A method for applying an embossed effect to the entire surface or different localized forms of cotton woven fabrics with a printing technique

Abstract

The invention relates to a method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or different locations of woven fabrics with conventional printing techniques for use in the textile industry.

Description

[0001] DESCRIPTION

[0002] A METHOD FOR APPLYING AN EMBOSSED EFFECT TO THE ENTIRE SURFACE OR DIFFERENT LOCALIZED FORMS OF COTTON WOVEN FABRICS WITH A PRINTING TECHNIQUE

[0003] Technical Field of the Invention

[0004] The invention relates to a method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or different locations of woven fabrics with conventional printing techniques for use in the textile industry.

[0005] State of the Art

[0006] Since the 20th century, steps have been taken in the textile industry to differentiate products and produce items with various pattern designs. Today, with evolving technology and fashion trends, the textile industry has embraced change and innovation in production. For this purpose, various methods and techniques are used, primarily weaving, finishing processes, sewing, and applique methods. Using these techniques, colored, embroidered, pleated, crinkled, and embossed effect etc. fabrics can be produced. Among these, embossed fabrics do not require ironing due to their wrinkled and puckered effect, providing ease of use. Therefore, since the demand for embossed fabrics is quite high due to their aesthetic appearance and advantages, the market potential is also high.

[0007] The production methods of embossed fabrics vary according to the fabric construction used. Embossed fabrics are commonly produced by weaving and knitting techniques, chemical treatment methods, and heat applications. To produce embossed fabrics with the weaving technique, the yarns must always be wound on two warp beams in groups of 10 to 16 in a narrow strip in the warp direction. Therefore, double warp beams are used in this method. The shrinkage effect is created on the fabric surface with different warp groups and different warp tensions. Thus, the tighter yarns remain straight, while the looser yarns create the wrinkling effect. The wrinkle effect can also become more pronounced with increasing weft density in the shrinkage area. Synthetic or cottoncontaining yarns can be used in this technique, however, since embossed fabric is difficult to weave, it is produced by a limited number of manufacturers. It is a low-profit and high-cost product due to its slow weaving speed. In addition, the patterns on fabrics produced with this technique are usually limited to column or square type. A circular knitting machine is used to produce embossed fabrics with knitting technique. On the circular knitting machine, raised textures are obtained with the loop formation of two needles set to 2x2 ribbing. As in the weaving technique, only column or square patterns are produced in this technique and limited pattern works are carried out.

[0008] When the production of embossed fabrics using thermal applications is examined, the desired embossed effect can be achieved on polyester-based synthetic fabrics. By heating metal molds, it is possible to transfer different patterns onto fabrics. The embossing roller has a three-dimensional designed roller whose pressure and temperature can be transmitted to the fabric. Depending on the depth of engraving on the hard roller, deep printing and flat printing effects are obtained. Depending on the working principle of the embossing machine and the characteristics of the printed pattern, the embossing process is examined under two categories: deep printing and flat printing. Deep printing (repeat printing) typically involves a two-roller system, where the motif engraved onto the hard roller has a great depth. Before the fabric is passed through, the design engraved on the steel roller is printed onto the elastic cylinder surface as if it were its negative. The deformation depth of engravings is always greater than the material thickness. Here the roller must rotate without slipping against each other. In the repeat printing embossing, a separate hard roller, elastic roller and repeat gears are required for each pattern. This not only increases the cost of production but also extends the preparation time required when switching from one pattern to another.

[0009] The method applied to provide embossed effect to cotton woven fabrics is chemical processes. In this technique, depending on a pattern, the fabric is pressed between a hard roller made of grooved / en graved metal, steel, brass, etc. and a flat roller. Meanwhile, NaOH (sodium hydroxide) with a certain degree of Be (borne) is transferred to the fabrics. Thus, contraction occurs in the areas where NaOH is present on the fabric and embossment occurs in other areas, resulting in a crinkled / shrinkage effect on the fabric surface. After this process, neutralization and washing of the fabric takes place in the washing tanks. The technical problems of this method are that it can only be applied on cotton woven fabrics, the effect cannot be created in different locations of the fabrics, it is limited to column or square type patterns, and the preparation time required when switching from one pattern to another pattern is long. When the embossed fabric production methods are examined, it is seen that only limited pattern works can be made. In addition, the embossed effect is not localized on the fabric surface, but on the entire surface of the fabrics. In addition, it may not be possible to recycle the patterned metal rollers used in both the heat treatment technique and chemical processes and use them in a different pattern. For this reason, column or square patterned metal rollers are mounted on the machine and come into contact with the fabrics. All these cause production to become difficult and workload and production cost to increase. Further, the application of different production techniques to fabrics of different constructions results in high investment costs. In addition, in the present technique, it is not possible to achieve both the embossed effect and the transparent fabric, which allows light to pass through with its lightweight and translucent structure, thus providing an aesthetic and elegant appearance, in a single step with the methods described above. The transparent effect achieved in the present technique can be achieved in conventional methods with weaving and knitting techniques. The creation of transparent and semi-transparent appearance on textile surfaces produced with different weaving and knitting repeats is easily achieved with yarn count and fabric density. Fabrics with this effect are produced with a weave and weaving repeat such that the warp and weft yarns are arranged side by side without overlapping each other. Yarn characteristics, count, weave and density calculations are directly proportional to the drape ability of semi-transparent fabrics.

[0010] Patent application no. US2429935A included in the state of the art relates to a method of producing a pleated or crinkled fabric without requiring abnormal shrinkage. In the prior art part of said document, it is explained that in the methods applied so far, in order to obtain the embossed effect, resin or a washable, chemical resistant substance can be placed on the parts of the fabric where a pattern is not desired, therefore after washing with NaOH, a pattern will be formed in places other than the aforementioned parts. However, the document does not achieve a see-through appearance in the final fabric.

[0011] Due to the reasons such as the limitations and insufficiency of the solutions in the existing technique, the inability to provide both the embossed effect and the transparent appearance to the cotton fabric with a single process, the high costs due to the requirement of multiple processes, and in conventional methods, only column and square type patterned fabrics being usually produced, i.e. there being a pattern limitation, and the embossed effect of these patterns being provided on the entire surface of the fabrics, it has become necessary to make an improvement in the relevant technical field.

[0012] Summary and Objects of the Invention

[0013] The invention describes a method to be used in the textile industry for applying an embossed (crepe) effect and a transparent appearance to the entire surface or different locations of woven fabrics with conventional printing techniques.

[0014] The object of the invention is to apply to the cotton fabric both an embossed effect and a transparent appearance in a single process. The sodium hydroxide repellent printing paste used in the invention penetrates both surfaces of the fabric in the conventional printing method with its high penetrating and high alkali resistance properties and NaOH repellency is provided. This gives the fabric both an embossed effect and a see-through (transparent) appearance.

[0015] Another object of the invention is to produce transparent fabrics with an embossed effect at low cost. With the method of the invention, both the embossed effect and transparent appearance are provided with a single process, eliminating the need for extra processes, thus realizing production at low cost.

[0016] An object of the invention is to produce transparent fabrics with an embossed effect with high efficiency. In the method of the invention, it is possible to transfer different patterns to fabrics by recycling the stencils used in the printing process. In this way, high production efficiency is achieved by achieving the embossed effect on different locations or the entire surface of the fabrics in the desired pattern, regardless of the fabric construction.

[0017] Another object of the invention is to achieve the desired embossed effect on the fabric without pattern limitation.

[0018] Description of the Drawings

[0019] Fig. 1. Product outputs obtained with the method of the invention. Detailed Description of the Invention

[0020] The invention relates to a method to be used in the textile industry for applying an embossed (crepe) effect and transparent appearance to the entire surface or different locations of woven fabrics in all desired / requested pattern types, different from the column and square type embossed effect available with conventional printing methods. In the method, NaOH (sodium hydroxide) repellent printing paste is used the said printing paste contains high purity short molecular chain polyurethane. Said polyurethane is an anionic aliphatic polyether-structured polyurethane polymer with a purity of 26%.

[0021] A method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or to different locations of woven fabrics of the invention comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring NaOH chemical to fabrics by impregnation method in NaOH bath, iv. washing the fabrics in the washing machine to ensure neutralization of the environment on the fabric, v. drying fabrics in the stenter machine.

[0022] In an embodiment of the invention, a method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or to different locations of woven fabrics of the invention comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring NaOH chemical to fabrics by impregnation method in 30-48 Be NaOH bath, iv. washing the fabrics in the washing machine with 6 tanks to ensure neutralization of the environment on the fabric, v. drying the fabrics in the stenter machine at 150-170 °C.

[0023] In an embodiment of the invention, a method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or to different locations of woven fabrics of the invention comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring the bath prepared by using 48 Be NaOH in an amount of 600 g / L to the fabrics in the impregnation method, iv. washing the fabrics in the washing machine with 6 tanks to ensure neutralization of the environment on the fabric, v. drying the fabrics in the stenter machine at 150 °C.

[0024] In the invention, NaOH shows a contraction / stretching behavior on the fabric surface due to the NaOH chemical substance creating a penetration reaction in the NaOH bath with the characteristic areas on the fabric surface where there is no NaOH repellent special printing paste. Therefore, the fabrics are given surface smoothness. The characteristic areas with NaOH repellent special printing paste on the fabric surface show passive / neutral behavior on the fabric surface since NaOH will not penetrate the NaOH chemical in the NaOH bath. Since contraction / stretching occurs in the characteristic areas where NaOH is present on the fabric surface, other areas where NaOH is not present show a blistering / shrinkage appearance.

[0025] In the method of the invention, the transparent appearance of the fabric is provided in the fixation process. The high purity short molecular chain polyurethane used in the method of the invention forms a transparent and strong film on the surface of the fabric at a temperature of 170 °C. Thus, a transparent appearance is obtained on the fabric. Furthermore, the requested pattern is transferred onto these rotary printing stencils with the help of a laser machine. The patterned stencil is used in the rotary printing technique. It is then possible to erase the pattern on this stencil, i.e. to recycle and reuse it. This process is realized by subjecting the stencil to the lacquer removal (stencil fading) process with the help of pressurized water. In addition, in the process step (iv) in the method of the invention, the first tank is neutralized in a solution of H2SO4(sulfuric acid) and water. In order to remove the remaining NaOH chemical from the fabric, the fabrics are washed in 2 cold tanks and 2 hot tanks (70-80 °C). Finally, the fabrics are treated with CH3COOH (acetic acid) and cold water solution in the last tank to ensure pH stability (pH=5.5-6).

[0026] The parameters of the fabric used as the starting material in the invention are given in Table 1 .

[0027] Table 1. Parameters of the cotton fabric of the invention.

[0028] In the method of the invention, any desired / requested pattern in the stencil can be transferred to cotton (low synthetic cotton fabric) woven fabrics by rotary printing technique (Fig. 1 ). Therefore, an embossed effect can be achieved not on the entire surface of the fabric but in different locations. Since rotary printing stencils are used in the patent method, it is very easy and cost-effective to apply different patterns by recycling the stencils (processing different patterns, reusing them again) through processes called fading. Industrial Applicability of the Invention

[0029] The invention relates to a method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or different locations of woven fabrics with conventional printing techniques for use in the textile industry, and is industrially applicable.

[0030] The invention is not limited to the above descriptions and the person skilled in the art can readily present other different embodiments of the invention. These should be considered within the protection scope of the invention claimed by the claims.

Claims

CLAIMS1. A method for applying an embossed (crepe) effect and a transparent appearance to the entire surface or to different locations of woven fabrics, characterized in that it comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring NaOH chemical to fabrics by impregnation method in NaOH bath, iv. washing the fabrics in the washing machine to ensure neutralization of the environment on the fabric, v. drying fabrics in the stenter machine.

2. The method according to claim 1 , characterized in that it comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring NaOH chemical to fabrics by impregnation method in 30-48 Be NaOH bath, iv. washing the fabrics in the washing machine with 6 tanks to ensure neutralization of the environment on the fabric, v. drying the fabrics in the stenter machine at 150-170 °C.

3. The method according to claim 2, characterized in that it comprises the process steps of: i. using a NaOH chemical-repellent printing paste in the conventional method of rotary printing, ii. ensuring the application of the printing paste to woven fabrics with the help of rotary printing stencils of the desired pattern, iii. transferring the bath prepared by using 48 Be NaOH in an amount of 600 g / L to the fabrics in the impregnation method,iv. washing the fabrics in the washing machine with 6 tanks to ensure neutralization of the environment on the fabric, v. drying the fabrics in the stenter machine at 150 °C.

4. The method according to any one of the preceding claims, characterized in that said NaOH chemical repellent printing paste comprises short molecular chain polyurethane of 26% purity, which is an anionic aliphatic polyether structured polyurethane polymer.

5. A fabric produced by the method according to any one of claims 1 -4.

6. The method according to any one of claims 1 -4, characterized in that the washing process in the 6-tank washing machine of process step (iv) comprises the process steps of: i. neutralizing the fabric in a solution of H2SO4(sulfuric acid) and water in the first tank, ii. washing fabrics in cold 2 tanks and 2 hot tanks (70-80 °C) in order to remove the remaining NaOH chemical from the fabric, iii. finally, treating the fabrics with CH3COOH (acetic acid) and cold water solution in the last tank to ensure pH stability (pH=5.5-6).

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