Sublayer Pre-Coating for Deep Sublimation Dyeing of Fibrous Composites

Solution Overview

Problem

Sublimation printing struggles with limited dye penetration in three-dimensional and open fibrous surfaces, leading to visible undyed spots and loss of color definition due to shallow dye penetration, especially in high-wear applications and embossed textures.

Innovation Solution

A fibrous composite with a polymeric sublayer pre-printed with sublimation inks, where the sublayer is tufted, stitch-bonded, or needle-punched, and then activated with heat and pressure to propel dyes deeper into the fabric, ensuring improved dye penetration and color retention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If sublimation printing is used on three-dimensional fibrous surfaces, then the process is simple and fast, but the dye penetration depth is insufficient leading to visible undyed spots

Engineering Contradiction:

Improveprinting speedVSAvoiddye penetration depth

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-coating the backing layer with sublimation dyes before the tufting or needle-punching process. This ensures that when yarns are inserted through the backing, the dye is already positioned at the roots of the yarns, eliminating the need for subsequent dyeing of hard-to-reach areas and ensuring uniform color penetration throughout the three-dimensional structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent inverts the conventional printing sequence by coating the backing layer first rather than attempting to print through or onto the finished three-dimensional surface. This reversal allows the dye to be deposited in a position where it can naturally migrate to all yarn surfaces during the forming process, solving the penetration depth problem while maintaining process efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If pre-colored backings are used to reduce contrast between yarn surfaces and backing, then color uniformity improves, but the roots of yarns remain undyed and become visible with wear

Engineering Contradiction:

Improvecolor uniformityVSAvoidcolor retention under wear

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent applies local quality by selectively coating only the backing layer with sublimation dyes, while leaving the yarns undyed initially. During the tufting or needle-punching process, the dye locally migrates to the yarn roots and surfaces through capillary action and heat, ensuring that the previously problematic undyed yarn roots become uniformly colored, thereby maintaining color uniformity even under wear conditions.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If sublimation dyes are printed from carrier paper onto the fabric surface, then the printing process is straightforward, but the dye penetration into deep structures is limited

Engineering Contradiction:

Improveprinting process simplicityVSAvoiddye penetration distance

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The patent applies preliminary action by pre-coating the backing layer with sublimation dyes before the tufting or needle-punching process. This ensures that when yarns are inserted through the backing, the dye is already positioned at the roots of the yarns, eliminating the need for subsequent dyeing of hard-to-reach areas and ensuring uniform color penetration throughout the three-dimensional structure.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent inverts the conventional printing sequence by coating the backing layer first rather than attempting to print through or onto the finished three-dimensional surface. This reversal allows the dye to be deposited in a position where it can naturally migrate to all yarn surfaces during the forming process, solving the penetration depth problem while maintaining process efficiency.

Inventive Principle:

Principle #13The other way round (Inversion)

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 achieves substantial depth of color and maintains color definition even with wear or embossing, preventing the exposure of undyed yarn roots and enhancing the appearance of fibrous composites.

Implementation Method 1

sublimation printing or dye sublimation printing transfers images, designs or colors onto a desired surface or material by converting a solid dye directly to a gaseous state

Methodology Applied

Scientific EffectSublimation: Sublimation

Implementation Method 2

Upon the application of heat or preferably heat and pressure, the sublimation dyes are propelled towards the top surface

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 3

Upon the application of heat or preferably heat and pressure, the sublimation dyes are propelled towards the top surface

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS11661701B2Deep sublimation dyeing of fibrous composites

Publication Date: 2023.05.30 ENGINEERED FLOORS LLC

AI summary

A textile composite contains a sublayer coated with unactivated solid sublimation dyes and incorporated with the layers of the textile composite or placed between a fabric layer and a backing layer. The sublimation dyes are activated with heat and pressure, and dying or coloring the inner strata of the textile composite.