Sublimation-Printed Woven Textiles With Embossed Embroidery Texture
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Solution Overview
Problem
Dye-sublimation printing on textiles has been limited to low luster, tightly woven, smooth weaves, making it difficult to achieve high luster and textured embroidered appearances, especially on dimensionalized fabrics which are considered impractical for sublimation dyeing due to quality degradation.
Innovation Solution
A method involving a woven textile substrate with dye sublimation particles and a thermosetting adhesive that imparts embossed dimensionality, allowing for high-quality sublimation dye transfer images with a realistic embroidered appearance on high loft, openly woven fabrics, using digital images of stitched designs and thermosetting adhesives that are A- or B-staged to maintain texture during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If sublimation dye printing is applied to dimensionalized fabrics with high surface dimensionality and open weave, then the fabric texture and luster are enhanced, but the image quality degrades with dithering and pixilation
Solution Approach 1:
The patent changes the physical and chemical parameters of the fabric surface by applying dimensionalization treatments (such as embossing, creping, or chemical finishing) to create controlled surface irregularities. This modifies how light interacts with the fabric to enhance luster while maintaining sufficient surface uniformity for high-quality sublimation printing, thereby resolving the contradiction between luster enhancement and image quality preservation
2Manufacturing precision
If sublimation dye printing is applied to tightly woven smooth fabrics, then high image quality is achieved, but luster and textured embroidered appearance cannot be obtained
Solution Approach 1:
The patent introduces surface dimensionality through dimensionalization treatments that create three-dimensional surface structures on the fabric. This adds vertical dimension (surface relief) and micro-dimensional variations that enhance light reflection and scattering, producing luster and textured appearance while maintaining the underlying fabric structure suitable for high-quality printing
3Shape
If high loft openly woven fabrics are used for sublimation printing, then textured appearance is achieved, but image clarity and sharpness are expected to degrade
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: fabric weave density, fiber diameter, surface finish characteristics, and printing process parameters (temperature, pressure, time). By carefully balancing these parameters, the fabric maintains high loft and open weave for texture while achieving sufficient surface uniformity and dye penetration for clear, sharp images without dithering or pixilation
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 method achieves high-resolution, clear, and sharp sublimation dye transfer images with a high degree of clarity and sharpness, equivalent to or better than those on shiny, smoothly woven surfaces, while maintaining the texture and luster of hand-stitched embroidery, overcoming previous challenges of dithering and pixilation on dimensionalized fabrics.
Implementation Method 1
During the dye-sublimation process, the dye-sublimation ink is converted into a gas that permeates the fabric and solidifies within the fibers
Implementation Method 2
The dried sublimation dye transfer can be placed onto a material, such as a fabric, and heated; the heat transfers the image to the material
Implementation Method 3
thermosetting the thermosetting adhesive to retain the embossed dimensionality of the textile
Data Source
AI summary
The present invention is directed to an unstitched design having the appearance of being stitched or embroidered. A stitched design is digitally imaged, and the digital image used to control dye sublimation printing of a representation of the image onto a desired surface. In one configuration, the surface is a woven textile.