Blanket printing process

Abstract

The invention discloses a blanket printing process which comprises the following steps: S1, collaborative pretreatment: carrying out low-temperature soft lustring on a blanket gray fabric to ensure that the surface fibers of the blanket gray fabric are consistent, and then carrying out low-temperature plasma irradiation treatment and digital printing: adopting a digital ink-jet printing mode, the blanket grey cloth treated in the step S1 and with the surface temperature maintained at 25-35 DEG C is subjected to pattern printing and stepped color fixing, specifically, the printed blanket is subjected to pre-color fixing for 5-10 min in a hot and humid environment at 45-55 DEG C and then transferred into saturated steam at 102-108 DEG C to be subjected to main color fixing, and efficient post-treatment is conducted; and finally, carrying out gradient heating and drying under a negative pressure condition at 65-75 DEG C. The low-temperature soft light has the beneficial effects that the fibers are oriented through low-temperature soft light, and a foundation is laid for uniform printing. According to low-temperature plasma treatment with a specific gas ratio, on the premise that fibers are not damaged, micro-etching can be carried out on the surfaces of the fibers, hydrophilic groups are introduced, and the wettability and permeability controllability of ink are greatly improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of blanket printing, and particularly relates to a blanket printing process. BACKGROUND

[0002] As a kind of home and decoration commonly used textile, the printing quality of blanket directly determines the product's aesthetic and value. The traditional blanket printing process, such as flat screen or rotary screen printing, generally has problems of insufficient pattern definition, poor color gradation, hardening of hand feeling, and easy color fading and color bleeding after washing. Especially for high-end super-soft and thick pile blankets, the above problems are particularly prominent. In recent years, digital inkjet printing technology has brought innovation to textile printing, which can achieve precise printing of complex patterns. However, direct application of digital printing to blanket products still faces great challenges. SUMMARY

[0003] The purpose of the present application is to solve the problems of long pile fibers and loose structure of the blanket, which can easily lead to excessive penetration of ink, resulting in blurred patterns and blurred edges. If the penetration is controlled, it may result in insufficient color yield on the surface. Blankets are often subjected to friction and washing during use. The dry and wet rubbing fastness and washing fastness of the prints under traditional processes, especially deep color patterns, are difficult to meet high standards at the same time.

[0004] The present application achieves the above-mentioned purposes by the following technical solutions: The present application provides a blanket printing process, which comprises the following steps: S1, synergistic pretreatment: low-temperature softening and glazing of the blanket gray fabric to make the surface fibers consistent, and then low-temperature plasma irradiation treatment is performed, the treatment power is 800-1200W, the treatment time is 30-90 seconds, and the treatment environment gas is a mixture of helium and oxygen, wherein the volume fraction of oxygen is 5%-15%; S2, digital printing: using digital inkjet printing method to print the pattern on the blanket gray fabric treated in step S1 and maintaining the surface temperature at 25-35℃; the ink used in printing is modified acid dye or reactive dye ink, and 1%-3% of nanoscale silk fibroin is additionally added to the ink based on the total weight of the ink; S3, stepwise fixation: the printed blanket is first pre-fixed at 45-55℃ in a humid heat environment for 5-10 minutes, and then transferred to a saturated steam at 102-108℃ for main fixation, and the fixation time is 12-25 minutes; S4, efficient post-treatment: the fixed blanket is sequentially subjected to cold water overflow washing, 40-50℃ warm water rapid washing, and neutral washing with a solution containing a cationic softener, and finally gradient temperature drying at 65-75℃ under negative pressure.

[0005] Further, the temperature of the low-temperature soft calendering in step S1 is 110-130 DEG C, and the calendering times are one on each side; the specific parameters of the low-temperature plasma irradiation treatment are: power 1000 W, time 60 seconds, and the oxygen content in the mixed gas of helium and oxygen is 10%.

[0006] Further, after the low-temperature plasma irradiation treatment in step S1, the blanket base fabric is also subjected to micro-liquid control, and the liquid carrying rate is controlled to be 15%-25% through uniform spraying, and the spraying liquid is soft water with a pH value of 6.0-6.5 and an electrical conductivity of less than 50 μS / cm.

[0007] Further, the particle size of the nanoscale silk fibroin in step S2 is 50-200 nm, and the adding method is to mix with the dye ink on line within 24 hours before printing.

[0008] Further, the printing resolution of the digital inkjet printing in step S2 is 600*600 dpi or above, and the variable droplet technology is used during the printing, and the minimum ink droplet volume is not greater than 10 picoliters.

[0009] Further, the relative humidity of the pre-fixing environment in step S3 is 85%-95%; the main fixing process is carried out in a special steaming machine, and the steaming machine is internally provided with an active circulating air system to ensure that the temperature and humidity field is uniform, and the temperature difference is less than ±1 DEG C.

[0010] Further, after the main fixing in step S3, before the cold water overflow rinsing in step S4, a rapid cooling step is further included: the blanket is blown with purified normal-temperature air to reduce the surface temperature to below 40 DEG C within 1-2 minutes.

[0011] Further, in the solution containing the cationic softener in step S4, the concentration of the softener is 8-15 g / L, the washing temperature is 40 DEG C, and the washing time is 8-15 minutes; the negative pressure condition is -0.02 to -0.05 MPa, and the specific process of the gradient temperature drying is: first drying at 65 DEG C for 10 minutes, and then increasing to 75 DEG C until completely dry.

[0012] Further, after the drying in step S4, online quality detection is further carried out, and a color difference and defect detection system based on machine vision is used to scan 100% of the printed products, and compared with the standard pattern.

[0013] Beneficial effects: 1. Synergistic pretreatment creates an ideal substrate: Low-temperature gentle light orients the fibers, laying the foundation for uniform printing. Low-temperature plasma treatment with specific gas ratios can micro-etch the fiber surface and introduce hydrophilic groups without damaging the fibers, greatly improving the wettability and penetration control of the ink. Subsequent micro-liquid control provides a stable microenvironment for the ink, preventing instantaneous excessive ink penetration due to overly dry fabric.

[0014] 2. Nanomaterial-modified ink achieves "molecular bridge" color fixation: The added nanoscale silk fibroin has active groups (such as -COOH, -NH2) on its surface that can form a strong bond with dye molecules and fiber molecules, acting as a "bridge" to significantly improve color fixation rate and color fastness; on the other hand, silk fibroin itself has excellent biocompatibility and smoothness, which helps to maintain or even improve the softness of the blanket. 3. Step-by-step color fixing maximizes fixing efficiency and quality: The pre-fixing stage allows dye molecules to complete initial migration and aggregation under mild conditions, avoiding dye "migration" and pattern blurring that may occur with direct high-temperature steaming. The main color fixing stage completes the final chemical bonding in saturated steam. This two-step method effectively reduces dye hydrolysis, resulting in more vibrant and durable colors.

[0015] 4. High-efficiency post-treatment ensures final quality: Multi-stage washing (cold water → warm water → softener) effectively removes excess dye while introducing softener to improve hand feel. Negative pressure gradient temperature drying technology lowers the boiling point of water under low pressure, achieving rapid low-temperature drying. This maximizes the protection of fiber elasticity and color vibrancy, avoiding the hardening of the hand feel and color changes caused by traditional high-temperature drying.

[0016] 5. Precise control throughout the entire process ensures consistency: From the control of fabric surface temperature, printing accuracy, uniformity in the steaming machine, to the final online inspection, the entire process has achieved refined and digital management, ensuring the high quality and batch stability of the final product. Attached Figure Description

[0017] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Combination Figure 1 The above describes a blanket printing process. Example 1 The fabric is made of 100% polyester ultra-soft blanket.

[0019] S1. Collaborative Pretreatment: The felt fabric is subjected to low-temperature softening and calendering at 120℃, once on each side. It is then sent to a low-temperature plasma treatment device for irradiation treatment under conditions of 1000W power, 60 seconds of treatment time, and a helium-oxygen mixture (oxygen content 10%). Immediately after treatment, it is uniformly sprayed with soft water with pH=6.2 and conductivity of 30μS / cm, controlling the liquid carryover rate to 20%.

[0020] S2. Digital Printing: The treated fabric is placed in a constant temperature chamber (30℃) until its surface temperature stabilizes at 30℃, then printed using a modified industrial digital inkjet printer. The ink used is a disperse dye ink with 2% nano-sized silk fibroin (particle size approximately 100nm) added. The silk fibroin is added 12 hours before printing via an online mixing system. The printing resolution is set to 600*600 dpi, using variable droplet technology with a minimum droplet size of 8 picoliters.

[0021] S3, Stepped Fixing: Transfer the printed blanket to a constant temperature and humidity chamber for pre-fixing at 50℃ and 90% relative humidity for 8 minutes. Then quickly transfer it to a dedicated steaming machine (internal temperature difference <±1℃) for primary fixing under saturated steam at 105℃ for 18 minutes. After primary fixing, immediately blow with purified cold air to reduce the surface temperature of the blanket to 35℃ within 90 seconds.

[0022] S4. High-efficiency post-treatment: After cooling, the blanket is subjected to the following steps in sequence: overflow rinsing with cold water for 5 minutes -> rapid rinsing with 45℃ warm water for 3 minutes -> washing with water in a 40℃ solution containing 12g / L cationic softener for 10 minutes. Finally, the blanket is sent to a negative pressure dryer (-0.03MPa), first dried at 65℃ for 10 minutes, then the temperature is increased to 75℃ until completely dry.

[0023] S5. Online Inspection: After drying, the blanket is fully scanned by a machine vision system to automatically identify and mark color differences and printing defects.

[0024] Example 2 The raw fabric is wool / acrylic blended blanket.

[0025] S1. Collaborative pretreatment: After heat treatment at 125℃, plasma treatment is performed (power 1100W, time 75 seconds, oxygen content 8%). Subsequently, micro-liquid is sprayed, with the liquid carry-over rate controlled at 18%.

[0026] S2, Digital Printing: The surface temperature of the fabric is maintained at 28°C. Printing is performed using an acidic dye ink containing 1.5% nanofiber protein (150nm particle size). Printing parameters are the same as in Example 1.

[0027] S3, Stepped Fixation: Pre-fixation conditions are 48℃ / 92%, 10 minutes. Main fixation is 104℃, 20 minutes. Subsequent rapid cooling.

[0028] S4. High-efficiency post-treatment: The water washing process is the same as in Example 1, with a fabric softener concentration of 10 g / L. The negative pressure drying conditions are -0.04 MPa, 65℃ (12 minutes) -> 75℃ (dry until completely dry).

[0029] The subsequent testing steps are the same.

[0030] Comparative Example The same batch of polyester blanket fabric is processed using traditional techniques: conventional heat treatment -> pad printing paste -> rotary screen printing -> one-time high-temperature steaming (180℃, 8 minutes) -> high-temperature washing at normal pressure (90℃) -> high-temperature drying at normal pressure (100℃).

[0031] Performance testing The performance of the finished blankets obtained in Examples 1 and 2 and the comparative example was tested, and the results are shown in the table below: Test Item Example 1 Example 2 Comparative Test Standard Image clarity: 96%, 95.5%, 85% (Image analysis software evaluation) Dry rubbing color fastness: Grade 4-5, Grade 3 (GB / T 3920) Wet rubbing color fastness grade 4-3 GB / T 3920 Softness +25% +23% Baseline (0%) Subjective evaluation and feel meter Test results show that the blankets prepared by the process of this invention are significantly superior to those prepared by traditional processes in terms of pattern clarity, color fastness, and softness, fully demonstrating the advanced nature and technical effectiveness of this invention. It will be apparent to those skilled in the art that this invention is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within this invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0032] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A blanket printing process, characterized in that: Includes the following steps; S1. Collaborative pretreatment: The blanket fabric is subjected to low-temperature softening calendering to make the surface fibers lie flat and uniform. Then, it is subjected to low-temperature plasma irradiation treatment with a treatment power of 800-1200W and a treatment time of 30-90 seconds. The treatment environment gas is a mixture of helium and oxygen, with oxygen accounting for 5%-15% by volume. S2. Digital printing: The pattern is printed on the blanket fabric that has been treated in step S1 and whose surface temperature is maintained at 25-35℃ using digital inkjet printing. The ink used for printing is a modified acid dye or reactive dye ink, which contains an additional 1%-3% of nano-scale silk fibroin by weight of the ink. S3, Step-by-step color fixing: The printed blanket is first pre-fixed in a humid and hot environment at 45-55℃ for 5-10 minutes, and then transferred to saturated steam at 102-108℃ for main color fixing, with a fixing time of 12-25 minutes. S4. High-efficiency post-treatment: After color fixing, the blanket is successively rinsed with cold water overflow, rinsed with warm water at 40-50℃, and then neutralized with water using a solution containing cationic softener. Finally, it is dried under negative pressure at a gradient temperature of 65-75℃.

2. The blanket printing process according to claim 1, characterized in that: The temperature of the low-temperature soft heat treatment in step S1 is 110-130℃, and the heat treatment is performed once on each side. The specific parameters of the low-temperature plasma irradiation treatment are: power 1000W, time 60 seconds, and oxygen content 10% in the helium and oxygen mixture.

3. The blanket printing process according to claim 2, characterized in that: In step S1, after the low-temperature plasma irradiation treatment, the blanket fabric is also subjected to micro-liquid control. The liquid content is controlled at 15%-25% by uniform spraying. The spray liquid is soft water with a pH of 6.0-6.5 and a conductivity of less than 50 μS / cm.

4. The blanket printing process according to claim 3, characterized in that: The nanoscale silk fibroin mentioned in step S2 has a particle size of 50-200 nm and is added by mixing it online with the dye ink within 24 hours before printing.

5. The blanket printing process according to claim 4, characterized in that: In step S2, the digital inkjet printing resolution is 600*600 dpi or higher, and variable droplet technology is used during printing, with the smallest droplet volume not exceeding 10 picoliters.

6. The blanket printing process according to claim 5, characterized in that: The relative humidity of the pre-fixing environment in step S3 is 85%-95%; the main fixing process is carried out in a dedicated steaming machine, which is equipped with an active circulating air system to ensure uniform temperature and humidity field and temperature difference of less than ±1℃.

7. A blanket printing process according to claim 6, characterized in that: After the primary color fixation in step S3 and before the cold water overflow rinsing in step S4, a rapid cooling step is also included: the blanket is blown with purified room temperature air to reduce its surface temperature to below 40°C within 1-2 minutes.

8. The blanket printing process according to claim 7, characterized in that: In step S4, the solution containing cationic softener has a softener concentration of 8-15 g / L, a water washing temperature of 40°C, and a water washing time of 8-15 minutes. The negative pressure condition is -0.02 to -0.05 MPa. The specific process of gradient temperature drying is as follows: first dry at 65°C for 10 minutes, then increase to 75°C until completely dry.

9. A blanket printing process according to claim 8, characterized in that: After drying in step S4, online quality inspection is also carried out. A machine vision-based color difference and defect detection system is used to scan the printed finished product 100% and compare it with the standard pattern.

10. A blanket printing process according to claim 9, characterized in that: The printed pattern of the blanket has a clarity (measured by edge sharpness) of no less than 95%, a dry rubbing color fastness of 4-5 or above, a wet rubbing color fastness of 4 or above, and the softness of the blanket is improved by more than 20% compared with traditional products (measured by a hand feel instrument).

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