Method and apparatus for continuously forming dye sublimation images in solid substrates
A method for forming a dye sublimation image in a substrate with a dye carrier having an image formed thereon of a sublimatic dyestuff is provided. The image of the dye carrier is placed against a first surface of the substrate. The substrate and dye carrier are conveyed along a path with a first part and a second part. A continuous pressure is provided against the first surface of the substrate in the first part and second part of the path and therebetween. The dye carrier is heated to a sublimation temperature in the first part of the path. The dye carrier is then cooled to a depressure temperature in the second part of the path.
1. A method of forming a formed object with a sublimated image, comprising:
providing a dye carrier with an image;
placing the image of the dye carrier in contact with a first surface of a substrate;
heating the dye carrier to a temperature above a glass transition temperature of the substrate, while in a continuous process machine, wherein the heating is sufficient to cause lamination of the dye carrier to the substrate;
cooling the dye carrier to a temperature below the glass transition temperature of the substrate, while in the continuous process machine;
heating the laminated dye carrier and substrate after cooling the dye carrier; and
thermal forming the laminated dye carrier and substrate after heating the laminated dye carrier and substrate, wherein the thermal forming of the dye carrier and substrate provides a greater than 40% elongation in a region of the substrate, and wherein the sublimated image is not thinned.
2. The method, as recited in claim 1 , wherein the providing the dye carrier with an image, comprises printing the image on the dye carrier using an ink jet printer.
3. The method, as recited in claim 1 , wherein the continuous process machine provides a continuous pressure from before heating the dye carrier until after cooling the dye carrier, wherein the continuous pressure limits shrinking, enlarging, extruding, and warping of the substrate in a plurality of directions during the steps of heating the dye carrier and cooling the dye carrier.
4. The method, as recited in claim 1 , wherein the heating the substrate heats the substrate to a temperature of at least 275° C.
5. A method of forming a sublimated image in a laminated substrate, comprising:
provide a film with an image on a first side of the film;
placing the film on a surface of a substrate so that the image is on and in contact with the surface of the substrate;
laminating by heat or adhesive the first side of the film to the substrate;
sublimating the image into the substrate;
cooling the laminated film and substrate, after the sublimating the image into the substrate;
heating the laminated film and substrate after cooling the laminated film; and
thermal forming the laminated film and substrate after heating the laminated film and substrate, wherein the thermal forming of the film and substrate provides a greater than 40% elongation in a region of the substrate, and wherein the sublimated image is not thinned.
6. The method, as recited in claim 5 , wherein the providing the film with an image, comprises:
placing the film in a printer; and
printing the image on the first side of the film.
7. The method, as recited in claim 6 , wherein the providing the film with an image, further comprises:
selecting a digital image on a computer; and
sending a command to the printer to print the digital image.
8. The method, as recited in claim 7 , wherein the selecting the digital image, comprises customizing the digital image.
9. The method, as recited in claim 5 , wherein the laminating the first side of the film to a substrate and the sublimating the image into the substrate are performed simultaneously.
10. The method, as recited in claim 5 , wherein the film is placed in contact with a surface of the substrate.
11. The method, as recited in claim 5 , wherein the first side of the film is in contact with a surface of the substrate.
12. A method of providing a sublimated image on a plastic substrate, wherein the substrate is a substrate film, comprising:
selecting a digital image on a computer;
using a computer printer to print the selected digital image on a dye carrier with dye sublimation inks;
placing the image of the dye carrier in contact with a first surface of a substrate film;
heating the dye carrier to a temperature above a glass transition temperature of the substrate film, while in a continuous process machine;
cooling the dye carrier to a temperature below the glass transition temperature of the substrate film, while in the continuous process machine;
removing the dye carrier from the substrate film after cooling the dye carrier, wherein the image has been sublimated into the first surface of the substrate film;
laminating the substrate film to a thicker substrate after removing the dye carrier from the substrate film, by heating the substrate film and thicker substrate to cause lamination;
heating the substrate; and
thermal forming the substrate, wherein the thermal forming of the substrate provides a greater than 40% elongation in a region of the substrate, and wherein the sublimated image is not thinned.