Dye-sublimated golf flag
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sublimation processes fail to simultaneously print images on both sides of a double-sided article in correct orientation without ink bleeding through, and often require separate pieces of fabric or additional barriers, limiting the production of high-quality, ultraviolet-resistant double-sided flags like golf flags.
Innovation Solution
A three-layer twill weave fabric is used, where horizontal threads are visible on both sides and vertical threads act as a dark barrier to prevent ink bleeding, allowing simultaneous sublimation of identical images on both sides using ultraviolet-resistant ink and a heat press process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate pieces of fabric are used for each side, then ink bleeding is prevented, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The fabric is segmented into three distinct layers (first fabric layer, barrier layer, second fabric layer) with each layer serving a specific function. The barrier layer is positioned between the two fabric layers to prevent ink bleeding while maintaining a single integrated fabric structure that eliminates the need for separate fabric pieces and complex assembly steps.
Solution Approach 2:
The fabric employs a composite structure combining different material layers: a first fabric layer, a barrier layer (which may be a non-woven material or differently woven layer), and a second fabric layer. This composite construction provides both the functionality of preventing ink bleeding and the simplicity of a single integrated fabric piece.
2Manufacturing precision
If additional barrier layers are added, then ink bleeding is prevented, but the number of components and assembly steps increase
Solution Approach 1:
The barrier function is merged into the fabric structure itself through the inclusion of a barrier layer within the three-layer construction. This eliminates the need for separate barrier components and reduces assembly steps, as the barrier functionality is integrated directly into the fabric rather than being added as a separate element.
Solution Approach 2:
The fabric uses a composite material structure where the barrier layer is an integral part of the fabric construction. This composite approach prevents ink bleeding while maintaining manufacturing simplicity, as the entire three-layer structure is treated as a single fabric component that can be manufactured and assembled as one unit.
3Ease of manufacture
If a single piece of fabric is used, then manufacturing is simplified, but ink bleeding between sides cannot be prevented
Solution Approach 1:
The single fabric piece is segmented into three functional layers, with the barrier layer specifically positioned to prevent ink bleeding between sides. This segmentation maintains the simplicity of using a single integrated fabric component while internally dividing it into layers that perform different functions, including ink barrier protection.
Solution Approach 2:
The single fabric piece is constructed as a composite material structure with three layers, where the intermediate barrier layer provides ink bleeding prevention. This composite construction allows the fabric to function as a single simplified component during manufacturing while inherently preventing ink bleeding through its multi-layer composition.
4Productivity
If standard sublimation process is used, then production is efficient, but images bleed through to the other side
Solution Approach 1:
The fabric structure is segmented into three layers with the barrier layer positioned to intercept and prevent ink transfer between sides during the sublimation process. This allows the use of efficient standard sublimation processes while maintaining precise image separation, as the barrier layer blocks ink migration during the high-temperature sublimation treatment.
Solution Approach 2:
The composite three-layer fabric structure enables the use of efficient standard sublimation processes while preventing image bleeding. The barrier layer within the composite structure acts as a thermal and chemical barrier during sublimation, allowing high-temperature processing for efficient production while maintaining precise image separation on each side.
5Reliability
If ultraviolet-resistant ink is used, then durability is improved, but ink bleeding through fabric remains an issue
Solution Approach 1:
The fabric is segmented into three layers with the barrier layer specifically designed to prevent ultraviolet-resistant ink from bleeding through to the other side. This segmentation allows the use of durable ultraviolet-resistant ink while maintaining precise image separation, as the barrier layer blocks ink migration regardless of the ink's ultraviolet resistance properties.
Solution Approach 2:
The composite three-layer fabric structure combines the durability benefits of ultraviolet-resistant ink with the ink-blocking properties of the barrier layer. This composite construction allows the use of highly durable ultraviolet-resistant ink for long-term outdoor applications while preventing ink bleeding through the fabric to the opposite side.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of double-sided flags with images in correct orientation on a single piece of fabric without bleeding, ensuring high-quality and durable ultraviolet-resistant prints, suitable for larger flags with consistent temperature distribution across the fabric.
Implementation Method 1
The threads in the vertical direction are not visible and act as a light and ink barrier between each side of the flag
Implementation Method 2
A double-sided dye-sublimated golf flag, printed with ultraviolet resistant ink, is created by simultaneously sublimating both sides of the golf flag
Data Source
AI summary
A double-sided sublimated article and method for producing the same is provided. The article may be a golf flag and is made up of a single piece of a three layer twill weaving fabric. The fabric is woven such that horizontal threads are visible and a vertical thread is not visible. Each side of the article may be simultaneously sublimated with an ultraviolet resistant ink to produce a double-sided sublimated article having images on each side in a correct orientation.