Forming resin substrates using dye sublimation and substrates formed using the same
Assignee3form, Inc.
InventorsWendy E. K. Langan, John E. C. Willham, Brent M. Burningham
Life of this patent
Estimating the term…
Abstract
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.
Claims22
In a architectural design environment, a method of decorating a resin substrate using dye sublimation, comprising:
- positioning at least one sublimation dye carrier on a resin substrate, having opposing first and second surfaces;
- applying equal heat and pressure uniformly and simultaneously to both the first and second opposing surfaces of the substrate, until a dye sublimates into and covers at least the entire first surface of the substrate;
- wherein the resin substrate remains substantially flat and uniform at each edge and corner;
- and
- removing the at least one sublimation dye carrier from the resin substrate.
A method of coloring a decorative resin substrate using dye sublimation without the use of a vacuum press, comprising:
- placing a first sublimation dye layer against a first surface of a substrate;
- placing a second sublimation dye layer against an opposing second surface of the substrate;
- applying heat and pressure uniformly and simultaneously, without the use of a vacuum press, to both the first and second opposing surfaces of the substrate, until the first and second dye layers sublimate a depth into and cover the entire first and second opposing surfaces of the substrate;
- cooling the first and second opposing surfaces of the substrate at the same rate;
- and
- removing the first and second sublimation dye carriers from the substrate.
In a architectural design environment, a method of decorating a resin substrate using dye sublimation, comprising:
- providing one or more resin substrates;
- positioning one or more sublimation dye carriers on at least one surface of one or more of the one or more resin substrates;
- applying equal heat and pressure to opposing outside surfaces of a laminate assembly comprising the one or more resin substrates and positioned one or more sublimation dye carriers;
- and
- removing each positioned sublimation dye carrier from the corresponding resin substrate;
- wherein:
- equal heat and pressure is applied, without the use of a vacuum press, uniformly and simultaneously to opposing surfaces of the laminate assembly until a dye from each dye carrier sublimates into the corresponding resin substrate on which it is positioned;
- and
- the resin substrate remains substantially flat and uniform at each edge and corner.
Dependencies are inferred from the claim text.