Digital printed fabric, manufacturing method for digital printed fabric, and digital printing ink
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Solution Overview
Problem
Existing dyeing processes for fabrics are resource-intensive and time-consuming, often requiring excessive dye solution and water usage, along with numerous pre-treatment steps, and fail to ensure adequate color fastness of the dyed fabric.
Innovation Solution
A three-stage thermal process is employed to form a digital printing ink by mixing dyes, crosslinking agents, and polyols, followed by the addition of aqueous bridging agents and chain extenders, with controlled reaction temperatures and times, allowing the ink to be directly printed onto the base cloth, forming a firm and complex network structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional dyeing process is used to dye fabric, then fabric can be dyed uniformly, but excessive consumption of dyeing solution, water resources, and energy occurs
Solution Approach 1:
The patent extracts the dyeing function from the traditional bulk dyeing process and applies it locally through digital printing technology. The inkjet printing system deposits dye precisely where needed on the fabric surface, eliminating the need to immerse the entire fabric in dyeing solution, thereby dramatically reducing energy and water consumption while maintaining color uniformity through digital control
Solution Approach 2:
The patent implements local quality by applying different dye concentrations and types to different regions of the fabric based on digital patterns. The inkjet printing system varies the dye application locally to achieve the desired design while minimizing overall dye and solution usage compared to uniform traditional dyeing
2Reliability
If traditional dyeing process is used to dye fabric, then fabric can be dyed, but plenty of pre-treatment steps are required before dyeing
Solution Approach 1:
The patent incorporates preliminary action by including pre-treatment agents and crosslinking agents within the ink formulation itself, eliminating the need for separate pre-treatment steps. The crosslinking agent reacts with the dye and fabric during or after printing to create strong bonds, achieving the same effect as traditional pre-treatment but integrated into the printing process
Solution Approach 2:
The patent merges multiple functions into the ink formulation: the ink contains dye for coloration, crosslinking agents for bonding, and pre-treatment agents for fabric preparation. This combination eliminates separate pre-treatment steps while ensuring good dyeing results through the synergistic action of these components
3Reliability
If digital printing ink is used to print on fabric, then washing and crocking fastness are improved, but complex thermal process is required
Solution Approach 1:
The patent uses parameter changes by controlling the molecular weight and structure of polyols at different stages of the thermal process. The first thermal process uses specific temperature and time parameters to form polymer dyes with certain properties, while the second thermal process uses different parameters to complete crosslinking, optimizing fastness at each stage
4Productivity
If digital printing ink is used to print on fabric, then manufacturing process is simplified, but reaction temperature control is critical
Solution Approach 1:
The patent employs parameter changes by defining specific temperature ranges for each thermal process stage rather than single fixed temperatures. The first thermal process operates at 70-90°C and the second at 90-120°C, providing flexibility in control while ensuring proper reaction progression and reducing the risk of defects from excessive temperature variation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enhances washing and crocking fastness of the printed fabric, reduces manufacturing costs, and eliminates the need for pre-treatment and high-temperature drying, making it suitable for various fabric types.
Implementation Method 1
A first thermal process including a step of mixing a dye, a crosslinking agent, and a polyol is performed, such that a polymer dye is formed, in which a reaction temperature of the first thermal process is between 70° C. and 90° C.
Implementation Method 2
A second thermal process including a step of mixing the polymer dye and an aqueous bridging agent is performed, such that a first mixture is formed, in which a reaction temperature of the second thermal process is between 90° C. and 120° C.
Implementation Method 3
A third thermal process including a step of mixing the first mixture and a chain extender is performed, such that the digital printing ink is formed, in which a reaction temperature of the third thermal process is between 120° C. and 150° C.
Data Source
AI summary
A digital printed fabric includes a base cloth and a digital printing ink disposed on the base cloth, and a manufacturing method for the digital printing ink includes the following steps. A first thermal process including mixing a dye, a crosslinking agent, and a polyol is performed, such that a polymer dye is formed, in which a reaction temperature of the first thermal process is between 70° C. and 90° C. A second thermal process including mixing the polymer dye and an aqueous bridging agent is performed, such that a first mixture is formed, in which a reaction temperature of the second thermal process is between 90° C. and 120° C. A third thermal process including mixing the first mixture and a chain extender is performed, such that the digital printing ink is formed, in which a reaction temperature of the third thermal process is between 120° C. and 150° C.