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 and continuous printing.
Innovation Solution
A method and assembly that utilize a single pass digital printing system with synchronized ink deposition and heat press transfer, ensuring high productivity and quality by feeding a web of carrier material through multiple digital printing stations and a heat press, maintaining precise control over speed and positioning to achieve consistent color transfer onto substrates like polyester fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple printers and calenders are used for large production cycles, then productivity is improved, but positioning errors and print-to-print color variations increase
Solution Approach 1:
The patent combines multiple printing stations and calenders into a single integrated machine, allowing continuous printing and heat transfer operations without removing the carrier from the machine. This eliminates positioning errors between separate devices while maintaining high productivity through continuous web-fed processing.
Solution Approach 2:
The invention implements continuous web-fed printing and heat transfer operations where the carrier moves continuously through multiple printing stations and calenders without interruption. This continuous process eliminates stopping and repositioning, ensuring consistent positioning accuracy while maintaining high production speed.
2Productivity
If multiple printers and calenders are used for large production cycles, then productivity is improved, but print-to-print color consistency deteriorates
Solution Approach 1:
The patent integrates multiple printing stations and calenders into one continuous machine, ensuring that all printing and heat transfer operations occur on the same carrier without removal. This eliminates variations between separate devices and ensures consistent color reproduction across all printed items.
Solution Approach 2:
The system incorporates control mechanisms that monitor and adjust printing parameters in real-time during continuous operation, ensuring consistent color output across all printing stations and preventing print-to-print color variations while maintaining high productivity.
3Device complexity
If conventional sublimation transfer printing is used, then equipment complexity is reduced, but positioning errors and color variations increase
Solution Approach 1:
The patent combines multiple printing stations, carrier transport units, and calenders into a single integrated machine. This reduces the number of separate devices needed while improving positioning accuracy through continuous web-fed processing and eliminating the need to remove and reposition the carrier between operations.
4Loss of substance
If thin transfer paper is used, then material cost is reduced, but positioning stability deteriorates
Solution Approach 1:
The patent replaces mechanical positioning methods with a web-fed system where the carrier is continuously fed through the machine in a controlled manner. This substitution allows the use of thin, cost-effective transfer paper while maintaining positioning stability through the continuous web handling mechanism and integrated transport system.
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, reducing the need for multiple printers and calenders, and allowing the use of thinner, cheaper transfer paper, thereby enhancing productivity and reducing costs.
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
Data Source
AI summary
A printing assembly for sublimation transfer printing includes: a feed mechanism by which a web of carrier is fed in a machine direction to a printer; the printer including: a carrier transport unit, controllably movable along a machine direction; digital printing stations for the deposition of sublimation ink or inks onto the carrier; a feed mechanism for the substrate material to be printed; a heat press for transferring the sublimation ink or inks onto the substrate material; and an outlet for the substrate material and used carrier, where the printing stations extend transversally to the machine direction and cover the width of carrier. A method for sublimation transfer printing may use the printing assembly.