines the position of the sheathing 136 based on sensor feedback. The housing 131 may also include a movable barrier 132 allowing access to the sheathing 136.

[0125] To remove the substrate from the object, image transfer system 110 may also include at least one substrate removal apparatus 117. The substrate removal apparatus 117 may include at least one removal tool to remove the substrate upon the completion of ink bonding to the target object via heat and / or pressure from heat and / or pressure apparatus 116. Referring to FIG. 20, in the illustrated example, substrate removal apparatus 117 includes a frame or housing 117a that straddles conveyor 111 and that includes or supports a cantilevered support 117b, such as a beam, which supports a removal assembly 139 and a conveyor 138 configured to move the removal assembly 139 along the support 117b between an operable position aligned over the conveyor 111 (and pallet 127 when conveyed to the removal apparatus 117) and a home position extended from the housing and no longer aligned over (laterally spaced from) the conveyor 111 or pallet 127. The removal assembly 139 may include at least one pressure applicator 140, such as a roller, configured to smooth the substrate and apply pressure thereto while maintaining theposition of the object. The substrate removal apparatus 117 may further include one or more additional retention devices, such as a clamp, to assist in holding the object in position during substrate removal. In some examples, the applied pressure is generated by a pneumatically controlled cylinder configured to move the pressure applicator 140 into engagement with the object. The removal assembly 139 further includes at least one removal tool 141. The removal tool 141 may incorporate technologies such as robotics, vacuum suction, or mechanical guide.

[0126] In the illustrated example, each of the removal tool 141 and pressure applicator may be brought into contact with the object using a pneumatically controlled cylinder. The at least one removal tool 141 may be configured as a clamp that includes an actuated engagement member 142 configured to engage an edge of the substrate and, upon retraction, retain the substrate between the engagement member 142 and a base portion of the removal tool 141. Thus, each of the pressure applicator and the removal tool can be moved from a raised position above the object and substrate to a lowered position to, respectively, engage and hold the object and the film-based substrate. Thus, when the removal tool is retracted, it can pull the film-based substrate while the object is being held in place by the pressure applicator. The removal tool and pressure applicator used for substrate removal is also controlled by the control system and may incorporate the feedback from sensors to verify the location of the substrate and object.

[0127] Similar to the previous method, the image transfer process starts in a loading location 113 where an operator can load an object onto a pallet 127, which may be positioned on the conveyor 111. At least one mechanical stop assembly 137 may be provided to provide position and location feedback of the pallet to properly position the object and prevent unintentional movement of the object in the loading location 113. As shown in Figs. 19A and 19B, similar to the above described stops, the mechanical stop assembly 137 may include a stop 138 that can be raised using an actuator, such as a pneumatic cylinder, to form a stop in the path of the object on the conveyor. Additionally, the stop 138 helps to align the object and may contain a sensor to detect object presence. The operator inputs object enhancement data into the control system through manual entry, a primary key or unique identifier used to store object data, or through Radio Frequency Identification technology. After the object is positioned on the pallet 127 and the object data is loaded into the control system, the operator triggers an activator and the control system processes the object data and converts it into a format compatible with the printer’stechnology, then transmits it to a plurality of printers through a communication link, such as an ethernet or router.

[0128] A printer 115 is selected according to a system algorithm, which is based on the availability of printers and / or substrate handling apparatuses. The selected printer 115 begins transferring the image based on the object data onto a substrate. During this time, the object is conveyed to the selected substrate handling apparatus 114. There is an optional process sequence where the object may be routed through a heat and / or pressure apparatus 116 before being conveyed to a substrate handling apparatus 114. One advantage of this optional heat and / or pressure apparatus 116 is to smooth the target surface of the object prior to transferable substrate positioning.

[0129] Similar to the control system in the first example of system 10, the control system of the conveyor 111 may use the feedback from a plurality of sensors to track the object. For example, the plurality of sensors may emit a signal using a wireless format, such as electromagnetic fields, infrared light, or sound waves. When the sensors detect the presence or absence of an object within a specific range, they may send a corresponding output signal to the control system. The sensors may be located in the housing 112 around the perimeter of the image transfer system 110 and in the aforementioned mechanical stops 137. When the object reaches the selected substrate handling apparatus 114, it may be aligned for printed substrate transfer using at least one mechanical stop assembly 137.

[0130] Within the selected substrate handling apparatus 114, the printed substrate is processed into a transferable form. The sequence of steps that the object data may experience, as illustrated in Figs. 15A-15H, is provided by way of example, and one or more steps may be performed in a different order, omitted, repeated, or otherwise modified in various examples. Referring to FIG.15 A, as the printed substrate is generated and output by the printer 115, it may be pushed onto the transportation platform 120. Once the printed portion on the substrate is fully positioned on the transportation platform 120, a clamp, vacuum suction or other suitable retention devices may be enabled by the control system to hold the printed substrate. The motor driving the separator mechanism 123 may be enabled to separate the printed substrate from the balance of or remaining portion of the substrate. The control system may initiate the motor that controls dispensing of particulate material from the particulate material applicator 119 while simultaneously directing the conveyor 122, along with the associated transportation apparatus121 and transportation platform 120, to move through the dispensed material. Once the printed substrate is coated with the particulate material, the transportation platform 120 may be commanded to tilt to a predefined angle and may be commanded to move in a vibratory or otherwise oscillatory manner. This movement, as noted, allows for dislodgement of loosely adhered or surplus particulate material into a designated collection area 124. As previously described, additional methods may be employed that utilize airflow dynamics to assist in dislodging excess particulate material.

[0131] After removal of excess particulate material from the substrate, the control system may then command the motor to advance the conveyor 122 through the treatment apparatus 125, wherein the particulate material is subjected to controlled thermal exposure sufficient to bond the particulate material to the ink. The conveyor 122 may be subsequently advanced to position the transportation apparatus 121 into alignment with the target object, after which the printed substrate may be oriented toward the object via operation of the transportation platform 120 motor. Relative movement between the platform and the object may then be produced by actuation of one or more pneumatically controlled cylinders 126, such that the printed substrate is brought into contact with the target surface of the object. The transportation platform 120 may be commanded to remove suction and may instead apply pressurized air to urge the substrate to detach from the transportation platform 120. The at least one pneumatically controlled cylinder 126 is commanded to retract and the transportation apparatus 121 may be commanded to return to a base position.

[0132] In systems that include multiple transportation platforms 120 and 120A, transfer of the substrate from one platform to another may occur at any stage of the process, for example, when a second platform is better suited to support, reorient, or otherwise handle the substrate during subsequent process steps. In one example, the printed substrate may be transferred to a different transportation platform 120A following removal of excess particulate material from the substrate, wherein the second transportation platform 120 A may be better suited for handling the substrate during thermal exposure in the treatment apparatus 125. The control system may initiate a series of commands for such a transfer, which may include aligning the transportation platforms 120 and 120A, actuating at least one pneumatically controlled cylinder 126 to lift the second transportation platform 120A, initiating vacuum suction on the second transportation platform 120A, releasing the clamp or other retention tool on the first transportation platform120, retracting the pneumatically controlled cylinder 126, and commanding the first transportation platform 120 to return to a base position. Following the transfer, the second transportation platform 120A may proceed through the remaining process steps as previously described.

[0133] The at least one mechanical stop assembly 137, which aligns the object with the substrate handling apparatus 114, may be commanded to retract and the object may then be conveyed on the conveyor 111 to at least one heat and / or pressure apparatus 116. Using the aforementioned mechanical stop assembly 137, the object may be aligned with the heating element 134. The control system enables the pneumatically controlled cylinder 135 causing the object to contact the heating element 134. The amount of time, temperature of the heating element, and / or pressure at which the object is held into the heating element are configured into the system as part of the object data. The configuration of these settings is dependent on object, substrate, and ink properties. The object is released from the heating element 134 and the pneumatically controlled cylinder 135 is returned to the initial position. The applied heat and / or pressure activates the particulate material embedded in the ink, leading to ink adhesion to the object.

[0134] After the ink has been bonded to the object, the object may then be conveyed on the conveyor 111 to at least one substrate removal apparatus 117. In one example, once object alignment is confirmed, the control system may initiate the conveyor 138 to drive the removal assembly 139 to be positioned at the nearest edge of the object support platform 128. The removal assembly 139 may include at least one pneumatically controlled cylinder that is actuated to engage the pressure applicator 140 with the substrate. The conveyor 138 may be commanded to move the substrate slowly along the processing path, thereby applying pressure across the entire length of the substrate. The control system may actuate an engagement member 142 to expose a gap configured to receive the edge of the substrate. The removal tool 141 may then be actuated to engage and clamp the edge of the substrate during retraction. The perimeter of the substrate does not contain bonded ink, thus the removal tool may utilize these sections for the removal process. The substrate is carefully and progressively separated from the object, ensuring a controlled detachment to avoid disruption to the bonded ink. Upon removal, the control system may instruct the removal tool to dispose of the substrate waste into a designated collection area.

[0135] The object containing the bonded ink may be commanded through an optional heat and / or pressure apparatus 116 succeeding the substrate removal apparatus 117. The objective ofthis apparatus may be to verify the complete adhesion of the ink to the target object and to enhance the finish quality of the print, creating a more consistent, smooth, and visually appealing result.

[0136] The object may then be conveyed on the conveyor 111 to an unloading location 118 to allow for inspection and safe removal of the enhanced object. Similar to the loading location 113, at least one mechanical stop assembly 137 is provided in this location to prevent unintentional movement of the object. Alternatively, inspection and removal of the object may also be completed at the loading location 113. If additional processing is necessary for the object, a control system notification will appear on the loading location 113 control. The operator may adjust object position in accordance with the requirements and the activator may be triggered to reinitiate the process.

[0137] The disclosure as illustrated and described utilizes supplied object data, which is processed to customize and enhance the object based on the predefined specifications.Additionally, the disclosure features parallel processing capabilities allowing for handling of multiple objects simultaneously.

[0138] It will be apparent to those skilled in the art that various modifications and adaptations to the examples can be made, without deviating from the intended functionality, as defined by the underlying principles and claims. Certain components from one example may be interchangeably utilized with those from another example to describe additional examples.

Claims

We claim:

1. An image transfer system for handling a film-based substrate, the image transfer system comprising:an image processing location comprising:a printer to apply ink to and form an image on a target surface of the filmbased substrate;a separator mechanism to separate a section of the film-based substrate with the image formed thereon;a platform configured to receive the section of the film-based substrate thereon;a particulate material dispenser to dispense particulate material on the target surface of the film-based substrate to form an adhesive;a treatment apparatus to direct heat to the section of the film-based substrate to heat the ink and the particulate material; andthe platform configured to hold the section of the film-based substrate optionally while being separated by the separator mechanism; andan object conveyor to convey an object to the image processing location, and the platform further configured to selectively reorient the section of the film-based substrate wherein the target surface of the film-based substrate faces the object and to deposit the section of the film-based substrate on the object while supported by the object conveyor at the image processing location.

2. The image transfer system of claim 1, further comprising a heating and / or pressure apparatus configured to apply heat and / or pressure to the section of the film-based substrate after being placed on the object.

3. The image transfer system of claim 2, wherein the heating and / or pressure apparatus comprises a first heating and / or pressure apparatus, further comprising a second heating and / or pressure apparatus to apply heat and / or pressure to the object before transferring the section of film-based substrate to the object.

4. The image transfer system of any above claim, wherein the platform is mounted for rotation to reorient the target surface of the film-based substrate to face the object and optionally configured to apply a vacuum to the film-based substrate or to clamp onto the film-based substrate to thereby hold the film-based substrate on the at least one platform.

5. The image transfer system of claim 1, wherein the platform includes a vacuum system or clamp to hold to the film-based substrate on the platform.

6. The image transfer system of claim 5, wherein the image handling system comprises a control system configured to control the operation of the conveyor, the printer, and the platform.

7. The image transfer system of claim 6, further comprising a feedback system configured to provide real-time data to the control system.

8. The image transfer system of any of claims 1-3, 5, 6, and 7, wherein the printer includes the separator mechanism and optionally another heating and / or pressure apparatus configured to apply heat and / or pressure to the object after the substrate is removed.

9. An automated method of transferring an image from a film-based substrate onto an object, said method comprising the steps of:applying ink to form an image on a target surface of the film-based substrate; applying a particulate material onto the target surface after applying the ink to form an adhesive;receiving and holding the film-based substrate with the image formed thereon; separating a section of the film-based substrate with the image formed thereon from the balance of the film-based substrate;supporting and conveying an object to an image processing location to receive the section of the film-based substrate;removing excess particulate matter on the section of the film-based substrate and optionally selectively reorienting the section of the film-based substrate while holding the film-based substrate so that excess particulate matter on the section of the film-based substrate will be removed under the force of gravity;positioning the section of the film-based substrate over the object wherein the image formed thereon faces the object; anddepositing the section of the film-based substrate on the object while supporting the object at the image processing location.

10. The method of claim 9, further comprising applying heat or heat and pressure to the object prior to depositing the film-based substrate on the object.

11. The method of claim 9, wherein said holding the film-based substrate further includes transferring the film-based substrate between a first substrate support, such as a first platform, and a second substrate support, such as a second platform.

12. The method of claim 9, wherein said positioning comprises rotating the section of the film-based substrate.

13. The method of claim 9, wherein said holding includes clamping onto or applying vacuum pressure to the film-based substrate to thereby hold the film-based substrate.

14. The method of any of claims 9-13, further comprising applying heat and / or pressure to the section of the film-based substrate after being placed on the object.

15. The method of claim 9, further comprising controlling the conveying, the applying ink, the applying the particulate material, and the positioning of the section of the film-based substrate using a control system.

16. The method of claim 15, further comprising providing real-time data to the control system relating to the object to allow adjustment to the method.

17. The method of claim 15 or 16, further comprising using one or more RFID tags to store and transmit data for identifying the object.

18. The image transfer system according to anyone of claims 1-3, 5, 6, and 7, wherein the platform comprises a transportation platform to transport the substrate, further comprising a pallet, said pallet comprising:a. an object support platform configured to support one or more objects for transport, the object support platform having an upper support surface;b. a cushion attached to the upper support surface of the object support platform, the cushion having a heat-resistant and compressible structure configured to conform to the shape of objects when pressure is applied;c. a tray configured to support the object support platform and configured to couple to a conveyor; andd. a support structure configured to secure and maintain a gap between the object support platform and the tray to accommodate an object supported by the object support platform that drapes over the platform.

19. The image transfer system of claim 18, wherein the object support platform and / or the support structure having a detachable coupling enabling the object support platform to be removed from the tray and / or support structure.

20. The image transfer system of claim 18, wherein the tray includes a perimeter and flanges around the perimeter configured to engage with alignment mechanisms on the conveyor to ensure proper positioning of the pallet during transport.

21. A substrate removal apparatus for removing a film-based substrate from an object, said substrate removal apparatus comprising:a substrate removal assembly with a removal tool and a pressure applicator;a removal assembly conveyor to convey the substrate removal assembly between an operative position over the object and film-based substrate and a home position; andwherein when the substrate removal assembly is moved to its operable position the substrate removal assembly is moved to be alignable over the object, and the pressure applicator is configured to be engageable with the object to hold the object, and the removal tool is configured to be engageable with the film-based substrate and, further, to be retractable to remove the film-based substrate from the object while being held by the pressure applicator.

22. The substrate removal apparatus according to claim 21, wherein the pressure applicator includes a roller and, optionally, further includes a cylinder to move the roller, for example, from a raised position above the object and the film-based substrate to a lowered position to engage and hold the object.

23. The substrate removal apparatus according to claim 21 or 22, wherein the removal tool is configured to clamp on the film-based substrate and, optionally, further includes a cylinder to move the removal tool, for example from a raised position above the object and the film-based substrate to a lowered position to engage the film-based substrate while the object is being held by the pressure applicator.

24. The substrate removal apparatus according to claim 22 or 23, further comprising a cantilevered support to support the removal assembly conveyor wherein when the removal assembly conveyor moves the substrate removal assembly to its home position the substrate removal assembly is no longer alignable over the object.

25. The substrate removal apparatus according to claim 22 or 23, further in combination with the image transfer system of claim 1, wherein the object conveyor conveys the object to the substrate removal apparatus.

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