Plastisol based composition for blocking dye migration from dyed polyester fabric into the print
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Solution Overview
Problem
Dye migration from polyester and polyester-cotton blended fabrics into prints is a significant issue, leading to discoloration, especially when plastisol inks are used, as they can leach dyes into the plasticizer, and existing solutions involve unstable hybrid inks containing PVC and formaldehyde, which are harmful to the environment.
Innovation Solution
A plastisol-based composition comprising an acrylic resin without vinyl chloride, a plasticizer, an organic wetting agent, a formaldehyde-free discharge agent, and an extender, which forms a protective layer on the fabric to prevent dye migration, using a process that involves flash curing and overprinting with a white ink to create a stable, environment-friendly print.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If plastisol inks are used for printing on dyed polyester fabric, then the print quality and color vibrancy are improved, but dye migration into the plasticizer causes discoloration of the fabric and printed image
Solution Approach 1:
A dye-blocking compound is introduced as an intermediary layer between the dyed polyester fabric and the plastisol print. This compound specifically prevents disperse dyes from migrating into the plasticizer while allowing the plastisol ink to maintain its color vibrancy and print quality. The intermediary layer resolves the contradiction by blocking the harmful dye migration pathway without interfering with the desired print properties.
Solution Approach 2:
The dye-blocking compound is applied to the fabric surface before printing with plastisol ink. This preliminary action creates a protective barrier that prevents dye migration during subsequent printing and curing processes. By performing the blocking action beforehand, the system prevents the harmful effect before it can occur, while still allowing the plastisol print to achieve its full color potential.
2Object-affected harmful factors
If hybrid inks containing PVC and phthalates are used to stop dye bleeding, then dye migration is blocked, but the composition becomes unstable and harmful to human health and the environment
Solution Approach 1:
The harmful components (PVC, phthalates, and formaldehyde-based discharge agents) are extracted and removed from the dye-blocking composition. The invention achieves effective dye migration blocking using alternative, environmentally friendly components that do not contain these harmful substances, thus resolving the contradiction between effectiveness and environmental safety.
Solution Approach 2:
The chemical composition parameters of the dye-blocking compound are changed to eliminate harmful substances. Instead of using PVC-phthalate-formaldehyde hybrid systems, the invention employs a water-based or alternative chemistry system that maintains dye-blocking effectiveness while removing toxic components, thereby protecting human health and the environment.
3Object-affected harmful factors
If discharge agents based on Zinc Formaldehyde Sulphoxylate are used to prevent dye bleeding, then dye migration is stopped, but formaldehyde is released which is detrimental to human health and the environment
Solution Approach 1:
Formaldehyde-based discharge agents are extracted and replaced with alternative discharge chemistry. The invention uses non-formaldehyde discharge agents that achieve the same dye migration prevention effect without releasing harmful formaldehyde, thus resolving the contradiction between effectiveness and environmental safety.
Solution Approach 2:
The invention converts the harmful formaldehyde-based chemistry into a beneficial formaldehyde-free alternative. By using environmentally safe discharge agents, the system achieves effective dye migration prevention while eliminating the harmful byproduct, thus turning a potentially harmful process into a beneficial and safe one.
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 solution effectively blocks dye migration, maintaining the original fabric color and preventing discoloration, while being free from harmful chemicals like formaldehyde and phthalates, thus ensuring environmental safety and improved productivity.
Implementation Method 1
the unfixed disperse dyes in the fabric has a tendency to dissolve in the plasticizer of the plastisol inks
Implementation Method 2
The disperse dyes also have a tendency to sublimate when heated, turning from a solid dye particle directly to a gas
Implementation Method 3
on heating to temperatures typically above 100° C. the plastisol composition gels to form a homogenous coalesced mass
Data Source
AI summary
The present disclosure relates to a plastisol based composition for blocking dye migration from a dyed polyester blended cotton fabric or 100% polyester fabric into a print on the fabric, the print being done with a plastisol based color dye on the dyed fabric. The plastisol based composition of the present disclosure comprises an acrylic based resin devoid of vinyl chloride moiety, a plasticizer, an organic wetting agent, a formaldehyde free discharge agent and an extender. A process for printing fabrics using the plastisol based composition of the present disclosure is also disclosed.