Forming resin substrates using dye sublimation and substrates formed using the same
View Patent ↗Implementations of the present invention relate generally to methods, systems, and apparatus for manufacturing aesthetically pleasing, resin-based sheets including color and/or multi-decorated images. In particular, at least one implementation includes subjecting at least one surface of a polymer sheet to uniform heat and pressure in order to sublimate a dye into the surface, and ensure that that polymer sheet is not warped or otherwise damaged during processing. Additional implementations include decorative architectural resin panels including a resin sheet having a dye sublimated into one or more surfaces in order to create an effect of depth or other aesthetic.
1. A decorative architectural resin panel, comprising:
a resin sheet having a thickness defined by a distance that is perpendicular to first and second opposing surfaces;
a first sublimated dye that covers the entire first surface, and extends by a first sublimation depth only partly into the thickness of the resin sheet; and
a second sublimated dye that covers the entire second surface, and extends by a second sublimation depth only partly into the thickness of the resin sheet;
wherein the first and second sublimation depths are separated by a portion of the thickness of the resin sheet containing no sublimated dye.
2. The panel as recited in claim 1 , wherein the combined first sublimation depth and the second sublimation depth comprise less than all of the thickness of the resin sheet.
3. The panel as recited in claim 1 , wherein:
the dye covering the first surface forms an image; and
the dye covering the second surface forms a complementary image.
4. The panel as recited in claim 3 , wherein at least one of the images covering the first and second surfaces comprises a solid color covering the entire surface area of the first or second surface.
5. The panel as recited in claim 3 , wherein at least one of the images covering the first and second surfaces comprises a color-to-color or color-to-clear faded image covering the entire surface area of the first or second surface.
6. The panel as recited in claim 1 , wherein the dye provides the decorative architectural resin panel with an effect of depth.
7. The panel as recited in claim 1 , wherein the resin sheet comprises one of polyvinyl chloride, poly (methyl methacrylate), thermoplastic polyester or co-polyester, polyurethane, cellulose-based thermoplastic, or polycarbonate.
8. The panel as recited in claim 1 , wherein the decorative resin panel comprises a texture on one or more outside surfaces.
9. The panel as recited in claim 1 , wherein the resin sheet is substantially translucent.
10. The panel as recited in claim 9 , wherein the laminate of multiple resin-based substrates comprises resins selected from the group consisting of polycarbonate, polyester, PVC, acrylic, and combinations and polymer alloys thereof.
11. The panel as recited in claim 1 , wherein the resin sheet comprises a laminate of multiple resin substrates.
12. The panel as recited in claim 1 , wherein the combined sublimation depths of the first and second dye is no more than fifteen-sixteenths of the thickness of the resin sheet.
13. A decorative architectural resin panel, comprising:
a resin sheet having a thickness defined by a distance that is perpendicular to first and second opposing surfaces;
a first sublimated dye that covers the entire first surface, and extends by a first sublimation depth only partly into the thickness of the resin sheet; and
a second sublimated dye that covers the entire second surface, and extends by a second sublimation depth only partly into the thickness of the resin sheet;
wherein:
the first and second sublimation depths are separated by a portion of the thickness of the resin sheet containing no sublimated dye; and
the decorative resin panel comprises a texture on one or more outside surfaces.
14. The panel as recited in claim 13 , wherein:
the dye covering the first surface forms an image; and
the dye covering the second surface forms a complementary image.
15. The panel as recited in claim 14 , wherein at least one of the images covering the first and second surfaces comprises a solid color covering the entire surface area of the first or second surface.
16. The panel as recited in claim 14 , wherein at least one of the images covering the first and second surfaces comprises a color-to-color or color-to-clear faded image covering the entire surface area of the first or second surface.
17. The panel as recited in claim 13 , wherein the dye provides the decorative architectural resin panel with an effect of depth.
18. The panel as recited in claim 13 , wherein the resin sheet comprises one of polyvinyl chloride, poly (methyl methacrylate), thermoplastic polyester or co-polyester, polyurethane, cellulose-based thermoplastic, polycarbonate, or combinations and polymer alloys thereof.
19. The panel as recited in claim 13 , wherein the resin sheet is substantially translucent.
20. The panel as recited in claim 13 , wherein the resin sheet comprises a laminate of multiple resin-based substrates.
21. The panel as recited in claim 13 , wherein the combined sublimation depths of the first and second dye is no more than fifteen-sixteenths of the thickness of the resin sheet.
22. A decorative architectural resin panel, comprising:
a resin sheet having a thickness defined by a distance that is perpendicular to first and second opposing surfaces;
a first sublimated dye that covers the entire first surface, and extends by a first sublimation depth only partly into the thickness of the resin sheet; and
a second sublimated dye that covers the entire second surface, and extends by a second sublimation depth only partly into the thickness of the resin sheet;
wherein:
the first and second sublimation depths are separated by a portion of the thickness of the resin sheet containing no sublimated dye; and
the resin sheet comprises one of polyvinyl chloride, poly (methyl methacrylate), thermoplastic polyester or co-polyester, polyurethane, cellulose-based thermoplastic, polycarbonate, or combinations and polymer alloys thereof.
23. The panel as recited in claim 22 , wherein the resin sheet is substantially translucent.
24. The panel as recited in claim 22 , wherein the decorative resin panel comprises a texture on one or more outside surfaces.
25. The panel as recited in claim 22 , wherein the dye provides the decorative architectural resin panel with an effect of depth.
26. The panel as recited in claim 22 , wherein the combined sublimation depths of the first and second dye is no more than fifteen-sixteenths of the thickness of the resin sheet.
27. The panel as recited in claim 22 , wherein:
the dye covering the first surface forms an image; and
the dye covering the second surface forms a complementary image.
28. The panel as recited in claim 27 , wherein at least one of the images covering the first and second surfaces comprises a solid color covering the entire surface area of the first or second surface.
29. The panel as recited in claim 27 , wherein at least one of the images covering the first and second surfaces comprises a color-to-color or color-to-clear faded image covering the entire surface area of the first or second surface.