Abstract: An illustrative dye sublimation apparatus may include a pair of printed sheets placed on either side of a substrate that allows for image infusion on both sides of the substrate. A second heat source, such as a heated plate, is included in order to heat the second printed sheet. Compared to the conventional systems in which a single heat source heats a single printed, the embodiments disclosed herein describe a process for simultaneous double-sided image infusion, which results in a substrate with sublimated images on both sides.

Abstract: Methods and systems for adjusting formulation of pigments for dye sublimation are disclosed. In one embodiment, the method includes receiving, by a processor, a selection of the substrate and the image to be dye sublimated into the substrate. The method also includes determining, by the processor, an amount of each pigment of sublimation ink to be used to print the image on a sheet based on a characteristic of the substrate. The method further includes printing, by a dye sublimation apparatus, the image on the sheet using the amount of each pigment of sublimation ink and infusing, by the dye sublimation apparatus, the image from the sheet into the substrate.

Abstract: An illustrative dye sublimation apparatus may include a texture sheet with a pattern to be applied to a substrate. More specifically, the texture sheet is pressed into the substrate during the dye sublimation process in order to apply the pattern from the texture sheet while the substrate is heated and simultaneously being infused with an image from a printed sheet. The pressure applied to the texture sheet can vary, for example based on the temperature. Compared to the conventional systems in which substrates are pre-textured, the embodiments disclosed herein describe a process for simultaneous image-infusion and texture-application, which results in a substrate that is both infused and textured.

Abstract: An illustrative dye sublimation apparatus (also referred to as a dye sublimation machine) may have a pair of conveyor belts to perform continuous sublimation cycles using a continuous feed of printed sheet and substrate. For example, the continuous feed dye sublimation apparatus may receive substrate directly from an extrusion machine, which saves time and effort over traditional methods that require separate preparing and loading steps. The pair of conveyor belts may then apply pressure and heat to the printed sheet and substrate in order to facilitate dye sublimation.

Abstract: An illustrative heating section of a dye sublimation machine may utilize a plurality of configurable pyrometers. The pyrometers may take the corresponding temperature measurements remotely without interacting with any mechanical moving parts of the dye sublimation machine and therefore may be more robust against breakage. The pyrometers may be directed at the membrane covering the printed sheet and therefore may provide more accurate temperature measurements. Furthermore, the angular orientation of the pyrometers may be configured that may allow the pyrometers to dynamically measure the temperature of multiple spots in the heating section. In addition to the pyrometers in the heating section, a plurality of pyrometers may be provided to measure the temperature in the cooling section of the dye sublimation machine.

Abstract: An illustrative dye sublimation apparatus may include a sealed chamber and a heating section. More specifically, the sealed chamber is thermally insulated and substantially airtight in order to keep the heat generated by the heating section within the sealed chamber. Compared to the conventional systems that are open-air and require direct heat, the embodiments disclosed herein generate a uniform or nearly uniform heat distribution throughout the sealed chamber, which results in a more consistent and efficient dye sublimation process.

Abstract: An illustrative dye sublimation apparatus (also referred to as a dye sublimation machine) may have at least four stations, each station implementing a discrete step of a sublimation cycle. Multiple beds are rotatably mounted such that the beds pass through the stations to perform the corresponding steps. Therefore, the sublimation apparatus may perform multiple sublimation cycles simultaneously with the beds containing printed sheets and substrates at different steps of the multiple sublimation cycles. As the beds are rotatably mounted, the sublimation apparatus may allow for a fixed loading and unloading station proximate to a fixed, dedicated personnel station.

Abstract: An illustrative dye sublimation apparatus may comprise a pressure housing in the heating component. The pressure housing may apply a positive pressure on a membrane covering a combination of a printed sheet and a substrate. The positive pressure applied by the pressure housing may cause the printed sheet and substrate to snugly press against each other throughout a heating cycle. Furthermore, the positive pressure applied by the pressure housing may be even or approximately even throughout an upper surface of the membrane. The dye sublimation apparatus may utilize the pressure housing in addition or as an alternative to a negative pressure applied by a vacuum pump.

Abstract: In an illustrative embodiment, a processor determines an ink coverage for a portion of an image and retrieves one or more input parameters for the portion. The processor may adjust the height of the print head (i.e., the distance between the print head and a paper where the image is to be printed) based upon the ink coverage and the one or more input parameters. In particular, the processor may optimize the height of the print head for image clarity while preventing head strikes. In some embodiments, the processor for may maintain the same height for an image. In other embodiments, the processor may dynamically adjust the height while printing for different portions of the image.

Abstract: An illustrative heating section in a dye sublimation apparatus may include one or more individually controllable fans. More specifically, a computer or a controller may control speed and/or orientation of the fans for a convective heat transfer to a printed sheet in the heating section. Furthermore, the speed and/or orientation of the fans may be dynamically adjusted based upon the temperature requirement of different stages of the dye sublimation process. Compared to the conventional systems that rely only upon radiative heat which generally results in non-uniform heat distribution within the heating section, the embodiments disclosed herein generate a uniform or nearly uniform heat distribution and also avoid hot spots within the heating section.

Abstract: Disclosed herein are thermoplastic polymer matrix compositions for a continuous fiber reinforced thermoplastic composite article, comprising at least one of poly(vinyl chloride) and/or chlorinated poly(vinyl chloride). Also disclosed herein are methods for formulating thermoplastic polymer matrix compositions suitable for impregnating continuous fibers for continuous fiber-reinforced thermoplastic composite articles, wherein the thermoplastic polymer matrix compositions have sufficient viscosity and thermal stability to impregnate continuous fibers and withstand thermal treatment at high temperatures and long residence times without decomposing.