Sublimation Dye Diffusion in Silica-Filled Polymer Surfaces
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Solution Overview
Problem
Sanitary items with surface images or prints tend to fade over time due to environmental influences and existing protective methods like varnish application are time-consuming and may not ensure color stability.
Innovation Solution
A method involving sublimation printing of dyes into polymer surfaces with silicon dioxide fillers, which increases porosity and allows the dye to diffuse deeper into the surface, enhancing color stability and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transparent layer of lacquer is applied to protect the image, then color stability is improved, but the process becomes time-consuming and may lead to poor results if the varnish layer is damaged
Solution Approach 1:
The patent extracts the protective function from a separate lacquer layer and integrates it into the substrate itself by incorporating silicon dioxide filler into the polymer material. This eliminates the need for a separate protective coating while maintaining color stability and wear resistance.
Solution Approach 2:
The patent merges the protective function with the substrate material by combining silicon dioxide filler with the polymer matrix. This creates a unified structure where the substrate itself provides both structural support and protective properties, eliminating the need for separate protective layers.
2Ease of manufacture
If the dye is applied on the surface, then the process is simple, but the image fades over time due to environmental influences and wear
Solution Approach 1:
The patent utilizes the porous structure created by silicon dioxide filler particles in the polymer matrix to enable dye penetration. The pores allow dye molecules to diffuse into the substrate and become trapped within the porous network, providing long-term color stability while maintaining a relatively simple manufacturing process.
Solution Approach 2:
The patent employs a composite material system consisting of polymer matrix and silicon dioxide filler to create a substrate with enhanced dye retention properties. The composite structure provides both the mechanical properties of the polymer and the porous structure of the filler, enabling improved color fastness.
3Reliability
If the polymer material has higher porosity to improve dye diffusion, then color stability is improved, but the surface wear resistance may be reduced
Solution Approach 1:
The patent optimizes the parameters of the silicon dioxide filler, including particle size, distribution, and concentration, to achieve a balance between porosity and wear resistance. By carefully controlling these parameters, the substrate provides sufficient pores for dye diffusion while maintaining adequate surface hardness and wear resistance through the reinforcing effect of the filler.
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 produces a color-stable and resistant image that withstands fading and wear, as the dye is embedded deeper within the surface, maintaining its appearance even as the surface wears down.
Implementation Method 1
heating the dye, diffusing the dye into the surface by sublimation and forming the image
Implementation Method 2
diffusing the dye into the surface by sublimation
Implementation Method 3
a porosity usually inherent in the polymer material with the silicon dioxide filler ensures good diffusion of the dye into the pores of the surface, especially at elevated temperatures
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for producing a color-stable orcolorfast image (10) in a surface (21) of a consumer product (20), in particular a sanitary ware, such as a shower tray, bathtub, washbasin, toilet seat, seat ring, floor or wall panel, apron for bathtubs, bathroom furniture or a household item, such as a chair, table, furniture, for example a sofa, wherein the method comprises the following steps: providing (100) the surface (21), wherein the surface (21) comprises or is formed from a polymer material (22), in particular a mineral casting, the polymer material (22) comprising at least one polymer (23) and a filler (24), and the filler (24) comprising silicon dioxide; providing (200) a dye for the image (10) to be produced; combining (300) the surface (21) and the dye; and heating (400) the dye (30), wherein the dye (30) diffuses into the surface (21) by sublimation and the image (10) is formed.