WO2004106082A1 - Thermal image transfer by sublimation or fusion - Google Patents

Thermal image transfer by sublimation or fusion Download PDF

Info

Publication number
WO2004106082A1
WO2004106082A1 PCT/IT2004/000306 IT2004000306W WO2004106082A1 WO 2004106082 A1 WO2004106082 A1 WO 2004106082A1 IT 2004000306 W IT2004000306 W IT 2004000306W WO 2004106082 A1 WO2004106082 A1 WO 2004106082A1
Authority
WO
WIPO (PCT)
Prior art keywords
objects
films
transfer
decorations
pressure
Prior art date
Application number
PCT/IT2004/000306
Other languages
French (fr)
Other versions
WO2004106082B1 (en
Inventor
Michele Giannini
Original Assignee
Michele Giannini
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Michele Giannini filed Critical Michele Giannini
Priority to EP04735091A priority Critical patent/EP1648711A1/en
Publication of WO2004106082A1 publication Critical patent/WO2004106082A1/en
Publication of WO2004106082B1 publication Critical patent/WO2004106082B1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00Duplicating or marking methods; Sheet materials for use therein
    • B41M5/025Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet
    • B41M5/035Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet by sublimation or volatilisation of pre-printed design, e.g. sublistatic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/16Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
    • B44C1/165Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
    • B44C1/17Dry transfer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/16Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
    • B44C1/165Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
    • B44C1/17Dry transfer
    • B44C1/1712Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B44DECORATIVE ARTS
    • B44CPRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/16Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
    • B44C1/165Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
    • B44C1/17Dry transfer
    • B44C1/1733Decalcomanias applied under pressure only, e.g. provided with a pressure sensitive adhesive
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/003Transfer printing
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06PDYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/003Transfer printing
    • D06P5/004Transfer printing using subliming dyes
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06QDECORATING TEXTILES
    • D06Q1/00Decorating textiles
    • D06Q1/12Decorating textiles 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B41PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41MPRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00Inking and printing with a printer's forme
    • B41M1/40Printing on bodies of particular shapes, e.g. golf balls, candles, wine corks

Definitions

  • the present invention relates to a method to transfer any image or color, printed or deposited in any way on flat sheets or films, suitable for the relative use, to surfaces of any suitable tridimensional or bidimensional object.
  • the transfer can be obtained by sublimation, if the images are printed or deposited using sublimatic inks or by physical transfer if the inks used are physically transferable, not sublimable.
  • This kind of transfer was done, in the prior art, by several equipments, designed for limited purpose, according to the kind and the shape of the object, and equipped with several tools.
  • the sublimatic transfer is done getting the object and relative decorated films or sheets, under temperature of 140- 200 °C and submitting them to a pressure of 1-4 atmosphere, for few seconds, or for several minutes if the low limit of temperature (140 °C) is used.
  • various press machines built, equipped with hot plates or hot matrices suitable to press between them the objects with relative films, by the aid of sheets of silicone rubber or Teflon, interposed between the matrices and the objects, covered with relative films, to warrant an uniform pressure on the zones to decorate.
  • the matrices must be heated and duly done, to warrant an uniform pressure on the films and soles. It also needs studying how to insert, in correct way, the films between the soles and relative matrices. If the soles are also free styled, the problems become enormous. The same is needed for other tridimensional objects of irregular and fanciful shapes, like crockery, objects for interior decoration, toys and so.
  • the relative method is called Dip Print (or Cubic Print) and consists in printing the decorations (with inks that opportunely sensitized becomes adhesive with the humidity) on water-soluble films that, after being extended on a watery surface, fluctuate on the same, and leaning the object then, pretreated with suitable varnishes or enamels, on the film fluctuating on the water, in contact with the decorations, pushing it then in depth.
  • the film with decorations under the push exerted by water, joins to objects, and the decorations pressed against the objects are attached to them. Then it needs eliminating the residual not dissolved film, drying the objects and giving a protecting varnish on the transferred decorations.
  • This method presents some limits, either for the treatment of objects that cannot be dealt by it, like the clothings and fabrics in general and other objects incompatible with immersion in water, or for the treatment of tridimensional objects of very complex shapes, for the inclusion of air bubbles between the film and the objects. Moreover it regards only the physical transfer and not also that sublimatic. What's more the method Dip Print (or Cubic Print) is valid in order to only decorate the objects on all surfaces, with designs in imitation of different materials, like wood, marble, briar root, nacre etc., but does not allow to decorate with "precise topic", as when pictures or designs are moved, with precise guideline and on zones very well defined of the objects.
  • the films must resist to the needed sublimation temperatures or to the physical heat transfer (140-200 °C, not limiting indication); 5 - in order to decorate objects of very complex shape or when a perfect spreading of the probable folds, shown by the films, on the zones to decorate of the object (after the vacuum packaging has happened) needs, films thermoretractable, in one or more directions, able to withdraw at temperatures lower than those at which the physical or sublimatic transfer happens, will be adopted: in other words the atmospheric pressure (or of other type, acting to the outside) pushes the film against the surfaces to decorate, while the retraction of the film spreads the folds;
  • the heat can be supplied by infrared radiations and/or by hot air circulation, or by overheated steam or in whichever other way compatible with our found;
  • the temperature of the packaging films is ever higher than that of the object surfaces to decorate, with which the films are in contact. This is obtained doing so that the films can absorb the greatest quantity of the supplied heat and thus doing so that they are not much or not at all transparent to the heat radiations, not much or not at all reflecting, and better also if they are black or of dark color, specially if the heating is carried out by infrared beams. Moreover in this case infrared beams are preferably adopted, with wavelength at the limit between the "high" values of the medium-waves and those "low” of the long-waves (dark irra- diators), of approximately 3-5 micron (not limiting indication).
  • the infrared beams with wavelengths comprised between 2,3 and 3,4 micron have a high power of penetration in nearly all the substances, there are adopted less penetrating waves, like those indicated, in order to heat the films to temperature higher than that of the superficial layers of the objects in them packaged, in contact with the films themselves. If the heating happens by hot air or by steam, the temperature of films is ever higher than that of the superficial layers of the objects to decorate: the films must be sufficiently good conductors of heat. The heating must sufficiently be express to assure the demanded jump of temperature.
  • the devices described in this point 7 are done in order to warrant that the sublimating gases of the decorations to transfer, printed or deposited on films, are not absorbed by the films themselves, but only by the surfaces of the objects to decorate.
  • sublimating gases change their state, from gas to solid, only at temperatures lower than those of sublimation, they are deposited and incorporated only on the surfaces of the treated objects that are at temperature lower than that of the films , if the devices before illustrated will be respected.
  • the same devices enable also the physical transfer of decorations, when it does not happen by sublimation.
  • Fig. 2 in a not limiting example, it shows in plant the sheet on which is printed the image to transfer on the shoe sole of Fig. 1.
  • the represented sheet is of double length than the normal needed sheet.
  • the sheets of double length are useful in order to avoid making appear, on the zone of heel, the line of splice between the decorations of two separate sheets.
  • Fig. 3 it represents, in side-view, a section, with a perpendicular plane, of the sheet or film of Fig. 2, showing the thickness very much magnified.
  • the film represented in this section is an example of many suitable films, according to our found: it is composed of 4 layers, but it can also be a film onolayer, of two, three or more than 4 layers.
  • Fig. In the Fig.:
  • the intermediate layer of the film sandwiched between the layers 3 and 3" (not limiting indication): it is a layer of "barrier film” against gases and vapors, which maintains the vacuum realized in the sealed vacuum packaging, according to our found.
  • the "barrier” layer in other executions, can be more than one only, generally alternated with other film layers like 3 and 3' or also of various other type;
  • Fig. 4 it represents, in plant, the same sheet, of fig. 2 and 3, refolded like an envelope, closed on 3 sides, two of which (6 and 7) are blocked by thermosealing obtained by the most suitable means, having the design to transfer, printed in specular way, that remain on the inner faces of the envelope in order to be transferred in correct way on the object.
  • thermosealing 6 and 7 - they are the others two sides closed by thermosealing.
  • Fig. 5 it represents in plant the envelope of fig. 4, and in side-view the shoe sole 9, inserted in the enve- lope: it is not yet sealed.
  • the shoe sole rests on the plane of the sheet so that its side-view shows in plant. This is one of the possible disposals of the sole with regard to the packaging sheets: other preferential are shown in fig. 8 and 9.
  • FIG. 8 it shows, in the same views of fig. 5, one of the preferential ways not limiting, to arrange the shoe sole between two preformed sheets or films. Both bring the decorations to transfer, printed before the preforming, with suitable registers (small crosses), to be respected in phase of decorations printing and of preforming and vacuum packaging of films, to do so that the image to transfer will be recomposed on the object in continuous and ordered way.
  • suitable registers small crosses
  • the films are thermosealed on four sides, rather than on three sides
  • the registers can be tridimensional: for example not limiting, they can be placed on the 4 small cones "males” thermoformed on the underlying sheet, that realize the centring with the overhanging sheet, matching with the relative 4 cones "females” thermoformed on this last
  • FIG. 9 it shows another way not limiting, to arrange the sole to decorate between the packaging films, unlike that of fig. 5 or fig. 8. It shows, in side-view, the longitudinal section, with a vertical plane, of a sole, placed between two packaging films, so as to rest on the flat film 27, put in horizontal position, before that the packaging and the exposure to the atmospheric pressure happens. In short the bottom is here rotate of 90°, on its longitudinal axis, with regard to the packaging films.
  • the sheet pointed out to the arch-support of sole it can also not bring decorations to transfer, because it is in contact with the zone of the sole not at view, on which the upper of shoe must be stuck. If realized with a ticker and/or more rigid film than the film 28, it makes so that the film 28, thin, flexible and elastic, covers all the sole surfaces remaining at view on the relative assembled shoe.
  • the film 28 can also be preformed and the film 27, if not preformed, can be preferably thermoretractable.
  • FIG. 11 it shows the view in plant of the pattern obtained "spreading in plane” the model obtained sticking, on the zone 13 of the Fig. 10, a transparent or translucent adhesive paper (not limiting indication), of dimensions wider than that of the zone 13.
  • the paper is cut out, along the contour 14 of 13, duly detached and spread in plane on a thin pasteboard (not limiting indication).
  • the plane pattern of the zone 13 is obtained cutting the thin pasteboard along the edge of the paper.
  • the same pattern is obtained also taking the surface of the zone 13 by tridimensional scanners, or isolating the same from the graphical file of the shoe sole 12, if this is planned at computer in tridimensional graphics, and spreading it in plane by suitable programs of computerized graphics.
  • FIG. 12 it shows (in plant) a way to attach the intermediate film (fig. 11): a film spreaded with removable adhesive, the shape of which is equal to that of the pattern of fig. 11 with some shelves 29, is stuck on the intermediate film (on the face that does not bring the decorations to transfer).
  • the shelves 29 can also edge all the pattern of fig. 11 without interruption.
  • - Fig. 13 it shows the view in plant of a part of the sheet or continuous film on which the pattern of fig. 11 is repeatedly designed, in order to optimize the cutting yeld and to establish the map according to which the decorations, to transfer on the three-dimensional objects, must be printed on the film (on the shoe sole 12 of fig. 10, in our not limiting example).
  • the map will be decided while the serigraphic printing panel is assembled, and the better yield is obtained proportioning the length and width of the panel so as to optimize the film use.
  • the designs 15, that reproduce the contour of the pattern of Fig. 11, are printed or not, on film, on the contour of the decorations, according the requirements.
  • the study in order to optimize the yield and relative map, for the decorations printing, can easily be obtained automatically, using suitable computerized programs.
  • FIG. 15 it shows, in side-view, the shoe sole 12, on which the intermediate film 17, cut out from the sheet or film of fig. 14 like the shape and measure of the pattern of fig. 11 , bringing the decorations to transfer, is berthed by removable adhesive. It is supposed to make a physical transfer.
  • FIG. 16 it shows the sole of fig. 15 inserted between two sheets (or an envelope or bag) 19 between which is vacuum packaged, according to our found, where:
  • FIG. 18 it shows, in side-view, the cross-sectional section (with a plane orthogonal to the straight lines generatrices of its constituting cylinder) of the pressure chamber, in which they are pointed out (designs not in scale):
  • 35 - they are the sections of the railroads in pair parallels to railroads 34, placed at a distance enabling the passage of pieces of the greatest overall dimension, in the sense of the height, arranged on the plane 35'
  • Fig. 19 it shows the side-view of the orthogonal cross-sectional section, with a vertical plane, of the tape transporting the object-carrier planes in the heating tunnel. It is showed, together with the Fig. 18, as the planes can proceed overlapped among them (not limiting indication) so that the overhanging planes rest on those underlying by the spacers in shape of small pillars (not limiting indication).
  • Fig. it is not in scale
  • 35' it is the section of the plane object-carrier sliding on railroad 35
  • Fig. 20 it shows in side-view the section of a mould, having flat and parallel external surfaces, with a vertical plane perpendicular to the horizontal faces of the mould. It is used to thermoform films presenting not excessive stretchings, or better, "adjustable" stretchings, when the thermoforming is executed.
  • FIG. 52' it shows the section of an infra red heating element, having wavelength at the limit between the high values of the medium-waves and those at low values of the long-waves (dark irradiators): 3-5 micron, not limiting indication.
  • the element is thermally isolated from the slab 50 and equipped with a reflecting surface projecting the beams against the film to thermoform in the cavity 51 53 - they are the air suction holes, for the vacuum thermoforming of the film. The air suction put the film against the cavity surfaces, during the thermoforming, and serves to recall it within the cavity, without stretching, before the complete closing of the mould, as cleared in the description of the Fig. 21
  • thermoform (not in scale)
  • Fig. 21 it is the plant-view of the slab 49: it shows the relative disposal of the slab itself, the chassis 56 and film, before beginning the thermoforming of the film.
  • the film is the film to thermoform in the cavity 51 , shown in plant in this Fig..
  • the film has a surface wider than the chassis, such that it can slip between 56 and 49, if pulled when the mould is open, but remaining present between them when the mould will be completely closed and the vacuum thermoforming of the film in the cavity 51 will follow.
  • the friction diminishes if the surfaces in contact with the film are Teflon- coated.
  • the vacuum packaging machines are divided in two main categories:
  • the object is sandwiched between two films, or between two faced faces of the same film (fig. 2), so that all the sides of the films, to be closed hermetically, after extracting the air, turn out inserted under the relative sealing bars of the machine.
  • the two films, or that only one folded in two (fig.
  • non-chamber vacuum packaging machines supplied with sealing bar: these realize the vacuum, without the use of a vacuum chamber, externally to the machine, extracting the air contained in an envelope or bag, of sealable film, in which is inserted the object to package. After having realized the vacuum, between the object and the "bag”, this is hermetically sealed by the sealing bar, that seal between them the two sheets of film that form the "mouth” of the bag.
  • This type of machine is able to realize a less pushed vacuum.
  • the object shape and its disposal in the envelope can be formed air pockets hardly extractable. This type of machine thus is more suitable for the treatment of objects of great dimensions or extended in length or in plane and having not complex shape.
  • the objects to deal with machine supplied with vacuum chamber must be contained in the space enclosed in the vacuum chamber or, vice versa, this must be proportionate so as to contain the objects of maximum dimension, among those to deal.
  • the "non-chamber vacuum packaging machines” are not conditioned by the dimension of the objects, but by the width of the relative bag: the length of the sealing bar of machine must be so long to completely seal the mouth of the bag.
  • Another element to be proportioned to the dimensions of the object is the vacuum pump and the power of the relative motor, that must be fitted to the volume of air to extract in order to realize the vacuum needed, according to the programmed job.
  • the films suitable, according to our found, are those that present the following characteristics:
  • thermoretractability in order to decorate objects having very complex shapes or when we want to eliminate probable folds, present on the films, on the zones to decorate: the films to adopt will be thermoretractable in one or more directions, according to the requirements;
  • thermoplastic polyester film type the Mylar OL12AT of the DuPont Teijin, formed with two film coex- truded, one of which is of biaxially oriented polyester (OPET) and the other is of amorphous polyester.
  • OPET biaxially oriented polyester
  • the layer of amorphous polyester is easily weldable with itself and with other films having an amorphous polyester layer (APET or PETG) or semicrystallme (CPET), giving a strong sealing, hardly openable without being cut.
  • the layer of biaxially oriented polyester gives to the film a great resistance to mechanical stresses, a good quality of "barrier” against gases and vapors and a good resistance to high temperatures.
  • This layer can be exposed to a "corona” treatment (not limiting indication) on the free face, to be metallized and in order to obtain a better "barrier” against gases and vapors.
  • the decorations must be printed in specular way on the amorphous polyester face, that will serve also in order to realize the sealing.
  • the thickness of the metallization layer is comprised between 150 and 300 Angstroms, not limiting indication. This film resists to temperature of approximately 200 °C for approximately 30 minutes and is suitable for the use in oven;
  • D - a polyester film like the Mylar CL of the DuPont Teijin, having a weldable external layer and an inner body that gives to the film characteristics of exceptional mechanical and high temperature resistance. It resists to temperatures of service of 225 °C. It has good "barrier” quality, increasable with a metallization layer. It is a good printing support, characteristic improvable with a "corona” treatment (not limiting indication);
  • E - a film of Polivinilriglymer (PVOH or PVA or PVAL) type N0606, produced by the Idroplast in Montecatini Terme, weldable and resistant to high temperatures until approximately 200 °C. It presents a good resistance to the mechanical stresses, is a very good support for printing and has good qualities of "barrier” against gases, excluding steam.
  • the quality of "barrier” can be improved inserting, by coextrusion or subsequent coupling, an EVOH layer (ethylvinylalcohol), between two its layers (not limiting indication). It has a very good suitability for the metallization.
  • the "barrier" against gases and vapors is ulteriorly improvable by more layers alternated of PVA and EVOH (not limiting indication), according to the outline: PVA-EVOH-PVA-EVOH-PVA (not limiting indication), and by a metallization layer on the external face (last layer of PVA).
  • the thickness of the layer of EVOH oscillates between 3 and 15 micron, and that of the metallized layer, between 150 and 300 Angstroms, not limiting indication.
  • the film can be biaxially pre-stretched in order to be made retractable by heat (thermoretractable), what allows to spread it perfectly on the objects, in the treatment by heat and before the beginning of the images transfer;
  • the objects to decorate that are supposed always perfectly clean and free from humidity, incrustations, powders or grease, can be of various materials, some of the which able to absorb and to tie in physical and/or chemical way the sublimation gases or to berth the decorations in the physical transfer, others not suitable for that. In these cases the objects are so dealt as to turn out receptive. That is obtained depositing and berthing, on the surfaces to decorate, a layer of material, receptive for the sublimation gases or able to berth the decorations of physical transfer, and resistant, without disadvantages, to the temperatures that the treatment demands, and to all the stresses to which the objects will be exposed, during the use.
  • the most used materials are varnishes, enamels or powders for covering, based on polyester and/or acrylic and/or poliuretanics and/or epoxy and/or siliconics or of other polymers and/or similar engineering resins, homopolymers and relative copolymers or terpolymers and probable possible alloys compatible with the objects to decorate, with the treatment that must undergo, and with the use to which are assigned.
  • varnishes, enamels or powders for covering based on polyester and/or acrylic and/or poliuretanics and/or epoxy and/or siliconics or of other polymers and/or similar engineering resins, homopolymers and relative copolymers or terpolymers and probable possible alloys compatible with the objects to decorate, with the treatment that must undergo, and with the use to which are assigned.
  • pre-treatment and/or post-treatment varnishes due the numerous variables from which depends, is made and tested in work course: these treatments make already part of the state of the art and technique in the field of decoration and paint job. If the objects are metallic, besides being cleaned up, they will be degreased and, in case, exposed to operations of pickling and other chemical or electrolytic treatments before the pre-paint job.
  • G - the zones to decorate are defined and are marked, in a way whichever, that is camouflaged or invisible, when the decoration is carried out, you see fig. 10: the zone 13, to decorate, is "marked” with the light small sign 14 (not limiting indication); H - the said zones (usually tridimensional) are copied, with the methods used in the shoe technique, by the stylists of the field, in order to obtain the flat pattern of the surfaces of the lasts (tridimensional) for shoes assembling: the zone 13, to decorate, is covered with suitable transparent or translucent adhesive paper, of dimensions wider than those of the zone 13, the adhesive paper is cut out along the contour 14, then the cut out paper is detached and is duly spread in plane on a thin pasteboard (not limiting indication).
  • the obtained model is designed on the film, on which the decorations must be printed, in the best rational way in order to obtain the best "yield” in the cut: it means to obtain the maximum possible number of patterns from the surface of the film.
  • the preliminary study of the outline of cut is made preferably by computer (not limiting indication) with a suitable graphical program (not limiting indication). From it, the "map”, according to which must be printed the decorations, is drawn. In fact the printing is so made that every pattern, cut out from the film, always brings the images in the correct place and guideline (in specular way), see fig. 11, 13 and 14.
  • the definition of the "map”, for the printing of decorations on the film generally is tied to means used for the printing.
  • the map will be decided while the serigraphic printing panel is assembled and the best yield is obtained proportioning the length and width of the panel so as to optimize the use of the film.
  • the cut is made in several ways, by shearing machines with suitable dies, by cut computerized tables, by hand with suitable tools, and in other ways, one of which not limiting, is that realized by cutting plotters or by printing-and-cutting plotters: by this last it is provided to print and to cut the several film pieces like the pattern of the zones to decorate.
  • the printing on the films is executed by inkjet printing or plotter, or by "change of phase” machines (that spray wax and/or fused resin, with incorporated probable heat fusible adhesive: "hot melt adhesive”) or by thermal transfer digital printers or by laser.
  • the plotters are able to execute the printing on film coils of width variable within wide limits (until 300 cm. and more).
  • the printing can also be made by offset or flexographic or rotogravure machines and also by serigraphy, without limitation for whichever other type, by heat or cold, able to print with inks or colors suitable for the "transfer". If only the colors are moved, these can be sprayed or simply smeared on the films.
  • the design or image can be traced, on the sheets or films, also by free hand;
  • the removable adhesive can also be such to volatilize at the temperatures of the treatment. It is sprayed on the face on which the decoration is printed. The smearing or spraying of the removable adhesive is carried out also, with some smearing or spreading machines, directly on the film from coils.
  • the adhesive in this case, is protected with siliconed films or paper (better if transparent or translucent), so that the film glued can be packaged in coils. We will call, from now, "intermediate film", every pattern cut out from the film as described.
  • the intermediate films are cut from these glued film coils in conformity with the pattern of the zones to decorate: the coil is arranged on a cutting plotter and the intermediate film, remaining attached to the siliconed film or paper until the moment of its use, is engraved.
  • This way to smear intermediate films is right for the sublimatic transfers, having care to adopt an adhesive that does not interfere with the sublimation, as said.
  • Tapes of this type are of common commercialization: a producer, for example not limiting, is the 3M (USA).
  • the adhesive tape can be replaced by a film, smeared with removable adhesive, having the same shape of the intermediate film pattern (you see fig. 11), but protuberant by the same along all its contour or also only in some zones (you see 29 of fig. 12) sufficiently to attach reliably the intermediate film on the zone to decorate (13 of fig. 10): this film must be attached on the intermediate film, on its face having no decorations, so that the protuberant parts 29 can be used in order to attach the intermediate film to the object.
  • the intermediate films are not necessarily like those described in the treatment of the FIRST TYPE (suitable for the vacuum packaging, according to our found), but they can be replaced also with paper for printers or photocopiers or with whichever other support suitable to be printed with sublimable or physically transferable inks, and attached on the zones to decorate, as illustrated.
  • the intermediate film is not, generally, exposed to mechanical stresses of traction or tear but often only to pressure. While the films suitable for the vacuum packaging must at least have part of characteristics of the films described for the FIRST TYPE, and that is:
  • Thermoretractable vacuum packaging films are adopted, in order to perfect the spreading of the films on the objects: for transfers of SECOND TYPE not always it is necessary to spread perfectly the folds of vacuum packaging films, specially if thin and very flexible films are adopted; L - the objects vacuum packaged, as illustrated in the previous K point, are heated, as in the treatments of FIRST TYPE, in order to transfer the decorations from the films to the objects. Arranging the FIRST TYPE method with that of SECOND TYPE, according to our found, it is possible to realize special decorations, with a method that we call of MIXED TYPE.
  • MIXED TYPE With the treatment of MIXED TYPE moreover it is possible to obtain, on the object to decorate, zones of reserve, were the original color of the object will be maintained, or which will be preserved from the decorations or from the colors which will be transferred on the object from vacuum packaging films. It is enough to put, by removable adhesive, on the zones of reserve, the intermediate films (bringing no decorations to transfer) cut out like the pattern of the zones to reserve, and to vacuum package the object, so prepared, in the packaging film bringing the decorations or the colors to transfer, and then to expose the object to the subsequent treatments in order to transfer the decorations, according to our found, to obtain the object decorated on all its surfaces unless those reserved.
  • the intermediate films berthed on the zones of reserve do not bring decorations and are able to oppose a good "barrier" against the passage of sublimation gases and a good protection against the physical transfer of the decorations.
  • MIXED TYPE intermediate and vacuum packaging films with simple transferable colors
  • the object at the end of the treatment will turn out colored in several colors, obtained some by reserve, others brought from intermediate films and from films of vacuum packaging: this becomes a new method in order to obtain objects colored in three or more colors, arranged in zones and ways very well defined, in a single treatment.
  • the reserve can be made also with regard to the zones decorated by intermediate films: the decorated object presents thus zones of reserve, with regard to the decorations transferred from intermediate films, and to those transferred from vacuum packaging films: also the treatments of SECOND TYPE can present zones of reserve.
  • the heating, for the transfer of decorations, according to our found, is preferably carried out in a tunnel (not limiting indication), equipped with heating elements by infrared beams, crossed by a tape conveyor, having an adjustable speed or intermittent advance.
  • the achievable temperatures on the objects and relative films are function of the radiation power, of heating elements, of the amount of the same placed in the tunnel, of the distance of the objects from the heating elements and of exposure time. Since it is demanded a very uniform heat distribution, it is provided to do not move the objects too much near the sources of heat, to put them on the tape conveyor so as to do not create wide zones of shadow, to cover the tunnel with reflecting inner surfaces and also to make the surface of the tape reflecting.
  • the heating can happen in a tunnel and also in a static oven by intermittent loading and unloading, in cycles of treatment of the sufficient duration to make happen the transfer of the decorations.
  • the static oven must be constructed with the same devices described for the tunnel, in order to warrant an uniform heating of all the objects dealt, or is planned with heating by circulation of hot air or mixed: by hot air and infrared beams.
  • the temperature in the tunnel or in the static oven is controlled and regulated with detectors and automatic regulators of temperature connected to the feeding system of the elements by infrared beams or to the hot air generators.
  • the heating is executed in a tunnel or in a static oven, in many cases it is enough to have at disposal heating elements by infrared beams (not limiting indication), of suitable shape and surface, and to direct the radiations on the objects by opportune orientation of the same as regards the objects or the relative zones to decorate, specially if that are partial zones of objects of great dimensions.
  • infrared beams not limiting indication
  • the pressure exerted on the object to decorate varies between 1 and 4 atmospheres: the pressure used often is elevated to the high values in order to decrease the time of transfer, since a higher pressure warrants a more uniform adhesion between the film and the object and thus a better transmission of heat and thus a reduction of transfer time.
  • the adhesion between the films and the objects to decorate happens in ongoing way and the pressure of approximately 1 Atmosphere is enough to transfer the decorations quickly and duly in the greatest part of the cases in which the objects are of not very complex shape.
  • the vacuum packaging of the objects enables to increase the pressure that pushes the vacuum packaging films on the relative objects, in the simplest and immediate way. It is enough to put the objects, vacuum packaged in the relative films, in a "pressure chamber". For the heat transfers this is heated until the temperature of approximately 200 °C and more, not limiting indication, where the objects remain for the time needed to make happen the transfer. But we remind that the temperatures for the sublimatic transfer can also be lower, as shown in the table at pag.
  • the characteristics of the "pressure chamber" can be of whichever type, with at least an openable side for the loading and unloading of the objects, and constructed in whichever suitable material able to bear the pressures that in it will be exerted.
  • Our description will be limited to illustrate a preferential model not limiting, having a cylindrical shape and constructed in stainless steel (see fig. 18).
  • the most rational and productive shape is that which presents, on the two mouths of the cylinder, two doors, openable towards the outside, that lend themselves very well to favor an express loading and unloading of the chamber, at the end of every cycle.
  • the job position of the chamber is preferably that horizontal, on line with the tunnel, with the two doors arranged, one (that of loading) in proximity of the escape of the objects from the tunnel, and the other (that of unloading) on line on the opposite side.
  • the chamber presents in its inside, along some its straights generatrices, some protuberant lists (not limiting indication), coupled and face to face, that form sliding railroads, on which to make slide some planes (not limiting indication) bringing the objects to deal according to our found.
  • the other planes have the same length of the first (not limiting indication) but a smaller width, you see fig. 18.
  • the pressure chamber is connected with an air compressor and presents a valve of air discharge, to set in action before every opening of the chamber, at the end of every cycle of treatment.
  • the pressure chamber is heated by circulation of diathermic oil or with electrical resistances (not limiting indication: the heating can happen in whichever other way compatible with our found), and the external surfaces are covered by insulator material in order to assure a correct insulation.
  • the inner surfaces of the chamber are preferably polished in order to favor the best reflection of the heat radiations and thus an uniform spread of the temperature on the objects to heat: the needed heat is supplied by radiation by the heated surfaces of the chamber.
  • the closing doors of the pressure chamber pivoted on suitable hinges, and equipped with the usual security systems, are hermetically closed by packings in rubber silicone, or other rubbers or engineering resins (not limiting indication) equally resistant to the high temperatures, because the same must resist also to the temperature of approximately 200 °C and more.
  • the opening of the doors is subjected to the opening of the air discharge valve, precautionary measure of normal equipment for whichever pressure chamber.
  • the two doors are opened and the planes with the objects already dealt are unloaded by the "tail" door, and the planes with the objects to deal are inserted by "head” door.
  • the pressure chamber is equipped with a manometer for the control of the pressure, with a safety valve and a thermostat in order to control, regulate and indicate the inner temperature of the chamber.
  • the gauging of the temperature is carried out by means of a probe that sticks out in the chamber, but isolated from its surfaces.
  • Another useful instrument for the equipment of the chamber, is a timer that, at expiring of the cycle time, emits sonorous and luminous marks (not limiting indication). Rendering the opening of the doors automatic, our pressure chamber is, in short, a pressure regulating autoclave, modified in order to be adapted to the use according to our found, with two openable doors, rather than one, like of customary, equipped in order to execute also a treatment by heat.
  • the constructive details of the described chamber are fixed by the precautionary measures of safety rules to which all the pressure containers or the autoclaves are subjected.
  • the objects to deal by heat, in the chamber are preferably preheated in the tunnel or in the static oven already described, until a temperature lower (but not much) than the minimal temperature able to obtain an "effective" sublimation or the softening of the inks or colors, constituting the printings to transfer physically.
  • the heating will be carried to the temperature, needed for the transfer, only after the objects to decorate are exposed at the wanted pressure.
  • the planes object-carriers can cross the tunnel placed side by side among them, and the relative tape conveyor is made of width equal to the sum of the widths of the planes.
  • the movement of the tape conveyor is of intermittent type: it advances at the end of every cycle in order to extract the planes that have already undergone the heating, and inserts those to expose to next cycle, remaining firm for the interval of time of the heating cycle.
  • the planes are included in a monolithic structure (open and accessible for the insertion and the extraction of the objects to decorate), decomposable, that comprises and assembles entirety them, the measures of this structure are such to allow the insertion in block of the same in the pressure chamber.
  • the sliding on wheels of the entire structure simplifies its loading and unloading, in the pressure chamber, and the motion of the same through the tunnel or the introduction and extraction from the static oven: the tunnel and the pressure chamber will be modified inside in order to help, respectively, the advance and the loading and unloading of the monolithic structure. If the objects to deal are of great dimensions, the structure can drive also a single "object" for time.
  • the heating of the objects in the pressure chamber is come true also by steam: this serves to heat the walls of the chamber and directly the objects, introducing in the chamber the overheated steam (not limiting indication).
  • the chamber is externally insulated in order to avoid heat dispersions.
  • the steam supplies the heat and the pressure.
  • the preheater of compressed air is not more needed, neither more the use of compressed air is foreseen.
  • the valves of income of the compressed air are replaced by valves suitable for the steam, and thus the discharge valves and the instruments of control and regulation of the temperature are replaced.
  • Adopting the overheated steam in order to supply heat and pressure our chamber is comparable with a large autoclave of sterilization, but suitable for the use according to our found, with two doors rather than one, able to supply pressures and temperatures higher than those of the autoclave of sterilization and yield more flexible, in order to execute cycles of job more various than those of sterilization.
  • the constructive details are fixed by the precautionary measures of safety rules that regard all the steam autoclaves.
  • the films, used for the vacuum packaging must have an excellent resistance to the high temperatures and a very good resistance and "barrier" against the steam and gases.
  • the exercisable pressure is conditioned by the value of the adopted temperature, in order to execute the transfer, and by the resistance of the film.
  • a film, packaged on an object, according to our found, can resist to the pressure until a given temperature value.
  • the elevation of the temperature moves the physical state of the film from that elastic to that thermoelastic and to that plastic, until the complete fusion. At plastic state it does not present the resistance to the mechanical stresses that it have at thermoelastic state.
  • Every film determines the maximum pressures and the relative adoptable temperatures in the transfer to execute, according to our found, considering that the vacuum packaging films do not have to be perforated neither torn, in the relative treatment.
  • the said heating of the objects and relative films can happen in whichever other way compatible with our found, and all must be considered in it re-entering. If the objects to decorate present deep or passing holes, there is the risk that the vacuum packaging films are perforated, in correspondence of the holes, under the atmospheric pressure or that exerted in the pressure chamber, preventing the prosecution of the treatment.
  • the disadvantage is overcome, well selecting the film, proportioning adequately the thickness and/or plugging temporarily the holes, before the vacuum packaging.
  • the disadvantage can be verified even if the objects present sharp edges or flashes (specially if they are metallic or of rigid material). If it is not possible to overcome the disadvantage by the selection of a film able to resist to the deriving stresses, it is necessary to round off the sharp edges and to eliminate flashes or to prevent however the films come in contact with them. If the objects present sharp points, so as to perforate the films, it is provided to hood or to dull the points before proceeding according to our found. In any case probable points or "deep throats" do not have to be such to expose the films to stretchings higher than those by them bearable. The problem becomes much more critic if the treatment is executed in the pressure chamber.
  • Objects with "deep throat” are, for example not limiting, some hollow vases of remarkable height, like a flower-pot of great dimensions or a large jar and the like.
  • the inner throat of the vase is a "deep throat”.
  • Assimilable to "deep throat” surfaces are also the inner surfaces of tubes or of other hollow wireworks or extruded objects having the cross-orthogonal sections also different from that circular, and the like.
  • it before the vacuum packaging of the object, it is provided to close the mouth of the "deep throat” with a cover or “stopper” in order to prevent the film buries in the "deep throat".
  • the cover must enable the passage of the air, in order to allow to realize the vacuum also in the deep cavity.
  • That described is a preferential shape of pressure chamber, suitable for executing on the objects to decorate the treatment demanded according to our found, in the case that the pressure of approximately 1 Atmosphere was insufficient in order to perfectly decorate the objects. It is not at all limiting, because other shapes of pressure chambers, able to make possible the treatments demanded according to our found, can replace that described, and all re-enter within the limits of our found.
  • the pressure chamber can be a chamber in reinforced concrete, dealt for making it airtight, with one or two doors with airtight closing, structured in order to resist to the maximum pressures that must be adopted (according to the precautionary measures of safety rules to which the pressure containers are subjected), of dimensions suitable for the several types and sizes of the objects to decorate, equipped with the instruments needed to supply, to regulate and indicate the temperatures, to execute the transfer of the decorations on the objects, according to our found, connected to an air compressor with interposed air compressed preheater (not limiting indication), equipped with manometers for the control of the pressure exerted in its inside.
  • the heating is done arranging, on its walls and/or ceiling, radiating elements by infrared beams, equipping it with reflecting walls, for an uniform distribution of the radiation and/or supplying it with a good system for the right circulation of the air.
  • Whichever pressure chamber, according to our found, can supply the total heating of the objects, but thus the times of the treatment in the chamber grow and, in order to maintain the same productivity, must be increased its length or its capacity: the preheating in a tunnel or in a static oven enables to earn time using less expensive machines, of other part already available because used in the treatments of objects that, according to our found, need not the pressure chamber.
  • the thin pasteboard will also prevent the atmospheric pressure coils the T-shirt (sealed in the vacuum packaging film, as nearby illustrated): the thin pasteboard must be well proportioned, in thickness and rigidity, and on it the T-shirt is folded and packaged. It is replaced by a sheet of paper or metallized and/or "barrier" film, when the said hardening is not demanded;
  • the T- shirt is totally or partially (at least by 65%) of man-made fibers, like the polyester, acrylic, poliuretanic, polyam- midic and the like, it is not necessary a pretreatment of the T-shirt. If instead it is of pure cotton or of high percentage of cotton or of other natural fibers, artificial and/or synthetic not directly receptive, it must be pre- treated in order to make it receptive to the sublimation gases.
  • the treatment consists in spraying, on the zone to decorate, a thin coating of varnish based on synthetic resins like polyester, acrylic, poliuretanic, siliconic or of other polymers and/or similar engineering resins, homopolymers, co-polymers, terpolymers or multipolymers and relative alloys.
  • the varnish must be compatible with the fibers of the T-shirt and receptive for the decorations to transfer; having high melting point, fixable intimately and firmly to the fibers themselves.
  • the fibers of the T-shirt are not receptive for the physical transfer: the zone to decorate must be pre- treated with a varnish suitable to berth firmly the decorations to transfer.
  • the T-shirt taken as example not limiting, can be decorated at the same time on the front and on the back, by the method of the FIRST TYPE or SECOND TYPE or MIXED TYPE: it is possible to decorate, in the same treatment, also the sleeves. In the treatments of SECOND TYPE and MIXED TYPE it is possible to execute decorations with zones of reserve, as before illustrated.
  • hats are preferably put on suitable plaster dies or of whichever other economic material, suitable to bear the treatment by heat and equally easily workable and mouldable by casting, so as that the hats can be worn.
  • suitable plaster dies or of whichever other economic material suitable to bear the treatment by heat and equally easily workable and mouldable by casting, so as that the hats can be worn.
  • the intermediate films with the decorations to transfer are attached.
  • Our method is easily adaptable to the various intimate and external articles of clothing, and for several uses, like stockings of whichever type, swimsuits, sportswear and competition, varied fashion apparel, and also for table cloths, napkins, doilies and other accessories for table, or furnishing, carpets, moquette and so on.
  • Our method is valid, either for the transfer of the decorations on the assembled apparel, or on the relative component parts. It must be considered that generally all the objects of this type will be preferably supported by sheets, slabs or by objects of suitable shape, thickness and suitable rigidities, having the function of the thin pasteboard or of the plaster dies, before illustrated. The supports are recovered at the end of the cycle and are re-used. In the sublimatic transfers, the apparel, or whichever other object to decorate, must be of light colors.
  • the sublimatic colors are not "covering", thus are not visible on the objects dealt, if the objects are black or in very dark colors.
  • the treatment by sublimation can be executed only supplying to pre-paint or to pre-color the zones to decorate, by clear inks and suitable products.
  • the articles or their constituting parts can be subjected to bleaching treatments, if are fabrics and apparel articles.
  • the problem does not exist because the used inks are usually of "covering" type and, if they are not such, they can easily be rendered covering. It remains to be considered a last advantage, offered by our found, adopting simple devices. Advantage very useful in the sublimatic transfer, but important also in that physical.
  • the tension of vapor of the substance increases by the growing of temperature, the pressure "of the ambient” is reduced creating the “vacuum” in the ambient and preventing the substance to sublimate is subjected to "compression” by whichever other body or substance present in the ambient or which delimits the substance to sublimate.
  • the tension of vapor increases by a factor 10 for each increase of temperature of approximately 10%, as it is from the following table:
  • the sublimation temperatures of the inks constituting the decorations can be reduced around to 90-125 °C (not limiting indication), if the sublimation of the inks is executed in an ambient where the pressure acting on them is very low, without lengthening the sublimation times.
  • the lowering of the "ambient pressure" to values very low allows to sublimate inks or pigments which, in the normal conditions of pressure, would not be sublimable.
  • thermoplastic materials constituting the films to adopt.
  • - ET Interval of temperature of softening or of glass transition
  • - KS field of fusion of the crystallites
  • thermoplastic moulding it marks "the minimal” temperature at which the material is thermoplastically formable (by injection within moulds or by extrusion to be reduced in drawings, slabs or film): in fact it is formable thermoplastically also to higher temperatures, until a maximum limit, above which the chemical decomposition of the material takes part.
  • Tg, Tm, ET, KS, TF characteristic temperatures
  • Polycarbonate 130 14 165 16 250 165-180
  • thermoform films of thermoplastic materials are important in order to establish if, and in what way, it is possible to thermoform films of thermoplastic materials.
  • thermoforming modalities interest directly our found in order to transfer the decorations by sublimation at low temperature, as later it is illustrated. In order to realize a "true" thermoforming, it needs:
  • thermoforming amorphous thermoplastic materials, above the Tg, and the partially crystalline materials, above the Tm, become thermoelastic materials and in this state can be formed with low stresses;
  • thermoforming also the simple “conformation” (without “freezing” the shape of the film on the object) according to our found.
  • V - the objects, so packaged and preheated, will be inserted in the pressure chamber, that is closed and maintained at the minimal temperature needed in order to execute the transfer at very low pressure: temperature to be defined in work course, putting to point the production cycle, and after having established the value of the "pressure very low” that we want to exert or can be exerted: considering that this pressure depends very much by the residual pressure present between the objects and the relative films of vacuum packaging and by the elastic return of the films themselves.
  • the correct parameters of execution are "put to point” it is adopted initially a temperature equal to that of preheating, varying then it in function of the variable cited, to fix it at the values optimal for the execution of the normal production.
  • the pressure chamber is then connected to a vacuum pump, rather than to a compressor or to a steam chamber. In this way it is used as decompression chamber.
  • the residual pressure in the chamber will be measured by the manometer, supplying that the same is lightly higher than the residual pressure existing between the object to decorate and the film in which the object is packaged under "vacuum”, and such to overcome also the residual elastic reactions (decreased) of the film "in thermoforming". In this way the pressure to which the inks, constituting the decorations to sublimate, are exposed, is that minimal set up in the pressure-decompression chamber.
  • this pressure is the minimal pressure enabled by the value of the residual pressure in the packaging and by the residual elastic reaction of the adopted film, under which it remains in contact with the object.
  • the lower is the residual pressure within the packaging and the residual elastic reaction of the film, the lower will be the pressure under which the sublimation happens, and the lower will be the needed temperature, without lengthening the time of sublimation. If this can arrive to be lower than the Tg or, respectively, Tm of the film, this would be really “thermoformed” on the object to decorate, as before defined.
  • the "effective thermoforming” blocks the residual elastic reactions of the film and this enables to operate at a lower “minimal pressure enabled", what favours the treatment at still lower temperature or a faster sublimation of the decorations.
  • the preheating mentioned at the previous U point can be executed directly in the pressure chamber itself (at atmospheric pressure) before proceeding as described in this W point: but by the separate preheating the productivity of the system is increased.
  • the transfer of the decorations happens by a method that we will call at "conditioned decompression".
  • the minimal decompression possible to carry out the transfer is conditioned" by the residual elastic reaction of the adopted film and by the existing residual pressure between the film and the object vacuum packaged in the same.
  • the method by "conditioned decompression”, according to our found, has the scope to minimize the pressure at which the decorations to transfer are exposed, in order to enable a fast sublimation of the same at the lowest temperatures possible.
  • the method by "conditioned decompression”, up to now described, is suitable for the sublimation of decoration of objects of not very complex shapes, where the objects to decorate, vacuum packaged, and the relative films of vacuum packaging, are not exposed to pressure higher than that atmospheric. But it is applicable also to the objects of shapes very complex, with pronounced undercut, tips and throats (that re-enter in the limits of resistance of the films adopted), always according to our found, by small variations to bring in the means and systems illustrated and in the execution modalities. We remind that the pressure chamber has been thought to enable the perfect adhesion of the films with the objects to decorate, also when these are of very complex shape and if the atmospheric pressure is not sufficient to warrant that the films are pushed in contact with all the points of the object in it packaged.
  • the method of transfer by sublimation that we called at "conditioned decompression” can be adopted equally operating as follows:
  • thermoforming of the films adopted in a tunnel or static oven, at a temperature comprised in the optimal interval to thermoform the films adopted, but being, at the same time, lower than that minimal needed to obtain the transfer of the decorations (at the normal atmospheric pressure): this allows to do a first thermoforming of the films on the objects.
  • This temperature depends on the type of adopted film: operating at temperatures at the low limits of the optimal interval of thermoforming;
  • thermoforming of films on the objects it is sufficient to increase it enough to let the films are conformed on the objects, without being perforated or torn.
  • the temperature of the preheated air is preferably that adopted for the preheating of the objects, as defined at the previous Z point. Caught up the thermoforming pressure sufficient to obtain the perfect conformation of the vacuum packaging films on the objects, without laceration of the same, it is maintained for the time needed to obtain the lowering of the elastic reactions of the films until the minimum values: in this way the "thermoforming" of the films on the objects of complex shape is perfecte .
  • the preheating can be executed in the pressure chamber itself, as seen at the W point;
  • the necessary temperature will be the lowest possible at the conditions of the "enabled minimal pressure", at which the transfer happens, or will be that thought more suitable to execute it in the cycle time pondered more convenient to adopt.
  • Temperature to define in the work course, in function of the film adopted, of the realized quality of the vacuum, within the packaging, between the films and the objects, of the "maximum” temperature bearable by "the sensitive” objects or by the relative vacuum packaging films, and of the shape of the objects more or less complex. If the "enabled minimal pressure” allows a remarkable reduction of the atmospheric pressure, the transfer can happen also without ulterior "heating".
  • the pressure chamber is equipped with all the instruments needed to make it a "pressure-decompression chamber". That is obtained connecting the pressure chamber, equipped with all the instruments needed for the treatment by pressure, with a vacuum pump.
  • the pressure chamber must be planned so as to resist to the atmospheric pressure (that acts to the outside) in all its parts, included the closing of the doors, when the vacuum is made in it.
  • the method described to the points Y, Z, A1, B1, C1, D1 can be varied at the points A1 and B1, adopting a pressure chamber separated from that of decompression.
  • the pressure chamber will be opened, the objects will be extracted and introduced in a decompression chamber, where the pressure will be lowered at the minimum value sufficient to maintain the films adherent to the objects ("minimal pressure enabled").
  • the previous and next treatments remain unchanged.
  • the method by "conditioned decompression", according to our found, is feasible also using, for the vacuum packaging, thermoretractable films. When the retraction happens, the films are carried to the temperatures of their optimal thermoforming interval, to thermoform them on the objects and to reduce to the minimum values their elastic reactions, thus the treatment at "conditioned decompression" is allowed.
  • PE polyethylene
  • PVC polyvinylchloride: preferably rigid
  • PS polystyrene
  • PMMA polymethylmethacrylate
  • the "barrier" films with very good capabilities to “barrier”, like the EVOH and the likes, that at the high temperatures present a worsening of their capabilities to “barrier”, can favorably be used (always coupled or coextruded with the said films of PE, PVC, PS, PMMA and the like). Films of this type, with three layers (with a layer of EVOH, or of another "barrier” film, between two film layers like those cited), can also easily be metallized on the face that goes to the outside of the packaging, realizing film with 4 layers, with "barrier” of excellent quality, at lower costs, but however suitable to transfer decorations to objects, as before illustrated.
  • films multilayer with "barrier” layers sandwiched between two or more layers of PE and/or PVC and/or PS and/or PMMA and homopolymers and/or co-polymers and/or terpoly- mers and/or multipolymers and the like and relative alloys.
  • These films can also be biaxially stretched in phase of coextrusion, so as to be made also thermoretractable.
  • the sequence could be, for example not limiting, PVC- EVOH-PVC-EVOH-PVC or PE-EVOH-PVC-EVOH-PE or PVC-EVOH-PE-EVOH-PS and analogous, varying also with other types of similar films and other ways of combination, giving film with 5 layers, with the ulterior possibility to metallize last layer that remains at view.
  • the layers can be also 7 (not limiting).
  • the films r ⁇ onolayer are moreover very interesting, obtained from new materials like the polyolefines by catalysts metallocene: more resistant, able to create "barrier” and easier to seal.
  • An example not limiting, is given by the "low density polyethylene linear metallocene”; a very good “barrier”, for example not limiting, is obtained also (with a film in only 3 layers) coextruding one layer of EVOH or of other "barrier” film sandwiched between two of these films.
  • the use of films with optimal interval of thermoforming at lower temperatures is of great importance when we want the transfer by sublimation at low temperature, according to our method by "conditioned decompression". Two cases can be presented:
  • thermoforming interval of which is of 165-180 "C
  • our method of transfer at low temperature (90°- 125° C) at "conditioned decompression” is practically inapplicable.
  • the temperature is reduced to values lower than 165 °C (Tm of the polycarbonate), for example to the temperature of 140-150 °C, the film will be "really" thermoformed on the object: this allows to reduce the "pressure enabled” at values much lower than the values that would be “enabled” if the film were only improperly thermoformed (only “conformed") on the object, according to our method by conditioned decompression. In his way the transfer becomes a quick transfer, by ulterior reduction of the pressure, rather than by elevation of the temperature.
  • the transfer can happen also at the temperatures of 90-125 °C (not limiting), if the pressure is immediately reduced at the minimum possible value.
  • the objects, included in the vacuum packaging films are nearly at ambient temperature, except the superficial lay- ers in contact with films, suspending the energy supply for the heating, they are able to cool the films with which are in contact. The reduction of temperature happens thus in correct way: the zones to decorate are at temperature lower than that of films, as arranged at the point 7. If the objects to deal resist to high temperatures only for short time, they can bear the described treatment. It is possible to conclude that, with film of this type, it is possible to execute sublimatic transfers of decorations on objects sensitive to heat, at "low on an average” temperatures, if the objects to deal resist to the high tips of heat, for short time.
  • our decompression chamber can be replaced by the "vacuum packaging chamber machines", for the sublimatic transfer of decorations, according to our method by "conditioned decompression”, if objects of not very complex shape are dealt , for which thus it needs not exert a pressure higher than that atmospheric to thermoform there the vacuum packaging films.
  • the "vacuum packaging chamber machine” is in a position to carry out all the functions useful to realize the treatment at "conditioned decompression", as demanded, according to our found; with the advantage that enables "to observe directly” at which minimal level can be reduced the pressure in its vacuum chamber (always of transparent material), without the film bearing off the object to decorate (“enabled minimal pressure”).
  • the "vacuum packaging chamber machine” can be used also for the treatment described in the case 2°, where it is foreseen that in order to obtain the sublimation of the decorations to transfer it needs heating the objects ulteriorly, also after having reduced the pressure at the "enabled minimum”: the heating is obtained irradiating by infrared beams, by irradiators disposed to the outside of the vacuum chamber, the objects put into it, thanks to its transparency to the radiations, as it has been assumed.
  • a material suitable to realize "transparent vacuum chambers" to light and to infrared beams is, for example not limiting, the glass-ceramic (Robax, Boroflat and Tempax of the Schott Glaswerkes, and Pyrex, Pyroceram and Vycor of the Cornig Glass Works, are some types of glass-ceramic: not limiting indication).
  • synthetic materials very transparent to light and to infrared beams and able to resist to the atmospheric pressure, during the radiation are valid, like the polymethylmethacrylate, polycarbonate, polyester and the like.
  • the infrared beams will be oriented so that their angle of incidence with the overhanging surface of the vacuum chamber (supposed mostly or nearly flat) are such to make minimal the reflection and the refraction of the same.
  • Infrared medium-waves beams are adopted (to which the cited glass-ceramic and synthetic materials turn out highly transparent), and vacuum packaging or intermediate films of black or dark color, with opaque surface, and good heat conductors, in order to make sure that the temperature of the films that bring the decorations to transfer is higher than that of the objects to decorate, which are in contact with them.
  • the medium-waves beams after having crossed the walls of the vacuum chamber, degrade to long-waves beams, to which the walls are not transparent, so in the vacuum chamber is obtained the greenhouse effect, that enables to heat electively the film in which the objects are packaged.
  • the heating of the objects in the vacuum chamber of the "vacuum packaging chamber machine” is executed also arranging the heating elements, opportunely shielded and with very diffuse irradiation, within the vacuum chamber: in this case the wavelength of the infrared beams must be at the limit between the "high” values of the medium-waves and those "low” of the long-waves (dark irradiators): of approximately 3-5 micron (not limiting indication).
  • the constituting materials of the vacuum chamber are not transparent to this type of radiations: thus, in the vacuum chamber, the action of elective heating of the vacuum packaging or intermediate films (of the said type), that bring the decorations to transfer, happens with the maximum efficiency (greenhouse effect). Carrying out the heating in this second way the vacuum chamber can also be of not transparent material, if the machine is not used for the "experimental” individuation of the "enabled minimal pressure".
  • the entire cycle of treatment of objects of not very complex shape, by "conditioned decompression" for the sublimatic transfer of decorations at low temperature, can thus be realized also with a system that foresees:
  • F1 - a tunnel or a static oven for the preheating of the objects vacuum packaged
  • G1 - a second "vacuum packaging chamber machine", or its equivalent, as said, in order to reduce the atmospheric pressure, at which the objects are exposed, at the "minimum enabled", according to our found: this second "vacuum packaging chamber machine” without the sealing bars, because it is not used for the vacuum packaging.
  • the sealing bars and all the mechanisms, circuits, and relative electrical or electronic equipments, to carry out the function that enables to seal the films or bags for vacuum packaging are not needed, but only the vacuum chamber, the relative pump and connected motor and the manometer for the gauging of the pressure in the vacuum chamber.
  • the treatment can be executed, even if it will be necessary to heat the objects ulteriorly, after having reduced the pressure at the "enabled minimum", in the vacuum chamber.
  • the pressure-decompression chamber as by us described, is more versatile and productive, but the adoption of the "vacuum packaging chamber machine” is useful in order to simplify, in the working practice, the “experimental” individuation of the “enabled minimal pressure” to set up in the pressure-decompression chamber, to have a faster put to point of the production cycles, to execute in the pressure-decompression chamber itself .
  • This second vacuum chamber machine for the treatment at conditioned decompression can be replaced by a container for vacuum having a structure suitable to bear the atmospheric pressure: in this container must be realized the vacuum, with a vacuum pump connected to it in stable way or not.
  • This is formed by a container and the relative cover that closes it hermetically by interposition, between the relative edges in contact, of a packing of soft and elastic material. If the pump is not connected in stable way, the vacuum is done sucking up the air included in the container, by a vacuum pump and the relative tube of connection, through a hole of circular shape, practiced generally on the cover of the container. When the extraction is executed, this hole is automatically closed hermetically by a stopper, generally of spherical shape, in soft and elastic material.
  • the container can be realized, completely or partially in transparent material (glass-ce- ramie, transparent glass-reinforced plastic, polymethylmethacrylate, polycarbonate, polyester) or not. If it is in transparent material, it enables all the advantages attributed to the "vacuum packaging chamber machine" that it replaces. If in not transparent material, the probable heating of the objects is obtained arranging heating elements, very well shielded to have a correct spread of the heat radiations, to the inside of the "vacuum container”: the inner surfaces are preferably reflecting.
  • the reduction of the pressure at the "minimum enabled” is not important, to facilitate the transfer, while instead it is important to be able to reach the fusion of the decorations, at the minimal temperatures, demanded by the characteristics of the objects to decorate.
  • the minimal pressure must be maintained at sufficiently high values to make firmly join the decorations to the surfaces of the objects, while the minimal temperature must assure the fusion of the decorations to transfer, reason for which the decoration by physical transfer of objects of enough simple shape happens as follows:
  • J1 - introduction of the objects in the decompression chamber in order to reduce the pressure at the minimal level, but sufficient to attach the decorations to the object, at the minimal temperature at which they reach their melting point: temperature supplied in the chamber itself.
  • the reduction of the pressure only serves to allow the vacuum packaging film to be heated until the temperature relative to the melting point of the decorations, without being perforated or being torn.
  • the decorations are firmly berthed on the objects. These are then freed from vacuum packaging films (not limiting indication) , after being cooled to ambient temperature (not limiting).
  • An example illustrative not limiting, of this treatment is given by a film formed by two external layers of polymethylmethacrylate, between which a PVDC layer (chloride of polyvinylidene) is sandwiched in order to improve the "barrier" against gases: film used as vacuum packaging film of an object to decorate, according to our found. The thickness of the said film is sufficient to avoid it will be torn, under the action of the atmospheric pressure, at the preheating temperature of 115 °C, considering the shape more or less complex of the object.
  • the treatment can be executed in an analogous way at the maximal temperature of 115 C C.
  • thermoretractable vacuum packaging films are adopted, the retraction must happen at a temperature lower than that of fusion of decorations and preferably also lower than the temperature at the low limit of the thermoforming optimal interval: 115 °C for the film of polymethylmethacrylate, 110 °C for the film of PVC.
  • the retraction can happen also at the temperature of 60 °C and the percentage of retraction can arrive to 80% of the surface of the adopted film.
  • suitable for the treatment according to our method by "conditioned decompression", to adapt the percentage, the temperature and the speed of retraction to the necessities of treatment.
  • the treatment at low temperature of the physical transfer of the decorations can be executed by the "vacuum packaging chamber machine", with the vacuum chamber “transparent to the infrared beams" (or by the "vacuum container", before described), as alternative or support to the decompression chamber, according to our found, when the adopted films need the treatment at low pressure.
  • the vacuum chamber (or the substitutive "vacuum container”) must be transparent to the infrared beams because transfers at low temperature and low pressure will be never had, without supplying to heat the objects, in the decompression chamber, to temperature higher than that of preheating, in the case of physical transfer. If these are not transparent, the heating is done arranging the heating elements by infrared beams within the chamber or the vacuum container, as before illustrated. Being a matter of physical transfers, it is but possible to avoid the treatment at low pressure, if are adopted decorations having low melting point and films having good resistance (at the atmospheric pressure) to the mechanical stresses under the temperature of the said low melting point of the decorations: transfers of decorations are obtained thus, at low temperature, without necessity of dealing the objects at low pressure.
  • the film tends to resume its own initial shape after a new heating, in part at temperatures lightly lower than its own Tg or Tm, and completely above them. It means that, if exposed to opportune heating, the film exerts a remarkable thermoretrac- tion, which presses the film on the object vacuum packaged in it: its initial shape is flat, which it will not be able to resume, but that pushes it to make a vigorous retraction. Thus in the vacuum packaging the folds are minimized and it is possible then to spread them completely, because the vacuum packaging film has been done efficaciously thermoretractable.
  • the object vacuum packaged between two films preformed After having sealed the object vacuum packaged between two films preformed (not limiting), these join to the object, after the exposure to the atmospheric pressure, nearly without introducing folds: exposing then the object, so packaged and under the action of the atmospheric pressure, to a heating able to carry the temperature of the films to the same value of that adopted to preform them or higher, or also lightly lower (close to that of the Tg and respectively of the Tm), they withdraw joining perfectly to the object.
  • the object may present such shapes that sometimes it is better to preform only one of the two films, sometimes both.
  • the object is a sphere, it is better to preform both films: the semi-caps (females) of the sphere are preformed on both vacuum packaging films in which the sphere is sealed under vacuum.
  • the semi-caps refer to a sphere of lightly increased diameter.
  • the preforming of films does not have necessarily to be such "to dress" perfectly the object. It is of great importance because enables to use a same type of preforming for several objects, of volume and shape not very different among them and such that the films join perfectly to the objects, when the withdrawal happens. This is important in the production of footwear soles and in all the productions in which series of measures of varied largeness of the same object are foreseen. For the footwear: the size series. In fact this possibility enables to realize the preforming, for example not limiting, on size number 42, in order to manufacture the sole sizes from 38 to 41: thus by two single moulds for preforming, it is possible to manufacture all the series of sizes from 35 to 41.
  • various shape or model not very different among them can be packaged, provided that all are insertable in the cavities preformed on the films and such that the probable folds, that will be formed during the vacuum packaging, can be spread when they are heated at the temperature at which the preforming has happened or also at higher temperature.
  • many types of systems of thermoforming of sheets or films are available, from those automatic with enormous potentialities of production to those handicraft that are however able to warrant a high productivity.
  • thermoforming under vacuum using the single matrix female, in order to avoid the higher cost of matrix male and female (specially if long series of production are not foreseen), and that the thermoforming must happen heating the film until carrying it to the thermoelastic state, freezing then the shape under tension on "cold" surfaces: in this way (and selecting the films opportunely) the forming is maintained (at ambient temperature) during all the vacuum packaging treatments that will be executed on them, according to our found.
  • the films will withdraw, in order to join perfectly to the objects, before the transfer will happen, when they will be heated, to be exposed to the treatments of decorations transfer.
  • the objects to deal are footwear soles:
  • N1 - one of the films generally is preformed, within which the soles will be vacuum packaged, or both if it is thought favorable; the preforming can also be executed by third parties. If the second film is not preformed, will be preferably thermoretractable;
  • every sheet contains more preformed cavity (not limiting: the sheet can also contain one single cavity: you see fig. 8);
  • the soles to decorate will be then vacuum packaged between these two sheets. Only three sides of the two sheets (not limiting: the sides can be also less than three) are sealed between them. If also the second sheet is preformed, the preforming must be such that the relative cavities must be superimposable among them, face to face.
  • the sheets, overlapped between them and with the objects to manufacture inserted between them, can be placed in the "vacuum packaging chamber machine", also without pre-sealing any side, if the machine is supplied with a continuous sealing bar, shaped such to be able to execute the welding along all the perimeter of the sheets themselves, without interruption;
  • T1 - the soles, sealed under vacuum, singularly or grouped (and among them separated) in the vacuum packaging sheets, are exposed to the treatments for the transfer of the decorations, according to our found, included at the occurrence the treatment in our pressure or pressure-decompression chamber.
  • the films to preform will bring or not the decorations to transfer, according to the requirements and the types of treatment to execute (FIRST TYPE, SECOND TYPE or MIXED TYPE).
  • the second sheet brings decorations, if the sole is inserted in the cavities of the first sheet so that the second (for example, 27 of the fig. 9) goes to contact only with the shoe arc-support of the sole.
  • the registries can be also three-dimensional (see description of fig. 8), made in way, it is, to fix the centring of the two sheets between them, by joint of male and female: for example not limiting, the small crosses can coincide with the points of small cones "males”, thermoformed on the underlying sheet, that fit in similar and relative cones "females", thermoformed in a similar way on the overhanging sheet.
  • V1 - to transform the treatment of FIRST TYPE in treatment of SECOND TYPE
  • W1 - to realize the preforming of the film so that the same does not be directly executed being gained from the flat shape of the film, but supplying to insert it in the cavity, where it must be thermoformed, without stretchings, so as to turn out inserted in the cavity in way "loose” and lightly draped, sufficient to do so that in the subsequent thermoforming operation, the film is completely extended on the surfaces of the cavity, without being stretched or being not much stretched.
  • a way, for example not limiting, in order to obtain this, is to adopt a mould formed by two slabs (see fig.
  • the film 54 to thermoform, is made to slide, by light friction, between the slab 49 and a chassis 56, hinged on the slab 49.
  • the friction is determined by the weight of chassis 56 and by the finish of the surfaces of the film, of the chassis itself and of the slab 49. Modifying the weight of the chassis or the finish of the said surfaces, the film can slide more or less easily. If the surfaces in contact with the film are Teflon-coated the friction is minimized.
  • thermoforming is executed closing the slab 50 of the mould on the slab 49, through the chassis 56, activating the heating of the element at infrared beams 52', for the time necessary to carry the temperature of the film at the value comprised in its optimal interval of thermoforming, and completing the suction that will enable the atmospheric pressure to thermoform the film on the cold surfaces of the cavity, as demanded.
  • the slab 49 can be cooled by continuous water or air circulation, to the occurrence.
  • thermoforming system enables either to minimize the stretching of the film to thermoform, or to regulate its stretching between a maximum value that is had if the film is thermoformed directly, without supplying to insert it partially, at cold, in the cavity, before passing to the final thermoforming, and a minimal value, that is obtained as before described.
  • the solution presented in figures 20 and 21 is given at illustrative scope not limiting: the introduction of the cold film within the cavity, to minimize its stretchings, before being blocked between the slabs of the mould, can be obtained also in several other ways.
  • the lips of one or both films must be modeled in opportune way, at least on the fourth side, to enable that the air can be sucked up.
  • at least one of the sheets is adopted, structured in order to enable the said suction: generally it is enough that, for example not limiting, one of the sheets presents some light groovings, on the face turned to the object to package, that enable the air to exit, until the moment of the sealing of the two films.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Vacuum Packaging (AREA)

Abstract

Method to transfer decorations, from films on which are printed, to whichever decorable objects. This method allows sublimatic and physical transfers. Specular images are printed on films, with sublimable or physically transferable inks, they are then brought in contact with the objects to decorate and transfer heat is supplied. This is obtained creating vacuum between films and objects, by vacuum machines able to seal objects inside films under vacuum. The films are barrier type ( thermoretractable, on the occurrence), able to bear the heat treatment temperatures. The objects of very complex shape, sealed in the films, are dealt in a pressure chamber before executing the transfer. Transfers at low temperature are executed in a decompression chamber. It is possible to print decorations also on intermediate films, positionable on the objects by repositionable adhesives. These, vacuum packaged as said, undergo the decorations transfers treatments.

Description

THERMAL IMAGE TRANSFER BY SUBLIMATION OR FUSION
II. BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to a method to transfer any image or color, printed or deposited in any way on flat sheets or films, suitable for the relative use, to surfaces of any suitable tridimensional or bidimensional object. The transfer can be obtained by sublimation, if the images are printed or deposited using sublimatic inks or by physical transfer if the inks used are physically transferable, not sublimable.
B. Prior Art
This kind of transfer was done, in the prior art, by several equipments, designed for limited purpose, according to the kind and the shape of the objet, and equipped with several tools. For example at present the sublimatic transfer is done getting the object and relative decorated films or sheets, under temperature of 140- 200 °C and submitting them to a pressure of 1-4 atmosphere, for few seconds, or for several minutes if the low limit of temperature (140 °C) is used. So there are various press machines built, equipped with hot plates or hot matrices suitable to press between them the objects with relative films, by the aid of sheets of silicone rubber or Teflon, interposed between the matrices and the objects, covered with relative films, to warrant an uniform pressure on the zones to decorate. In production the shapes and dimensions of the objects had been standardized to avoid buying a new press machine and/or new tools whenever the shapes and dimensions change. The decoration of tridimensional objects is limited to that of cylindric shape or flat shape (like tiles or plates) or "nearly flat" (like bas-relief, or glasses frames). The "prior art" technologies and machines, with the relative tools, are not able to decorate, for example, shoe soles, because these have a variety of shapes, limited only by the imagination of shoe stylists. Also to decorate only very simple shoe soles it needs doing matrices, by current technology, to apply the right pressure on the zones to decorate, in double quantity of shoe sizes (for each size must be decorated a right and a left foot) and so it needs for each style of shoe sole. The matrices must be heated and duly done, to warrant an uniform pressure on the films and soles. It also needs studying how to insert, in correct way, the films between the soles and relative matrices. If the soles are also free styled, the problems become enormous. The same is needed for other tridimensional objects of irregular and fanciful shapes, like crockery, objects for interior decoration, toys and so.
For sublimatic transfer the temperatures go from about 190-200 °C, to do the transfer in a few seconds (about 20 seconds, under press machine), to lower temperature to do the transfer in longer time, as shown in the following list:
TEMPERATURE SUBLIMATION TIME
180 °C 30"
170 °C 60"
160 °C 90"
150 °C 5'
140 °C 10'
Considering the great lengthening of the transfer times, when the temperature is reduced (the times of treatment at 140 °C are 20 times longer than those at 180 °C), it is possible to understand the reasons to operate at the high limits of temperature, by using the methods at present in use (dealing with a single piece at a time). The same machines and methods are adopted for physical transfers (not sublimatic): the demanded temperatures are approximately at the same level. In this case the transfer depends on the inks fusion temperatures used for the printing of decorations: carrying them in contact with the objects and heating them to the softening or fusion temperature of their constituting materials, it is possible to transfer them on the objects, detaching them from the films. The technology now used is centralized on the modalities to transfer the decorations on flat or tridimensional cylindrical objects, or on objects of very simple shapes that draw very little from the "flat shape", like buckles or buttons, glasses, ceramic tiles or tiles in general, plates and the like. For tridimensional shapes more complex, like extruded bars with open or close cross-sectional section or objects of spherical shape or of other geometric, or not, regular or irregular various shapes, licences has been demanded and obtained that resolve, case by case, the problem, realizing "ad hoc" machines and tools for the solution of every dealt case. A single patent licence has resolved the problem in more general way, also presenting some limits for objects of very complex shapes. The relative method is called Dip Print (or Cubic Print) and consists in printing the decorations (with inks that opportunely sensitized becomes adhesive with the humidity) on water-soluble films that, after being extended on a watery surface, fluctuate on the same, and leaning the object then, pretreated with suitable varnishes or enamels, on the film fluctuating on the water, in contact with the decorations, pushing it then in depth. The film with decorations, under the push exerted by water, joins to objects, and the decorations pressed against the objects are attached to them. Then it needs eliminating the residual not dissolved film, drying the objects and giving a protecting varnish on the transferred decorations.
This method presents some limits, either for the treatment of objects that cannot be dealt by it, like the clothings and fabrics in general and other objects incompatible with immersion in water, or for the treatment of tridimensional objects of very complex shapes, for the inclusion of air bubbles between the film and the objects. Moreover it regards only the physical transfer and not also that sublimatic. What's more the method Dip Print (or Cubic Print) is valid in order to only decorate the objects on all surfaces, with designs in imitation of different materials, like wood, marble, briar root, nacre etc., but does not allow to decorate with "precise topic", as when pictures or designs are moved, with precise guideline and on zones very well defined of the objects.
III. SUMMARY OF INVENTION
Our found is based on the important consideration that, in order to transfer images or designs, printed on sheets or films, on other objects of variable shape and consistence, tridimensional rigid, semirigid or elastic, flat rigid or soft, that they need also of a pressure to be transferred, the method to follow must be such to supply the needed pressure without use of matrices, realized in function of the shape and consistency of the object. One avoids thus the onerousness of their cost, the losses of time and the insufficient flexibility and productivity that achieves. The pressure must be uniform, in order to realize a clear image transfer, crisp and without defects. It needs but, before thinking how to exercise an uniform pressure, trying a way in order to carry to duly tight contact the designs or images, printed on the sheets or films, with the surfaces to decorate of whichever shape, and also this way must be independent from the particular shape and consistency of the object to decorate. Our found resolves the before exposed problems adopting the following processes, systems, devices and materials, entirely constituting essential and integrating part of our found: you see also the fig. 1 , 2, 3, 4, 5, 6 and 7 and relative descriptions:
1 - adoption of films of sealable synthetic and/or artificial material, able to be closed, containers-shaped, watertightly at perfect seal of air, or generally of gas; the perfect seal must be maintained until the completion of the transfer cycle, thus the films to adopt will be "barrier films": impermeable to gases and vapors;
2 - preventive deposition on films, by suitable means, of specular images or colors to transfer, with subli- mable or physically transferable inks, on the face going in contact with the surfaces to decorate (fig. 2);
3 - vacuum packaging of the objects, within the films, using vacuum packaging machines, similar to those used for foodstuffs. Vacuum machine with synthetic dome or with vacuum chamber, or vacuum machines doing external suction, supplied with bars to seal the films. Thus the spreading of the films on the objects to decorate, and an uniform pressure (of approximately 1 Atmosphere) acting on the sheets and relative objects, enough to enable a duly transfer, if the objects do not have very complex shape, is obtained: (fig. 4, 5, 6);
4 - being a matter of transfer by heat, the films must resist to the needed sublimation temperatures or to the physical heat transfer (140-200 °C, not limiting indication); 5 - in order to decorate objects of very complex shape or when a perfect spreading of the probable folds, shown by the films, on the zones to decorate of the object (after the vacuum packaging has happened) needs, films thermoretractable, in one or more directions, able to withdraw at temperatures lower than those at which the physical or sublimatic transfer happens, will be adopted: in other words the atmospheric pressure (or of other type, acting to the outside) pushes the film against the surfaces to decorate, while the retraction of the film spreads the folds;
6 - the objects vacuum packaged, as described at the previous points 1-5, are carried to the needed temperature and for the time useful to obtain the transfer: the preferential temperature oscillates between 140 and 200 "C (not limiting indication). The heat can be supplied by infrared radiations and/or by hot air circulation, or by overheated steam or in whichever other way compatible with our found;
7 - it is made so that the temperature of the packaging films is ever higher than that of the object surfaces to decorate, with which the films are in contact. This is obtained doing so that the films can absorb the greatest quantity of the supplied heat and thus doing so that they are not much or not at all transparent to the heat radiations, not much or not at all reflecting, and better also if they are black or of dark color, specially if the heating is carried out by infrared beams. Moreover in this case infrared beams are preferably adopted, with wavelength at the limit between the "high" values of the medium-waves and those "low" of the long-waves (dark irra- diators), of approximately 3-5 micron (not limiting indication). Since the infrared beams with wavelengths comprised between 2,3 and 3,4 micron (medium-waves) have a high power of penetration in nearly all the substances, there are adopted less penetrating waves, like those indicated, in order to heat the films to temperature higher than that of the superficial layers of the objects in them packaged, in contact with the films themselves. If the heating happens by hot air or by steam, the temperature of films is ever higher than that of the superficial layers of the objects to decorate: the films must be sufficiently good conductors of heat. The heating must sufficiently be express to assure the demanded jump of temperature. The devices described in this point 7 are done in order to warrant that the sublimating gases of the decorations to transfer, printed or deposited on films, are not absorbed by the films themselves, but only by the surfaces of the objects to decorate. In fact, since sublimating gases change their state, from gas to solid, only at temperatures lower than those of sublimation, they are deposited and incorporated only on the surfaces of the treated objects that are at temperature lower than that of the films , if the devices before illustrated will be respected. The same devices enable also the physical transfer of decorations, when it does not happen by sublimation. In fact being the superficial layers of the objects to decorate, at temperature lower than that of the films bringing the decorations, these, that are in contact, at fused state, with the said superficial layers, are cooled off on the superficial layers and consolidated on them attaching with them so well to be easily detached from the support films, in contact of which the inks are at fused state, thus with a far weaker adhesion force. The different adhesion forces are also assured opportunely realizing the films that bear the decorations: for illustrative example not limiting, the film layers (bearing the decorations) are coated with an antiadhesive product or with a product able to limit the adhesion of decoration with them.
8 - when the required transfer time is passed, the objects are got out of the action of the heat sources and it is waited for their cooling, in order to free them from the films (not limiting indication) and to submit them to probable other finish or protective operations. Often, specially when other finish operations are not foreseen, it is better to leave the objects in the vacuum packaging films, in order to protect them from scratches or abrasions, until its use.
Schematically our found is based on the 8 points above listed, to be developed, detailed and completed, in the following description, with some important and useful variants that perfect and widen the effectiveness of our found. The vacuum packaging and sealing of the objects, to decorate, within suitable films, according to our found, allows a great flexibility otherwise than other systems adopting membranes integral with the vacuum system in order to carry the films, bringing the decorations, in contact with the surfaces to decorate. The other proposed solutions, in fact, force to complete the transfer operations maintaining the objects and the films, with the decorations to transfer, within the membranes and the vacuum systems with which they are integral, until the end of the cycle, eliminating in the starting stage the possibility to take advantage of devices able to im- prove the quality of transfer, to shorten the times and to adapt the treatment to the materials involved. In our found, no membranes are needed because the vacuum packaged film itself supplies, under the push of atmospheric pressure, to lock the object after being executed the vacuum packaging (and relative sealing) and being exposed the object so packaged to atmospheric pressure. This makes simple and immediate, at the same time, carry out every successive cycle of treatment on a great number of objects, while the other solutions are limited to decorate a single object for every cycle: our found increases thus the productivity and simplifies the systems. It is possible to operate also at lower temperatures than those adopted in the methods in use.
IV. BRIEF DESCRIPTION OF THE DRAWINGS
In order to describe our found, we will often refer, for illustrative not limiting scope, to the case in which the objects are shoe soles, but our found is valid in order to decorate whichever other object, of whichever shape, dimension and suitable material. The description refers to the attached tables of designs, enclosed in the present patent application, as follows. IN TABLE 1:
- Fig. 1 it represents in side-view a shoe sole to decorate.
- Fig. 2 in a not limiting example, it shows in plant the sheet on which is printed the image to transfer on the shoe sole of Fig. 1. The represented sheet is of double length than the normal needed sheet. The sheets of double length are useful in order to avoid making appear, on the zone of heel, the line of splice between the decorations of two separate sheets. In the Fig.:
1 - (outlined line) indicates the line of the sheet bending that goes to contact with the posterior part of heel, as shown in fig. 5. This is not really realized on the film, but is a line of reference in order to illustrate the descriptions we are doing;
2 - it shows the image, printed on sheet, to transfer on the shoe sole of Fig. 1.
- Fig. 3 it represents, in side-view, a section, with a perpendicular plane, of the sheet or film of Fig. 2, showing the thickness very much magnified. The film represented in this section is an example of many suitable films, according to our found: it is composed of 4 layers, but it can also be a film onolayer, of two, three or more than 4 layers. In the Fig.:
3 and 3' - they are two layers of the film with good resistance to mechanical and heat stresses, to which will be exposed during the treatment, according to our found. The layer 3, with the decorations to transfer, goes to contact with object surfaces. It is weldable in order to enable the vacuum packaging according to our found;
4 - it is the intermediate layer of the film, sandwiched between the layers 3 and 3" (not limiting indication): it is a layer of "barrier film" against gases and vapors, which maintains the vacuum realized in the sealed vacuum packaging, according to our found. The "barrier" layer, in other executions, can be more than one only, generally alternated with other film layers like 3 and 3' or also of various other type;
5 - it is the layer remaining to the outside of packaging. It can be a metallic very thin layer (nearly always aluminum: 150-300 Angstrom, not limiting indication), in order to improve the capabilities to "barrier" of film. It improves also the resistance to the several stresses, that the film will have to undergo, in the transfer of decorations, and its thermal conductivity. It is preferably opaque or blackened, not reflecting, for a better absorption of the heat supplied from the outside. It can also be not metallic and, when present, often possesses quality of good heat absorption and transmission, and of physical and/or chemical protection of other film layers, and can moreover contribute to the improvement of the "barrier" against gases and vapors.
- Fig. 4 it represents, in plant, the same sheet, of fig. 2 and 3, refolded like an envelope, closed on 3 sides, two of which (6 and 7) are blocked by thermosealing obtained by the most suitable means, having the design to transfer, printed in specular way, that remain on the inner faces of the envelope in order to be transferred in correct way on the object. In the Fig.:
1 - it is the third side closed, not by sealing, but because it stays on the line of bending of the double sheet of fig. 2. This is a particular case while generally also this side can be closed by sealing, as shown in fig.
8;
6 and 7 - they are the others two sides closed by thermosealing.
- Fig. 5 it represents in plant the envelope of fig. 4, and in side-view the shoe sole 9, inserted in the enve- lope: it is not yet sealed. The shoe sole rests on the plane of the sheet so that its side-view shows in plant. This is one of the possible disposals of the sole with regard to the packaging sheets: other preferential are shown in fig. 8 and 9. In the Fig.:
1 - it is the line of bending of the sheet shown in fig. 2, closed like an envelope as in fig. 4;
9 - it is the shoe sole inserted in the envelope of fig. 4.
- Fig. 6 it represents, in the same views of fig. 5, the shoe sole 9 vacuum packaged in the envelope of fig. 4. When the vacuum packaging of the sole in the envelope and the following exposure to atmospheric pressure is done, the envelope is adherent to sole, with the design to transfer in contact with the sole surfaces to decorate: the atmospheric pressure, acting on the outside of the packaged sole, pushes the film and the relative decorations against sole surfaces. In the Fig.:
9 - it represents the sole in side-view;
8 - it is the fourth side of the envelope of fig. 4 and 5, sealed under the sealing bar of the vacuum packaging machine, after the vacuum having been done between the envelope and sole.
- Fig. 7 it represents, in side-view, the sole freed from the packaging film wrapping it vacuum-packaged: the sole appears decorated with the decorations transferred from the film.
- Fig. 8 it shows, in the same views of fig. 5, one of the preferential ways not limiting, to arrange the shoe sole between two preformed sheets or films. Both bring the decorations to transfer, printed before the preforming, with suitable registers (small crosses), to be respected in phase of decorations printing and of preforming and vacuum packaging of films, to do so that the image to transfer will be recomposed on the object in continuous and ordered way. In the Fig.
24 - they are the weldings that seal, vacuum-packaged, the shoe sole between the two films. In this case which differs from that of fig. 5 and 6, the films are thermosealed on four sides, rather than on three sides
25 - they are 4 registers disposed on the two sheets: they are fixed to the outside of the zone enclosed by sealed sides (not limiting indication). If both sheets are thermoformed, the registers can be tridimensional: for example not limiting, they can be placed on the 4 small cones "males" thermoformed on the underlying sheet, that realize the centring with the overhanging sheet, matching with the relative 4 cones "females" thermoformed on this last
26 - it indicates the shoe sole inserted in the cavities preformed on the two sheets. The obtained cavities are part on the first sheet and part on that second, so that when are assembled between them face to face, reproduce the shape "females" of the sole: little wider than the sole, as from the detailed description.
- Fig. 9 it shows another way not limiting, to arrange the sole to decorate between the packaging films, unlike that of fig. 5 or fig. 8. It shows, in side-view, the longitudinal section, with a vertical plane, of a sole, placed between two packaging films, so as to rest on the flat film 27, put in horizontal position, before that the packaging and the exposure to the atmospheric pressure happens. In short the bottom is here rotate of 90°, on its longitudinal axis, with regard to the packaging films. In Fig.:
27 - it is the sheet pointed out to the arch-support of sole, it can also not bring decorations to transfer, because it is in contact with the zone of the sole not at view, on which the upper of shoe must be stuck. If realized with a ticker and/or more rigid film than the film 28, it makes so that the film 28, thin, flexible and elastic, covers all the sole surfaces remaining at view on the relative assembled shoe. The film 28 can also be preformed and the film 27, if not preformed, can be preferably thermoretractable.
28 - it is the sheet thinner and more elastic than sheet 27, destined to cover all the sole surfaces at view, when the packaging and thermo-retraction are done. This disposal of the sole between the films comes true also preforming the films 27 and 28.
IN TABLE 2:
- Fig. 10 it shows in side-view a sole to decorate by the treatment of SECOND TYPE, where:
12 - it is the sole to decorate
13 - it is the zone to decorate
14 - it is the line that marks the zone to decorate constituted, in this not limiting case, by a light small sign traced directly in the mould by which the sole is formed.
- Fig. 11 it shows the view in plant of the pattern obtained "spreading in plane" the model obtained sticking, on the zone 13 of the Fig. 10, a transparent or translucent adhesive paper (not limiting indication), of dimensions wider than that of the zone 13. The paper is cut out, along the contour 14 of 13, duly detached and spread in plane on a thin pasteboard (not limiting indication). The plane pattern of the zone 13 is obtained cutting the thin pasteboard along the edge of the paper. The same pattern is obtained also taking the surface of the zone 13 by tridimensional scanners, or isolating the same from the graphical file of the shoe sole 12, if this is planned at computer in tridimensional graphics, and spreading it in plane by suitable programs of computerized graphics.
- Fig. 12 it shows (in plant) a way to attach the intermediate film (fig. 11): a film spreaded with removable adhesive, the shape of which is equal to that of the pattern of fig. 11 with some shelves 29, is stuck on the intermediate film (on the face that does not bring the decorations to transfer). The shelves 29 can also edge all the pattern of fig. 11 without interruption.
- Fig. 13 it shows the view in plant of a part of the sheet or continuous film on which the pattern of fig. 11 is repeatedly designed, in order to optimize the cutting yeld and to establish the map according to which the decorations, to transfer on the three-dimensional objects, must be printed on the film (on the shoe sole 12 of fig. 10, in our not limiting example). Where:
15 - they are the designs that reproduce the shape of the pattern of fig. 11 , organized so as to optimize the cutting yield. The obtained disposal of designs decides the map according to which the decorations must be printed on sheet in order to obtain that these fall in the right place and with the correct orientation to transfer on the shoe sole 12 the wanted decorations, see fig. 14. The outline of the organization of the designs 15 appears only on the screen of the computer of the operating person in charge to analyze the yield of the cut and only serves to establish the map according to which the decorations must be printed on the film. The methods in order to establish this map are closely connected to the means with which the printing will be executed. For example not limiting, if it is carried out by digital printing, it is preferable to execute the operation by computer, if by serigraphic methods, the map will be decided while the serigraphic printing panel is assembled, and the better yield is obtained proportioning the length and width of the panel so as to optimize the film use. The designs 15, that reproduce the contour of the pattern of Fig. 11, are printed or not, on film, on the contour of the decorations, according the requirements. The study in order to optimize the yield and relative map, for the decorations printing, can easily be obtained automatically, using suitable computerized programs.
- Fig. 14 it shows the view in plant of the same film of fig. 13, where:
16 and 16" - show the decorations printed on the designs 15. In the treated example not limiting, the background of the pattern of fig. 11 is entirely colored, thus the design 15 is also pointed out, that reproduces the contour of the pattern of fig. 11 , as well as the decorations "at design" 16 and 16'.
- Fig. 15 it shows, in side-view, the shoe sole 12, on which the intermediate film 17, cut out from the sheet or film of fig. 14 like the shape and measure of the pattern of fig. 11 , bringing the decorations to transfer, is berthed by removable adhesive. It is supposed to make a physical transfer. In Fig.:
17 - it is the intermediate film, supposed transparent, berthed on the zone to decorate
16 - it shows the decorations, printed on intermediate film, to transfer on bottom 12, with the relative background, that has been supposed colored. It is supposed that the removable adhesive is smeared or sprayed, on the face of the film that brings the decorations, and that it does not interfere with the physical transfer of the same. Otherwise the intermediate film 17 will be positioned on the zone to decorate in the way illustrated in fig. 12 or in an equivalent way.
- Fig. 16 it shows the sole of fig. 15 inserted between two sheets (or an envelope or bag) 19 between which is vacuum packaged, according to our found, where:
12 - it indicates the sole to decorate, in side-view, inserted in the envelope 19: the sole is arranged, in them, so that its side-view coincides with the view in plant of the envelope
19 - it indicates two sheets or the envelope in which the sole 12 is vacuum packaged
20 - it indicates the sealing on the contour of sheets or envelope
17 - it indicates the intermediate film with the decorations to transfer, blocked on "the characterized" zone, between the two sheets (or envelope) 19, and pressed against the said zone by the atmospheric pressure or higher pressure exerted in our pressure chamber, on the occurrence - Fig. 17 it shows, in side-view, the sole 12 decorated as required, freed from the packaging film 19 and intermediate film, where:
22 - it shows the color of background transferred on the shoe sole 12
23 - it shows the decorations, brought back on the background color, transferred on sole 12. IN TABLE 3:
- Fig. 18 it shows, in side-view, the cross-sectional section (with a plane orthogonal to the straight lines generatrices of its constituting cylinder) of the pressure chamber, in which they are pointed out (designs not in scale):
33 - it is the circular crown of cylinder section
34 - they are the sections of the sliding railroads (not limiting indication), disposed on two ends of the circumference inner diameter of the cylinder section, parallels to its straight lines generatrices
34' - it is the section of the plane of maximum width sliding on railroads 34
35 - they are the sections of the railroads in pair parallels to railroads 34, placed at a distance enabling the passage of pieces of the greatest overall dimension, in the sense of the height, arranged on the plane 35'
35' - it is the section of the plane sliding on railroads 35
37 - they are the sections of the railroads in pair parallels to the railroads 34, placed at a distance enabling the passage of pieces having the greatest overall dimension, in the sense of the height, arranged on the plane 34'
37' - it is the section of the plane sliding on railroads 37
36 and 36", 38 and 38' - as described, mutatis mutandis, for 35, 35' and 37, 37'.
- Fig. 19 it shows the side-view of the orthogonal cross-sectional section, with a vertical plane, of the tape transporting the object-carrier planes in the heating tunnel. It is showed, together with the Fig. 18, as the planes can proceed overlapped among them (not limiting indication) so that the overhanging planes rest on those underlying by the spacers in shape of small pillars (not limiting indication). In the Fig. (it is not in scale):
39 - it is the section of the small pillars supporting the rolls dragging the tape
40 - they are the sections of the hinges of the rolls and of the relative bearings
41 - it is the section of rolls
42 - they are the sections of the tape
34' - it is the section of the plane object-carrier of maximum width 43 - they are the sections of the spacers resting on 34" and on which the plane 35' rests
35' - it is the section of the plane object-carrier sliding on railroad 35
44 - they are the sections of the spacers resting on 35' and on which the plane 37' rests 37' - it is the section of the plane object-carrier sliding on railroad 37
45 - they are the sections of the spacers resting on 37' and on which the plane 36' rests 36' - it is the section of the plane object-carrier sliding on railroad 36
46 - they are the sections of the spacers that rest on 36' and on which the plane 38' rests 38' - it is the section of the plane object-carrier sliding on railroad 38
- Fig. 20 it shows in side-view the section of a mould, having flat and parallel external surfaces, with a vertical plane perpendicular to the horizontal faces of the mould. It is used to thermoform films presenting not excessive stretchings, or better, "adjustable" stretchings, when the thermoforming is executed. In the Fig.:
49 - it is the section of the base slab of the mould and brings the print "female" 51 of the object to decorate: the section with the vertical plane is in the longitudinal sense of the print
50 - it represents the same section of the second slab of mould
51 - it represents the section of the print "female" or cavity
52 - it shows the section of a zone, dug in the slab 50, where an infrared heating element 52', overlapping the print "female" 51 when the mould is closed, will be fixed
52' - it shows the section of an infra red heating element, having wavelength at the limit between the high values of the medium-waves and those at low values of the long-waves (dark irradiators): 3-5 micron, not limiting indication. The element is thermally isolated from the slab 50 and equipped with a reflecting surface projecting the beams against the film to thermoform in the cavity 51 53 - they are the air suction holes, for the vacuum thermoforming of the film. The air suction put the film against the cavity surfaces, during the thermoforming, and serves to recall it within the cavity, without stretching, before the complete closing of the mould, as cleared in the description of the Fig. 21
54 - it represents in section the film to thermoform (not in scale)
55 - it shows the section of the holes that enable the inflow of the ambient air over the film to thermoform, when the vacuum is created, in the closed mould, within the cavity 51
56 - they represent the section of the chassis shown in plant in fig. 21
- Fig. 21 it is the plant-view of the slab 49: it shows the relative disposal of the slab itself, the chassis 56 and film, before beginning the thermoforming of the film. In the Fig.:
56 - it is the plant-view of the chassis, shown in section in the Fig. 20
57 - they are the stirrups, connecting the chassis 56 to the slab 49, through the hinges 58
58 - they are the hinges with which the chassis 56 is coupled to the slab 49
54 - (outlined zone) it is the film to thermoform in the cavity 51 , shown in plant in this Fig.. The film has a surface wider than the chassis, such that it can slip between 56 and 49, if pulled when the mould is open, but remaining present between them when the mould will be completely closed and the vacuum thermoforming of the film in the cavity 51 will follow. The friction diminishes if the surfaces in contact with the film are Teflon- coated.
The Tables and designs, above illustrated, represent only machines, equipments, executive modalities, and illustrative examples not limiting of our found, in the case, it also not limiting, that the objects to decorate are shoe soles.
V. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The vacuum packaging machines are divided in two main categories:
A - The "vacuum packaging chamber machines", or machines equipped with vacuum chamber, supplied with sealing bars: by these machines the vacuum is done between the films and the object to decorate, arranging in suitable way the object between two films in the vacuum chamber, extracting the air contained in the vacuum chamber and sealing the films between them, so that the object is sealed vacuum packaged between the films, before the air will be introduced again under the vacuum chamber. The object is sandwiched between two films, or between two faced faces of the same film (fig. 2), so that all the sides of the films, to be closed hermetically, after extracting the air, turn out inserted under the relative sealing bars of the machine. The two films, or that only one folded in two (fig. 2), can also be pre-sealed, on one or more sides, or preformed like an envelope or bag in which the object to manufacture will be inserted (fig. 4 and 5): in this case, the envelope containing the object is disposed in the machine with the side not sealed under the sealing bars of the machine and, after extracted the air, the fourth side will be sailed (fig. 6). These machines are able to realize the highest vacuum (until 0,3 mbar) and moreover the best vacuum quality;
B - The "non-chamber vacuum packaging machines", supplied with sealing bar: these realize the vacuum, without the use of a vacuum chamber, externally to the machine, extracting the air contained in an envelope or bag, of sealable film, in which is inserted the object to package. After having realized the vacuum, between the object and the "bag", this is hermetically sealed by the sealing bar, that seal between them the two sheets of film that form the "mouth" of the bag. This type of machine is able to realize a less pushed vacuum. Moreover, according with the object shape and its disposal in the envelope, can be formed air pockets hardly extractable. This type of machine thus is more suitable for the treatment of objects of great dimensions or extended in length or in plane and having not complex shape. The objects to deal with machine supplied with vacuum chamber, must be contained in the space enclosed in the vacuum chamber or, vice versa, this must be proportionate so as to contain the objects of maximum dimension, among those to deal. While the "non-chamber vacuum packaging machines" are not conditioned by the dimension of the objects, but by the width of the relative bag: the length of the sealing bar of machine must be so long to completely seal the mouth of the bag. Another element to be proportioned to the dimensions of the object is the vacuum pump and the power of the relative motor, that must be fitted to the volume of air to extract in order to realize the vacuum needed, according to the programmed job. The films suitable, according to our found, are those that present the following characteristics:
- good weldability in order to facilitate the vacuum packaging;
- resistance to the temperatures of sublimation of dye pigments or to the sufficient softening of the resins and/or waxes of the physical transfer inks, in the case of decoration by physical transfer;
- resistance to the stresses that will be exerted on them, when the vacuum packaging happens, or during the subsequent treatments;
- good "barrier" capability against gases and steam;
- good printing support for the images to transfer, improvable by "corona" or flame or plasma treatments or by suitable chemical treatments;
- heat absorption and conduction sufficient for the use to which they are used;
- good flexibility and elasticity in order to well conform to the shapes of the objects to decorate;
- low coefficient of friction with the object surfaces in order to avoid anomalous stretchings;
- thermoretractability in order to decorate objects having very complex shapes or when we want to eliminate probable folds, present on the films, on the zones to decorate: the films to adopt will be thermoretractable in one or more directions, according to the requirements;
- variable thickness within wide limits, according to the dimensions and the complexity of the object shapes, and oscillating between 20 and 500 micron (not limiting indication).
Currently many films are in commerce that possess all the characteristics listed and suitable to execute the decoration of whichever object, according to our found. In general these are composed with several layers, selected so that, all together, they can supply the characteristics needed for the demanded use, see fig. 3.
We illustrate, for only illustrative not limiting scope, some films, suitable for the use according to our found, obtained by connection of several films or layers of suitable materials, in phase of their extrusion and blowing, or by subsequent connection, as follows:
C - a thermoplastic polyester film type the Mylar OL12AT of the DuPont Teijin, formed with two film coex- truded, one of which is of biaxially oriented polyester (OPET) and the other is of amorphous polyester. The layer of amorphous polyester is easily weldable with itself and with other films having an amorphous polyester layer (APET or PETG) or semicrystallme (CPET), giving a strong sealing, hardly openable without being cut. The layer of biaxially oriented polyester gives to the film a great resistance to mechanical stresses, a good quality of "barrier" against gases and vapors and a good resistance to high temperatures. This layer can be exposed to a "corona" treatment (not limiting indication) on the free face, to be metallized and in order to obtain a better "barrier" against gases and vapors. The decorations must be printed in specular way on the amorphous polyester face, that will serve also in order to realize the sealing. The thickness of the metallization layer is comprised between 150 and 300 Angstroms, not limiting indication. This film resists to temperature of approximately 200 °C for approximately 30 minutes and is suitable for the use in oven;
D - a polyester film like the Mylar CL of the DuPont Teijin, having a weldable external layer and an inner body that gives to the film characteristics of exceptional mechanical and high temperature resistance. It resists to temperatures of service of 225 °C. It has good "barrier" quality, increasable with a metallization layer. It is a good printing support, characteristic improvable with a "corona" treatment (not limiting indication);
E - a film of Polivinilalcool (PVOH or PVA or PVAL) type N0606, produced by the Idroplast in Montecatini Terme, weldable and resistant to high temperatures until approximately 200 °C. It presents a good resistance to the mechanical stresses, is a very good support for printing and has good qualities of "barrier" against gases, excluding steam. The quality of "barrier" can be improved inserting, by coextrusion or subsequent coupling, an EVOH layer (ethylvinylalcohol), between two its layers (not limiting indication). It has a very good suitability for the metallization. Therefore it is suitable, in the shape of simple monolayer or coextruded or coupled in three layers, for the decoration of objects according to our found, in the cases in which the transfer happens in absence of humidity; and also in presence of humidity if the external face (not in contact with the objects) is metallized. In the shape of coextruded in three layers, with a layer of EVOH (not limiting indication) between two of PVA, and with the external face metallized, the film improves remarkably the "barrier" against gases and vapors. The "barrier" against gases and vapors is ulteriorly improvable by more layers alternated of PVA and EVOH (not limiting indication), according to the outline: PVA-EVOH-PVA-EVOH-PVA (not limiting indication), and by a metallization layer on the external face (last layer of PVA). The thickness of the layer of EVOH oscillates between 3 and 15 micron, and that of the metallized layer, between 150 and 300 Angstroms, not limiting indication. The film can be biaxially pre-stretched in order to be made retractable by heat (thermoretractable), what allows to spread it perfectly on the objects, in the treatment by heat and before the beginning of the images transfer;
F - the same film of PVA, in three layers, with an intermediate layer of EVOH (not limiting indication), coextruded between two amorphous polyester film (APET), according to the outline: APET-PVA-EVOH-PVA-APET, not limiting indication. This film in 5 layers presents an excellent "barrier" against gases and steam, resistance to the temperatures and to mechanical stresses. If pre-stretched biaxially it becomes thermoretractable, as said at the point E. The same film realized in 3 or 2 layers, and a PVDC coating (like the Saran of the DuPont: not limiting indication) in substitution of the layer of EVOH, according to the outline PVA-PVDC-PVA-APET, or PVA-PVDC-APET (not limiting indication), presents the same characteristics of very good "barrier" and resistance to the mechanical stresses and a face (that of PVA, in contact with the objects to decorate) that is a very good support for the printing of the decorations to transfer. We have given some examples not limiting, of films suitable for the decoration of objects, according to our found; the examples can be extended to other films, realized with synthetic materials that differ from those cited, able to improve the quality of "barrier" against gases or the resistance to high temperatures, or such to reduce its own cost, without damaging the least characteristics of quality for a suitable transfer of decorations, according to our found.
The objects to decorate, that are supposed always perfectly clean and free from humidity, incrustations, powders or grease, can be of various materials, some of the which able to absorb and to tie in physical and/or chemical way the sublimation gases or to berth the decorations in the physical transfer, others not suitable for that. In these cases the objects are so dealt as to turn out receptive. That is obtained depositing and berthing, on the surfaces to decorate, a layer of material, receptive for the sublimation gases or able to berth the decorations of physical transfer, and resistant, without disadvantages, to the temperatures that the treatment demands, and to all the stresses to which the objects will be exposed, during the use. The most used materials are varnishes, enamels or powders for covering, based on polyester and/or acrylic and/or poliuretanics and/or epoxy and/or siliconics or of other polymers and/or similar engineering resins, homopolymers and relative copolymers or terpolymers and probable possible alloys compatible with the objects to decorate, with the treatment that must undergo, and with the use to which are assigned. In the case of physical transfer without sublimation, when the transfer has happened, it can be useful to give on the object a transparent protecting varnish hand, equal or compatible with that used before the treatment and with the transferred decorations.
The choice, in detail, of pre-treatment and/or post-treatment varnishes, due the numerous variables from which depends, is made and tested in work course: these treatments make already part of the state of the art and technique in the field of decoration and paint job. If the objects are metallic, besides being cleaned up, they will be degreased and, in case, exposed to operations of pickling and other chemical or electrolytic treatments before the pre-paint job.
The method until now described is very valid in order to decorate objects with designs or images in imitation of various, natural or artificial materials like, for example, pretended wood, false leather, pretended marble, briar root, or images of floral background, still life, and so on, or in order to transfer only single colors. In these cases in fact the design or the color to transfer is printed on all the surface of the film, and is transferred on all the surfaces of the object in contact with the film. If instead the images are with "precise topic" and must be transferred "only" on exactly determined zones of the objects and with a precise guideline, we operate in other way. We call FIRST TYPE the case up to now described and SECOND TYPE that relative to the transfer with "precise topic" very well determined on zones characterized with accuracy and exactly delimited on the object to decorate.
We describe the modifications of our found relative to the SECOND TYPE: the description refers to the particular case not limiting, of decoration of shoe soles:
G - the zones to decorate are defined and are marked, in a way whichever, that is camouflaged or invisible, when the decoration is carried out, you see fig. 10: the zone 13, to decorate, is "marked" with the light small sign 14 (not limiting indication); H - the said zones (usually tridimensional) are copied, with the methods used in the shoe technique, by the stylists of the field, in order to obtain the flat pattern of the surfaces of the lasts (tridimensional) for shoes assembling: the zone 13, to decorate, is covered with suitable transparent or translucent adhesive paper, of dimensions wider than those of the zone 13, the adhesive paper is cut out along the contour 14, then the cut out paper is detached and is duly spread in plane on a thin pasteboard (not limiting indication). Cutting out the thin pasteboard along the edges of the adhesive paper, the flat pattern of the zone 13 in thin pasteboard is had, see fig. 11. The copying of the zone to decorate and the spreading in plane of the same can be executed also by computerized machines, like the digital tridimensional scanner (digitizers 3D) with relative computer and graphical programs suitable for the spreading in plane. Or it will be done isolating the surface of the zone 13, from the graphical file of shoe sole 12 (if planned at computer, in tridimensional graphics) and spreading it in plane by the said suitable programs of computerized graphics.
I - the obtained model is designed on the film, on which the decorations must be printed, in the best rational way in order to obtain the best "yield" in the cut: it means to obtain the maximum possible number of patterns from the surface of the film. The preliminary study of the outline of cut is made preferably by computer (not limiting indication) with a suitable graphical program (not limiting indication). From it, the "map", according to which must be printed the decorations, is drawn. In fact the printing is so made that every pattern, cut out from the film, always brings the images in the correct place and guideline (in specular way), see fig. 11, 13 and 14. The definition of the "map", for the printing of decorations on the film, generally is tied to means used for the printing. For example, if it is carried out by digital printing, it is better to execute the study of the map by computer; if with serigraphic methods, the map will be decided while the serigraphic printing panel is assembled and the best yield is obtained proportioning the length and width of the panel so as to optimize the use of the film. The cut is made in several ways, by shearing machines with suitable dies, by cut computerized tables, by hand with suitable tools, and in other ways, one of which not limiting, is that realized by cutting plotters or by printing-and-cutting plotters: by this last it is provided to print and to cut the several film pieces like the pattern of the zones to decorate. The printing on the films is executed by inkjet printing or plotter, or by "change of phase" machines (that spray wax and/or fused resin, with incorporated probable heat fusible adhesive: "hot melt adhesive") or by thermal transfer digital printers or by laser. The plotters are able to execute the printing on film coils of width variable within wide limits (until 300 cm. and more). The printing can also be made by offset or flexographic or rotogravure machines and also by serigraphy, without limitation for whichever other type, by heat or cold, able to print with inks or colors suitable for the "transfer". If only the colors are moved, these can be sprayed or simply smeared on the films. The design or image can be traced, on the sheets or films, also by free hand;
J - the pieces cut out from the films, have the shape of the pattern (fig. 11), obtained as before described, and bring, in the right position and guideline, the images to transfer (fig. 14 and 15). Every piece so cut out is sprayed, on all the surface or only on some partial zones, in the points more critical for a correct anchorage, with removable adhesive spray (not limiting indication), resistant to the temperatures of sublimatic or physical transfer, and attached on the correspondent zone to decorate. Some not limiting examples of adhesive of this type are: "DyeTrans ProSpray" of the Conde* (USA), "Mount Spray" and "Spray Re-Mount" of 3M (USA), "R Spray" (adhesive repositionable of Italian Saratoga). Conde' assures that its adhesive "DyeTrans ProSpray" resists to the sublimation temperatures and it does not interfere with the transfer of the sublimation gases on the surfaces to decorate. The removable adhesive can also be such to volatilize at the temperatures of the treatment. It is sprayed on the face on which the decoration is printed. The smearing or spraying of the removable adhesive is carried out also, with some smearing or spreading machines, directly on the film from coils. The adhesive, in this case, is protected with siliconed films or paper (better if transparent or translucent), so that the film glued can be packaged in coils. We will call, from now, "intermediate film", every pattern cut out from the film as described. According to a preferential way not limiting, the intermediate films are cut from these glued film coils in conformity with the pattern of the zones to decorate: the coil is arranged on a cutting plotter and the intermediate film, remaining attached to the siliconed film or paper until the moment of its use, is engraved. This way to smear intermediate films is right for the sublimatic transfers, having care to adopt an adhesive that does not interfere with the sublimation, as said. Being a matter of physical transfer, it is preferable do not interpose the adhesive between the decoration and the object, less than, also in this case, an adhesive that does not interfere with the transfer of the decorations or that is able to volatilize at the temperatures adopted for the treatment, is used. If a similar adhesive is not had, it must be smeared only on the zones bringing no images. In the example not limiting, which we illustrated in the fig. 10, 11 , 13, 14, 15 and 16, there are not zones bringing no images, because the color of background printed on the intermediate film is moved also, thus the smearing on the film in coils is not right, if the decorations are done by physical transfer and the suitable adhesive is not had. In these cases, the anchorage of the intermediate film on the zones to decorate is carried out using some pieces of adhesive tape (removable), resistant to the temperatures at which the treatment happens, applied on the no printed face of the intermediate film, on the zones more suitable to enable a sure and correct anchorage, on the edges of the intermediate film and on the adjacent surfaces of the object. Tapes of this type are of common commercialization: a producer, for example not limiting, is the 3M (USA). In the most difficult cases the adhesive tape can be replaced by a film, smeared with removable adhesive, having the same shape of the intermediate film pattern (you see fig. 11), but protuberant by the same along all its contour or also only in some zones (you see 29 of fig. 12) sufficiently to attach reliably the intermediate film on the zone to decorate (13 of fig. 10): this film must be attached on the intermediate film, on its face having no decorations, so that the protuberant parts 29 can be used in order to attach the intermediate film to the object. Thus we have attached the image to transfer, in contact with the zone to decorate, in precise way and with the correct guideline; executing the treatment, the film so applied will be detached from the object, and the removable adhesive, if not able to volatilize by heat, will remain attached to the film, leaving cleaned up and decorated the object;
K - in order to obtain the transfer of the decorations, the uniform pressure and the heat needed to do the correct sublimatic or physical transfer of the decorations, must be exerted on the surfaces in contact. That is obtained inserting the object so prepared between two films (or between two faced faces of the same film, or in an envelope or bag formed with the film) sealable or such to be closed hermetically, and supplying to their vacuum packaging, according to our found (as illustrated in the description of the FIRST TYPE): you see the fig. 15, 16 and 17. In the treatment of the SECOND TYPE, the intermediate films are not necessarily like those described in the treatment of the FIRST TYPE (suitable for the vacuum packaging, according to our found), but they can be replaced also with paper for printers or photocopiers or with whichever other support suitable to be printed with sublimable or physically transferable inks, and attached on the zones to decorate, as illustrated. In fact in this case (SECOND TYPE) the intermediate film is not, generally, exposed to mechanical stresses of traction or tear but often only to pressure. While the films suitable for the vacuum packaging must at least have part of characteristics of the films described for the FIRST TYPE, and that is:
- good weldability in order to facilitate the vacuum packaging;
- resistance to the temperatures needed for the sublimation, or for the sufficient softening of transfer inks, in the case of decoration by physical transfer;
- resistance to the stresses exerted on them, when the vacuum packaging happens, and during next treatments;
- good "barrier" suitability against gases and vapors, in order to maintain the vacuum in the package;
- good flexibility and elasticity in order to easily conform to the shapes of the objects to decorate;
- low coefficient of friction with intermediate films in order to avoid they will move the same, during the vacuum packaging, from the positions in which they have been berthed;
- perfect transparency to the heat radiations, differently from what demanded in the treatment of FIRST TYPE (but the case where is there the risk that the said transparency can enable the heating of the surfaces, to decorate, to temperatures higher than those of the films that bring the decorations to transfer). In fact, in the treatment of SECOND TYPE, the vacuum packaging films do not bring decorations to transfer, because these are printed on the intermediate films or sheets. Thus these intermediate films must absorb, at the best, the heat radiations. Or they must be good conductors of heat, if the vacuum packaging films are able to absorb the heat radiations, as arranged in the treatment of the FIRST TYPE: in this case the vacuum packaging films also must be good heat conductors. Thermoretractable vacuum packaging films are adopted, in order to perfect the spreading of the films on the objects: for transfers of SECOND TYPE not always it is necessary to spread perfectly the folds of vacuum packaging films, specially if thin and very flexible films are adopted; L - the objects vacuum packaged, as illustrated in the previous K point, are heated, as in the treatments of FIRST TYPE, in order to transfer the decorations from the films to the objects. Arranging the FIRST TYPE method with that of SECOND TYPE, according to our found, it is possible to realize special decorations, with a method that we call of MIXED TYPE. Operating according to the method of MIXED TYPE it is possible to transfer decorations with "precise topic" within decorations with not "precise topic" like, for example not limiting, a particular rose or picture on a background decorated like pretended wood or feint nacre: the rose or picture put in positions very much characterized of the object to decorate and the background reproduced on the remaining zones. The rose or picture printed on the intermediate film and berthed, by the removable adhesive, on the zones "characterized" and marked of the object, the background, in imitation of nacre, printed on the vacuum packaging film of the object. When the transfer happens the whole object remains decorated in nacre unless on the zones where the intermediate films have been berthed, bringing the decoration of the rose or picture. By treatments of MIXED TYPE it is easy to decorate the objects so that the decorations with "precise topic" are on the zones where just are demanded and, at the same time, to decorate the rest of the object by decorations with not "precise topic" or to transfer on the rest of the object only single colors. This is of great importance because it enables to finish the object completely by the only single treatment of MIXED TYPE, eliminating probable next or preventive operations of paint job, to give to the object the decorations and the demanded base or background colors. Thus, for example not limiting, in the production of PU shoe soles, the paint spraying of the zones where the decorations, at design, are not present, and the construction of the relative spraying masks, is avoided. With the treatment of MIXED TYPE moreover it is possible to obtain, on the object to decorate, zones of reserve, were the original color of the object will be maintained, or which will be preserved from the decorations or from the colors which will be transferred on the object from vacuum packaging films. It is enough to put, by removable adhesive, on the zones of reserve, the intermediate films (bringing no decorations to transfer) cut out like the pattern of the zones to reserve, and to vacuum package the object, so prepared, in the packaging film bringing the decorations or the colors to transfer, and then to expose the object to the subsequent treatments in order to transfer the decorations, according to our found, to obtain the object decorated on all its surfaces unless those reserved. The intermediate films berthed on the zones of reserve do not bring decorations and are able to oppose a good "barrier" against the passage of sublimation gases and a good protection against the physical transfer of the decorations. If instead for the treatment of MIXED TYPE intermediate and vacuum packaging films with simple transferable colors are adopted, the object at the end of the treatment will turn out colored in several colors, obtained some by reserve, others brought from intermediate films and from films of vacuum packaging: this becomes a new method in order to obtain objects colored in three or more colors, arranged in zones and ways very well defined, in a single treatment. In the technology in use that is obtained by subsequent paint jobs of every color and by the use of appropriated paint masks: one series of masks for each color. The reserve can be made also with regard to the zones decorated by intermediate films: the decorated object presents thus zones of reserve, with regard to the decorations transferred from intermediate films, and to those transferred from vacuum packaging films: also the treatments of SECOND TYPE can present zones of reserve.
The heating, for the transfer of decorations, according to our found, is preferably carried out in a tunnel (not limiting indication), equipped with heating elements by infrared beams, crossed by a tape conveyor, having an adjustable speed or intermittent advance. The achievable temperatures on the objects and relative films are function of the radiation power, of heating elements, of the amount of the same placed in the tunnel, of the distance of the objects from the heating elements and of exposure time. Since it is demanded a very uniform heat distribution, it is provided to do not move the objects too much near the sources of heat, to put them on the tape conveyor so as to do not create wide zones of shadow, to cover the tunnel with reflecting inner surfaces and also to make the surface of the tape reflecting. Moreover, by a correct circulation of the air in the tunnel, the maximum uniformity of the temperature is had. The heating can happen in a tunnel and also in a static oven by intermittent loading and unloading, in cycles of treatment of the sufficient duration to make happen the transfer of the decorations. The static oven must be constructed with the same devices described for the tunnel, in order to warrant an uniform heating of all the objects dealt, or is planned with heating by circulation of hot air or mixed: by hot air and infrared beams. The temperature in the tunnel or in the static oven is controlled and regulated with detectors and automatic regulators of temperature connected to the feeding system of the elements by infrared beams or to the hot air generators. Not always the heating is executed in a tunnel or in a static oven, in many cases it is enough to have at disposal heating elements by infrared beams (not limiting indication), of suitable shape and surface, and to direct the radiations on the objects by opportune orientation of the same as regards the objects or the relative zones to decorate, specially if that are partial zones of objects of great dimensions.
In the technology in use (by presses that deal an object at a time), the pressure exerted on the object to decorate varies between 1 and 4 atmospheres: the pressure used often is elevated to the high values in order to decrease the time of transfer, since a higher pressure warrants a more uniform adhesion between the film and the object and thus a better transmission of heat and thus a reduction of transfer time. But according to our found the adhesion between the films and the objects to decorate happens in impeccable way and the pressure of approximately 1 Atmosphere is enough to transfer the decorations quickly and duly in the greatest part of the cases in which the objects are of not very complex shape. But in the cases in which that is not enough, for the excessive complexity of the surfaces to decorate, that are concave and convex or with remarkable undercut, our found foresees also to increase the pressure on the films and relative objects. In fact, according to our found, the vacuum packaging of the objects enables to increase the pressure that pushes the vacuum packaging films on the relative objects, in the simplest and immediate way. It is enough to put the objects, vacuum packaged in the relative films, in a "pressure chamber". For the heat transfers this is heated until the temperature of approximately 200 °C and more, not limiting indication, where the objects remain for the time needed to make happen the transfer. But we remind that the temperatures for the sublimatic transfer can also be lower, as shown in the table at pag. 1 , and that according to our found it is possible to operate to the low limits of the temperatures shown in the table, because the extension of the time of the treatment by heat, from few seconds to some minutes, does not influence the productivity. In fact operating at the high temperatures, with cycle cadences of 20 seconds, the time of loading and unloading of the chamber would be longer than the cycle cadence time. But every cycle, according to our found, can deal hundreds and also thousands of pieces, according to the dimensions of the chamber and of the objects to decorate. Thus our found allows to obtain transfers at the low limits of the temperatures, shown in the cited table, and to avoid exposing materials and objects, delicate or sensitive to heat, at excessive temperatures: without decreasing the productivity. We describe in detail, at only illustrative not limiting scope, the characteristics of the "pressure chamber". Its shape can be of whichever type, with at least an openable side for the loading and unloading of the objects, and constructed in whichever suitable material able to bear the pressures that in it will be exerted. Our description will be limited to illustrate a preferential model not limiting, having a cylindrical shape and constructed in stainless steel (see fig. 18).
The most rational and productive shape is that which presents, on the two mouths of the cylinder, two doors, openable towards the outside, that lend themselves very well to favor an express loading and unloading of the chamber, at the end of every cycle. The job position of the chamber is preferably that horizontal, on line with the tunnel, with the two doors arranged, one (that of loading) in proximity of the escape of the objects from the tunnel, and the other (that of unloading) on line on the opposite side. The chamber presents in its inside, along some its straights generatrices, some protuberant lists (not limiting indication), coupled and face to face, that form sliding railroads, on which to make slide some planes (not limiting indication) bringing the objects to deal according to our found. We consider the cross-sectional orthogonal section of the chamber, that is of circular shape (a circular crown), you see fig. 18. We arrange the railroads 34 of the first couple, one to an end and the other to the other end of a diameter of the circumference of inner section, parallels to the straight generatrices of the cylinder. These two first railroads supply to support the widest of the object-carrier plane 34', to insert in the cylinder. The length of the plane is equal to the length of the cylinder itself (not limiting indication). While above and below to the first couple of lists, constituting the railroads of the central zone of the chamber, other railroads are arranged (35, 36, 37 and 38), to couples, parallels and equidistant from the first couple (34), on the same part with regard to the plane placed on the two first railroads, at a distance such to allow the passage of the objects of maximum encumbrance in height, that will be deposited on the various planes. The other planes have the same length of the first (not limiting indication) but a smaller width, you see fig. 18. The pressure chamber is connected with an air compressor and presents a valve of air discharge, to set in action before every opening of the chamber, at the end of every cycle of treatment. The air compressed supplied from the compressor, dehumidified (not limiting indication), before entering in the pressure chamber, is preheated in a heat exchanger with "tubular bundle", interposed between the compressor and the pressure chamber: the preheating of the air is optional. The pressure chamber is heated by circulation of diathermic oil or with electrical resistances (not limiting indication: the heating can happen in whichever other way compatible with our found), and the external surfaces are covered by insulator material in order to assure a correct insulation. The inner surfaces of the chamber are preferably polished in order to favor the best reflection of the heat radiations and thus an uniform spread of the temperature on the objects to heat: the needed heat is supplied by radiation by the heated surfaces of the chamber. The closing doors of the pressure chamber, pivoted on suitable hinges, and equipped with the usual security systems, are hermetically closed by packings in rubber silicone, or other rubbers or engineering resins (not limiting indication) equally resistant to the high temperatures, because the same must resist also to the temperature of approximately 200 °C and more. The opening of the doors is subjected to the opening of the air discharge valve, precautionary measure of normal equipment for whichever pressure chamber. At the end of the cycle of treatment, when the air compressed discharge valves are opened, the two doors are opened and the planes with the objects already dealt are unloaded by the "tail" door, and the planes with the objects to deal are inserted by "head" door. Finished the loading and unloading cycle, the doors are closed again and the compressed preheated air is again inserted, in the pressure chamber, for the execution of the new cycle. The unloaded hot air, from the pressure chamber, at the end of every cycle is recovered in order to be re-used in the succeeding cycles for the warm air or warm water production, for the heating of the premises or other uses. The pressure chamber is equipped with a manometer for the control of the pressure, with a safety valve and a thermostat in order to control, regulate and indicate the inner temperature of the chamber. The gauging of the temperature is carried out by means of a probe that sticks out in the chamber, but isolated from its surfaces. Another useful instrument, for the equipment of the chamber, is a timer that, at expiring of the cycle time, emits sonorous and luminous marks (not limiting indication). Rendering the opening of the doors automatic, our pressure chamber is, in short, a pressure regulating autoclave, modified in order to be adapted to the use according to our found, with two openable doors, rather than one, like of customary, equipped in order to execute also a treatment by heat. The constructive details of the described chamber are fixed by the precautionary measures of safety rules to which all the pressure containers or the autoclaves are subjected.
The objects to deal by heat, in the chamber, are preferably preheated in the tunnel or in the static oven already described, until a temperature lower (but not much) than the minimal temperature able to obtain an "effective" sublimation or the softening of the inks or colors, constituting the printings to transfer physically. The heating will be carried to the temperature, needed for the transfer, only after the objects to decorate are exposed at the wanted pressure.
Diversely the transfer of the images can happen with slobbers or "moved" effect like the photos taken with not "firm" hand. The planes object-carriers can cross the tunnel placed side by side among them, and the relative tape conveyor is made of width equal to the sum of the widths of the planes. Another preferential solution, not limiting indication, foresees the use of spacers among the planes, and the crossing of the tunnel (of width that does not prevent the passage of the maximum plane) is had with the planes overlapped among them: those overhanging have as support points the spacers itselves, put between them and the underlying planes, you see fig. 19. If the planes of loading and unloading are adopted, the movement of the tape conveyor is of intermittent type: it advances at the end of every cycle in order to extract the planes that have already undergone the heating, and inserts those to expose to next cycle, remaining firm for the interval of time of the heating cycle. In another preferential solution, the planes are included in a monolithic structure (open and accessible for the insertion and the extraction of the objects to decorate), decomposable, that comprises and assembles entirety them, the measures of this structure are such to allow the insertion in block of the same in the pressure chamber. In this case the sliding on wheels of the entire structure simplifies its loading and unloading, in the pressure chamber, and the motion of the same through the tunnel or the introduction and extraction from the static oven: the tunnel and the pressure chamber will be modified inside in order to help, respectively, the advance and the loading and unloading of the monolithic structure. If the objects to deal are of great dimensions, the structure can drive also a single "object" for time. The heating of the objects in the pressure chamber is come true also by steam: this serves to heat the walls of the chamber and directly the objects, introducing in the chamber the overheated steam (not limiting indication). The chamber is externally insulated in order to avoid heat dispersions. Using overheated steam it is possible to obtain the wished pressure at the temperature demanded for the transfer of the images: the steam supplies the heat and the pressure. Moreover the preheater of compressed air is not more needed, neither more the use of compressed air is foreseen. The valves of income of the compressed air are replaced by valves suitable for the steam, and thus the discharge valves and the instruments of control and regulation of the temperature are replaced. Adopting the overheated steam in order to supply heat and pressure, our chamber is comparable with a large autoclave of sterilization, but suitable for the use according to our found, with two doors rather than one, able to supply pressures and temperatures higher than those of the autoclave of sterilization and yield more flexible, in order to execute cycles of job more various than those of sterilization. The constructive details are fixed by the precautionary measures of safety rules that regard all the steam autoclaves.
For the treatment by steam it is demanded that the films, used for the vacuum packaging, must have an excellent resistance to the high temperatures and a very good resistance and "barrier" against the steam and gases. The exercisable pressure is conditioned by the value of the adopted temperature, in order to execute the transfer, and by the resistance of the film. A film, packaged on an object, according to our found, can resist to the pressure until a given temperature value. The elevation of the temperature moves the physical state of the film from that elastic to that thermoelastic and to that plastic, until the complete fusion. At plastic state it does not present the resistance to the mechanical stresses that it have at thermoelastic state. The characteristics of every film determine the maximum pressures and the relative adoptable temperatures in the transfer to execute, according to our found, considering that the vacuum packaging films do not have to be perforated neither torn, in the relative treatment. The said heating of the objects and relative films, can happen in whichever other way compatible with our found, and all must be considered in it re-entering. If the objects to decorate present deep or passing holes, there is the risk that the vacuum packaging films are perforated, in correspondence of the holes, under the atmospheric pressure or that exerted in the pressure chamber, preventing the prosecution of the treatment. The disadvantage is overcome, well selecting the film, proportioning adequately the thickness and/or plugging temporarily the holes, before the vacuum packaging. The disadvantage can be verified even if the objects present sharp edges or flashes (specially if they are metallic or of rigid material). If it is not possible to overcome the disadvantage by the selection of a film able to resist to the deriving stresses, it is necessary to round off the sharp edges and to eliminate flashes or to prevent however the films come in contact with them. If the objects present sharp points, so as to perforate the films, it is provided to hood or to dull the points before proceeding according to our found. In any case probable points or "deep throats" do not have to be such to expose the films to stretchings higher than those by them bearable. The problem becomes much more critic if the treatment is executed in the pressure chamber. Objects with "deep throat" are, for example not limiting, some hollow vases of remarkable height, like a flower-pot of great dimensions or a large jar and the like. The inner throat of the vase is a "deep throat". Assimilable to "deep throat" surfaces are also the inner surfaces of tubes or of other hollow wireworks or extruded objects having the cross-orthogonal sections also different from that circular, and the like. In these cases, before the vacuum packaging of the object, it is provided to close the mouth of the "deep throat" with a cover or "stopper" in order to prevent the film buries in the "deep throat". The cover must enable the passage of the air, in order to allow to realize the vacuum also in the deep cavity. That is obtained realizing the covers or stoppers, of porous material (partially or totally), or supplied with small holes; or assembling them to the objects so as to enable the vent of the air, present in the deep cavities. The decoration, in these cases, happens only on the external surfaces.
That described is a preferential shape of pressure chamber, suitable for executing on the objects to decorate the treatment demanded according to our found, in the case that the pressure of approximately 1 Atmosphere was insufficient in order to perfectly decorate the objects. It is not at all limiting, because other shapes of pressure chambers, able to make possible the treatments demanded according to our found, can replace that described, and all re-enter within the limits of our found. For ulterior illustrative example not limiting, the pressure chamber can be a chamber in reinforced concrete, dealt for making it airtight, with one or two doors with airtight closing, structured in order to resist to the maximum pressures that must be adopted (according to the precautionary measures of safety rules to which the pressure containers are subjected), of dimensions suitable for the several types and sizes of the objects to decorate, equipped with the instruments needed to supply, to regulate and indicate the temperatures, to execute the transfer of the decorations on the objects, according to our found, connected to an air compressor with interposed air compressed preheater (not limiting indication), equipped with manometers for the control of the pressure exerted in its inside. The heating is done arranging, on its walls and/or ceiling, radiating elements by infrared beams, equipping it with reflecting walls, for an uniform distribution of the radiation and/or supplying it with a good system for the right circulation of the air. Whichever pressure chamber, according to our found, can supply the total heating of the objects, but thus the times of the treatment in the chamber grow and, in order to maintain the same productivity, must be increased its length or its capacity: the preheating in a tunnel or in a static oven enables to earn time using less expensive machines, of other part already available because used in the treatments of objects that, according to our found, need not the pressure chamber.
Our found is extensible to the decoration of objects like fabrics and articles of clothing. The application of our method to the decoration, for example not limiting, of a T-shirt, to execute by the method described as SECOND TYPE (not limiting indication), it is arranged as follows:
M - location and marking of the zone to decorate;
N - construction of the pattern of that zone, obtainable in immediate way, in this case;
O - cut of the film or intermediate sheet (with the relative decorations) according to the said pattern;
P - positioning of the film, thus cut, and its implantation on the zone to decorate, made by a removable adhesive or by adhesive film, as illustrated, or in whichever other suitable way;
Q - insertion of a sheet of thin pasteboard (not limiting indication) under the zone to decorate, in order to avoid the transferred images will soil the other part of T-shirt that does not be decorated. The thin pasteboard will also prevent the atmospheric pressure coils the T-shirt (sealed in the vacuum packaging film, as nearby illustrated): the thin pasteboard must be well proportioned, in thickness and rigidity, and on it the T-shirt is folded and packaged. It is replaced by a sheet of paper or metallized and/or "barrier" film, when the said hardening is not demanded;
R - insertion of the T-shirt, thus folded, in a "barrier" film or folder or bag formed by it, and its vacuum packaging, according to our found;
S - heat treatment for the sublimatic or physical transfer of the images. In the sublimatic transfer, if the T- shirt is totally or partially (at least by 65%) of man-made fibers, like the polyester, acrylic, poliuretanic, polyam- midic and the like, it is not necessary a pretreatment of the T-shirt. If instead it is of pure cotton or of high percentage of cotton or of other natural fibers, artificial and/or synthetic not directly receptive, it must be pre- treated in order to make it receptive to the sublimation gases. The treatment consists in spraying, on the zone to decorate, a thin coating of varnish based on synthetic resins like polyester, acrylic, poliuretanic, siliconic or of other polymers and/or similar engineering resins, homopolymers, co-polymers, terpolymers or multipolymers and relative alloys. The varnish must be compatible with the fibers of the T-shirt and receptive for the decorations to transfer; having high melting point, fixable intimately and firmly to the fibers themselves. The same is worth if the fibers of the T-shirt are not receptive for the physical transfer: the zone to decorate must be pre- treated with a varnish suitable to berth firmly the decorations to transfer. These varnishes must also resist to the use for which the article of clothing will be used: suitable products are of normal production and commercialization, and the said treatments make part of the state of the art and of the technique in use. According to our found, the T-shirt, taken as example not limiting, can be decorated at the same time on the front and on the back, by the method of the FIRST TYPE or SECOND TYPE or MIXED TYPE: it is possible to decorate, in the same treatment, also the sleeves. In the treatments of SECOND TYPE and MIXED TYPE it is possible to execute decorations with zones of reserve, as before illustrated. Another not limiting example is given by the decoration of the hats that, with the technology in use, is executed, on suitable presses, on an element for time: according to our method, this is executed on many elements at the same time. The hats are preferably put on suitable plaster dies or of whichever other economic material, suitable to bear the treatment by heat and equally easily workable and mouldable by casting, so as that the hats can be worn. On the zones of the hats to decorate, thus worn on the relative "dies" (not limiting indication), in case of treatment of SECOND TYPE, the intermediate films with the decorations to transfer are attached. Then these, with the relative dies, are vacuum packaged, in weldable films having "barrier" capability to gases, according to our found, and are dealt to heat, in order to obtain the transfer of the decorations, as described. Operating according to our method it is possible to not only decorate many hats in the same treatment, but every hat can be decorated in more complete and attractive way, being possible to decorate, besides the peak, whichever other zone of the remaining part of the hat and every zone can be decorated with various decorations and/or colors. In the same way, and in other ways, always according to our found, it is possible to decorate motor-bike or emergency helmet and all the similar objects. Our method is easily adaptable to the various intimate and external articles of clothing, and for several uses, like stockings of whichever type, swimsuits, sportswear and competition, varied fashion apparel, and also for table cloths, napkins, doilies and other accessories for table, or furnishing, carpets, moquette and so on. Our method is valid, either for the transfer of the decorations on the assembled apparel, or on the relative component parts. It must be considered that generally all the objects of this type will be preferably supported by sheets, slabs or by objects of suitable shape, thickness and suitable rigidities, having the function of the thin pasteboard or of the plaster dies, before illustrated. The supports are recovered at the end of the cycle and are re-used. In the sublimatic transfers, the apparel, or whichever other object to decorate, must be of light colors. The sublimatic colors are not "covering", thus are not visible on the objects dealt, if the objects are black or in very dark colors. In this case the treatment by sublimation can be executed only supplying to pre-paint or to pre-color the zones to decorate, by clear inks and suitable products. Or the articles or their constituting parts can be subjected to bleaching treatments, if are fabrics and apparel articles. For the physical transfers by heat the problem does not exist because the used inks are usually of "covering" type and, if they are not such, they can easily be rendered covering. It remains to be considered a last advantage, offered by our found, adopting simple devices. Advantage very useful in the sublimatic transfer, but important also in that physical. For this purpose we illustrate how it is possible to lower a lot the transfer temperatures of decorations by sublimation, by an appropriate use of the equipments until now described here. That is possible, without lengthening the times of the treatment, shortening them instead, if a very low pressure is exerted "on the decorations themselves". The sublimation speed of a substance depends on its tension of vapor and on the existing pressure "in the atmosphere" in which it is placed: the higher its tension of vapor and the lower the ambient pressure is, the easier and faster its sublimation is. The tension of vapor of the substance increases by the growing of temperature, the pressure "of the ambient" is reduced creating the "vacuum" in the ambient and preventing the substance to sublimate is subjected to "compression" by whichever other body or substance present in the ambient or which delimits the substance to sublimate.
For example, for the aluminum, the tension of vapor increases by a factor 10 for each increase of temperature of approximately 10%, as it is from the following table:
TEMPERATURE (°C) TENSION OF VAPOR (millimeter HG)
882 0,00001
972 0,0001
1082 0,001
1207 0,01
1347 0,1
1547 1
The lowering of the ambient pressure, while a solid substance is sublimated, allows either the sublimation at lower temperature, at the same speed, or a faster sublimation at the same temperature, as it happens for the evaporation of a liquid. Operating so that the inks or the colors, constituting the decorations to sublimate, are under sufficiently low pressure, it is possible to lower the decorations sublimation temperatures by approximately 30%-40% (not limiting indication) without lengthening its time of sublimation. It means that the sublimation temperatures of the inks constituting the decorations, usually adopted, which oscillate between 140 and 180 °C, at atmospheric pressure, can be reduced around to 90-125 °C (not limiting indication), if the sublimation of the inks is executed in an ambient where the pressure acting on them is very low, without lengthening the sublimation times. In some cases the lowering of the "ambient pressure" to values very low allows to sublimate inks or pigments which, in the normal conditions of pressure, would not be sublimable. Thus, according to this varying of our found, it is possible to execute the decoration printing to transfer by sublimation, adopting also some inks that "usually" are not suitable for this type of transfer. The possibility to lower the sublimation temperatures, is very important because allows, on one hand to deal objects that are not able to bear high temperatures, on the other to save time (with remarkable increase of productivity) and energy, and moreover to adopt also films, for the vacuum packaging, that do not resist to high temperatures, but are very valid, according to our found, at lower temperatures, besides more economic and easy to be found.
For this purpose our found foresees the use of our pressure chamber as decompression chamber, as we will go to illustrate in detail after having analyzed some characteristics of the thermoplastic materials constituting the films to adopt. We consider the following characteristic temperatures of thermoplastic materials:
- Tg: glass transition temperature;
- Tm: temperature of fusion of the "crystallites" (the "crystallites" are present only in the crystalline or partially crystalline thermoplastic materials);
- ET: Interval of temperature of softening or of glass transition; - KS: field of fusion of the crystallites;
- TF: minimal temperature of thermoplastic moulding: it marks "the minimal" temperature at which the material is thermoplastically formable (by injection within moulds or by extrusion to be reduced in drawings, slabs or film): in fact it is formable thermoplastically also to higher temperatures, until a maximum limit, above which the chemical decomposition of the material takes part. We present a table in which are brought the values of the characteristic temperatures, before listed (Tg, Tm, ET, KS, TF), for some of the main thermoplastic materials, emphasizing the temperatures of the "optimal thermoforming interval" for each of them. The data brought back in the table do not have the pretension to be "exact", but approximates and lightly variable, also among products of the same type supplied from various producers:
PLASTIC MATERIALS Tg ET Tm KS TF Termof.Optim.lnterv. in °C
Polycarbonate 130 14 165 16 250 165-180
Polypropylene -30 12 165 7 180 160-170
Polyethylene (dens. 0,95) -100 7 125 14 200 130-140
Polyethylene (dens. 0,92) -80 10 110 10 175 120-130
Polymethylmethacrylate 90 14 200 115-150
Polystyrene modified 80 10 180 110-140
PVC rigid 75 12 170 110-140
PVC flexible -50 40 gum -elastic 160
The illustrated "characteristic" temperatures are important in order to establish if, and in what way, it is possible to thermoform films of thermoplastic materials.
The thermoforming modalities interest directly our found in order to transfer the decorations by sublimation at low temperature, as later it is illustrated. In order to realize a "true" thermoforming, it needs:
- carrying the material to thermoform to a temperature higher than the Tg, for the amorphous thermoplastic materials, or Tm, for the partially crystalline thermoplastic materials: limits above which "the optimal interval of thermoforming" is found. In fact the amorphous thermoplastic materials, above the Tg, and the partially crystalline materials, above the Tm, become thermoelastic materials and in this state can be formed with low stresses;
- exposing it to the stress needed to perfectly conform it on the object: there are sufficient low stresses;
- "freezing" its shape, cooling it under tension, until a temperature sufficiently below the Tg or, respectively, the Tm.
But for the needs relative to our found, it needs not realize a "true" thermoforming, because our objective is that "to conform the film on the object to decorate" and to hold it in contact with the object, at the lower pos- sible pressure, until the transfer of decorations happens. In short, according to our found, it is enough to maintain the film in contact with the object to decorate, also when the external pressure on the film is reduced at a minimum, able only to overcome the residual elastic reactions of the film, conformed on the object, and the counter-pressure exerted, from the inside of the packaging, by the residual gases hardly extractable. Later we will indicate with the term "thermoforming" also the simple "conformation" (without "freezing" the shape of the film on the object) according to our found. We are now able to illustrate our method to execute the transfers, with low temperature of sublimation, from vacuum packaging films and/or intermediate films, to the objects to decorate, as follows:
T- vacuum packaging of the objects within films, according to our found;
U - introduction of the same in the tunnel or the static oven to expose them to preheating at a temperature comprised in the optimal interval of thermoforming, but being, at the same time, lower than that minimal needed to obtain the transfer of the decorations (at normal atmospheric pressure). Since it is attempted to execute transfers at low temperature, it is better to operate at the low limits of the optimal interval of thermoforming. The films, that are pressed on the objects at the pressure of approximately 1 atmosphere, at this temperature, are easily thermoformable or "conformable" on them. After a sufficient interval of time in these conditions the residual elastic reactions of the films are decreased;
V - the objects, so packaged and preheated, will be inserted in the pressure chamber, that is closed and maintained at the minimal temperature needed in order to execute the transfer at very low pressure: temperature to be defined in work course, putting to point the production cycle, and after having established the value of the "pressure very low" that we want to exert or can be exerted: considering that this pressure depends very much by the residual pressure present between the objects and the relative films of vacuum packaging and by the elastic return of the films themselves. In the phases in which the correct parameters of execution are "put to point", it is adopted initially a temperature equal to that of preheating, varying then it in function of the variable cited, to fix it at the values optimal for the execution of the normal production.
W - the pressure chamber is then connected to a vacuum pump, rather than to a compressor or to a steam chamber. In this way it is used as decompression chamber. The residual pressure in the chamber will be measured by the manometer, supplying that the same is lightly higher than the residual pressure existing between the object to decorate and the film in which the object is packaged under "vacuum", and such to overcome also the residual elastic reactions (decreased) of the film "in thermoforming". In this way the pressure to which the inks, constituting the decorations to sublimate, are exposed, is that minimal set up in the pressure-decompression chamber. From now on, we will call this pressure "minimal pressure enabled" or at "minimum enabled": in fact it is the minimal pressure enabled by the value of the residual pressure in the packaging and by the residual elastic reaction of the adopted film, under which it remains in contact with the object. The lower is the residual pressure within the packaging and the residual elastic reaction of the film, the lower will be the pressure under which the sublimation happens, and the lower will be the needed temperature, without lengthening the time of sublimation. If this can arrive to be lower than the Tg or, respectively, Tm of the film, this would be really "thermoformed" on the object to decorate, as before defined. The "effective thermoforming" blocks the residual elastic reactions of the film and this enables to operate at a lower "minimal pressure enabled", what favours the treatment at still lower temperature or a faster sublimation of the decorations. The preheating mentioned at the previous U point can be executed directly in the pressure chamber itself (at atmospheric pressure) before proceeding as described in this W point: but by the separate preheating the productivity of the system is increased.
X - when the time needed for the transfer is passed, the ambient air is inserted in the chamber and the atmospheric pressure is restored, before the chamber will be opened to extract the decorated objects and to introduce the new objects for next cycle. In this way, according to our found, the transfer of the decorations happens by a method that we will call at "conditioned decompression". In fact the minimal decompression possible to carry out the transfer "is conditioned" by the residual elastic reaction of the adopted film and by the existing residual pressure between the film and the object vacuum packaged in the same. The method by "conditioned decompression", according to our found, has the scope to minimize the pressure at which the decorations to transfer are exposed, in order to enable a fast sublimation of the same at the lowest temperatures possible. It is very different from the normal transfer "under vacuum", because this maintains the inks, of decorations, compressed, between the surfaces of the objects to decorate and the relative membranes or film (on which the decorations themselves are brought), under the action of the atmospheric pressure or of probable higher pressures acting from the outside. By the normal transfer "under vacuum" the pressure "of the ambient", in which are placed the decorations to sublimate, is not that of the "vacuum" created between the membranes or films and the surfaces to decorate, but that which acts from the outside on the membranes or films themselves and, through these, also on the residual gases at the inside of the vacuum packaging.
The transfer for the sublimation of the decorations before described, can be executed also in other way, varying the ways described at the points V and W, as follows:
V - introduction (of the objects vacuum packaged: see the point V) in the pressure-decompression chamber maintained at temperature lower than the Tg (for film of amorphous synthetic material) or Tm (for film of partially crystalline synthetic material) of the vacuum packaging films, a little enough to obtain the "effective thermoforming" of vacuum packaging films on the relative objects (it is enough that this temperature is, by approximately 10-15 °C, not limiting indication, lower than the Tg or, respectively, Tm of the films). In this way the pressure in our decompression chamber can be reduced to much lower values, because it does not have more to counterbalance the elastic reactions of films and the pressure of residual gases, hardly extractable, present to the inside of the packaging;
W - to await that the temperature of the films is lowered to the level of temperature of the decompression chamber and to supply then to reduce the pressure sufficiently to obtain the demanded sublimatic transfer of the decorations on the objects. If the transfer of decorations happens by treatments of SECOND TYPE and the intermediate films, bringing the decorations to transfer, are put on the zones to decorate, by removable or repo- sitionable adhesive, smeared or sprayed on all the surface of the films, the shifting of the vacuum packaging films, during the treatment at low pressure, does not cause the shifting of the intermediate films (if the adhesives used resist to the temperatures) and thus does not influence the correct execution of the transfer. That allows to reduce the pressure of the decompression chamber in "not conditioned" way. In this case it will be operated with a simple "treatment by decompression": the minimal pressure acting on the decorations, when the vacuum packaging film bears off the object, is given by the force of adhesion of the adhesive used to berth the intermediate films.
The method by "conditioned decompression", up to now described, is suitable for the sublimation of decoration of objects of not very complex shapes, where the objects to decorate, vacuum packaged, and the relative films of vacuum packaging, are not exposed to pressure higher than that atmospheric. But it is applicable also to the objects of shapes very complex, with pronounced undercut, tips and throats (that re-enter in the limits of resistance of the films adopted), always according to our found, by small variations to bring in the means and systems illustrated and in the execution modalities. We remind that the pressure chamber has been thought to enable the perfect adhesion of the films with the objects to decorate, also when these are of very complex shape and if the atmospheric pressure is not sufficient to warrant that the films are pushed in contact with all the points of the object in it packaged. Thus, for objects of complex shape, the method of transfer by sublimation, that we called at "conditioned decompression", can be adopted equally operating as follows:
Y - vacuum packaging of the objects according to our found;
Z - preheating of the same, in a tunnel or static oven, at a temperature comprised in the optimal interval to thermoform the films adopted, but being, at the same time, lower than that minimal needed to obtain the transfer of the decorations (at the normal atmospheric pressure): this allows to do a first thermoforming of the films on the objects. This temperature depends on the type of adopted film: operating at temperatures at the low limits of the optimal interval of thermoforming;
A1 - introduction of the objects, so packaged in the films, in the pressure chamber and increase "gradually" of the pressure, by air compressed preheated (not limiting indication), until the perfect thermoforming of films on the objects: it is sufficient to increase it enough to let the films are conformed on the objects, without being perforated or torn. The temperature of the preheated air is preferably that adopted for the preheating of the objects, as defined at the previous Z point. Caught up the thermoforming pressure sufficient to obtain the perfect conformation of the vacuum packaging films on the objects, without laceration of the same, it is maintained for the time needed to obtain the lowering of the elastic reactions of the films until the minimum values: in this way the "thermoforming" of the films on the objects of complex shape is perfecte . The preheating can be executed in the pressure chamber itself, as seen at the W point;
B1 - expulsion of the compressed air, used to increase the chamber pressure, and subsequent activation of the vacuum pump, to lower the pressure to the minimal value, sufficient to maintain the films adherent to the objects ("minimal pressure enabled");
C1 - wait for the time necessary to transfer the decorations from the films to the objects: the necessary temperature will be the lowest possible at the conditions of the "enabled minimal pressure", at which the transfer happens, or will be that thought more suitable to execute it in the cycle time reputed more convenient to adopt. Temperature to define in the work course, in function of the film adopted, of the realized quality of the vacuum, within the packaging, between the films and the objects, of the "maximum" temperature bearable by "the sensitive" objects or by the relative vacuum packaging films, and of the shape of the objects more or less complex. If the "enabled minimal pressure" allows a remarkable reduction of the atmospheric pressure, the transfer can happen also without ulterior "heating". As it has been said: a sufficient lowering of the pressure allows to lower the temperature of sublimation, without lengthening the transfer times. Thus the treatment is conditioned by the optimal thermoforming interval of the adopted films: for films having this interval comprising or exceeding the minimal temperature necessary to the transfer at the "enabled minimal pressure", it happens without ulterior "heating": only lowering the pressure, in the chamber, to the "minimum enabled".
D1 - when the needed transfer time is passed, gradually the ambient air is inserted in the chamber and the atmospheric pressure is restored, before the chamber will be opened, to extract the objects decorates and to introduce those new for next decoration cycle. In order to execute the treatment by the method by "conditioned decompression" when the objects are of complex shape, the pressure chamber is equipped with all the instruments needed to make it a "pressure-decompression chamber". That is obtained connecting the pressure chamber, equipped with all the instruments needed for the treatment by pressure, with a vacuum pump. For the use also as decompression chamber the pressure chamber must be planned so as to resist to the atmospheric pressure (that acts to the outside) in all its parts, included the closing of the doors, when the vacuum is made in it. The method described to the points Y, Z, A1, B1, C1, D1 can be varied at the points A1 and B1, adopting a pressure chamber separated from that of decompression. In this case, when the perfect conformation of the films on the objects (as described) in the pressure chamber is obtained, the compressed air will be expelled, the pressure chamber will be opened, the objects will be extracted and introduced in a decompression chamber, where the pressure will be lowered at the minimum value sufficient to maintain the films adherent to the objects ("minimal pressure enabled"). The previous and next treatments remain unchanged. In this case it is possible also to vary next treatments, as described in the previous points V, W. The method by "conditioned decompression", according to our found, is feasible also using, for the vacuum packaging, thermoretractable films. When the retraction happens, the films are carried to the temperatures of their optimal thermoforming interval, to thermoform them on the objects and to reduce to the minimum values their elastic reactions, thus the treatment at "conditioned decompression" is allowed.
The advantages obtainable operating at low pressure and low temperature are not only these, another advantage of great importance must be considered, consisting in the possibility, or better, the necessity to adopt, for the vacuum packaging, also films that need not resist to the temperatures of 140-180 °C, but only to temperatures much lower 90-125 "C (not limiting indication). Much more economic films and of wider use can be adopted like, for example not limiting, film of PE (polyethylene), PVC (polyvinylchloride: preferably rigid), PS (polystyrene), PMMA (polymethylmethacrylate) and the like, and homopolymers and/or co-polymers and/or ter- polymers or multipolymers and/or relative alloys with other co-polymers and/or terpolymers or multipolymers with them compatible and the like. Also the "barrier" films, with very good capabilities to "barrier", like the EVOH and the likes, that at the high temperatures present a worsening of their capabilities to "barrier", can favorably be used (always coupled or coextruded with the said films of PE, PVC, PS, PMMA and the like). Films of this type, with three layers (with a layer of EVOH, or of another "barrier" film, between two film layers like those cited), can also easily be metallized on the face that goes to the outside of the packaging, realizing film with 4 layers, with "barrier" of excellent quality, at lower costs, but however suitable to transfer decorations to objects, as before illustrated. It is possible to adopt also films multilayer, with "barrier" layers sandwiched between two or more layers of PE and/or PVC and/or PS and/or PMMA and homopolymers and/or co-polymers and/or terpoly- mers and/or multipolymers and the like and relative alloys. These films can also be biaxially stretched in phase of coextrusion, so as to be made also thermoretractable. For example not limiting, it is possible to coexstrude these films with some alternated layers of EVOH and of PVC (and/or of PE and/or of others), with the layers to the ends in PVC or PE or PS or PMMA and the likes: the sequence could be, for example not limiting, PVC- EVOH-PVC-EVOH-PVC or PE-EVOH-PVC-EVOH-PE or PVC-EVOH-PE-EVOH-PS and analogous, varying also with other types of similar films and other ways of combination, giving film with 5 layers, with the ulterior possibility to metallize last layer that remains at view. The layers can be also 7 (not limiting). The films rπonolayer are moreover very interesting, obtained from new materials like the polyolefines by catalysts metallocene: more resistant, able to create "barrier" and easier to seal. An example not limiting, is given by the "low density polyethylene linear metallocene"; a very good "barrier", for example not limiting, is obtained also (with a film in only 3 layers) coextruding one layer of EVOH or of other "barrier" film sandwiched between two of these films. The use of films with optimal interval of thermoforming at lower temperatures (films less resistant to the high temperatures) is of great importance when we want the transfer by sublimation at low temperature, according to our method by "conditioned decompression". Two cases can be presented:
1* - the pressure, in the pressure-decompression chamber, is reduced to the "minimum enabled" and, at this minimum, the sublimation happens at the temperature that the objects have. This has the value at which the thermoforming (at atmospheric pressure) has happened or lightly lower, due to the normal cooling of the objects as soon as they escape from the tunnel or are extracted from the static oven: it is not necessary "to heat" the objects, in the decompression chamber.
2° - the reduction of the pressure at the "minimum enabled", does not allow the sublimation of the decorations to transfer, at the temperature at which the objects are: it will need heating the objects, in the decompression chamber, to temperature higher than that at which the thermoforming has happened, but lower than that needed at "normal" pressure.
If, for example not limiting, a polycarbonate film is adopted, the optimal thermoforming interval of which is of 165-180 "C, our method of transfer at low temperature (90°- 125° C) at "conditioned decompression" is practically inapplicable. In fact, it is possible "to thermoform" the said film, by heating at a minimal temperature of 165 °C, under atmospheric pressure (if the objects have a not very complex shape: otherwise they must be "thermoformed" in our pressure chamber): thus in any case the treatment does not happen at low temperature, as we want, but at minimum 165 °C, enough high temperature. Indeed so high that, if the heating is not executed quickly, the transfer by sublimation happens before the film will be thermoformed, what involves also a not duly transfer ("moved" effect). Our method by conditioned decompression thus, in this case, does not enable to execute transfers at low temperature, even if it allows to operate at low pressure: it but enables to execute the sublimatic transfers at the minimal, "nearly normal", temperature of 165 °C, but at much higher speed than that "normal". This is a great advantage, because enables to remarkably increase the speed of the transfers by sublimation. Moreover if, after having carried the temperature of the film to 165 °C and having "conformed" the film on the object to deal, the temperature is reduced to values lower than 165 °C (Tm of the polycarbonate), for example to the temperature of 140-150 °C, the film will be "really" thermoformed on the object: this allows to reduce the "pressure enabled" at values much lower than the values that would be "enabled" if the film were only improperly thermoformed (only "conformed") on the object, according to our method by conditioned decompression. In his way the transfer becomes a quick transfer, by ulterior reduction of the pressure, rather than by elevation of the temperature. Lowering the temperature below the Tm of the film, as soon as executed the "thermoforming" (at the temperature of 165 °C), the transfer can happen also at the temperatures of 90-125 °C (not limiting), if the pressure is immediately reduced at the minimum possible value. Since the objects, included in the vacuum packaging films, are nearly at ambient temperature, except the superficial lay- ers in contact with films, suspending the energy supply for the heating, they are able to cool the films with which are in contact. The reduction of temperature happens thus in correct way: the zones to decorate are at temperature lower than that of films, as arranged at the point 7. If the objects to deal resist to high temperatures only for short time, they can bear the described treatment. It is possible to conclude that, with film of this type, it is possible to execute sublimatic transfers of decorations on objects sensitive to heat, at "low on an average" temperatures, if the objects to deal resist to the high tips of heat, for short time.
Thus It happens that, in order to execute the treatment of decorations transfer at low temperature, it needs adopting films thermoformable at low temperatures and, as said, this possibility depends on the type of the adopted film. If, for example not limiting, a rigid film of PVC is adopted, the optimal thermoforming interval of which is of 110-140 °C, it can easily be thermoformed at 115 °C and, supposing that the "enabled minimal pressure" is of 0.05 Atm and that, at this pressure, "the effective" sublimation happens at the temperature of 90 °C, reducing the pressure to 0.05 Atm the transfer demanded would be obtained at the temperature of 115 °C, without ulterior heating, indeed much before the pressure comes down to the value of 0.05 Atm. Instead, supposing that the sublimation, under the pressure of 0.05 Atm, happens at the temperature of 125 °C, the objects will be heated until 125 °C, after having reduced the pressure at 0.05 Atm, in order to obtain the demanded transfer.
In the case 1", before described, our decompression chamber can be replaced by the "vacuum packaging chamber machines", for the sublimatic transfer of decorations, according to our method by "conditioned decompression", if objects of not very complex shape are dealt , for which thus it needs not exert a pressure higher than that atmospheric to thermoform there the vacuum packaging films. In fact, for the use described in the case 1°, the "vacuum packaging chamber machine" is in a position to carry out all the functions useful to realize the treatment at "conditioned decompression", as demanded, according to our found; with the advantage that enables "to observe directly" at which minimal level can be reduced the pressure in its vacuum chamber (always of transparent material), without the film bearing off the object to decorate ("enabled minimal pressure"). It is enough to insert the objects into the vacuum chamber, already regularly vacuum packaged and sealed in the relative films, according to our found, preheated (at the normal atmospheric pressure) to the temperature comprised in the optimal thermoforming interval, as described, and to do the vacuum in the vacuum chamber. If the "thermoforming" of the films and the vacuum created, in the vacuum packaging of the objects, have been pushed so as to enable to reduce the pressure, in the vacuum chamber, until the limit at which the sublimation happens at the temperature at which the objects preheated are found, without the film bearing off the object, we will have obtained the wanted transfer. Through the transparent vacuum chamber it is observed when the film, in consequence of the reduction of pressure in the vacuum chamber, bears off the object: on the manometer of the machine it is read the value of the pressure or depression existing in the vacuum chamber when the shifting of the film happens. If, at the attainment of this value of pressure, the transfer already has happened, we can assume this value of the pressure (or, more better, that lightly higher that precedes it) as value to set up, in our pressure-decompression chamber (or in the "vacuum packaging chamber machine" itself), in order to execute the transfers, at the temperature adopted in the preheating, according with our method by "conditioned decompression". This temperature is comprised in the optimal thermoforming interval (of temperature) of the selected film and, if this interval has the limits, or at least the inferior limit, at temperatures of low values, the transfer happens at low temperature.
But adopting for the construction of the vacuum chamber a completely or "very" transparent material to infrared beams, besides to luminous beams, the "vacuum packaging chamber machine" can be used also for the treatment described in the case 2°, where it is foreseen that in order to obtain the sublimation of the decorations to transfer it needs heating the objects ulteriorly, also after having reduced the pressure at the "enabled minimum": the heating is obtained irradiating by infrared beams, by irradiators disposed to the outside of the vacuum chamber, the objects put into it, thanks to its transparency to the radiations, as it has been assumed. A material suitable to realize "transparent vacuum chambers" to light and to infrared beams is, for example not limiting, the glass-ceramic (Robax, Boroflat and Tempax of the Schott Glaswerkes, and Pyrex, Pyroceram and Vycor of the Cornig Glass Works, are some types of glass-ceramic: not limiting indication). But also synthetic materials very transparent to light and to infrared beams and able to resist to the atmospheric pressure, during the radiation, are valid, like the polymethylmethacrylate, polycarbonate, polyester and the like. The infrared beams will be oriented so that their angle of incidence with the overhanging surface of the vacuum chamber (supposed mostly or nearly flat) are such to make minimal the reflection and the refraction of the same. Infrared medium-waves beams are adopted (to which the cited glass-ceramic and synthetic materials turn out highly transparent), and vacuum packaging or intermediate films of black or dark color, with opaque surface, and good heat conductors, in order to make sure that the temperature of the films that bring the decorations to transfer is higher than that of the objects to decorate, which are in contact with them. The medium-waves beams, after having crossed the walls of the vacuum chamber, degrade to long-waves beams, to which the walls are not transparent, so in the vacuum chamber is obtained the greenhouse effect, that enables to heat electively the film in which the objects are packaged. The heating of the objects in the vacuum chamber of the "vacuum packaging chamber machine" is executed also arranging the heating elements, opportunely shielded and with very diffuse irradiation, within the vacuum chamber: in this case the wavelength of the infrared beams must be at the limit between the "high" values of the medium-waves and those "low" of the long-waves (dark irradiators): of approximately 3-5 micron (not limiting indication). The constituting materials of the vacuum chamber are not transparent to this type of radiations: thus, in the vacuum chamber, the action of elective heating of the vacuum packaging or intermediate films (of the said type), that bring the decorations to transfer, happens with the maximum efficiency (greenhouse effect). Carrying out the heating in this second way the vacuum chamber can also be of not transparent material, if the machine is not used for the "experimental" individuation of the "enabled minimal pressure". The entire cycle of treatment of objects of not very complex shape, by "conditioned decompression" for the sublimatic transfer of decorations at low temperature, can thus be realized also with a system that foresees:
E1 - a "vacuum packaging chamber machine", endowed with sealing bars, at the beginning of the cycle, for the vacuum packaging of the objects to decorate. Inasmuch as are dealt objects of not very complex shape, the vacuum packaging can be executed also with a "non-chamber vacuum packaging machine", if there do not arise problems due to not extractable air pockets;
F1 - a tunnel or a static oven for the preheating of the objects vacuum packaged;
G1 - a second "vacuum packaging chamber machine", or its equivalent, as said, in order to reduce the atmospheric pressure, at which the objects are exposed, at the "minimum enabled", according to our found: this second "vacuum packaging chamber machine" without the sealing bars, because it is not used for the vacuum packaging. In fact, for the use demanded to this machine, the sealing bars and all the mechanisms, circuits, and relative electrical or electronic equipments, to carry out the function that enables to seal the films or bags for vacuum packaging, are not needed, but only the vacuum chamber, the relative pump and connected motor and the manometer for the gauging of the pressure in the vacuum chamber. Realizing the vacuum chamber of this second machine with material "very transparent to infrared beams", the treatment can be executed, even if it will be necessary to heat the objects ulteriorly, after having reduced the pressure at the "enabled minimum", in the vacuum chamber. For the normal production the pressure-decompression chamber, as by us described, is more versatile and productive, but the adoption of the "vacuum packaging chamber machine" is useful in order to simplify, in the working practice, the "experimental" individuation of the "enabled minimal pressure" to set up in the pressure-decompression chamber, to have a faster put to point of the production cycles, to execute in the pressure-decompression chamber itself . This second vacuum chamber machine for the treatment at conditioned decompression, can be replaced by a container for vacuum having a structure suitable to bear the atmospheric pressure: in this container must be realized the vacuum, with a vacuum pump connected to it in stable way or not. This is formed by a container and the relative cover that closes it hermetically by interposition, between the relative edges in contact, of a packing of soft and elastic material. If the pump is not connected in stable way, the vacuum is done sucking up the air included in the container, by a vacuum pump and the relative tube of connection, through a hole of circular shape, practiced generally on the cover of the container. When the extraction is executed, this hole is automatically closed hermetically by a stopper, generally of spherical shape, in soft and elastic material. Applying a manometer to the container it is also possible to know the value of the residual pressure. The container can be realized, completely or partially in transparent material (glass-ce- ramie, transparent glass-reinforced plastic, polymethylmethacrylate, polycarbonate, polyester) or not. If it is in transparent material, it enables all the advantages attributed to the "vacuum packaging chamber machine" that it replaces. If in not transparent material, the probable heating of the objects is obtained arranging heating elements, very well shielded to have a correct spread of the heat radiations, to the inside of the "vacuum container": the inner surfaces are preferably reflecting. Adopting a similar "vacuum container", for the treatments at conditioned decompression, it is easier and more economic to adapt the dimensions of the decompression chamber to those of the objects to deal. Also for objects of complex shape it is possible to adopt the cited machines in the aforesaid system, if the objects are dealt before in a pressure chamber and then are undergone to the treatment at conditioned decompression: system feasible if a pressure chamber separated from the decompression chamber, as before illustrated, is used.
The advantages obtainable executing the transfer at low pressure, according with our found, in the case of sublimatic transfer, can be obtained also in the case of physical heat transfer, if inks are adopted, for the decorations printing, constituted with resins and/or waxes (incorporating probable relative heat fusible adhesives "hot melt adhesive") having melting point lower than that usually used.
For the physical transfer is not the treatment at low pressure that improves the "transferability" of the inks at lower temperatures, as it happens by the sublimatic transfer. But vice versa, if inks transferable at lower temperatures are adopted, it is possible to adopt more economic films and of wider availability, that usually have a smaller resistance to mechanical stresses under heat treatments and that must be used thus for treatments at lower pressure. The use of inks transferable at lower temperatures, for the physical transfer, is "necessary" if objects, that do not resist to higher temperatures, must be decorated. But if physical transfer is dealt, the reduction of the pressure at the "minimum enabled" is not important, to facilitate the transfer, while instead it is important to be able to reach the fusion of the decorations, at the minimal temperatures, demanded by the characteristics of the objects to decorate. In fact the minimal pressure must be maintained at sufficiently high values to make firmly join the decorations to the surfaces of the objects, while the minimal temperature must assure the fusion of the decorations to transfer, reason for which the decoration by physical transfer of objects of enough simple shape happens as follows:
H1 - vacuum packaging of the objects to deal, according to our found;
11 - preheating of the same, in the tunnel or in the static oven (not limiting), at a temperature lower than that relative to the melting point of the decorations. Temperature at which the vacuum packaging film must have a sufficient resistance for the use for which it is used, at atmospheric pressure, but that is also suitable to enable its thermoforming on the object to decorate, under the action of the atmospheric pressure itself (approximately 1 Atm): this temperature will be within the optimal thermoforming interval of the adopted film;
J1 - introduction of the objects in the decompression chamber in order to reduce the pressure at the minimal level, but sufficient to attach the decorations to the object, at the minimal temperature at which they reach their melting point: temperature supplied in the chamber itself. The reduction of the pressure only serves to allow the vacuum packaging film to be heated until the temperature relative to the melting point of the decorations, without being perforated or being torn.
K1 - when the fusion temperature of the decorations is reached, they adhere to the object surfaces, with a force higher than that present between them and the film which supports them;
L1 - re-entry of the air at ambient temperature, gradually, in the decompression chamber, in order to bring back the objects under atmospheric pressure. The introduction of the air produces at the same time a lowering of the temperature and an increase of the pressure, thus the vacuum packaging films are cooled while the pressure increases so they would not have to be tom or to be perforated. The probable perforation or laceration of vacuum packaging films, under the action of the atmospheric pressure, in this phase, it does not more influence the feasibility of the transfer, as it already has happened. In order to avoid the laceration, can be introduced air at lower temperature than that atmospheric, to fast cool the films, before that the pressure reaches the value of that atmospheric of the place in which we work;
M1 - when the treatment has been executed, the decorations are firmly berthed on the objects. These are then freed from vacuum packaging films (not limiting indication) , after being cooled to ambient temperature (not limiting). An example illustrative not limiting, of this treatment, is given by a film formed by two external layers of polymethylmethacrylate, between which a PVDC layer (chloride of polyvinylidene) is sandwiched in order to improve the "barrier" against gases: film used as vacuum packaging film of an object to decorate, according to our found. The thickness of the said film is sufficient to avoid it will be torn, under the action of the atmospheric pressure, at the preheating temperature of 115 °C, considering the shape more or less complex of the object. Let it be of 125 °C the fusion temperature of the decorations and of 0,1 Atm the minimal pressure necessary to make join the decorations to the object. After the introduction in the pressure-decompression chamber, the pressure is reduced to 0.1 Atm and subsequently the temperature is increased until 125 °C. The lessening of the pressure enables to increase the temperature, until the melting point of the decorations, without the film being torn. The maximum temperature reached during the treatment is of 125 °C: the assumed temperature of fusion of the decorations. For example not limiting, adopting a rigid film of PVC of the same type (two layers of PVC sandwiching a PVDC layer), the optimal thermoforming interval of temperature of which is of 110-140 °C, and assuming that the fusion temperature of the decorations is of 115 °C, the treatment can be executed in an analogous way at the maximal temperature of 115 CC. If thermoretractable vacuum packaging films are adopted, the retraction must happen at a temperature lower than that of fusion of decorations and preferably also lower than the temperature at the low limit of the thermoforming optimal interval: 115 °C for the film of polymethylmethacrylate, 110 °C for the film of PVC. For the PVC film the retraction can happen also at the temperature of 60 °C and the percentage of retraction can arrive to 80% of the surface of the adopted film. Generally it is possible, for several types of films, suitable for the treatment according to our method by "conditioned decompression", to adapt the percentage, the temperature and the speed of retraction to the necessities of treatment. Also the treatment at low temperature of the physical transfer of the decorations, can be executed by the "vacuum packaging chamber machine", with the vacuum chamber "transparent to the infrared beams" (or by the "vacuum container", before described), as alternative or support to the decompression chamber, according to our found, when the adopted films need the treatment at low pressure. The vacuum chamber (or the substitutive "vacuum container") must be transparent to the infrared beams because transfers at low temperature and low pressure will be never had, without supplying to heat the objects, in the decompression chamber, to temperature higher than that of preheating, in the case of physical transfer. If these are not transparent, the heating is done arranging the heating elements by infrared beams within the chamber or the vacuum container, as before illustrated. Being a matter of physical transfers, it is but possible to avoid the treatment at low pressure, if are adopted decorations having low melting point and films having good resistance (at the atmospheric pressure) to the mechanical stresses under the temperature of the said low melting point of the decorations: transfers of decorations are obtained thus, at low temperature, without necessity of dealing the objects at low pressure. In these cases thus it is sufficient and simpler to operate at low temperature and at atmospheric pressure. The problems can arise if the films adopted are so poorly flexible (or for the objects shape complexity) as to not be able to adhere perfectly to the objects to decorate, at the low temperature relative to that of fusion of the decorations, and under the simple atmospheric pressure. The correction of this disadvantage can involve to have to increase the pressure or the temperature or both. Having to decorate objects that do not resist to the high temperatures, the pressure will have to be only increased, if this had to be sufficient and had not to involve other problems for the resistance of vacuum packaging films and for the objects to decorate. If also the pressure increase had to give problems, it will have been forced to operate at low pressure and low temperature, with films more suitable, even if less resistant to the high temperatures, according to our method by "conditioned decompression".
We are now able to illustrate adequately a different way to manufacture the objects vacuum packaged, if the heat retraction of the vacuum packaging film is not sufficient to spread the folds that it presents on the zones to decorate. In fact, in these cases, it is better to preform the film, to shape (female) of the object, thermoforming it, at the thermoelastic state, within its own "optimal thermoforming interval", and "to freeze" its preforming under tension, by cooling sufficiently enough under its own Tg (if the material of the film is thermoplastic amorphous not crystalline) or of its own Tm (if partially crystalline). The films to use have the Tg and/or respectively the Tm of value higher than the ambient temperature in which we work. Thus the film tends to resume its own initial shape after a new heating, in part at temperatures lightly lower than its own Tg or Tm, and completely above them. It means that, if exposed to opportune heating, the film exerts a remarkable thermoretrac- tion, which presses the film on the object vacuum packaged in it: its initial shape is flat, which it will not be able to resume, but that pushes it to make a vigorous retraction. Thus in the vacuum packaging the folds are minimized and it is possible then to spread them completely, because the vacuum packaging film has been done efficaciously thermoretractable. After having sealed the object vacuum packaged between two films preformed (not limiting), these join to the object, after the exposure to the atmospheric pressure, nearly without introducing folds: exposing then the object, so packaged and under the action of the atmospheric pressure, to a heating able to carry the temperature of the films to the same value of that adopted to preform them or higher, or also lightly lower (close to that of the Tg and respectively of the Tm), they withdraw joining perfectly to the object. The object may present such shapes that sometimes it is better to preform only one of the two films, sometimes both. When, for example not limiting, the object is a sphere, it is better to preform both films: the semi-caps (females) of the sphere are preformed on both vacuum packaging films in which the sphere is sealed under vacuum. It is better that the semi-caps refer to a sphere of lightly increased diameter. The preforming of films does not have necessarily to be such "to dress" perfectly the object. It is of great importance because enables to use a same type of preforming for several objects, of volume and shape not very different among them and such that the films join perfectly to the objects, when the withdrawal happens. This is important in the production of footwear soles and in all the productions in which series of measures of varied largeness of the same object are foreseen. For the footwear: the size series. In fact this possibility enables to realize the preforming, for example not limiting, on size number 42, in order to manufacture the sole sizes from 38 to 41: thus by two single moulds for preforming, it is possible to manufacture all the series of sizes from 35 to 41. Moreover, with the same preforming, various shape or model not very different among them can be packaged, provided that all are insertable in the cavities preformed on the films and such that the probable folds, that will be formed during the vacuum packaging, can be spread when they are heated at the temperature at which the preforming has happened or also at higher temperature. In commerce many types of systems of thermoforming of sheets or films are available, from those automatic with enormous potentialities of production to those handicraft that are however able to warrant a high productivity. For the purpose of our found we will only say that it is preferable to adopt systems for the thermoforming under vacuum using the single matrix female, in order to avoid the higher cost of matrix male and female (specially if long series of production are not foreseen), and that the thermoforming must happen heating the film until carrying it to the thermoelastic state, freezing then the shape under tension on "cold" surfaces: in this way (and selecting the films opportunely) the forming is maintained (at ambient temperature) during all the vacuum packaging treatments that will be executed on them, according to our found. The films will withdraw, in order to join perfectly to the objects, before the transfer will happen, when they will be heated, to be exposed to the treatments of decorations transfer. In short it is proceeded as follows, reporting us to an illustrative not limiting example, in which the objects to deal are footwear soles:
N1 - one of the films generally is preformed, within which the soles will be vacuum packaged, or both if it is thought favorable; the preforming can also be executed by third parties. If the second film is not preformed, will be preferably thermoretractable;
01 - the sheets are cut, in such dimensions to be correctly contained in the machine for the vacuum packaging that will be adopted: in this way every sheet contains more preformed cavity (not limiting: the sheet can also contain one single cavity: you see fig. 8);
P1 - a sole to decorate is inserted in every cavity;
Q1 - the second sheet, preformed or not, is sealed on this sheet: the soles to decorate will be then vacuum packaged between these two sheets. Only three sides of the two sheets (not limiting: the sides can be also less than three) are sealed between them. If also the second sheet is preformed, the preforming must be such that the relative cavities must be superimposable among them, face to face. The sheets, overlapped between them and with the objects to manufacture inserted between them, can be placed in the "vacuum packaging chamber machine", also without pre-sealing any side, if the machine is supplied with a continuous sealing bar, shaped such to be able to execute the welding along all the perimeter of the sheets themselves, without interruption;
R1 - the sheets are inserted, with the soles inserted between them, under the vacuum machine, in order to make the vacuum between the two sheets and to seal the fourth side (or all the sides not sealed);
S1 - the soles and the sheets are extracted from the vacuum machine and, between the two sheets, are executed the weldings, intermediate to the several soles, to be able to separate they among them (not limiting indication), maintaining them vacuum packaged. Before extracting "the whole" from the vacuum machine, as soon as it is opened, the sheets, in which the soles are packaged under vacuum, are pushed, by the atmospheric pressure, and compressed against the soles themselves, to which they join, forming few small folds, due to the not perfect correspondence of the volume and the shape of the preformed cavity, to the volume and shape of the sole inserted in it. Exposing "the whole" to a heating at temperature near equal or higher than that of the Tg or respectively Tm of the films adopted, these are duly spread being pressed against the soles in them vacuum packaged. The weldings, between the two films, intermediate to the soles, can be executed immediately after the exposure to the atmospheric pressure and before that the films are heated in order to obtain the thermoretraction, or after: or they are not at all executed. They can also be executed at the same time of the sealing under vacuum of the two sheets, if the sealing bars, of the "vacuum packaging chamber machine", are realized so as to surround, without interruption, the edges of the two sheets, and all the cavities preformed on them. The sealing bars, if long series of production are foreseen, can also be modeled so as to follow the contour of the prints (females) thermoformed on the sheets;
T1 - the soles, sealed under vacuum, singularly or grouped (and among them separated) in the vacuum packaging sheets, are exposed to the treatments for the transfer of the decorations, according to our found, included at the occurrence the treatment in our pressure or pressure-decompression chamber. The films to preform will bring or not the decorations to transfer, according to the requirements and the types of treatment to execute (FIRST TYPE, SECOND TYPE or MIXED TYPE). Moreover, for example not limiting, for the footwear soles, it is not necessary that the second sheet brings decorations, if the sole is inserted in the cavities of the first sheet so that the second (for example, 27 of the fig. 9) goes to contact only with the shoe arc-support of the sole. This part of the sole is stuck to the upper and thus it is not necessary that it is decorated, but probable exceptions in case of transparent soles. If the decorations to transfer are present, either on the first or on the second sheet, the problem to harmonize the decorations of the first sheet with those of the second one, so that the image to transfer will be recomposed on the object in continuous and ordered way, may arise. This is obtained fixing registries (small crosses) on the sheets and respecting them, either at the moment of the printing of decoration on the sheets, or when these are preformed, or when they are sealed between them. This requirement is found if the preforming of the sheets is made in order to arrange between them the soles as shown in fig. 8: in this case (operating with sheets preformed) it is opportune to preform either the first or the second sheet. If the vacuum packaging sheets are both preformed, the registries can be also three-dimensional (see description of fig. 8), made in way, it is, to fix the centring of the two sheets between them, by joint of male and female: for example not limiting, the small crosses can coincide with the points of small cones "males", thermoformed on the underlying sheet, that fit in similar and relative cones "females", thermoformed in a similar way on the overhanging sheet. If the treatment of several soles inserted and packaged between the two sheets, as before illustrated, had to give problems of distortion of the sheets, under the action of the atmospheric pressure and/or of the subsequent thermoretraction, such to cause a not perfect and stable vacuum packaging of every sole, according to our found, the soles will be singularly vacuum packaged. This disadvantage is avoided if the sealing bars are modeled at shape of the contour of the prints thermoformed on the sheets. Executing treatments of FIRST TYPE, the decorations, brought back on the films, can meet with remarkable deformations, due to the stretchings to which the films are exposed; deformations that could be not influential, if the decorations are only single colors or represent imitations of materials that are not, usually, in regular shapes, but that in many cases could be unacceptable. In these cases various alternative solutions can be adopted, of which we give some examples not limiting, in order to place remedy to the disadvantage, as follows:
U1 - to compensate, in phase of printing, the deformation, that the decorations will undergo when the film is thermoformed, so that the decorations will acquire their normal shape only after the film is thermoformed and carried to join to the surfaces of the object to decorate, remaining distorted, in equal and contrary sense (and in specular way), when are seen printed on the flat film: this is feasible, when possible, with suitable graphical computerized programs;
V1 - to transform the treatment of FIRST TYPE in treatment of SECOND TYPE;
W1 - to realize the preforming of the film so that the same does not be directly executed being gained from the flat shape of the film, but supplying to insert it in the cavity, where it must be thermoformed, without stretchings, so as to turn out inserted in the cavity in way "loose" and lightly draped, sufficient to do so that in the subsequent thermoforming operation, the film is completely extended on the surfaces of the cavity, without being stretched or being not much stretched. A way, for example not limiting, in order to obtain this, is to adopt a mould formed by two slabs (see fig. 20 and 21), one of which (49) brings the print "female" 51 , of the object to deal, and the other (50), in correspondence, a cavity 52 used to lodge a heating element 52', by infrared beams having wavelength suitable for the heating of adopted film 54. The film 54, to thermoform, is made to slide, by light friction, between the slab 49 and a chassis 56, hinged on the slab 49. The friction is determined by the weight of chassis 56 and by the finish of the surfaces of the film, of the chassis itself and of the slab 49. Modifying the weight of the chassis or the finish of the said surfaces, the film can slide more or less easily. If the surfaces in contact with the film are Teflon-coated the friction is minimized. The sliding of the film, to insert it in the cavity 51, is obtained, when the mould is open and still cold, sucking up air from the cavity 51, through the holes 53. In this way the film is pushed within the cavity 51 by the atmospheric pressure, while of other part it is refrained, by the friction, between the chassis 56 and the slab 49, along all the edges that encircle the cavity. Regulating the speed of suction of the air, the weight of the chassis, the finish of the surfaces of the chassis and of the slab in contact with the film, the superficial finish of the film and its tenacity, the portion of film that can be thus pushed within the cavity, without stretching, remains only function of the time employed for the said suction of the air: the time will be regulated and fixed, so that the film can enter in the cavity remaining so "loose" and draped, to minimize its stretching during the thermoforming. The dimensions of the film are such that it turns out inserted, between the chassis 56 and slab 49, also after having been "pushed" within the cavity, as said, and the mould will be completely closed, before executing the thermoforming (you see fig. 21). After the pre-suction of the air, the thermoforming is executed closing the slab 50 of the mould on the slab 49, through the chassis 56, activating the heating of the element at infrared beams 52', for the time necessary to carry the temperature of the film at the value comprised in its optimal interval of thermoforming, and completing the suction that will enable the atmospheric pressure to thermoform the film on the cold surfaces of the cavity, as demanded. In order to maintain at cold these surfaces, the slab 49 can be cooled by continuous water or air circulation, to the occurrence. The before illustrated thermoforming system enables either to minimize the stretching of the film to thermoform, or to regulate its stretching between a maximum value that is had if the film is thermoformed directly, without supplying to insert it partially, at cold, in the cavity, before passing to the final thermoforming, and a minimal value, that is obtained as before described. The solution presented in figures 20 and 21 is given at illustrative scope not limiting: the introduction of the cold film within the cavity, to minimize its stretchings, before being blocked between the slabs of the mould, can be obtained also in several other ways. As, for further example not limiting, using shapes "males", arranged in the cavity 52 (together with the heating element 52'), centered with regard to the cavity 51 , being dimensioned opportunely smaller than the cavity 51 , instead of the pre-suction of the air in the cavity 51 , or combining together these two systems, or adopting other several systems similar or not: all systems that re-enter within the limits of our found. The treatment described here is obtained also executing the subsequent vacuum packaging of the object by a "non- chamber vacuum packaging machine": in this case the sheets, between which the objects must be packaged, must be sealed on three sides. Arranging the two films, present on the fourth side, between the sealing bars of the said machine, the air included between the preformed sheets, before illustrated, is sucked up, and the fourth side is sealed, when the suction is completed. Using the "non-chamber vacuum packaging machines", the lips of one or both films must be modeled in opportune way, at least on the fourth side, to enable that the air can be sucked up. Or at least one of the sheets is adopted, structured in order to enable the said suction: generally it is enough that, for example not limiting, one of the sheets presents some light groovings, on the face turned to the object to package, that enable the air to exit, until the moment of the sealing of the two films.
What up to now illustrated is related to an example of objects to decorate having a three-dimensional shape varied and in some way elastic and of "small" dimensions, like the shoe soles, or of soft and flexible objects like the fabrics or the clothings. But, as already said, our found is extensible to objects of whichever shape, volume and consistency, beginning from smaller objects and, if we want, also microscopical, until objects of important dimensions like the skis, the parts or members of cycles, motorcycles, accessories and parts of car, furniture parts, seats for furnishing, doors, dividing walls prefabricated and panels for furnishing, bathtubs, skate board, windsurf tables, flanks of truck or boats or floating or aircrafts and so on. It is enough to wrap the object, to decorate, in a film having the base characteristics (before listed) necessary for the application of our found, of suitable thickness to bear the stresses to which it will be exposed, to do the vacuum between the film and the object to decorate, sealing this last under vacuum in the film, and to heat the intermediate or the vacuum packaging film, bringing the decorations, and the superficial layers of the object in contact with the film, to the temperature necessary for the heat transfer of the decorations printed on the film itself (in the treatment of FIRST TYPE) or on the intermediate film (in the treatment of SECOND TYPE) or on both (in the treatment of MIXED TYPE). All operations these that demand the adjustment of the vacuum machines, of the tunnels or static oven or of the heating elements and of the probable pressure or pressure-decompression chambers, to the dimensions of the objects to deal, when these exceed the capacity of the machines and equipments adopted. Of other part, in the case in which the objects to decorate are small or very small, it is possible to still package under vacuum more objects in the same vacuum packaging film, thus increasing more the productivity and reducing the cost of the materials "to lose" used. That is already possible with objects of the dimensions of footwear soles. All the materials "to lose" are easily, usefully and rationally recovered for a differentiated collection. All the films used and "to throw" are easily storable by type, and reducible in bales compressed of homogeneous material, directly retrievable by simple operations of milling and/or granulation and re-melting. The films metallized re-enter in this category, being the entity of the metallization paltry with regard to the weight of the film that acts as substrate. Using paper sheets, you see the treatment by the methods of SECOND TYPE or MIXED TYPE, also these would be selected, when the objects decorated will be freed from their coverings, and compressed in bales of single paper, for the recovery.

Claims

1 - Method to transfer characters, designs or images, in one or more colors, also of photographic type, or only single colors, from the sheets, skins, films or other suitable several supports on which they are printed, on other objects, of whichever shape and material, suitable to be decorated. In particular: sublimatic or physical heat transfer of characters, designs, images or colors on soles and others footwear components or on assembled footwears. The method consists in printing in specular way on the said sheets or films or skins the characters, designs, images or colors to transfer, with suitable inks sublimable or physically transferable by heat, and in doing so that the same are brought to duly tightened contact with the surfaces of the objects on which we want to to carry out the transfer and in supplying opportunely the heat needed to carry out the transfer. This is obtained, according to our found, interposing the objects between the said films and creating the vacuum between these (which bring the decorations to transfer) and the objects themselves, by "vacuum packaging chamber machines" for foodstuffs (or vacuum machines similar or equivalent) that seal hermetically, under vacuum, the films between them. When the sealing has happened, introducing again the air in the vacuum machine, the films will be pressed, on the surfaces of the objects, by the atmospheric pressure. The value of the pressure thus exerted on the films is of 1 Atm (at the normal conditions: at sea level and 0 °C). The vacuum packaging of the object to decorate, according to our found, supplies at the same time the matrix, counter-shape or mould in which the object is exposed to pressure, the design, or decoration to transfer, already positioned in contact with the surfaces to decorate, and the uniform pressure needed for a good transfer. The transfer happens heating the objects, so packaged, to the temperature needed to obtain the effective sublimation of the sublimable inks, or the fusion of the resins and/or waxes (with probable relative adhesive, fusible by heat, incorporated: "hot melt adhesive") constituting the inks for the physical transfer by heat: approximately 140-180 °C (not limiting indication: you see table at pag. 1), you see the fig. 1 , 2, 3, 4, 5, 6 and 7. When the time necessary for the physical or sublimatic heat transfer of the image is passed, leaving to cool the objects and the relative films, for the time needed to carry them to the ambient temperature (not limiting indication), and freeing them from the films in which they have been packaged (not limiting indication), the objects decorated are ready to bear probable other treatments or to be directly packaged for the delivery. Often, specially when other finish operations are not foreseen, it is better to leave the objects in the relative vacuum packaging films, that will protect them against probable scratches or abrasions until the moment of its use at the final customer. The printing or the placement of the images on the said sheets, skins or films happens by printing machines of whichever type, provided that it is done using the inks suitable for the demanded transfer. The machines can be, either digital: inkjet, plotter, by laser, by thermal transfer or by spray of resins and/or waxes (solid inkjet), with probable relative heat fusible adhesive (hot melt adhesive) incorporated, and the like; or flexographic, offset, rotogravure. The printing can happen also (with the suitable inks and/or pigments) by whichever other type of printing machine or printing or decorating system, by heat or cold, included the silk-screen printing, not excluded the "by hand free tracing". The objects to decorate are considered always perfectly clean and free from detaching materials, incrustations, powders, humidity, grease or fat that hinder the correct transfer; or will be exposed to a washing and/or whichever other type of chemical and/or physical cleaning, and subsequent drying, before the other treatments. The metallic objects, for example, must be cleaned up, degreased and exposed to operations of pickling and other physical, chemical or elechtrolytical treatments and, preferably, to a pre-paint job with suitable varnishes or enamels.
The films suitable for the scope according to the present method, can be monolayer or multilayer (see fig. 3) and they all are that possess the following characteristic:
- good sealability in order to facilitate the vacuum packaging;
- resistance to the temperatures needed for the sublimation of sublimable pigments of colors, or for the sufficient softening of the resins and/or waxes, mixed or not with heat fusible adhesive (hot melt adhesive), constituting the inks with which are printed the decorations to transfer physically;
- resistance to the stresses that will be exerted on them when the vacuum packaging has happened , or during the subsequent treatments;
- good "barrier" capability against gases and steam, to maintain the "vacuum", in the described packag- ings, during the heat or cold treating;
- good printing support for the designs, the images or colors to transfer. For films which do not present at least one face able to be a good support of printing, it is enough to execute, on the face to print, a "corona" or flame or plasma treatment, or suitable chemical treatments, in order to make it suitable for this purpose;
- sufficient absorption and conduction of the heat for the treatments according to our found;
- good flexibility and elasticity to be easily conformed to the shapes of the objects to decorate;
- low friction with the surfaces to decorate to avoid holds or anomalous stretchings of the films;
- capability to absorb the greatest amount of the supplied heat and thus they must be, preferably, not much or not at all transparent to the heat radiations, neither reflecting, still better if also of black or dark color.
With films having these characteristics, proceeding to the transfer of decorations, according to our found, the temperature of the vacuum packaging films is ever higher than that of the surfaces to decorate, with which they are in contact. If the heating is carried out by infrared beams, this result is assured adopting infrared beams with wavelength at the limit between the "high" values of the medium-waves and those "low" of the long- waves (dark irradiators): of approximately 3-5 micron (not limiting indication). If the heating happens by hot air or by steam, the temperature of vacuum packaging films is ever higher than that of the superficial layers of the objects to decorate. The films must possess a sufficient capability of heat conduction. The heating must sufficiently be express, in order to warrant the demanded jump of temperature, between the film and the surfaces, with it in contact. These devices are necessary to warrant that the sublimating gases of the decorations to transfer, printed on the films, are not absorbed by the films themselves, but only by the surfaces of the objects to decorate. The same devices enable also the physical transfer of decorations, when the transfer to execute is not by sublimation;
- the thickness of films vary within wide limits, according to adopted film, the dimensions and complexity of objects shape and generally oscillates between 20 and 500 micron, not limiting indication;
- for the decoration of the objects of complex shape, or when a perfect spreading of the probable folds, that the films had to present on the zones to decorate of the object (after the vacuum packaging happens), is indispensable, films thermoretractable in one or more directions will be adopted, able to withdraw at temperatures lower than those at which the physical or sublimatic transfer happens. The atmospheric pressure (or of other type, acting to the outside of the packaging) supplies to push the film against the surfaces to decorate, instead the retraction of the film is needed to spread the folds. Usually the thermoretractable films withdraw at temperatures lower than those at which the physical or sublimatic transfer happens. Otherwise those are adopted that satisfy this condition: you see also claim 4. All the films having the characteristics before listed are suitable for the decoration of three-dimensional objects, of whichever shape, dimension and material able to be decorated, according to the present method, and all they are re-entering thus in the present claim, included those described, in the illustrating not limiting examples, in the attached description at the points C, D, E and F.
2 - Method, according to the claim 1 , in which, if the heat retraction of the vacuum packaging films is not sufficient to perfectly spread the folds that they present on the zones to decorate, the films will be preformed, to shape (female) of the object to decorate, by thermoforming them at thermoelastic state, within their own "thermoforming optimal interval" (of temperature), and then "freezing" their preforming, under tension, by cooling sufficiently under their own Tg (if the material of the films is thermoplastic amorphous not crystalline) or Tm (if partially crystalline). The films to use have the Tg or, respectively, the Tm of value higher than the temperature of the ambient in which we work. It is not necessary that the film forming is such "to dress" perfectly the objects. That is of great importance because enables to use the same type of preforming for several objects, of various volume and shape not very different among them, and such that, when the withdrawal happens, the films join perfectly on them. This is important in the production of footwear soles and in all the productions in which series of measures of varied largeness of the same object are foreseen. For the footwear: the size series. In fact this possibility enables to realize the forming, for example not limiting, on size 42, in order to manufacture the soles from 38 to 41, thus, with two single moulds of preforming it is possible to manufacture all the series of sizes from 35 to 41. Moreover, with the same preforming, soles of shape or model not very different among them can also be packaged, provided that all insertable in the cavities, preformed on the films, and such that probable folds, having to be formed during the vacuum packaging, can be spread, when they are heated at the temperature at which the preforming has happened or also at higher temperature. The printing of the films, their thermoforming, the sealing under vacuum of the objects and next treatments of transfer, relative to this claim, are executed in the ways and with the devices illustrated in the attached description at the points N1, 01, P1, Q1, R1, S1 and T1 and in the relative designs, that all here are claimed entirety. Moreover if treatments of FIRST TYPE are executed, the decorations, brought back on films, could undergo remarkable deformations, due to the stretchings to which the films are exposed; deformations that could not influence, if the decorations to transfer are only single colors or represent imitations of materials that are not introduced, of norm, in very regular shapes, but that in many cases could be unacceptable. In these cases the solutions described in the U1, V1 and in all the W1 points, of the attached description, are adopted, all that here are claimed as described and as illustrated also in the relative designs. For example not limiting, it is easy to decorate a sphere, without deforming in unacceptable way the decorations, also with a treatment of the FIRST TYPE, preforming, as described in the point W1, the two vacuum packaging films to shape of the two constituting semi-caps of the sphere itself, with diameter, preferably, lightly increased.
3 - Method, according to the previous claims, in which, if the vacuum packaging films bring the decorations to transfer, as demanded by the treatments of FIRST TYPE, and are preformed, according to the previous claim, as described in the W1 point of the attached description and illustrated in the relative designs, it is possible to decorate the objects with original and exclusive decorations, taking advantage of the fact that the thermoforming of preprinted films produces, on the same, stretchings such to deform the images or the decorations on them printed. Organizing and opportunely controlling this "disadvantage" it is possible to decorate the objects with original images and decorations having particular or grotesque effects. For example not limiting, printing opportunely, on the film, a normal woman's picture, it is possible to transfer on the object a picture with "Modigliani effect", making so that it comes out opportunely lengthened by the stretching undergone by the film during the thermoforming. Analogous images increased or in other ways deformed in grotesque way can be obtained. The images turn out more or less deformed according to the film is exposed to stretchings more or less pushed.
4 - Method, according to the previous claims, in which the vacuum machines, for the vacuum packaging of the objects to decorate, can be of several models and dimensions, referable to two fundamental types, operating with different modalities: the "vacuum packaging chamber machines" and the "non-chamber vacuum packaging machines" or similar or equivalent machines. Both types are illustrated at the A and B points, in the attached description. Their adoption, in our found, is claimed also as illustrated at the cited points A and B. The "vacuum packaging chamber machines", equipped with a vacuum chamber, can seal the objects under vacuum between two film (fig. 8, 9, 16), between two faces faced of same film (fig. 2, 4, 5, 6) or within envelopes or bags, supplying to seal, when the vacuum is carried out, all the sides not pre-sealed. While the "non-chamber vacuum packaging machines" extract the air only from envelopes or bags (containing the objects), prepackaged with the adopted films, and seal their mouth, when the vacuum is carried out. When, in order to vacuum package the objects, the envelopes or bags are used, it is better to establish their dimensions so that they are not too much abundant but fit closely enough on the objects, when these are inserted, before beginning the vacuum packaging, in order to avoid the films will present excessive folds to spread, when the vacuum packaging is done. The same advantage will be obtained (on "vacuum packaging chamber machines"), exerting on vacuum packaging films, suitable tractions, during the vacuum packaging, if envelopes or bags are not adopted. It is important to spread the folds when they interest zones to decorate, otherwise they do not influence the transfer quality. If thermoretractable films or envelopes are adopted, their thermoretraction is obtained (after the objects have been there vacuum packaged) for the precise scope to spread probable folds that will be formed, on the zones to decorate, under the action of the atmospheric pressure, that pushes the films against the surfaces to decorate. If the object is packaged between two films, sometimes it will be enough that only one is thermoretractable. For objects extended in length, like tubes or drawings or extruded objects, it is better to adopt tubular films, sailed at an extremity, enough elastic to be threaded on the objects like an adherent stocking: extracting the air and sealing the other end, the object is vacuum packaged, within the tubular film (see also claim 18). If the said object has a section (cross-sectional orthogonal) circular, the film is adherent to all its external surfaces and pressed on the same by the pressure present in the ambient in which we work: for drawings or extruded objects with unlike (cross-sectional orthogonal) section, if the film does not join, at the said pressure, on all the surfaces to decorate, also when the thermoretraction is carried out, (due to the excessive complexity of the surfaces to decorate, that appear, for example, concave and convex or with remarkable undercuts), a treatment in our pressure chamber is executed. For treatments of FIRST TYPE or MIXED TYPE, the decorations go externally printed on the tubular film (if it is born in shape of tube) in specular way: this is then turned like a sock, before being threaded on the object. The film (also for objects extended in length) can be realized also in shape of envelope or bag, of the demanded length and width, and threaded on the object. The envelope or bag is obtained sealing, according to our found, between them, two films bringing the decorations to transfer or folding opportunely one film, pre-decorated, assuming as overturning axis for its bending, the median line in the sense of its length ("monofold" film) and sealing the open side and the bottom, except the mouth, that will be hermetically sealed after having extracted the air, in the operation of vacuum packaging of the object (tubes or drawings or extruded objects and the like), according to our found.
5 - Method, according to the previous claims, in which, executing the vacuum packaging by "vacuum packaging chamber machines", equipped with vacuum chamber, these are equipped with a device that enables the re-entry "gradually" of the air (at the pressure of the ambient in which we work) in the vacuum chamber, in order to avoid the laceration of the film, due to the sudden and intense stress to which this would be otherwise exposed: vacuum machines equipped with this device are available in commerce. Moreover equipping these vacuum machines with a coil, which passes through a refrigerator cell, and making it cross by the air that is inserted gradually in the vacuum chamber, cold air will be put there.
6 - Method, according to the previous claims, in which the objects to package under vacuum, according to our found, can be disposed, as regards the sheets that bring the decorations to transfer, in several ways, everyone of which is more or less favorable, with regard to the others, according to the purpose to pursue. For illustrative not limiting example, if the objects are footwear soles, the preferential disposal of the sole with regard to vacuum packaging films can be as illustrated in the fig. 5, 6 and 8, or can be as illustrated in fig. 9 (not limiting indication) either if the vacuum packaging film is preformed, as illustrated in the claim 2, or if is not preformed. The descriptions, illustrating the fig. 5, 6, 8 and 9, besides the figures themselves, make integrant part of this claim. What claimed is worth, in analogous way, for other objects that present problems similar or solvable with the same devices.
7 - Method, according to the previous claims, in which, if the objects to decorate are not able to absorb sublimating gases or to berth the decorations to transfer physically, they are dealt to make them receptive. That is obtained depositing and berthing, on the surfaces to decorate, a layer of material, receptive for the sublimating gases, or such to berth the decorations to transfer physically and to resist, without disadvantages, to the temperatures demanded by the treatment, and to the stresses to which the objects will be exposed, during the use. Varnishes, enamels or coating powders, based on polyester and/or acrylic and/or poliuretanic and/or epoxy and/or siliconic resins or on other similar polymers and/or engineering resins, homopolymers and relative co-polymers, terpolymers or polypolymers and probable alloys, compatible with the objects to decorate, with the treatment to undergo, and with the use to which are assigned, are the most suitable. In the physical transfer, it can turn out opportune to give, on the object decorated, a protecting hand of transparent varnish equal, analogous or compatible with that used before the treatment, and with the decorations transferred. The transfers by sublimation demand that the objects to decorate or the varnishes or enamels of pretreatment are white or in light colors.
8 - Method, according to the previous claims, in which, if the transfers will be made on very precise and delimited zones of the object, the treatment is defined of SECOND TYPE and is executed with the modalities and the means illustrated in the attached description at the points G, H, I, J, K, L and in the relative figures 10, 11 , 12, 13, 14, 15, 16 and 17, that all are claimed here. These modalities and means, defined as treatment of SECOND TYPE, partially differ from those illustrated at the points by 1 to 8 of the attached description and in the claim 1 , that we define: treatment of FIRST TYPE. When the transfer of decorations is executed with the treatment of SECOND TYPE, and the vacuum packaging films adopted are enough thin and flexible, it cannot be important to supply to spread the probable folds formed on vacuum packaging films, because these would not influence the quality of the transfer.
9 - Method, according to the previous claims, in which, in the treatment of SECOND TYPE, the intermediate films can be simple sheets of paper for photocopiers or for printers, or of whichever other suitable material: not always it is demanded that they possess all the characteristics needed for the vacuum packaging films, according to our found.
10 - Method, according to the previous claims, in which, arranging together the method of FIRST TYPE and that of SECOND TYPE, according to our found, special decorations are accomplished by a method that we call MIXED TYPE. This enables, to transfer decorations with "precise topic" and on very well identified and opportunely marked zones of the object, brought back on the intermediate films, within decorations with not "precise topic", brought back on vacuum packaging films and transferred on all the surfaces of the object being in contact with them. Thus the object can be decorated completely, eliminating probable subsequent or preventive operations of paint job (in order to complete the coloration of the objects decorated) and the relative masks of paint job. The method enables also to obtain zones of reserve, as regards to decorations and/or colors transferred by the vacuum packaging films, and to those transferred by the intermediate films. The intermediate films, which have the pattern of the zone to be reserved and that do not bring decorations to transfer, are berthed on the zones to reserve, in contact of the same: these are films giving good "barrier" capability against the probable gases of sublimation and good protection against the physical transfer of the decorations. If in the treatment of MIXED TYPE intermediate and vacuum packaging films with transferable colors as well as intermediate films to create zones of reserve are adopted, at the end of the treatment the object turn out colored in several colors, obtained some by reserve, others brought by intermediate and vacuum packaging films: this becomes a new method in order to obtain objects colored in three or more colors, arranged in zones and ways very well defined, in a single treatment. In the technology in use that is obtained by successive paint jobs of each color and by the use of paint job masks. Also in the treatments of SECOND TYPE decorations can be executed having zones of reserve. In any case, in order to create zones of reserve, the intermediate films must be berthed to the object before those intermediate, used for treatments of the SECOND TYPE or of MIXED TYPE bringing decorations or colors to transfer.
11 - Method, according to the previous claims, in which the heating or the preheating is carried out, on a great amount of objects also different among them, in a tunnel equipped with tape, proceeding by adjustable speed or by intermittence, or in a static oven, heated by infrared beams and/or by hot air circulation: this enables to obtain the physical or sublimatic transfer of the decorations also at the low limits of the temperatures adopted in the technology currently in use (140-180 °C: you see table at pag. 1). It is possible to decorate whichever object suitable to be decorated, in the same production cycle and by the same technology and same "machine" (but the fact to hold account of great variations of dimensions), according to our found. The heating can also be carried out by a single infrared beams heating, of shape and dimensions suitable, directing the radiations on the zones to heat, in opportune way, specially if they are partial zones of objects of great dimensions. The temperature in the tunnel or static oven is controlled and regulated with suitable probes for temperature gauging, interacting with the feeding system of the infrared beams elements and/or with the hot air generators (not limiting indication).
12 - Method, according to the previous claims, in which, for objects of very complex shapes, the atmospheric pressure or that of the ambient in which we work, acting on the objects packaged in the films, can be increased introducing the objects in a "pressure chamber". This, for the heat transfers, can be heated, in a whichever way, compatible with our found, to temperature of approximately 200 °C and more (not limiting indication): the objects to deal are held for the time necessary to let the transfer happen, with or without preventive preheating. The pressure chamber is connected with an air compressor and, preferably, with a preheater of compressed air. If the treatment happens in the pressure chamber, the transfer can be obtained, by sublimation or by simple physical transfer, also at the low limits of the temperatures adopted in the technology in use (140- 180 °C: you see table to pag. 1), because it is executed at the same time on many objects rather than on a single object for time.
13 - Method, according to the previous claims, in which the shape of the pressure chamber can be of whichever type, with at least an openable side for the loading and unloading of the objects to expose to pressure, and constructed in whichever material able to bear the pressures that must be exerted in it. A preferential model, not limiting, has the cylindrical shape and is constructed in stainless steel. It presents on the two mouths of the cylinder two doors openable towards the outside, being very well suitable to help an express loading and unloading of the pressure chamber, at the end of each cycle of treatment. The closing doors, hinged by suitable sturdy hinges, and equipped with the usual security systems, are closed hermetically on the chamber, by packings of rubber silicone or other rubbers or engineering resins, not limiting indication, equally resistant to high temperatures. The opening of the doors is subjected to the opening of the compressed air discharge valve: precautionary measure of safety rules of normal equipment for whichever pressure chamber. The chamber is equipped with a manometer in order to control the pressure, with a safety valve, with a thermostat and a probe (protuberant in the chamber but isolated from its surfaces) to regulate and indicate the temperature at which the objects are exposed, and with a timer for the control of the cycles. The chamber brings inside some railroads (not limiting indication) of sliding, opportunely disposed, for the loading and unloading of the object-carrier planes (not limiting indication), or it can be modified in order to enable the loading and unloading of a monolithic structure assembling the several planes together: this can be used also for the loading and unloading of single objects of large dimensions. Fig. 18 shows a not limiting example of the pressure chamber. Fig. 19 illustrates a not limiting example of tape conveyor with the object-carrier planes. The constructive details of the pressure chamber or autoclave described are fixed by the precautionary measures of safety rules to which all the pressure containers or the autoclaves are subjected.
14 - Method, according to the previous claims, in which, when the loading and unloading planes are adopted (not limiting indication), the movement of the tape conveyor is of intermittent type: it proceeds quickly, at the end of every cycle of heating, in order to extract the planes with the objects having already undergone the heating, introducing at the same time the planes with the objects that will have to be exposed to next cycle. In another preferential solution, the planes are included in a monolithic structure (open and accessible for the insertion and extraction of the objects to decorate), in case decomposable, comprising and assembling them together, the overall dimensions of which allow the insertion in block of the same in the pressure chamber. In this case the sliding on wheels of the entire structure simplifies the loading and unloading, in the pressure chamber, and the moving through the heating tunnel or the introduction and extraction from the static oven: equipments to be modified in order to help the sliding on wheels. If the objects are tubes (or drawn bars or extruded articles and the like), the said monolithic structure can be a suitable undercarriage pipe-carrier or bar- carrier equipped with sliding wheels, equipped with soft supports in order to avoid the laceration of the vacuum packaging films.
15 - Method, according to the previous claims, in which the heating of the objects in the pressure chamber can be realized also by overheated steam, which supply the heat needed and the pressure demanded. The working and control instruments of the compressed air pressure chamber are replaced by instruments suitable for the working and control of a chamber heated by overheated steam. Adopting this steam to supply heat and pressure, our pressure chamber is comparable with a large autoclave of sterilization, suitable for the use demanded according to our found, with two openable doors rather than only one (not limiting indication), able to supply pressures and temperatures higher than those adopted in the autoclaves of sterilization and made much more flexible, in order to execute job cycles very much various. Also in this case the constructive details are fixed by the precautionary measures of safety rules to which all the steam autoclaves are subjected.
16 - Method, according to the previous claims, where that described is a preferential shape of pressure chamber. Other shapes can replace it and they all re-enter in our found. For ulterior illustrative example not limiting, the pressure chamber could be a chamber, opportunely formed, in reinforced concrete, dealt to make it airtight, having one or two airtight doors, structured in order to resist to the maximum pressures to adopt (in the ways fixed by the precautionary measures of safety rules to which all the pressure containers are subjected), of dimensions suitable for the several types and largenesses of the objects to decorate, equipped with all the instruments useful to supply, to regulate and to indicate the temperatures necessary in order to execute the transfer of decorations on the objects to decorate, connected to an air compressor equipped with an air compressed preheater (not limiting indication) and with manometers for the control of the pressure exerted in its inside. In a pressure chamber of this type, the final heating of the objects, to cause the transfer of the decorations, is obtained arranging, on its walls and ceiling, radiating elements by infrared beams, equipping it with reflecting walls and/or with a good system for the right hot air circulation. Every pressure chamber can be used as decompression chamber, if it is structured and planned so that every its organ or member resists to the atmospheric pressure (or to that existing in the ambient in which we work), when it is used as decompression chamber.
17 - Method, according to the previous claims, in which the heating of the objects in the pressure chamber can be realized in whichever way compatible with our found.
18 - Method, according to the previous claims, in which, if the objects to decorate present deep or passing holes, the vacuum packaging films can be perforated, in correspondence of the holes, under the atmospheric pressure or that exerted in the pressure chamber, preventing the prosecution of the treatment. The disadvantage is overcome, selecting opportunely the vacuum packaging film and proportioning well the thickness and/or plugging temporarily the holes, before making the vacuum packaging. Also the sharp edges, the spiky tips or flashes must be avoided or rounded off, if the objects are metallic or of rigid material. If the objects present "deep throats" it is better to plug their income by suitable stoppers, of material partially or totally porous or supplied with very small holes, or it is better to assemble the stoppers to the objects so as to enable the vent of the air present in the deep cavities, to allow to realize the vacuum also in them, without the vacuum packaging film is torn.
19 - Method, according to the previous claims, in which the objects to decorate are not only three-dimensional rigid solids and more or less elastic, but also soft and flexible objects like the linen, naperyes, clothes, carpets, leather and the like. The application of our method to the decoration, for example not limiting, of a T- shirt or hats or motor-bike or emergency helmet and of all the similar objects, as in detail illustrated in the attached description at points M, N, O, P, Q, R, and in all the S point, all making part of this claim, shows that it can be extended to all the assembled articles of clothing or to their component parts or accessories and to objects of very varied shapes and materials, not only by the same operating method but also by the same machines and equipments and maintaining a very high productivity.
20 - Method, according to the previous claims, in which, with an appropriated use of our pressure chamber, the transfer temperature of the decorations by sublimation can be lowered a lot, according to our method by "conditioned decompression". That is possible, without lengthening the times of the treatment, if we work exerting, "on the decorations themselves", a very low pressure. Thus the pressure chamber is used as a decompression chamber: the pressure chamber is connected with a vacuum pump to reduce the pressure to the "minimum enabled", that is to the minimal pressure able to maintain the vacuum packaging films still in contact with the surfaces to decorate. The "minimal pressure enabled" depends on the residual pressure existing between the vacuum packaging films and the objects in them packaged under vacuum, and by the residual elastic reaction of the films conformed on the objects during the preheating, at the temperatures comprised within the optimal interval of thermoforming of the films themselves. The reduction of the pressure, in the chamber and thus on the objects in it dealt and on the decorations to transfer, enables a transfer at temperatures lower than those necessary at the atmospheric pressure (or at pressure higher than that atmospheric), as in detail illustrated in the attached description at the points T, U, V, W, X and in the variants V and W all making part of this claim. For treatments of the SECOND TYPE, as illustrated at the variant W, the treatment by "conditioned decompression" can become treatment by "not conditioned decompression" or simply "treatment by decompression".
21 - Method, according to the previous claims, in which, operating in accordance with our method by "conditioned decompression", at very low pressure values, it is possible to sublimate inks or pigments that, at the normal conditions of pressure, are not sublimable or it would be at very high temperatures. According to this variant of our found, it is possible to execute the printing of decorations to transfer by sublimation also with inks or pigments that do not turn out suitable for this type of transfer at the normal conditions of treatment.
22 - Method, according to the previous claims, in which, also for the objects of complex shape, the transfer can be carried out by sublimation at very low pressure and at temperature lower than that normal, according to the method by "conditioned decompression". The objects, packaged under vacuum in the relative films, and preheated to temperatures at the low limits of their optimal intervals of thermoforming, are exposed to pressure (in the pressure chamber heated preferably to the temperature of the preheating), in order to conform the films to the objects. When the thermoforming happens, with relative lessening of the elastic films reactions to the minimum values, the pressure is lowered until the "minimum enabled", in order to obtain the sublimatic transfer at low temperature and low pressure, as in detail illustrated in the attached description, at the points Y, Z, A1, B1, C1, D1, they all making part of this claim. The decompression chamber can also be separated from the pressure chamber. Thus, after the thermoforming of the film on the objects in the pressure chamber, these are moved to decompression chamber and the treatment continues as illustrated at the points B1 and next, or also as described at the variants V and W.
23 - Method, according to the previous claims, in which the method by "conditioned decompression" is applicable also when vacuum packaging thermoretractable films are adopted. When the retraction happens, the films are heated to the temperatures of their own optimal interval of thermoforming, to thermoform them on the objects, reducing to the minimum values their elastic reactions, enabling thus the treatment by "conditioned decompression".
24 - Method, according to the previous claims, characterized by the fact that, with the method by "conditioned decompression", vacuum packaging films are adopted which do not have to resist to the temperatures of 180-200 °C, but to lower temperatures, 90-125 °C (not limiting indication): much more economic and of wider use like, for example not limiting, film of PE, PVC, PS, PMMA and others, having the optimal interval of thermoforming at low levels (110-140 °C: not limiting indication), homopolymers or co-polymers, terpolymers or polypolymers and relative alloys with other compatible homopolymers, co-polymers, terpolymers or polypoly- mers. Also the "barrier" films, like the EVOH and the like, introducing a remarkable reduction of their "barrier" capability at the high temperatures , are thus usable, generally sandwiched between two or more layers of PE and/or PVC and/or PS and/or PMMA homopolymers and/or co-polymers, terpolymers or polypolymers and the like, and relative alloys. For illustrative example not limiting, an EVOH film coextruded, at sandwich, between two film of PVC, presents a good "barrier" against gases, improvable by a metallization on the external face, at view, of the film. It can biaxially also be stretched in phase of coextrusion, so that it becomes also thermoretractable. In order to improve its resistance and "barrier" against gases, it can be coextruded with more layers alternated of EVOH and PVC (and/or PE, PS, PMMA and relative co-polymers and/or alloys and the like), minding that the EVOH layers are always inner to the others. For treatments of this type the films monolayer like, for example not limiting, the "polyethylene, low density, linear metallocene" are moreover very valid films. For example not limiting moreover, a film that enables a very good "barrier" against gases and vapors, that is very valid for the use according to our method by "conditioned decompression", is obtained coextruding, at sandwich, between two or more layers of this film, the relative layers of EVOH (and/or of other "barrier" film).
25 - Method, according to the previous claims, characterized by the fact that, in order to realize sublimatic transfers at low temperature, vacuum packaging films with "optimal interval of thermoforming" at low temperature are needed. In the treatments at low pressure and low temperature, according to our method by conditioned decompression, the optimal interval of thermoforming plays an important role: within the said interval the thermoforming or the conformation of the film on the object to decorate is easy. In fact if the temperatures of this interval are high (150-180 °C), the method does not enable to execute transfers at low temperature, even if it allows to operate at low pressure: in this case the sublimatic transfers at the usual temperatures (140-180 °C) can be executed but at very high speed. Thus the film is thermoformed first on the object, at a temperature comprised in its optimal interval of thermoforming (that is at the high levels of temperature: 150-180 °C), and then the pressure is lowered, according to our method by "conditioned decompression", causing a fast sublimation of the decorations. Or a treatment at "medium temperature" can be executed, if the objects bear the high temperatures at least for short time: the films, in which the objects are packaged under vacuum are quickly heated, and the heating is suspended as soon as the films are conformed on the objects. In this way the films are cooled by the objects in them packaged: executing the thermoforming of the films at the low limit of their optimal interval of thermoforming, their cooling to temperature tower than their own Tg (if amorphous) or Tm (if partially crystalline) is thus easy: in this way the films are quickly ("really") thermoformed on the objects and that enables to reduce the pressure, in the decompression chamber, in order to execute the transfer according to our method by "conditioned decompression", but also at low temperature. Thus our method by "conditioned decompression" enables to execute treatments of transfer at low pressure and low temperature, with films having the optimal interval of thermoforming at low levels of temperature, without lengthening the time of "the normal" treatment, and, with film having optimal interval of thermoforming at high levels, to execute, either treatments of transfer at the usual temperatures but at very high speed (because at low pressure), or treatments at "medium temperature" (high for short time and low after), without lengthening the time of "the normal" treatment: energy and/or time saving. In the attached description (pag. 23-24) are brought back the illustrative examples not limiting, relative to the films of Polycarbonate and PVC, that here are claimed with all the relating observations and deductions.
26 - Method, according to the previous claims, in which the decompression chamber can be replaced by a "vacuum packaging chamber machine", for treatments by "conditioned decompression", if are dealt objects of shape not much complex (see the case 1β in the attached description), or if a decompression chamber separated from the pressure chamber is adopted. The vacuum chamber machine is thus simpler than that usually used for the vacuum packaging, because the bars to seal the vacuum packaging films and all the equipments for their driving or service are not needed.
27 - Method, according to the previous claims, in which the treatment by "conditioned decompression" can be executed with the vacuum chamber machine, also when it is foreseen that, in order to obtain the sublimation of the decorations, it needs heating the objects ulteriorly, also after having reduced the pressure to the "minimum enabled" (you see the case 2" in the attached description): it is enough to adopt for the construction of the vacuum chamber a material completely or "much" transparent to the infrared and luminous beams like, for example not limiting, the glass-ceramic. Also the polymethylmethacrylate, polycarbonate, polyester and the like are suitable for this use, if they are structured to resist to the stresses on them exerted (by the atmospheric pressure or by the pressure of the ambient in which they operate), at the temperatures to which they will be exposed during the treatment. The adoption of the vacuum chamber machine, having transparent surfaces, enables "to observe directly" to which minimal value can be reduced the pressure in the vacuum chamber, without the film bearing off the object: this value is that lightly higher than the value read on the manometer of the machine as soon as the film bears off. In this way the "vacuum packaging chamber machine" is useful, for the small and medium quantity production or for samplings and in order to find experimentally the minimal "pressure enabled" to set up in the treatments by "conditioned decompression", that will be execute in our pressure-decompression chamber. The "vacuum packaging chamber machine" can be adopted even if the vacuum chamber is of not transparent material. In this case the probable heating of the objects to deal is carried out arranging heating elements, to the inside of the "vacuum packaging chamber machine", opportunely shielded to obtain a suitable spread of the heat radiations: the inner surfaces of the vacuum chamber must be reflecting for the infrared beams adopted.
28 - Method, according to the previous claims, in which our decompression chamber, replaceable by a "vacuum packaging chamber machine", as described in the claims 26 and 27, can be replaced also by a simple "vacuum container" having a structure suitable to bear the atmospheric pressure (or that existing in the ambient in which we work). In this container the vacuum is realized by a vacuum pump, connected with it in stable way or not. The "vacuum container" is formed by a base container and the relative cover, that closes it hermetically by interposition, among the relative edges to contact, of a packing of soft and elastic material. If the pump is not connected in stable way, the vacuum is come true sucking up the air included in the container, through a vacuum pump and a tube of connection, from a hole, practiced on the container that, when the extraction is executed, is automatically closed hermetically, under the action of the atmospheric pressure, by a stopper, generally of spherical shape, in soft and elastic material: the diameter of the stopper must be greater than that of the hole. Applying a manometer to the container it is possible also to know the value of the residual pressure in the container. The container can be realized, completely or partially, in material transparent to the luminous and infrared beams (glass-ceramic, glass-reinforced plastic or other transparent composite materials, polymethylmethacrylate, polycarbonate, polyester and the like) or not. If it is of transparent material, it enables all the advantages obtainable with a "vacuum packaging chamber machine", having a transparent vacuum chamber, as illustrated. If it is of not transparent material, the probable heating of the objects to deal is carried out arranging heating elements, to the inside of the "vacuum container", opportunely shielded to have a right spread of the heat radiations. It is better that the inner surfaces of the container are reflecting for the infrared beams adopted. Using a similar container for the treatments by conditioned decompression, it is much easy and economic to adapt the dimensions of the decompression chamber to those of the objects to deal. For objects extended in length, like tubes or bars, the said container can be a tube of suitable length and diameter, having as cover one or both the closing stoppers of the tube.
29 - Method, according to the previous claims, in which, if always the objects are not of shape very complex (or a pressure chamber separated from the decompression chamber will be adopted, if they are of complex shape), the complete cycle of treatment by "conditioned decompression", for the sublimatic transfer of the decorations at low temperature and low pressure, can be realized also with a system arranged as follows:
- a "vacuum packaging chamber machine", at the beginning of the cycle. A "non-chamber vacuum packaging machine" can be adopted also, if problems due to hardly extractable air pockets do not arise;
- a tunnel or static oven in order to heat or pre-heat the objects vacuum packaged;
- a pressure chamber, if the objects are of shape very complex; in this case the tunnel or the static oven are not indispensable;
- a second vacuum chamber machine or its equivalent. As in detail illustrated at the E1, F1 points and in all the G1 point, in the attached description, that they all make part of this claim. The same system serves in order to execute sublimatic transfers at low pressure, at the normal temperatures (140-180 °C), if these are borne by the constituting materials of the vacuum chamber machine or "vacuum container" and by the objects to decorate, but at much higher speed, you see claim 25.
30 - Method, according to the previous claims, in which the advantages obtainable, executing the transfer of decorations at low temperature and low pressure, if the transfer is by sublimation, are also had if it is a physical heat transfer, if inks by physical transfer, constituted with the resins and/or waxes (and relative heat fusible adhesive) having low temperature of fusion "acceptable" for the transfers on objects that do not resist at the high temperatures, are adopted for the decorations printing. For the physical transfer without sublimation, it is the low fusion temperature of the decorations, not the low pressure exerted, that favours the transfer at low temperature. Instead the pressure must be maintained at values enabling that the decorations to transfer will be pressed on the surfaces of the objects enough to make join them to the same: as illustrated at the points H1, 11, J1, K1, L1 and at all the M1 point, with the relative examples not limiting, relating to the films of PMMA and PVC, and with the relative observations, brought back in the attached description, that they all make part of this claim.
31 - Method, according to the previous claims, in which, being a matter of heat physical transfers and if decorations at low fusion temperature and vacuum packaging film with good resistance (at the said temperature) to the stresses, due to the atmospheric pressure or to higher pressure, are adopted, it is possible to obtain transfers at low temperature without necessity to deal the objects at low pressure.
32 - Method, according to the previous claims, in which, executing sublimatic or physical transfers, according to our method by "conditioned decompression", with film suitable for treatment at low temperature and low pressure, or physical transfers at low temperature, it is possible to decorate, not only the soles, heels or uppers or others parts component of the footwear, but the entire footwear, completely assembled, without damaging the relative constituent materials, neither the cement used for its assemblage, by transfers of FIRST TYPE, SECOND TYPE or MIXED TYPE. With the method by "conditioned decompression" or by low temperature, it is possible without destroying the shoe, as instead it would happen by the methods of transfer at the normal temperatures. The same is worth for whichever other object the decoration of which presents equal or similar problems, or also different, but with the same prejudicial problems tied to the temperatures and/or pressures, during the treatment, and/or to the quality of the decorations to realize.
33 - Method, according to the previous claims, in which the treatment by "conditioned decompression" is much helpful also in all the cases in which cements, adhesives, special films and other products and production accessories are used, that would be damaged if treatment are adopted at temperatures higher than their own limits of tolerance (like some "barrier" films and the like).
34 - Method, according to the previous claims, in which our found is extensible to objects of wide variable shape and volume, beginning from objects smaller than the footwear soles until objects of important dimensions like the skis, accessories and parts of car and motorcycles , furniture parts, doors, dividing walls prefabricated and panels for furnishing, bathtubs, skate-board, windsurf tables, flanks of truck or boats or aircrafts and so on. It is enough to wrap the object in films with the characteristics demanded for the application of our found and with the suitable thickness to bear the stresses to which they will be exposed, to create the vacuum between the films and the object and to seal this, under vacuum, in the films. It needs heating the films, bringing the decorations, and the superficial layers of the object, in contact with films, to the necessary temperature for the heat transfer of the decorations, according to our found. These will be printed on the vacuum packaging films themselves (in treatment of FIRST TYPE) or on the intermediate films (in treatment of SECOND TYPE) or on both (in treatment of MIXED TYPE, but being a treatment "with reserve"). All operations that demand the adjustment of vacuum machines, tunnels, static oven or of simple elements for heating and of probable chambers of pressure, or pressure-decompression or substitutive machines or vacuum machines, to the dimensions of the objects to deal, when these exceed the capacity of the machines and of the systems adopted. On the same system, built to deal objects of great dimensions it is possible to deal also a multiplicity of objects of less great dimensions of whichever shape and consistency, without varying the essential modalities of execution of the treatments.
35 - Method, according to the previous claims, in which, if the objects to decorate are small or very small, it is possible to vacuum package more "objects" in the same vacuum packaging film, increasing thus the productivity and reducing the cost of the materials "to lose" used. This is already possible with objects having the dimensions of the footwear soles.
36 - Method, according to the previous claims, in which the several ways of decorations transfer, by us illustrated (sublimatic and physical transfer) and the several TYPES (FIRST TYPE, SECOND TYPE and MIXED TYPE), are executable in a single treatment: it is enough in fact to execute the transfer at the temperature demanded by the treatment (sublimatic or physical transfer) that needs the higher temperature. In the same way, in virtue of our method of transfer by "conditioned decompression", it is possible also to execute, in a single treatment at low temperatures, the physical and sublimatic transfers. In fact it is enough to adopt for the printing of the decorations, for the physical transfer, the resins and/or waxes (with or without the probable adhesive: hot melt adhesive) with melting point at low temperature and to execute the transfer with our method at low pressure and low temperature, in the pressure-decompression chamber (or other equivalent systems, you see the claims previous): thus at the fusion temperature of the decorations by physical transfer, the transfer by sublimation will be had also, if it is provided to lower the pressure in the decompression chamber (or in the machine with vacuum chamber or in the substitutive "vacuum container") enough to allow also the sublimation of the sublimable decorations, also maintaining it at levels sufficient to assure, on the fused decorations, the pressure needed to make join them to the surfaces of the object to decorate.
37 - Method, according to the previous claims, characterized by the fact that it enables to execute, with a single treatment of transfer, decorations by sublimatic transfer on decorations by physical transfer. This result is obtained printing, first, on the intermediate film and/or on the vacuum packaging film, the decorations in sublimatic colors , on the zones where they are demanded, and printing subsequently, on them and on the remaining zones (relative to other zones to decorate) the colors by physical transfer, having care that these are of light or white colors, in correspondence of the zones where the decorations by sublimatic transfer are printed, and are also receptive for gases of sublimation of the sublimatic colors. When the objects, packaged in the said films, are exposed to the treatment of the FIRST TYPE or SECOND TYPE or MIXED TYPE, to obtain the transfer of the decorations, it is enough that the temperature, the pressure and the time adopted for the transfer are those necessary to obtain correctly, either the transfer by sublimation, or that physical, to attain the object will be decorated, by physical transfer on all the surfaces to decorate, and will present some zones where, on the decorations transferred physically, are present decorations transferred by sublimation. Treatments of this type are moreover useful, for example not limiting, if the object to decorate is in dark colors. In these cases, with the varying of our method claimed here, it is possible, by a single treatment of transfer, to cover with light colors (physically transferred) the zones of the sole on which, at the same time, the sublimatic decorations are moved, and to cover also with other colors (always transferred physically) the other zones. If the decorations by physical transfer are only colors able to be sprayed on the films or applicable by simple serigraphy, the use of solid inkjet or thermal transfer printers is also avoided, being possible to equally decorate the objects, as demanded, only using printers by sublimatic inks. Adopting inks by physical transfer with low melting point and films with optimal interval of thermoforming, with at least the inferior limit at low level of temperature, what above is obtained also at low temperature, by our method of decoration by "conditioned decompression" and its variants.
38 - Method, according to the previous claims, in which special decorations are possible. The object is made, or pre-painted, of light color or white: it is decorated by sublimation on some zones, according to one (or more) of methods illustrated, and then it is entirely colored by colors suitable to be brushed away. The sublimatic decorations resist to the brushing, thus brushing the objects, more energetically on the decorated zones and less on the others, decorations will be obtained with a special effect, due to the fact that the decorations transferred by sublimation appear on the object, with contours vanished, "fused" with the remaining zones with brushed effect. The several zones turn out "fused" among them with an effect otherwise not obtainable. Having colors able to be brushed away, physically transferable, the effects claimed here will be obtained differently also, depositing, on intermediate films or on vacuum packaging films, first the colors able to be brushed and then the decorations with sublimatic inks. Transferring then the decorations, from the films to the objects, and brushing them, decorations with the same special effects are obtained. If the objects are of dark color, the method claimed here is still valid, if is provided to print, in the end, on the colors and decorations printed on the films, as said, also some covering light colors, physically transferable, able to be not brushed away, as described in the previous claim.
39 - Method, according to the previous claims, in which, what claimed in the previous claim is obtained even if the sublimatic decorations are replaced by physically transferable decorations, resistant to the brushing. In this case, and if a complete substitution will be done, the starting color of the object, even if it is dark, does not influence the type of treatment.
40 - Method, according to the previous claims, characterized by the fact that all the operations relative to the transfers of decorations in the pressure or pressure-decompression chamber (or by the substitutive systems, you see the claims previous) are organized for the execution with computerized systems of automation (not limiting indication), that supply to control temperatures, pressures and times of cycle, to close and to open the valves and doors, to load and unload the planes or the relative monolithic structures and to memorize the various operating programs to execute automatically, in the succession demanded by the job program preplanned in function of the characteristics of the objects to decorate and relative vacuum packaging films adopted. Also all the vacuum packaging operations are organized to be executed by vacuum packaging automatized equipments that enable to execute automatically the vacuum packaging of the objects to decorate, beginning from the flat film supplied in coils,.
41 - Method, according to the previous claims, in which, realizing the decoration and/or coloration of the footwear soles, as illustrated in the claim 10, besides the cited advantage to eliminate the paint job masks, the operation of rasping the soles, on the zones to be cemented to the upper, that currently is needed in order to eliminate the varnishes that are deposited by the methods of paint job in use, will be eliminated. According to our found the deposition of varnishes or decorations by physical transfer can be avoided, on these zones, dealing them like zones of reserve. If the transfer of the decorations and/or of the colors is by sublimation and the material of the sole is compatible with the used cement, the rasping is not necessary, even if colors or images are deposited on the zones to be cemented. This claim is extended also to all other objects for which the decoration or painting and the subsequent assemblage, with others parts component of the assembled product, presents similar or analogous problems.
42 - Method, according to the previous claims, in which the zones to decorate on clothes, leather, carpets, fabrics and the like (you see claim 19), are not flat but with relief on the object like, for example not limiting, letters, words or designs with more or less pronounced relief, to decorate with images or colors different from those of base of the clothes or of the objects in general. In these cases the intermediate or vacuum packaging film, that brings the decorations to transfer can be preformed so as to reproduce, in correspondence of the cambered or relieved zones to decorate, the print "female" of the said zones, as said in the claim 2. If the colors or the images to transfer risk to be transferred also on the base zones, these are protected, at the occurrence, with a barrier film (that does not bring decorations) cut out at design of the print that the cambered zones trace on the object, so as to be threaded through these, before the preformed film, until being settled on the base zones themselves of the object, along all their contour of intersection with the said zones in relief, and by one wrap of width sufficient to give the demanded protection. If the film is very thin and flexible, and the zones to decorate present reliefs or cambers not a lot emphasized, and enough firm, it is possible to avoid the preforming of the film. The same is claimed also for all the objects that present the same problems with letters, words or ornaments at relief or cambered, to decorate with images or colors different from those of base of the object.
43 - Method, according to the previous claims, in which for the tunnels, the static ovens and pressure-decompression chambers or chambers or containers of decompression having not transparent surfaces, the black surfaces can replace the inner reflecting surfaces, in order to warrant an uniform distribution of the temperatures on the objects to deal by heat.
44 - Method, according to the previous claims, in which they are extended to all the types of objects able to be decorated, according to our method, and to all means, machines and/or equipments equal, similar or analogous to those used for the several treatments, as it turns out from all the claims, the descriptions, the illustrations and the designs enclosed, that they all are of not limiting type and presented for illustrative scope and that they all are claimed here.
PCT/IT2004/000306 2003-05-29 2004-05-27 Thermal image transfer by sublimation or fusion WO2004106082A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP04735091A EP1648711A1 (en) 2003-05-29 2004-05-27 Thermal image transfer by sublimation or fusion

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITBA2003A000026 2003-05-29
ITBA20030026 ITBA20030026A1 (en) 2003-05-29 2003-05-29 METHOD FOR TRANSFERRING CHARACTERS, DRAWINGS, IMAGES, COLORS,

Publications (2)

Publication Number Publication Date
WO2004106082A1 true WO2004106082A1 (en) 2004-12-09
WO2004106082B1 WO2004106082B1 (en) 2005-01-06

Family

ID=33485493

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IT2004/000306 WO2004106082A1 (en) 2003-05-29 2004-05-27 Thermal image transfer by sublimation or fusion

Country Status (3)

Country Link
EP (1) EP1648711A1 (en)
IT (1) ITBA20030026A1 (en)
WO (1) WO2004106082A1 (en)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2918907A1 (en) * 2007-07-20 2009-01-23 Hiona Inspiration Soc Par Acti METHOD FOR FIXING A DECORATION ON A SLIDING BOARD
GB2470195A (en) * 2009-05-12 2010-11-17 Idt Systems Ltd Dye sublimation printing
ES2376437A1 (en) * 2012-01-27 2012-03-14 Winkler International, S.A. Procedure for printing an object and printer machine. (Machine-translation by Google Translate, not legally binding)
US8609583B2 (en) 2008-10-03 2013-12-17 Peter John Hoggard Sublimation printing
ITPR20130039A1 (en) * 2013-05-06 2014-11-07 Boccaccini S P A FOOTWEAR
EP2910677A1 (en) * 2014-02-21 2015-08-26 Spannrit Schuhkomponenten GmbH Printed shoe insole blanks of foamed plastic material
EP2918185A1 (en) * 2014-03-11 2015-09-16 Spannrit Schuhkomponenten GmbH Shoe insole blanks of foamed plastic material
EP3006220A1 (en) * 2010-08-19 2016-04-13 Redbox Technology Limited Transfer printing process using a metalized transfer medium
WO2017062191A1 (en) * 2015-10-09 2017-04-13 3M Innovative Properties Company Method of manufacturing decorative object, method of repairing decorative object, transfer member, and decorating kit
WO2017155993A1 (en) * 2016-03-09 2017-09-14 Donald D. Sloan, Trustee Of The Donald D. Sloan Trust, And His Successor And Successors, Under The Fourteenth Amendment To And Complete Restatement Of The Donald D. Sloan Trust Dated December 17, 2013 Textile treatment for sublimation ink transfers
US9999546B2 (en) 2014-06-16 2018-06-19 Illinois Tool Works Inc. Protective headwear with airflow
IT202000015289A1 (en) * 2020-06-25 2021-12-25 Atiu S R L PROCESS AND EQUIPMENT FOR DECORATION OF OBJECTS USING SUBLIMATIC INKS.
CN115179671A (en) * 2022-07-08 2022-10-14 杭州航民百泰首饰有限公司 Gold negative surface colorful process and stamping die
US11529820B2 (en) * 2016-03-01 2022-12-20 Simple Green Co., Ltd. Method for manufacturing wear and tear-indicating product
CN115771348A (en) * 2021-09-08 2023-03-10 张光群 Laminating printing equipment and forming method
US11643559B2 (en) 2017-07-25 2023-05-09 Magnomer, Inc. Methods and compositions for magnetizable plastics
US11812816B2 (en) 2017-05-11 2023-11-14 Illinois Tool Works Inc. Protective headwear with airflow

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10549564B2 (en) 2017-05-31 2020-02-04 Nike, Inc. Sublimation over print

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3818823A (en) * 1969-10-27 1974-06-25 Buckbee Mears Co Heated, vacuum-pressure press
WO2000030868A1 (en) * 1998-11-20 2000-06-02 Tito Trevisan Method and apparatus for producing a silicone film for industrial decoration of objects
GB2345661A (en) * 1998-07-13 2000-07-19 Robobond Ltd Decorating ornamented articles
WO2002072301A1 (en) * 2001-03-14 2002-09-19 Key-Tech, Inc. Method and apparatus for printing a dye image onto a three dimensional object

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3818823A (en) * 1969-10-27 1974-06-25 Buckbee Mears Co Heated, vacuum-pressure press
GB2345661A (en) * 1998-07-13 2000-07-19 Robobond Ltd Decorating ornamented articles
WO2000030868A1 (en) * 1998-11-20 2000-06-02 Tito Trevisan Method and apparatus for producing a silicone film for industrial decoration of objects
WO2002072301A1 (en) * 2001-03-14 2002-09-19 Key-Tech, Inc. Method and apparatus for printing a dye image onto a three dimensional object

Cited By (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009030835A2 (en) * 2007-07-20 2009-03-12 Hiona Inspiration Method for applying a decoration on a sliding board
WO2009030835A3 (en) * 2007-07-20 2009-06-04 Hiona Inspiration Method for applying a decoration on a sliding board
FR2918907A1 (en) * 2007-07-20 2009-01-23 Hiona Inspiration Soc Par Acti METHOD FOR FIXING A DECORATION ON A SLIDING BOARD
US8609583B2 (en) 2008-10-03 2013-12-17 Peter John Hoggard Sublimation printing
GB2470195A (en) * 2009-05-12 2010-11-17 Idt Systems Ltd Dye sublimation printing
EP3006220A1 (en) * 2010-08-19 2016-04-13 Redbox Technology Limited Transfer printing process using a metalized transfer medium
ES2376437A1 (en) * 2012-01-27 2012-03-14 Winkler International, S.A. Procedure for printing an object and printer machine. (Machine-translation by Google Translate, not legally binding)
ITPR20130039A1 (en) * 2013-05-06 2014-11-07 Boccaccini S P A FOOTWEAR
EP2910677A1 (en) * 2014-02-21 2015-08-26 Spannrit Schuhkomponenten GmbH Printed shoe insole blanks of foamed plastic material
EP2918185A1 (en) * 2014-03-11 2015-09-16 Spannrit Schuhkomponenten GmbH Shoe insole blanks of foamed plastic material
US9999546B2 (en) 2014-06-16 2018-06-19 Illinois Tool Works Inc. Protective headwear with airflow
US11166852B2 (en) 2014-06-16 2021-11-09 Illinois Tool Works Inc. Protective headwear with airflow
WO2017062191A1 (en) * 2015-10-09 2017-04-13 3M Innovative Properties Company Method of manufacturing decorative object, method of repairing decorative object, transfer member, and decorating kit
US10703130B2 (en) 2015-10-09 2020-07-07 3M Innovative Properties Company Method of manufacturing decorative object, method of repairing decorative object, transfer member, and decorating kit
US11529820B2 (en) * 2016-03-01 2022-12-20 Simple Green Co., Ltd. Method for manufacturing wear and tear-indicating product
WO2017155993A1 (en) * 2016-03-09 2017-09-14 Donald D. Sloan, Trustee Of The Donald D. Sloan Trust, And His Successor And Successors, Under The Fourteenth Amendment To And Complete Restatement Of The Donald D. Sloan Trust Dated December 17, 2013 Textile treatment for sublimation ink transfers
US11812816B2 (en) 2017-05-11 2023-11-14 Illinois Tool Works Inc. Protective headwear with airflow
US11643559B2 (en) 2017-07-25 2023-05-09 Magnomer, Inc. Methods and compositions for magnetizable plastics
IT202000015289A1 (en) * 2020-06-25 2021-12-25 Atiu S R L PROCESS AND EQUIPMENT FOR DECORATION OF OBJECTS USING SUBLIMATIC INKS.
WO2021260613A1 (en) * 2020-06-25 2021-12-30 Volpato, Alessandro Method and apparatus for decorating objects by means of sublimatic inks
CN115771348A (en) * 2021-09-08 2023-03-10 张光群 Laminating printing equipment and forming method
CN115179671A (en) * 2022-07-08 2022-10-14 杭州航民百泰首饰有限公司 Gold negative surface colorful process and stamping die
CN115179671B (en) * 2022-07-08 2023-09-05 杭州航民百泰首饰有限公司 Gold negative film surface dazzling technology and imprinting mold

Also Published As

Publication number Publication date
WO2004106082B1 (en) 2005-01-06
ITBA20030026A1 (en) 2004-11-30
EP1648711A1 (en) 2006-04-26

Similar Documents

Publication Publication Date Title
EP1648711A1 (en) Thermal image transfer by sublimation or fusion
US7691470B2 (en) Laminate structure with polycarbonate sheets
KR20170035306A (en) Fabric sublimation transfer method of dyeing able to reduce environmental pollution
CN102712121A (en) Method for manufacturing an injection-molded object
US20100193382A1 (en) Provision of images on surfaces
US10309056B2 (en) Method for heat transfer onto textiles and expansible multilayer complex therefor
KR101395449B1 (en) Ornament sticker
US5976296A (en) Transfer printing of complex objects
US7767600B1 (en) Detachable, domed three-dimensional design or image for industrial wash
US7575651B2 (en) Method for applying web material to a molded plastic object
KR102565760B1 (en) Decorative film using TPU film and method for manufacturing the decorative film
US5868801A (en) Method for applying a pattern on to a thermoplastic workpiece and an object produced according to the method
KR20030067042A (en) Printing method for leather and the printed leather thereof
JPH0453688B2 (en)
CN101019704A (en) Sole printing process
JPH02111512A (en) Decorative sheet for forming and manufacture of decorated formed item using therewith
JPH02187322A (en) Manufacture of tubular or pipe-shaft-like plastic product with projected and recessed pattern
JPS63221099A (en) Transfer film
JP2003159898A (en) Three-dimensional pattern transfer sheet
KR200168933Y1 (en) Heat-transfer paper for label made of thermosetting material
KR200251229Y1 (en) Synthetic resin material
JP2548601Y2 (en) Bags / bags
JPH01295811A (en) Injection molded product equipped with decorative cloth and manufacture thereof
JPS62179918A (en) Manufacture of colored and deformed plastic part
ITAN20010019A1 (en) PROCESS FOR THE MOLDING OF FOAMS IN EXPANDED POLYURETHANE

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): GM KE LS MW MZ NA SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

B Later publication of amended claims

Effective date: 20041129

121 Ep: the epo has been informed by wipo that ep was designated in this application
WWE Wipo information: entry into national phase

Ref document number: 2004735091

Country of ref document: EP

WWP Wipo information: published in national office

Ref document number: 2004735091

Country of ref document: EP