Method and apparatus for forming dye sublimation images in solid plastic

Apparatus for forming a dye sublimation image in a substrate utilizing a dye carrier having an image formed thereon of a sublimatic dyestuff, the apparatus comprising:

• a platen, for disposing thereon a substrate, the substrate having further disposed thereon a dye carrier such that the sublimatic dyestuff is in contact with the substrate;
• a membrane for covering the substrate, the dye carrier, and at least a portion of the platen;
• an atmospheric clamping system for applying, in operative combination with the membrane, a uniform clamping pressure to the substrate and the dye carrier;
• a heating device for heating the substrate and the dye carrier from their ambient temperature to a first temperature and for a period of time requisite to form the image in the substrate while the uniform clamping pressure is applied to the substrate and the dye carrier;
• and
• a cooling device for cooling the substrate and the dye carrier to a second temperature while the uniform clamping pressure is applied to the substrate and the dye carrier, following the heating thereof.

Apparatus for forming a dye sublimation image in a rigid plastic substrate having a specific set of technical performance specifications, said image formed with a dye carrier having a reverse image formed thereon of a sublimatic dyestuff, said apparatus comprising in operative combination:

• a platen assembly including a platen defining at least one perforation therethrough and a spectacle frame hingedly attached to one side of said platen, said spectacle frame defining an aperture;
• an elastomeric membrane disposed over said aperture for covering at least a portion of said platen and said substrate and said dye carrier when said substrate and said dye carrier are disposed on said platen;
• a first thermally conductive plate rendered partially hollow by the formation therein of at least one chamber;
• a heater for providing a controllable flow of a heating fluid through said chamber of said first thermally conductive plate;
• and
• a quantity of said heating fluid at least partially filling said chamber of said first thermally conductive plate, said quantity of said heating fluid rendered controllably heatable by said heater;
• a table for receiving thereon said platen assembly;
• disposed on said table, a thermal imaging unit defining a first passage therein, said thermal imaging unit having said first thermally conductive plate disposed therein whereby said first thermally conductive plate is rendered capable of reversible downward motion;
• positioning means for reversibly positioning said platen assembly within said first passage and in substantial alignment with said first thermally conductive plate;
• a first press disposed within said thermal imaging unit for reversibly urging said first thermally conductive plate into contact with said membrane;
• first retractor spring further disposed within said first passage for reversibly retracting said thermally conductive plate from contact with said membrane;
• a second thermally conductive plate rendered partially hollow by the formation therein of at least one chamber;
• a cooler for providing a controllable flow of a coolant through said chamber of said second thermally conductive plate;
• and
• a quantity of said coolant at least partially filling said chamber of said second thermally conductive plate, said quantity of said coolant rendered controllably coolable by said cooler;
• further disposed on said table, a cooling unit defining a second passage therein, said cooling unit having said second thermally conductive plate disposed therein whereby said second thermally conductive plate is rendered capable of reversible downward motion;
• second positioning means for reversibly positioning said platen assembly within said second passage and in substantial alignment with said second thermally conductive plate;
• a second press disposed within said cooling unit for reversibly urging said second thermally conductive plate into contact with said membrane;
• a second retractor spring further disposed within said second passage for reversibly retracting said second thermally conductive plate from contact with said membrane;
• and
• a control unit for controlling at least one of a temperature of said first thermally conductive plate, a first time interval where said first thermally conductive plate is urged into contact with said membrane, a temperature of said second thermally conductive plate, and a second time interval where said second thermally conductive plate is urged into contact with said membrane,
• whereby said image is formed within said substrate by means of dye sublimation, without degradation of any of said technical performance specifications of said substrate.

A method for forming a dye sublimation image in a substrate with a dye carrier having an image formed thereon of a sublimatic dyestuff, the method comprising:

• disposing the substrate on a platen;
• disposing the dye carrier on the substrate such that the sublimatic dyestuff is in contact with the substrate;
• covering the substrate, the dye carrier, and at least a portion of the platen with a membrane;
• applying a uniform clamping pressure to the substrate and the dye carrier with the membrane;
• heating the substrate and the dye carrier from their ambient temperature to a first temperature for a period of time requisite to form the image in the substrate;
• and
• following the heating of the substrate and the dye carrier, cooling the substrate and the dye carrier to a second temperature.

A method for forming a dye sublimation image in a solid substrate utilizing a dye carrier having thereon a sublimatic dyestuff, the method comprising:

• superposing the substrate over a platen;
• disposing the dye carrier on the substrate such that the sublimatic dyestuff is in contact with the substrate;
• covering the substrate, the dye carrier, and at least a portion of the platen with a membrane;
• inducing a positive pressure differential between the ambient atmosphere above the membrane and the atmosphere under the membrane, thereby applying a clamping pressure to the substrate and the dye carrier with the membrane, urging the dye carrier into intimate contact with the solid substrate, and urging the substrate into a substantially planar form;
• heating the substrate and the dye carrier from their ambient temperature to a first elevated temperature for a period of time requisite to form an image in the substrate from the sublimatic dyestuff while continuing to urge the substrate into the substantially planar form;
• and
• following the heating of the substrate and the dye carrier, cooling the substrate and the dye carrier to a second, lowered temperature while continuing to urge the substrate into the substantially planar form.