Dye sublimation printing processes
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Solution Overview
Problem
Conventional direct to film printing methods using water-based pigmented inks and polymer powders are inadequate for transferring dye sublimation inks onto substrates, particularly due to poor adhesion and wash fastness issues.
Innovation Solution
The use of a polyester powder applied to inkjet-printed dye sublimation inks on a polymer-coated film, which is then melted and transferred onto a substrate using a heat press, allowing for superior adhesion and image transfer due to the affinity of the dye sublimation ink with the polyester structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymer powders (polyurethanes, polyacrylics, polyvinylchlorides, etc.) are used in direct to film printing, then the printing process can be performed, but the adhesion and wash fastness of the printed image deteriorates
Solution Approach 1:
The patent changes the material parameter of the powder from conventional polymers to polyester powder, which has specific chemical affinity for dye sublimation inks. This parameter change resolves the contradiction by enabling both good adhesion and compatibility with dye sublimation ink simultaneously.
Solution Approach 2:
The patent uses a composite approach by combining polyester powder with polymer coated film to create a transfer medium that achieves both strong adhesion to dye sublimation inks and good wash fastness, resolving the contradiction between adhesion reliability and material compatibility.
2Device complexity
If dye sublimation ink is printed directly onto substrate, then the process is simplified, but the versatility of substrate materials is limited
Solution Approach 1:
The patent introduces polymer coated film as an intermediary carrier between the inkjet printer and the final substrate. This mediator enables the printing process to work with diverse substrate materials while maintaining process simplicity, as the ink is first deposited on the film then transferred to various substrates.
Solution Approach 2:
The patent segments the printing process into two distinct stages: ink deposition on polymer film, and subsequent transfer to substrate. This segmentation allows each stage to be optimized independently, maintaining simplicity in the printing stage while expanding substrate versatility in the transfer stage.
3Manufacturing precision
If heat pressing is applied to melt polyester powder, then image transfer from film to substrate is achieved, but energy consumption increases
Solution Approach 1:
The patent utilizes the phase transition of polyester powder from solid to molten state through heat pressing. This phase transition enables the powder to flow and bond the ink image to the substrate, achieving high transfer quality. The energy consumption is optimized by controlling the heating parameters to achieve just enough melting for effective transfer.
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
This method enhances dry and wet crock results, color density, and wash fastness of the printed images, providing improved durability and longevity of the printed products.
Implementation Method 1
The polyester powder is applied to the printed image or design, and melted by either placing the film into an oven or heat pressing it
Implementation Method 2
the film is placed face down (i.e., melted powder side down) onto the substrate and pressed. This allows the printed image to transfer from the film to the substrate via the melted polyester powder
Data Source
AI summary
Provided are direct to film printing methods and processes for printing dye sublimation ink comprising: inkjet printing a design on a polymer coated film using dye sublimation ink; applying a polyester powder to the printed design on the polymer coated film to form a powdered printed design; melting the polyester powder; and transferring the powdered printed design from the polymer coated film to a substrate.