A kind of printing carpet production process

Abstract

The present invention relates to the field of carpet production technology, and in particular to a printed carpet production process, comprising: digital pattern input; editing, color separation and optimization of digital image files through a CAD system to generate a file format suitable for use by a digital printing machine; preparation of plain white polyester; digital printing; soaking the printed carpet in a color fixing solution for the first color fixing, and then spraying the color fixing solution for the second color fixing; cleaning the surface of the carpet after printing and color fixing; efficient drying; finished product inspection and packaging. The printed carpet production process described in the present invention significantly improves printing accuracy and design flexibility, reduces energy consumption and water resource consumption, and reduces environmental pollution through digital pattern processing, low-temperature color fixing and efficient drying; selects environmentally friendly color fixing agents and cross-linking agents to improve product quality and environmental performance; realizes flexible and efficient customized production, meets market demand while reducing production costs, and enhances the market competitiveness of enterprises.

Description

Technical Field

[0001] The invention relates to the technical field of carpet production, in particular to a production process of a printed carpet. Background Art

[0002] In the traditional production process of printed carpets, a combination of inkjet printing and steam color fixation is usually used. Specifically, the production process includes spinning yarn into cloth, gluing cloth into semi-finished products, manually preparing dye slurry, spraying the dye slurry onto the carpet, fixing the color through a 100°C saturated steam steamer, washing away excess dye slurry with clean water, and high-temperature drying. Although this traditional process can achieve a certain printing effect, it has many shortcomings. First, the process of manually preparing dye slurry is not only complicated and time-consuming, but also easily leads to color inconsistency due to human factors, affecting the quality of the final product. Secondly, steam color fixation requires a large amount of natural gas to generate high-temperature steam, which has low energy utilization and increases production costs. In addition, the washing process consumes a large amount of clean water and produces a large amount of wastewater, which puts great pressure on the environment. Finally, the traditional printing method is limited by the length of the "flower return" and is difficult to meet the modern market's demand for personalized and complex patterns. With the increasing requirements of consumers for environmental protection and high-quality products, the limitations of traditional processes have gradually emerged, and a more efficient, environmentally friendly and flexible production process is urgently needed to replace the existing technology. Therefore, we propose a printed carpet production process. Summary of the invention

[0003] The main purpose of the present invention is to provide a printed carpet production process, which can effectively solve the problems in the background technology.

[0004] To achieve the above object, the technical solution adopted by the present invention is:

[0005] A printed carpet production process comprises the following steps:

[0006] S1. Digital pattern input: Use image acquisition equipment to convert design drawings or physical samples into digital image files;

[0007] S2. Data processing: Edit, color separate and optimize the digital image files through the CAD system to generate a file format suitable for digital printing machines;

[0008] S3. Preparation of white polyester fabric: Prepare white polyester fabric, make sure its surface is clean and dust-free, and its size meets the printing requirements, and then install the white polyester fabric on the digital printing machine;

[0009] S4, digital printing: Start the digital printing machine, and the computer controls the micro-piezoelectric inkjet nozzle to directly spray the dye liquid on the plain white polyester according to the preset pattern. At the same time, the nozzle automatically adjusts the spraying parameters to adapt to different materials and pattern requirements;

[0010] S5, low temperature color fixing: send the printed carpet into the low temperature color fixing device, soak it in the color fixing solution for the first color fixing, and then spray the color fixing solution for the second color fixing;

[0011] S6. Surface treatment: Clean the surface of the carpet after printing and fixing;

[0012] S7, efficient drying: the cleaned carpet is sent to an efficient drying device for drying. The efficient drying device is internally configured with multi-layer circulating air ducts and infrared heating elements to ensure that the carpet is evenly heated and shorten the drying time;

[0013] S8. Finished product inspection and packaging: Use quality inspection instruments to inspect the finished carpets after drying to ensure that they meet quality standards, and cut, trim and package qualified carpets.

[0014] Preferably, in S1, the image acquisition device is any one of a high-resolution scanner and a digital camera, and the resolution of the digitized image is not less than 300 dpi.

[0015] Preferably, in S1, if it is an original design, the pattern can be created directly using computer graphics software.

[0016] Preferably, in S2, the data processing specifically includes the following steps:

[0017] S201: Importing the digitized image file into the CAD system;

[0018] S202: Adjust the pattern size, position and color to ensure it meets the carpet size and design requirements;

[0019] S203: Using the color separation function of the CAD system, the pattern is decomposed into multiple color layers to meet the multi-nozzle requirements of the digital printing machine;

[0020] S204: planning the moving path of the printing head to ensure that there is no overlap or omission during the printing process;

[0021] S205: Export the processed pattern into a file format suitable for a digital textile printing machine, ensuring that the file contains all necessary printing information.

[0022] Preferably, in said S203, it further includes performing color correction and optimization on complex patterns before decomposing the patterns into multiple color layers.

[0023] Preferably, in S205, the file format includes but is not limited to TIFF, EPS and PDF, and the printing information includes but is not limited to color mode, resolution and bleed line.

[0024] Preferably, in S5, the color fixing solution is a mixed solution of an environmentally friendly color fixing agent and a cross-linking agent.

[0025] Preferably, the environmentally friendly color fixing agent is a cationic color fixing agent or a natural plant extract color fixing agent, and the cross-linking agent is a polyurethane cross-linking agent or a natural plant extract cross-linking agent.

[0026] Preferably, the fixing temperature is controlled at 60-80°C for 10-15 minutes.

[0027] Preferably, in S6, cleaning the surface of the carpet after printing and fixing specifically includes:

[0028] S601, Preliminary cleaning: Use a water-absorbing roller to gently roll on the carpet surface to absorb excess water and residual dye;

[0029] S602, Deep cleaning: For residues that are difficult to remove, use a negative pressure vacuum pump for secondary cleaning;

[0030] S603, Final Check: Wipe the carpet surface again with a clean damp cloth to ensure that no residue remains.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] 1. The present invention ensures that every link from design to production is highly accurate through digital pattern input and data processing steps. The design drawings or physical samples are converted into digital image files using high-resolution scanners or digital cameras, ensuring the clarity and detail retention of the original pattern. Especially in original design, the application of computer graphics software allows designers to freely create complex and delicate patterns. The color separation function and path planning in the CAD system further optimize the printing effect of the pattern, ensuring that each color layer can be accurately sprayed on the plain white polyester. This high-precision digital printing technology can not only achieve the perfect reproduction of complex patterns such as color gradients and moire patterns, but also break the limitation of the length of "flower return" in traditional printing technology, greatly expanding the space for textile pattern design and meeting the market demand for personalized and high-end carpets.

[0033] 2. The present invention adopts low-temperature color fixing technology and efficient drying equipment, which greatly reduces energy consumption and water waste. The traditional high-temperature steam color fixing method requires a large amount of natural gas to produce saturated steam, while the present invention uses environmentally friendly color fixing agents and cross-linking agents to achieve rapid and stable dye fixation at a relatively low temperature of 60-80°C, reducing energy demand. In addition, no large amount of clean water is required for flushing during the color fixing process, which avoids the waste of water resources and reduces wastewater discharge. The efficient drying device is internally configured with multi-layer circulating air ducts and infrared heating elements to ensure that the carpet is evenly heated while shortening the drying time, further saving energy. These improvement measures not only reduce production costs, but also meet the current social requirements for green manufacturing and sustainable development, and help enterprises achieve energy conservation and emission reduction goals.

[0034] 3. The environmentally friendly color fixing agent and cross-linking agent selected in the present invention are non-toxic and harmless environmentally friendly materials, such as cationic color fixing agent, natural plant extract color fixing agent, polyurethane cross-linking agent, etc. These additives not only improve the binding force between the dye and the fiber, enhance the wet fastness, friction fastness and light resistance of the carpet, but also avoid the release of harmful substances, and ensure the health and safety of consumers. In particular, the natural plant extract color fixing agent and cross-linking agent have good biodegradability and antibacterial and mildew-proof functions, and are suitable for the production of ecological textiles. By strictly testing the quality of the finished products, it is ensured that each carpet meets the high quality standards and improves the market competitiveness of the products. At the same time, the entire production process strictly abides by environmental protection laws and regulations, reduces the impact on the environment, and reflects the social responsibility of the enterprise.

[0035] 4. The digital production process of the present invention not only improves work efficiency, but also reduces quality fluctuations caused by human factors, ensuring the stability and consistency of the production process. Especially in small-batch customized production, the advantages of the present invention are particularly obvious. Since the production process realizes computerized digital production, enterprises can quickly adjust production plans according to customer needs, and even achieve same-day delivery, which can be obtained immediately. This flexible and efficient production model can not only meet the diverse needs of the market, but also help enterprises better respond to market changes, improve customer satisfaction and market response speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 The present invention is a flow chart of a printed carpet production process. DETAILED DESCRIPTION

[0037] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0038] like Figure 1 As shown, a printed carpet production process comprises the following steps:

[0039] S1. Digital pattern input: Use image acquisition equipment to convert design drawings or physical samples into digital image files;

[0040] Wherein, the image acquisition device is any one of a high-resolution scanner and a digital camera, and the resolution of the digitized image is not less than 300dpi.

[0041] Among them, if it is an original design, you can directly use computer graphics software to create the pattern.

[0042] S2. Data processing: Edit, color separate and optimize the digital image files through the CAD system to generate a file format suitable for digital printing machines;

[0043] The data processing specifically includes the following steps:

[0044] S201: Importing the digitized image file into the CAD system;

[0045] S202: Adjust the pattern size, position and color to ensure it meets the carpet size and design requirements;

[0046] S203: Using the color separation function of the CAD system, the pattern is decomposed into multiple color layers to meet the multi-nozzle requirements of the digital printing machine;

[0047] Furthermore, for complex patterns, color correction and optimization are performed before decomposing the patterns into multiple color layers.

[0048] S204: planning the moving path of the printing head to ensure that there is no overlap or omission during the printing process;

[0049] S205: Export the processed pattern into a file format suitable for a digital textile printing machine, ensuring that the file contains all necessary printing information.

[0050] Furthermore, the file format includes but is not limited to TIFF, EPS and PDF, and the printing information includes but is not limited to color mode, resolution and bleed line.

[0051] S3. Preparation of white polyester fabric: Prepare white polyester fabric, make sure its surface is clean and dust-free, and its size meets the printing requirements, and then install the white polyester fabric on the digital printing machine;

[0052] S4, digital printing: Start the digital printing machine, and the computer controls the micro-piezoelectric inkjet nozzle to directly spray the dye liquid on the plain white polyester according to the preset pattern. At the same time, the nozzle automatically adjusts the spraying parameters to adapt to different materials and pattern requirements;

[0053] S5, low temperature color fixing: send the printed carpet into the low temperature color fixing device, soak it in the color fixing solution for the first color fixing, and then spray the color fixing solution for the second color fixing;

[0054] Wherein, the color fixing solution is a mixed solution of an environmentally friendly color fixing agent and a cross-linking agent.

[0055] Furthermore, the environmentally friendly color fixing agent is a cationic color fixing agent or a natural plant extract color fixing agent, and the cross-linking agent is a polyurethane cross-linking agent or a natural plant extract cross-linking agent.

[0056] Wherein, the fixing temperature is controlled at 60-80°C and the duration is 10-15 minutes.

[0057] S6. Surface treatment: Clean the surface of the carpet after printing and fixing;

[0058] Among them, cleaning the surface of the carpet after printing and fixing includes:

[0059] S601, Preliminary cleaning: Use a water-absorbing roller to gently roll on the carpet surface to absorb excess water and residual dye;

[0060] S602, Deep cleaning: For residues that are difficult to remove, use a negative pressure vacuum pump for secondary cleaning;

[0061] S603, Final Check: Wipe the carpet surface again with a clean damp cloth to ensure that no residue remains.

[0062] S7, efficient drying: the cleaned carpet is sent to an efficient drying device for drying. The efficient drying device is internally configured with multi-layer circulating air ducts and infrared heating elements to ensure that the carpet is evenly heated and shorten the drying time;

[0063] S8. Finished product inspection and packaging: Use quality inspection instruments to inspect the finished carpets after drying to ensure that they meet quality standards, and cut, trim and package qualified carpets.

[0064] The present invention ensures that every link from design to production is highly accurate through digital pattern input and data processing steps. The design drawings or physical samples are converted into digital image files using high-resolution scanners or digital cameras, ensuring the clarity and detail retention of the original pattern. In particular, the application of computer graphics software allows designers to freely create complex and delicate patterns when designing original designs. The color separation function and path planning in the CAD system further optimize the printing effect of the pattern, ensuring that each color layer can be accurately sprayed on the plain white polyester. This high-precision digital printing technology can not only achieve the perfect reproduction of complex patterns such as color gradients and moire patterns, but also break the limitation of the length of "flower return" in traditional printing processes, greatly expanding the space for textile pattern design, and meeting the market demand for personalized and high-end carpets; the present invention adopts low-temperature color fixing technology and efficient drying devices, which greatly reduces energy consumption and water waste. The traditional high-temperature steam color fixing method requires a large amount of natural gas to generate saturated steam, while the present invention uses environmentally friendly color fixing agents and cross-linking agents to achieve fast and stable dye fixation at a lower temperature of 60-80°C, reducing energy demand. In addition, a large amount of clean water is not required for flushing during the color fixing process, which avoids the waste of water resources and reduces wastewater discharge. The high-efficiency drying device is internally configured with multi-layer circulating air ducts and infrared heating elements to ensure that the carpet is evenly heated while shortening the drying time, further saving energy. These improvement measures not only reduce production costs, but also meet the current social requirements for green manufacturing and sustainable development, and help enterprises achieve energy conservation and emission reduction goals; the environmentally friendly color fixing agent and cross-linking agent selected by the present invention are non-toxic and harmless environmentally friendly materials, such as cationic color fixing agents, natural plant extract color fixing agents, polyurethane cross-linking agents, etc. These additives not only improve the binding force between dyes and fibers, enhance the wet fastness, friction fastness and light resistance of carpets, but also avoid the release of harmful substances, and ensure the health and safety of consumers. In particular, natural plant extract color fixing agents and cross-linking agents have good biodegradability and antibacterial and mildew-proof functions, and are suitable for the production of ecological textiles. By strictly testing the finished products, it is ensured that each carpet meets high quality standards and improves the market competitiveness of the products. At the same time, the entire production process strictly abides by environmental protection laws and regulations, reduces the impact on the environment, and reflects the company's sense of social responsibility; the digital production process of the present invention not only improves work efficiency, but also reduces quality fluctuations caused by human factors, ensuring the stability and consistency of the production process. Especially in small-batch customized production, the advantages of the present invention are particularly obvious. Since the production process realizes computerized digital production, enterprises can quickly adjust production plans according to customer needs, and even achieve same-day delivery, which can be taken immediately. This flexible and efficient production model can not only meet the diverse needs of the market, but also help companies better respond to market changes, improve customer satisfaction and market response speed.

[0065] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A printed carpet production process, characterized in that: The following steps are involved: S1. Digital pattern input: Use image acquisition equipment to convert design drawings or physical samples into digital image files; S2. Data processing: Edit, color separate and optimize the digital image files through the CAD system to generate a file format suitable for digital printing machines; S3. Preparation of white polyester fabric: Prepare white polyester fabric, make sure its surface is clean and dust-free, and its size meets the printing requirements, and then install the white polyester fabric on the digital printing machine; S4, digital printing: Start the digital printing machine, and the computer controls the micro-piezoelectric inkjet nozzle to directly spray the dye liquid on the plain white polyester according to the preset pattern. At the same time, the nozzle automatically adjusts the spraying parameters to adapt to different materials and pattern requirements; S5, low temperature color fixing: send the printed carpet into the low temperature color fixing device, soak it in the color fixing solution for the first color fixing, and then spray the color fixing solution for the second color fixing; S6. Surface treatment: Clean the surface of the carpet after printing and fixing; S7, efficient drying: the cleaned carpet is sent to an efficient drying device for drying. The efficient drying device is internally configured with multi-layer circulating air ducts and infrared heating elements to ensure that the carpet is evenly heated and shorten the drying time; S8. Finished product inspection and packaging: Use quality inspection instruments to inspect the finished carpets after drying to ensure that they meet quality standards, and cut, trim and package qualified carpets.

2. A printed carpet production process according to claim 1, characterized in that: In S1, the image acquisition device is any one of a high-resolution scanner and a digital camera, and the resolution of the digitized image is not less than 300 dpi.

3. A printed carpet production process according to claim 1, characterized in that: In S1, if it is an original design, the pattern can be directly created using computer graphics software.

4. A printed carpet production process according to claim 1, characterized in that: In S2, the data processing specifically includes the following steps: S201: Importing the digitized image file into the CAD system; S202: Adjust the pattern size, position and color to ensure it meets the carpet size and design requirements; S203: Using the color separation function of the CAD system, the pattern is decomposed into multiple color layers to meet the multi-nozzle requirements of the digital printing machine; S204: planning the moving path of the printing head to ensure that there is no overlap or omission during the printing process; S205: Export the processed pattern into a file format suitable for a digital textile printing machine, ensuring that the file contains all necessary printing information.

5. A printed carpet production process according to claim 4, characterized in that: In the S203, it also includes performing color correction and optimization on a complex pattern before decomposing the pattern into multiple color layers.

6. A printed carpet production process according to claim 4, characterized in that: In S205, the file format includes but is not limited to TIFF, EPS and PDF, and the printing information includes but is not limited to color mode, resolution and bleed line.

7. The process for producing a printed carpet according to claim 1, characterized in that: In S5, the color fixing solution is a mixed solution of an environmentally friendly color fixing agent and a cross-linking agent.

8. A printed carpet production process according to claim 7, characterized in that: The environmentally friendly color fixing agent is a cationic color fixing agent or a natural plant extract color fixing agent, and the cross-linking agent is a polyurethane cross-linking agent or a natural plant extract cross-linking agent.

9. The process for producing a printed carpet according to claim 1, characterized in that: The fixing temperature is controlled at 60-80° C. and the fixing time is 10-15 minutes.

10. The process for producing a printed carpet according to claim 1, characterized in that: In S6, the surface of the carpet after printing and fixing is cleaned, which specifically includes: S601, Preliminary cleaning: Use a water-absorbing roller to gently roll on the carpet surface to absorb excess water and residual dye; S602, Deep cleaning: For residues that are difficult to remove, use a negative pressure vacuum pump for secondary cleaning; S603, Final Check: Wipe the carpet surface again with a clean damp cloth to ensure that no residue remains.

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