Method of manufacturing dye-sublimation printed elements

Patent metadata

Field	Value
Publication number	US-9505203-B2
Application number	US-95634410-A
Country	US
Kind code	B2
Filing date	Nov 30, 2010
Priority date	Nov 30, 2010
Publication date	Nov 29, 2016
Grant date	Nov 29, 2016

Abstract

A method for manufacturing printed elements may include receiving an order including data representing indicia. The indicia may be printed by dye-sublimation on a surface of a first material. The first material may be positioned adjacent to and between a second material and a dye retention layer. The first material, the second material, and the dye retention layer may be compressed and heated, such as in a thermalbonding process, to secure the first material to the second material. Custom-ordered indicia of a comparatively high quality may thereby be imparted to printed elements, including textile elements, cushioning elements, and a variety of other products.

First claim

The invention claimed is:

1. A method of manufacturing a printed element, comprising:
printing indicia by dye-sublimation on a first surface of a first material, wherein a second surface of the first material that generally opposes the first surface is to be thermal bonded to a second material after the indicia is printed on the first surface;
inhibiting transfer of re-sublimated dye away from the first material when the second surface of the first material is thermal bonded to the second material, wherein inhibiting transfer of re-sublimated dye includes positioning a dye-retention layer including a dye-resistant material directly adjacent to the first surface of the first material and the indicia that is printed on the first surface;
positioning the second surface of the first material adjacent to the second material, such that the first material and the indicia are positioned between the second material and the dye retention layer, the dye-retention layer being positioned directly adjacent to the first surface of the first material on which the indicia is printed and the second material being positioned adjacent the second surface of the first material;
positioning the dye retention layer between the first material and a heating plate; and
compressing and heating the first material, the second material, and the dye retention layer to secure the first material to the second material,
wherein compressing and heating includes securing the first material to the second material by forming at least one polymer bond.

2. The method of claim 1 , further comprising a step of receiving an order including data representing the indicia.

3. The method of claim 2 , wherein the printing of the indicia by dye-sublimation is done on a surface of the first material according to the data representing the indicia.

4. The method of claim 1 , wherein the first material is a polyester mesh material.

5. The method of claim 1 , wherein the dye retention layer is selected from a group consisting of a wax paper, a release paper, a polymer sheet, and a material having a plasticized surface.

6. The method of claim 1 , wherein the second material is a polymer foam material.

7. The method of claim 1 , wherein the step of printing is performed at a first temperature and the step of compressing and heating is performed at a second temperature, the first temperature being greater than the second temperature.

8. The method of claim 7 , wherein (a) the first material is a textile material, (b) the dye retention layer is a non-absorbent material, (c) the second material is a polymer foam material.

9. The method of claim 7 , wherein the step of compressing and heating includes forming a cushioning component by (a) pressing the dye retention layer against the first material and (b) pressing the first material against the second material.

10. The method of claim 1 , further comprising a step of removing the dye retention layer.

11. The method of claim 1 , wherein the second material includes a plurality of polymer foam elements.

12. The method of claim 11 , wherein the first material is a first textile structure, and the step of positioning includes locating the plurality of polymer foam elements between the first textile structure and a second textile structure.

13. The method of claim 12 , wherein at least one of the first textile structure and the second textile structure includes a polymer mesh material.

14. The method of claim 12 , wherein the second textile structure includes at least one of a polymer mesh material and a part of a base material of an article of apparel.

15. The method of claim 12 , wherein the step of compressing and heating secures the first textile structure to at least one of the second textile structure and the polymer foam elements.

16. The method of claim 12 , further comprising steps of (a) removing the dye retention layer and (b) incorporating the first textile structure, the second textile structure, and the polymer foam elements into an article of apparel.

17. A method of manufacturing a printed element, comprising:
printing indicia by dye-sublimation on a first material;
inhibiting transfer of re-sublimated dye away from the first material by positioning the first material and the indicia adjacent to a dye-retention layer;
positioning the first material adjacent to a second material, such that the first material and the indicia are positioned between the second material and the dye retention layer, wherein the dye-retention layer includes a surface to which transfer of a sublimation-printed dye is inhibited and wherein the dye-retention layer is positioned adjacent a surface of the first material on which the indicia is printed and the second material is positioned adjacent an opposite surface;
positioning the dye retention layer between the first material and a heating plate;
compressing and heating the first material, the second material, and the dye retention layer to secure the first material to the second material by forming at least one polymer bond; and
removing the dye retention layer, wherein the step of printing is performed at a first temperature and the step of compressing and heating is performed at a second temperature, the first temperature being greater than the second temperature.

Assignees

• Turner David
• Nike Inc

Inventors

• Turner David

Classifications

• B32B38/145 Primary

  Printing · CPC title

• D06Q1/00

  Decorating textiles · CPC title

• D06Q1/08

  by fixation of mechanical effects, e.g. calendering, embossing or Chintz effects, using chemical means · CPC title

• D06P5/004

  using subliming dyes · CPC title

• D06Q1/12

  by transferring a chemical agent or a metallic or non-metallic material in particulate or other form, from a solid temporary carrier to the textile {(for uniform treatment D06M23/02)} · CPC title