An illustrative dye sublimation apparatus may include a texture sheet with a pattern to be applied to a substrate. More specifically, the texture sheet is pressed into the substrate during the dye sublimation process in order to apply the pattern from the texture sheet while the substrate is heated and simultaneously being infused with an image from a printed sheet. The pressure applied to the texture sheet can vary, for example based on the temperature. Compared to the conventional systems in which substrates are pre-textured, the embodiments disclosed herein describe a process for simultaneous image-infusion and texture-application, which results in a substrate that is both infused and textured.

An illustrative dye sublimation apparatus may include a pair of printed sheets placed on either side of a substrate that allows for image infusion on both sides of the substrate. A second heat source, such as a heated plate, is included in order to heat the second printed sheet. Compared to the conventional systems in which a single heat source heats a single printed, the embodiments disclosed herein describe a process for simultaneous double-sided image infusion, which results in a substrate with sublimated images on both sides.

The present invention further relates a sublimation printing process of a multilayer system comprising a polyester top layer and at least one heat sensitive polymer layer whereby a temperature gradient is applied during sublimation printing such that the heat sensitive polymer layer is maintained at a temperature below its melting temperature and the polyester top layer is maintained at a temperature above its glass transition temperature to allow diffusion of a sublimation dye into the polyester top layer. The temperature gradient is maintained by using a heat sink element beneath the heat sensitive polymer layer. The temperature gradient can also be maintained by cooling the heat sink element. The cooling preferably occurs with a circulating coolant. The heat sink element comprises a polymer, a ceramic or a metal. The invention further relates to a sublimation printed multilayer system comprising a polyester top layer and at least one heat sensitive polymer layer. The present invention also relates to the multilayer system in the manufacturing of textile, tents, outdoor gear, apparel, clothing, bags, jackets, gloves.

An apparatus for texturing a plastic substrate, while forming a dye sublimation image in the plastic substrate, wherein the plastic substrate has a first side and a second side, is provided. A textured cover is on a side of a platen, wherein the platen is on a first, untextured side of the textured cover. A first side of the dye carrier is on a second, textured side of the textured cover, and wherein the plastic substrate is supported on a second side of the dye carrier, wherein a first side of the plastic substrate is supported by the dye carrier, wherein the textured side of the textured cover has a texture to be transferred to the plastic substrate. A membrane is on the second side of the plastic substrate. A vacuum pump provides a vacuum between the membrane and the platen. A heater is positioned to heat the plastic substrate.

Various of the disclosed embodiments concern printing systems configured to deposit flexible dye sublimation inks onto flexible transfer materials. Together, the flexible ink and transfer material allow images to be transferred onto complex-shaped, i.e. non-planar, surfaces of a substrate. The flexible ink may be, for example, a thermoformable UV dye sublimation ink or a superflexible UV dye sublimation ink. In order to transfer an image onto the substrate, the transfer material is pressed onto the surface of the substrate. The substrate, transfer material, or both are heated to a temperature sufficient to cause the ink to sublimate. During the sublimation process, dye is able to permeate the substrate and form a transferred image. The flexible ink formulation may also include a soluble or solvent-sensitive component. In such embodiments, a solvent can be jetted onto the substrate and/or transfer material to remove residual ink.

The present disclosure provides an apparatus for printing an image on a substrate with an irregular surface using dye sublimation, the apparatus comprising: an autoclavable envelope bag comprising a sealable opening and a first port; a breather material to hold in place a paper carrying colorants forming the image on the irregular surface; a hollow metal receptacle comprising a second port that connects with the first port on the autoclavable envelope bag, a third port that connects to a vacuum pump, and a valve that opens and closes the third port; and a vacuum pump with a tube that connects with the third port on the hollow metal receptacle. Also provided is a method of printing an image on a substrate with an irregular surface using dye sublimation with the disclosed apparatus.

A sublimation printing production line for a workpiece having a cylindrical outer surface includes a sublimation paper loading station, workpiece wrapping station, a baking station, and a sublimation paper dismantling stations. The sublimation paper loading station has a workpiece conveyor belt and a sublimation paper conveyor belt that operate synchronously and in parallel. The sublimation paper is positioned on to an elastic fastening jacket, which is then tightly wrapped around the workpiece with the ends buckled together to secure the sublimation paper to the workpiece and making the sublimation image clearer, more colorful, and ensuring the quality of the sublimation.

A panel includes a thermoset material, and an image comprising sublimation ink. The sublimation ink is absorbed in the thermoset material. The rigid component may be a rigid structure formed by the thermoset material. The panel may be for a bath or shower enclosure.

A process for printing on to a 3-dimensional article is described. An image is printed on to a first side of a stretchable carrier membrane having a first side and a second side. The membrane is mounted in a plane within a frame between a heating chamber defined on one side of the membrane, and an article receiving chamber defined on the other side of the membrane. A 3-dimensional article to be printed is placed on to a generally flat platen positioned generally parallel to the said plane, optionally with a nest for the article thereon, within the article receiving chamber. A thermo- and vacuum-forming step is performed in which there is relative movement of the platen with respect to the membrane in a direction perpendicularly to the said plane to bring the article into register with the image printed on the membrane and to carry the article into intimate contact with the membrane through the said plane into the heating chamber. A source of vacuum is applied to the membrane from the said other side, and heat is applied to the membrane from the said one side at a first temperature sufficient to soften the membrane, whereby the membrane is thermo- and vacuum-wrapped at least partially about the article with the membrane in intimate contact with surface details of the article. A dye-diffusion step is performed in which infra-red radiation is applied to the article with the membrane wrapped therearound using at least two infra-red sources to heat the membrane and underlying surface of the article over substantially a half-spherical solid angle uniformly to a temperature in excess of the first temperature and for a time sufficient to cause the printed image to diffuse into the surface of the article but insufficient to damage the article.

A printing assembly is disclosed for thermal transfer printing onto a surface of a substrate. The assembly comprises at least one first printing system comprising a transfer member having opposite front and rear sides with an imaging surface on the front side, a coating station at which a monolayer of thermoplastic particles is applied to the imaging surface, an imaging station at which energy is applied by a thermal print head, optionally via the rear side of the transfer member, to selected regions of the imaging surface to render particles coating the selected regions tacky, a transfer station at which the imaging surface of the transfer member and the substrate surface are pressed against each other to transfer to the substrate the particles that have been rendered tacky to form an adhesive image; and at least one more printing system downstream from the first system.