Modular sublimation transfer printing apparatus

• US 9,403,394 B2
• Filed: 04/24/2014
• Issued: 08/02/2016
• Est. Priority Date: 07/25/2013
• Status: Active Grant

• Current Assignee: Hillman Group Incorporated (Hillman Solutions Corp.)
• Original Assignee: Hillman Group Incorporated (Hillman Solutions Corp.)
• Inventors: Rosner, Brian, Will, Gary Edward, Solace, Bryan Keith
• Primary Examiner(s): Tran, Huan
• Application Number:
  US14/261,202
• Publication Number:
  US 20150029289A1
• Time in Patent Office: 831 Days
• US Class Current: 1/1
• CPC Class Codes: B41F 16/0046 with means for applying print under heat and pressure, e.g. using heat activable adhesive
• CPC Class Codes: B41F 16/0073 with means for printing on specific materials or products
• CPC Class Codes: B41F 16/008 for printing on three-dimensional articles
• CPC Class Codes: B41F 16/0093 Attachments or auxiliary devices
• CPC Class Codes: B41J 2/315 characterised by selective application of heat to a heat sensitive printing or impression-transfer material B41J2/385, B41J2/435 take precedence
• CPC Class Codes: B41M 5/0041 Digital printing on surfaces other than ordinary paper B41M5/0082 takes precedence; printing on textiles D06P5/00
• CPC Class Codes: B41M 5/0082 Digital printing on bodies of particular shapes sublimation or volatilisation of pre-printed design B41M5/035
• CPC Class Codes: B41M 5/0094 by thermal printing
• CPC Class Codes: B41M 5/025 by transferring ink from the master sheet
• CPC Class Codes: B41M 5/035 by sublimation or volatilisation of pre-printed design , e.g. sublistatic B41M5/0256 takes precedence; printing on textiles D06P5/00
• CPC Class Codes: B41M 5/0358 characterised by the mechanisms or artifacts to obtain the transfer, e.g. the heating means, the pressure means or the transport means
• CPC Class Codes: B44C 1/162 Decalcomanias with a transfer layer comprising indicia with definite outlines such as letters and with means facilitating the desired fitting to the permanent base
• CPC Class Codes: G07F 11/70 in which the articles are formed in the apparatus from components, blanks, or material constituents
• CPC Class Codes: G07F 17/42 for ticket printing or like apparatus , e.g. apparatus for dispensing of printed paper tickets or payment cards

Abstract

A safe, integrated dye sublimation transfer printer apparatus is disclosed. The apparatus is configured to print one or more images onto transfer media, then align the transfer media onto a substrate. A selected product to receive the sublimated image is positioned on top of the transfer media, and the apparatus brings the transfer media and one or more heating platens into contact to sublimate the image. The heating platen is configured to sublimate one or more opposing sides of a product substantially simultaneously in a single thermal cycle. In some embodiments, the apparatus may be incorporated into a fully-enclosed vending machine to provide on-demand personalized sublimated products and accessories for a consumer.

Claims

1. A method for sublimating images on a product, comprising:

printing one or more images identified by a customer for the product on a transfer media;

positioning the transfer media on a substrate;

positioning at least one product onto the transfer media;

folding the transfer media to substantially surround the product, wherein at least one printed image is positioned onto one or more opposing sides of the product to be sublimated;

configuring a single thermal cycle for a single heating platen such that the images will be sublimated substantially simultaneously onto each side of the product in a single thermal cycle,

wherein configuring a single thermal cycle comprises configuring a programmed pressure of about 30 to about 40 psi, and

wherein the programmed pressure is applied via a press ram comprising one or more springs with a known spring constant and a sensor configured to measure the spring displacement;

bringing the single heating platen and transfer media into contact; and

sublimating at least one image from the transfer media to each side of the product using the configured single thermal cycle of the single heating platen.

2. The method of claim 1, wherein positioning the transfer media on a substrate further comprises securing at least a portion of the transfer media into contact with the substrate with one or more clamps.

3. The method of claim 1, further comprising translating the substrate from a home position into alignment with the single heating platen.

4. The method of claim 1, wherein bringing the single heating platen and transfer media into contact further comprises translating one or more of the substrate and the single heating platen.

5. The method of claim 4, wherein the single heating platen and transfer media are brought into contact by one of a mechanical cam system, hydraulic system, or pneumatic system.

6. The method of claim 1, wherein configuring a single thermal cycle further comprises configuring at least one of a programmed temperature or duration.

7. The method of claim 1, wherein positioning the transfer media on a substrate further comprises transporting the transfer media from a printer that printed the one or more images identified by a customer for the product on the transfer media to the substrate via a motorized feeder tray.

8. An automated sublimation apparatus for sublimating an image on a product, comprising:

a dye sublimation transfer printer configured to receive a digital image file representing an image, the dye sublimation transfer printer configured to print the received image on a transfer media;

a substrate configured to receive the transfer media;

one or more heating platens configured to sublimate the printed image onto one or more opposing sides of the selected product;

a housing substantially enclosing the dye sublimation transfer printer, substrate, and one or more heating platens in a manner that prevents a user from contacting the enclosed components; and

a user interface device configured to permit the user to determine an image for printing.

9. The apparatus of claim 8, further comprising one or more clamps configured to secure at least a portion of the transfer media into contact with the substrate.

10. The apparatus of claim 8, wherein the substrate further comprises a linear motion stage, and the substrate is configured to translate, via the linear motion stage, from a home position to a position in alignment with the one or more heating platens.

11. The apparatus of claim 8, further comprising a motorized folding arm mechanism configured to:

fold the transfer media to substantially surround the product; and

unfold the transfer media subsequent to sublimation of the image by the one or more heating platens.

12. The apparatus of claim 11, wherein the motorized folding arm mechanism is further configured to assist in removing the transfer media from the substrate.

13. The apparatus of claim 8, wherein the apparatus further comprises at least one of a motorized cam system, a hydraulic system, or a pneumatic system configured to bring the transfer media and one or more heating platens into contact.

14. The apparatus of claim 13, wherein the apparatus further comprises a hydraulic system, the hydraulic system comprises one or more of a pump, a regulator, a reservoir, a hydraulic actuator, and a control valve.

15. The apparatus of claim 14, wherein the apparatus further comprises:

one or more springs loaded by the hydraulic actuator with a known spring constant; and

a sensor configured to measure the spring displacement of the one or more springs.

16. The apparatus of claim 8, wherein the dye sublimation transfer printer further comprises a motorized feeder tray that is configured to transport the transfer media to the substrate.

17. A vending apparatus for providing a user with a customized sublimated product, comprising:

a dye sublimation transfer printer configured to receive a digital image file representing an image from the user and further configured to print the received image on a transfer media;

a substrate configured to receive the transfer media;

one or more product storage containers configured to store a plurality of products;

a robotic transport mechanism configured to place the transfer media on the substrate, retrieve a selected product from a storage container, and position the product on the transfer media;

one or more heating platens configured to engage the transfer media and sublimate the printed image onto one or more opposing sides of the selected product in a single thermal cycle;

a cooling system configured to cool the sublimated product to at least about an ambient temperature;

a delivery opening configured to provide the cooled product to the user;

a housing substantially enclosing the dye sublimation transfer printer, substrate, one or more product storage containers, robotic transport mechanism, one or more heating platens, and cooling system in a manner that prevents a user from contacting the enclosed components; and

a user interface device configured to permit the user to determine one or more images for printing, select one of the plurality of products on which to sublimate the one or more images, and facilitate payment by the user for the sublimated product.

18. The vending apparatus of claim 17, wherein the substrate further comprises a linear motion stage, and the substrate is configured to translate, via the linear motion stage, from a home position to a position in alignment with the one or more heating platens.

19. The vending apparatus of claim 17, wherein the robotic transport mechanism is configured to translate along an H-shaped track, and comprises a telescoping robotic arm.

20. The vending apparatus of claim 17, wherein the robotic transport mechanism comprises multiple end effectors.

21. The vending apparatus of claim 17, wherein the received image is modified to permit sublimation of the image onto the product.

22. The vending apparatus of claim 17, wherein the robotic transport mechanism comprises an end effector comprising one or more of a mechanical implement configured to interface with a product storage container and a sensor configured to determine information associated with the product storage container.

23. The vending apparatus of claim 22, wherein the end effector comprises a sensor configured to determine information associated with the product storage container.

24. The vending apparatus of claim 23, wherein the apparatus is configured to transmit the information to a remote server.

25. The vending apparatus of claim 23, wherein the determined information comprises a count of the inventory that the product storage container contains.

26. The vending apparatus of claim 25, wherein the apparatus is configured to alter the information displayed to a user on the user interface device based on the determined count of inventory.

27. The vending apparatus of claim 26, wherein the alteration comprises one or more of an indication that a product or accessory is out of stock or an indication that only a certain quantity of products or accessories less than or equal to the determined count of inventory are available.

28. The vending apparatus of claim 23, wherein the determined information comprises information associated with one or more of the vending apparatus, the product contained within the product storage container, the manufacturer of the vending apparatus, a retailer hosting the vending apparatus, or a third party.

29. The vending apparatus of claim 28, wherein the apparatus is configured to compile a report comprising the determined information.

30. The vending apparatus of claim 29, wherein the apparatus is further configured to display the report to a user via the user interface device.

31. The vending apparatus of claim 17, wherein the user interface device is configured to transmit or receive information from a mobile application associated with one or more of a manufacturer of the vending apparatus, a retailer hosting the vending apparatus, or a third party.

32. The vending apparatus of claim 31, wherein the information comprises one or more of information associated with the user'"'"'s desired product to be sublimated, information associated with an image or text to be sublimated on the product, information associated with payment for the sublimated product, information comprising a location of the nearest vending apparatus, or a code configured to facilitate access by the user interface device to information associated with a saved transaction ordered from the mobile application.

33. The vending apparatus of claim 17, wherein the user interface device is configured to:

prompt the user to determine if additional sublimated products are desired;

provide the user with information enabling later orders of additional sublimated products; and

transmit information associated with the sublimation task to a remote server to facilitate later orders of additional sublimated products.

34. The vending apparatus of claim 33, wherein the later orders are to be produced at a remote facility associated with one or more of a manufacturer of the vending apparatus, a retailer hosting the vending apparatus, or a third party and shipped to the user.

35. The vending apparatus of claim 17, further comprising one or more clamps configured to secure at least a portion of the transfer media into contact with the substrate.

36. The vending apparatus of claim 17, further comprising a motorized folding arm mechanism configured to:

fold the transfer media to substantially surround the product; and

unfold the transfer media subsequent to sublimation of the image by the one or more heating platens.

37. The vending apparatus of claim 36, wherein the motorized folding arm mechanism is further configured to assist in removing the transfer media from the substrate.

38. The vending apparatus of claim 17, wherein the apparatus further comprises:

one or more springs loaded by a hydraulic actuator with a known spring constant configured to bring the transfer media and one or more heating platens into contact with a known pressing force; and

a sensor configured to measure the spring displacement of the one or more springs.

39. The vending apparatus of claim 38, wherein the known pressing force is about 30 psi to about 40 psi.

40. The vending apparatus of claim 17, wherein the dye sublimation transfer printer further comprises a motorized feeder tray that is configured to transport the transfer media to the substrate.

41. The vending apparatus of claim 40, wherein the motorized feeder tray further comprises one or more sensors that detect when to stop feeding the transfer media to the substrate.

42. The vending apparatus of claim 17, wherein the cooling system comprises a heat sink in the form of a plate comprised of a thermally conductive material selected from the group consisting of copper, brass, aluminum, and steel.

43. The vending apparatus of claim 42, wherein the plate includes one or more grooves or slits.

44. The vending apparatus of claim 17, wherein one of the one or more storage containers contains a product comprising multiple sublimatable items etched onto the product that may be individually punched out.