Method and an assembly for sublimation transfer printing
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Solution Overview
Problem
Existing sublimation transfer printing technologies face challenges with speed and consistency, particularly in large production cycles, due to positioning errors and print-to-print color variations, making them less suitable for high-volume production.
Innovation Solution
A method and assembly that utilize single pass digital printing stations synchronized with a carrier transport unit and a heat press to efficiently transfer sublimation ink from transfer paper to a substrate, ensuring high productivity and quality by using a feed mechanism, digital printing stations extending transversally to cover the width of the carrier, and a heat press for optimal temperature and time conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sublimation transfer printing is used, then color quality and bonding durability are improved, but printing speed and productivity deteriorate
Solution Approach 1:
The printing system is divided into multiple independent digital printing stations (CMYK and additional colors) that operate simultaneously in parallel, each depositing its specific color onto the carrier web as it moves through the system. This segmentation allows high-speed printing while maintaining quality through synchronized multi-color deposition.
Solution Approach 2:
The system employs continuous web feeding of carrier material through the printing stations and heat press without interruption. The carrier web moves continuously through all printing stations and the heat press in a single pass, eliminating stop-start operations and maximizing productivity while maintaining consistent ink bonding quality.
2Productivity
If multiple printers and calenders are used for large production, then productivity is improved, but positioning precision and color consistency deteriorate
Solution Approach 1:
Multiple digital printing stations (CMYK plus additional colors) are merged into a single integrated printing system that operates in parallel on the same moving carrier web. This consolidation eliminates the need for multiple separate printers and calenders, maintaining positioning accuracy through a unified synchronized system while achieving high production volumes.
Solution Approach 2:
The system dynamically synchronizes the operation of multiple printing stations with the continuous movement of the carrier web. Each printing station operates dynamically in response to the web's position and speed, ensuring precise color registration and positioning accuracy even at high printing speeds and production volumes.
3Productivity
If single pass digital printing is used, then printing speed is improved, but print-to-print color consistency deteriorates
Solution Approach 1:
The system incorporates feedback mechanisms that monitor and adjust the operation of each digital printing station based on real-time conditions. This feedback control ensures consistent color deposition across multiple prints at high speeds by dynamically compensating for variations in ink flow, carrier web tension, and printing station alignment.
Solution Approach 2:
The system precisely controls and adjusts critical parameters including ink deposition quantity, carrier web speed, and heat press temperature and duration. By maintaining optimal parameter ranges and making real-time adjustments, the system achieves both high printing speed and consistent color quality across all printed substrates.
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 approach enables high-speed, high-quality sublimation transfer printing with consistent color registration and positioning, achieving printing speeds of over 11 m/min while maintaining the durability of sublimation ink bonding with the substrate, reducing the need for additional fixation steps and allowing the use of thinner, cheaper transfer paper.
Implementation Method 1
Dye sublimation inks, also known as disperse dye inks, are made of high purity and ultra-fine particle disperse dyes that can change from solid to gas without entering liquid phase
Implementation Method 2
The heat press is then used to transfer the image onto the substrate material. Recommended transfer temperatures range from 180-230 °C, with a transfer time of 30-60 seconds
Data Source
Figure 1
Figure 2
AI summary
The invention provides a method for sublimation transfer printing, and a printing assembly comprising: •a feed mechanism (2) by which a web of carrier (1) is fed in a machine direction to a printer (4); •the printer (4) comprising: o a carrier transport unit (3), controllably movable along a machine direction; o digital printing stations (5) for the deposition of sublimation ink or inks (6) onto the carrier (1); •a feed mechanism (8) for the substrate material (7) to be printed; •a heat press (9) for transferring the sublimation ink or inks (6) onto the substrate material (7); and •an outlet (10) for the substrate material (7) and used carrier (1), wherein the printing stations (5) extend transversally to the machine direction and cover the width of carrier (1).