Method for forming dye sublimation images in and texturing of solid substrates

1. A method for texturing a thermoplastic substrate, while forming a dye sublimation image in the thermoplastic substrate, comprising:

forming a stack comprising a thermoplastic substrate and a plurality of processing layers, wherein the plurality of processing layers comprise a dye carrier having a dye image of dye sublimation ink formed thereon and an elastomeric membrane and wherein at least one of the processing layers of the stack is textured;

providing a vacuum pressure on the stack through the elastomeric membrane, wherein the stack is clamped together;

heating the stack to at least a sublimation temperature of the stack, which causes the dye sublimation ink to sublimate and penetrate through a side of the thermoplastic substrate, creating the dye sublimation image in the thermoplastic substrate and wherein texture from at least one of the process layers is transferred to the thermoplastic substrate;

cooling the thermoplastic substrate to a release temperature, which causes the thermoplastic substrate to be rigid;

removing the vacuum pressure after the thermoplastic substrate is cooled to the release temperature; and

removing the thermoplastic substrate from the stack.

2. The method, as recited in claim 1 , further comprising thermoforming the thermoplastic substrate.

3. The method, as recited in claim 1 , wherein the heating the stack to the sublimation temperature of the stack heats the stack to a temperature greater than a glass transition temperature of the thermoplastic substrate.

4. The method, as recited in claim 1 , wherein the dye carrier is a textured dye carrier and further comprising forming the textured dye carrier, comprising:

providing a dye carrier sheet;

forming texture on at least one side of the dye carrier sheet; and

forming an image on the dye carrier sheet.

5. The method, as recited in claim 4 , wherein the forming texture on the at least one side of the dye carrier sheet comprises using at least one of an additive process, a molding process, a deformation process, or a subtractive process.

6. The method, as recited in claim 4 , wherein the forming the texture on the side of the dye carrier sheet comprises using a subtractive process on the side of the dye carrier sheet comprising at least one of laser cutting, water jet cutting, drilling, planing, milling, electrical discharge machining, electrochemical machining, electron beam machining, photochemical machining, or traditional machining the side of the dye carrier sheet.

7. The method, as recited in claim 4 , wherein the forming the texture on the side of the dye carrier sheet comprises performing an additive process on the side of the dye carrier sheet, comprising at least one of 3D printing or welding on the side of the textured dye carrier.

8. The method, as recited in claim 4 , wherein the forming texture on the at least one side of the dye carrier sheet comprises performing a deformation process on the dye carrier sheet, wherein the deformation process comprises at least one of stamping, extrusion, pultrusion, rolling, forging, or die forming.

9. The method, as recited in claim 4 , wherein the forming of the texture on the side of the dye carrier sheet comprises constructing the dye carrier sheet using a weaving process.

10. The method, as recited in claim 4 , wherein the forming of the texture on the side of the dye carrier sheet comprises constructing the dye carrier sheet using a knitting process.

11. The method, as recited in claim 4 , wherein the textured dye carrier is of at least one of paper, plastic, rubber, wood, fabric, fiberboard, cardboard, or metal.

12. The method, as recited in claim 1 , wherein the providing the vacuum pressure provides a clamping pressure across the stack.

13. The method, as recited in claim 1 , wherein the vacuum pressure is at least 5 pounds per square inch.

14. The method, as recited in claim 1 , wherein the release temperature is a temperature which causes the thermoplastic substrate to be rigid.

15. The method, as recited in claim 14 , further comprising removing the dye carrier from the thermoplastic substrate.

16. A method for texturing a thermoplastic substrate, while forming a dye sublimation image in the thermoplastic substrate, comprising:

placing a textured dye carrier having an image formed thereon of a dye sublimation ink on a side of the thermoplastic substrate to form a stack;

providing a clamping pressure on the stack, wherein the stack is clamped together; and

heating the stack to at least a sublimation temperature of the stack, which causes the dye sublimation ink to sublimate and penetrate through the side of the thermoplastic substrate, creating the dye sublimation image in the thermoplastic substrate and wherein texture from the textured dye carrier is transferred to the thermoplastic substrate;

cooling the thermoplastic substrate to a release temperature, which causes the thermoplastic substrate to be rigid;

removing the clamping pressure after the thermoplastic substrate is cooled to the release temperature; and

removing the thermoplastic substrate from the stack.

17. The method, as recited in claim 16 , further comprising thermoforming the thermoplastic substrate.

18. The method, as recited in claim 16 , wherein the sublimation temperature of the stack is greater than a glass transition temperature of the thermoplastic substrate.

19. The method, as recited in claim 16 , further comprising forming the textured dye carrier, comprising:

providing a dye carrier sheet;

forming texture on at least one side of the dye carrier sheet; and

forming the image on the dye carrier sheet.

20. The method, as recited in claim 16 , wherein the providing the clamping pressure comprises providing a vacuum pressure through an elastomeric membrane.