Film Transfer Layer for Durable Graphics on Customizable Articles
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Solution Overview
Problem
Existing graphical transfer processes for customizable articles, such as sports balls, do not produce durable graphics, which can wear off quickly due to direct ink bonding with the substrate.
Innovation Solution
A process involving a graphic printed on a polyurethane film transfer layer, applied using a press with heat and pressure, where the film transfer layer bonds with the article's surface to seal and shield the graphic, using eco-solvent ink and a carrier layer for application and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct ink bonding with substrate is used, then manufacturing process is simple, but graphic durability is poor
Solution Approach 1:
The patent introduces a film transfer layer as an intermediary between the graphic (ink) and the substrate (article surface). The ink is printed on the film transfer layer rather than directly on the substrate, and this layer is then transferred to the article surface. This intermediary layer protects the ink from direct contact with the substrate, preventing wear and improving graphic durability while maintaining a manageable process through standardized transfer steps.
Solution Approach 2:
The patent applies preliminary action by printing the graphic on the film transfer layer before the actual transfer to the article. The film transfer layer is prepared with the ink graphic in advance, and then the entire assembly is transferred to the article surface in one step. This preliminary preparation ensures the graphic is already protected and positioned correctly before final application, improving durability without significantly increasing overall process complexity.
2Duration of action of stationary object
If film transfer layer is added, then graphic durability is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the graphic (ink), the protective film transfer layer, and the carrier layer into a single integrated transfer assembly. This consolidation allows all components to be handled and transferred together as one unit, simplifying the manufacturing process despite the added complexity of multiple layers. The merged assembly maintains graphic longevity while managing process complexity through unified handling.
Solution Approach 2:
The patent employs a flexible film transfer layer that can conform to the article surface while protecting the ink graphic. This thin film structure provides durability and longevity to the graphic without adding significant bulk or complexity to the transfer assembly. The flexible nature of the film allows it to be integrated into the transfer process without requiring complex rigid structures.
3Reliability
If ink is printed on film transfer layer, then graphic is protected from wear, but manufacturing steps increase
Solution Approach 1:
The patent replaces direct mechanical bonding of ink to substrate with a thermal or chemical transfer process. The ink is printed on the film transfer layer using standard printing methods, then the entire assembly is transferred to the article through heat or chemical activation rather than direct mechanical application. This substitution protects the graphic from wear during transfer while maintaining manufacturing efficiency by using automated transfer processes.
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
The method results in a more durable graphic application, as the ink is bonded within a film layer rather than directly to the substrate, enhancing longevity and visibility through the film transfer layer.
Implementation Method 1
a heating portion (226) configured to apply heat and pressure to transfer the graphic to the customizable article
Implementation Method 2
where the film transfer layer bonds with the exterior surface of the customizable article
Data Source
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AI summary
Customizable articles and a method of customization are disclosed. The method produces customizable articles having a graphic or pigment arrangement sandwiched between a film transfer layer and an exterior surface of the customizable articles. The process involves aligning a customizable article and a graphical transfer assembly on a press assembly, heating the press assembly, and applying pressure to the customizable article using the press. After removing the customizable article from the press assembly, the process comprises removal of the carrier layer and inspection of the resulting customizable article.