Sublimation Shrink Sleeve With Microchannels for Complex Shapes
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Solution Overview
Problem
Existing sublimation transfer methods struggle to achieve uniform and high-fidelity decoration on objects with complex shapes, such as those with concavities and convexities, due to issues like gas accumulation, pressure variability, and difficulty in maintaining intimate contact between the carrier sheet-like medium and the object, leading to defects like wrinkles and imperfections in the transferred image.
Innovation Solution
A method using a shrink-wrap sheet-like element with an irregular surface featuring micro-channel systems to drain air and gases, combined with a controlled pressure difference to ensure uniform adhesion and effective transfer of sublimatic inks on objects with complex shapes and improve the quality and fidelity of the image transferred onto the object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sheet-like medium made of thermo-elastoplastic material is used for sublimation transfer, then the image can be transferred to the object, but the medium causes loss of resolution when stretched and forms wrinkles when compressed, leading to defects in the transferred image
Solution Approach 1:
The patent introduces a frame structure that divides the carrier medium into smaller, controlled segments. The frame locks the perimetric edges of the carrier sheet, creating defined zones that prevent uncontrolled stretching and wrinkling. This segmentation allows the medium to maintain its structural integrity while still enabling image transfer.
Solution Approach 2:
The patent applies controlled temperature and pressure parameters during the sublimation process. By carefully controlling the heating temperature and applying appropriate pressure through the frame structure, the carrier medium undergoes phase changes that enable ink transfer while maintaining dimensional stability and preventing deformation.
2Manufacturing precision
If frames are used to lock perimetrically carrier sheet-like media and apply pressure difference to achieve sublimation, then image transfer can be achieved, but control of deformations is impossible, causing instability in contact and graphic inaccuracies
Solution Approach 1:
The patent applies different properties to different parts of the system. The frame structure provides rigid constraint at the perimetric edges while allowing flexibility in the central imaging area. This local differentiation enables stable contact and accurate image transfer without requiring complete rigid control of the entire carrier medium.
3Manufacturing precision
If the object is wrapped with carrier sheet-like medium and vacuum bag is used to transmit process pressure, then decoration can be achieved, but joints from frames and plastic deformation limits of bags cause lack of uniformity in pressures applied, leading to graphic imperfections
Solution Approach 1:
The patent extracts and removes the vacuum bag from the system, replacing it with a direct frame-based pressure application mechanism. By eliminating the intermediate vacuum bag, the system achieves more uniform pressure distribution without the limitations of bag plastic deformation, while maintaining manageable complexity through the frame structure.
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 provides improved image quality and fidelity on objects with complex shapes by ensuring uniform pressure and gas removal, reducing operational complexity and cost, and maintaining intimate contact between the carrier and the object.
Implementation Method 1
an irregular surface which has the function of creating, between the sheet-like element and the object to be decorated, channel systems at which a throttling of the contact points between the surface of the sheet-like element and the surface of the object to be decorated occurs, said channel systems being adapted to allow a complete draining of the air and other gases interposed between the sheet-like element and the object to be decorated
Implementation Method 2
at least partial shrink-wrapping of said shrink-wrap sheet-like element on said object to be decorated by applying heat
Implementation Method 3
applying heat to obtain the sublimation of the inks and their consequent transfer from the sheet-like medium to the object to be decorated
Implementation Method 4
creating a difference in pressure between the inside and the outside of the sleeve, so as to determine, on the inner side of said sleeve, a hydrostatic pressure lower than that acting on its outer side
Data Source
AI summary
A method for decorating objects by means of sublimatic inks, which provides for the steps that consist in providing a shrink-wrap sheet-like element to which at least one layer of sublimatic inks is applied and joining two opposite ends of the sheet-like element in order to obtain a sleeve with the face of the sheet-like element directed toward the inside of the sleeve, inserting axially in the sleeve at least one object to be decorated, applying heat in order to obtain an at least partial shrink-wrapping of the sleeve, creating a difference in pressure between the internal side and the external side of the sleeve in order to establish a lower hydrostatic pressure on the inner side of the sleeve than on its outer side, and applying heat in order to cause the sublimation of the sublimatic inks.