Printed Polyester Ribbon Processing for Elasticity and Image Definition
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Solution Overview
Problem
Existing processes for producing ribbons with printed decorations often compromise elasticity while maintaining image definition, particularly in ribbons made from discontinuous fibers, where thermo-fixing steps can cause significant shrinkage and loss of elasticity.
Innovation Solution
A process involving sequential sanforizing units with controlled humidification and compacting stages before and after sublimation printing, utilizing steam and braking belts to manage fiber shrinkage and maintain elasticity, followed by cooling to lock fibers in compacted positions, ensuring high elasticity and image definition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a thermo-fixing step is applied before sublimation printing to prevent shrinkage and maintain image definition, then manufacturing precision of the printed decoration is improved, but the elasticity of the ribbon deteriorates
Solution Approach 1:
The invention applies a preliminary sanforizing treatment (mechanical compaction with humidity control) before sublimation printing to pre-stabilize the ribbon dimensions and reduce shrinkage during printing, thereby maintaining image definition without requiring subsequent high-temperature thermo-fixing that would damage elasticity
Solution Approach 2:
The invention changes the parameters of the compaction process by controlling humidity levels and applying mechanical pressure at specific temperatures (below the thermo-fixing range), thereby achieving dimensional stability through physical compaction rather than thermal setting, which preserves the elastic properties of the ribbon
2Reliability
If high temperature is applied during sublimation printing to transfer the decoration, then the printed decoration becomes permanent and indelible, but the ribbon shrinks and loses elasticity
Solution Approach 1:
The sanforizing treatment is performed as a preliminary action before sublimation printing to pre-compact the ribbon fibers and reduce their tendency to shrink during the high-temperature printing process, thereby allowing the full sublimation temperature to be used for permanent decoration transfer while minimizing elastic loss
Solution Approach 2:
The invention provides beforehand cushioning against shrinkage by applying mechanical compaction and humidity control before printing, creating a buffer that absorbs the dimensional changes that would otherwise occur during high-temperature sublimation, thereby protecting the ribbon's elasticity while ensuring decoration permanence
3Stability of the object's composition
If mechanical compaction is applied to reduce shrinkage while preserving elasticity, then elasticity is improved, but image definition may deteriorate due to fiber movement during printing
Solution Approach 1:
The invention uses controlled humidity (water mist or steam) during mechanical compaction to facilitate fiber rearrangement and settling, thereby achieving stable compaction that prevents both shrinkage and fiber movement during printing, simultaneously preserving elasticity and maintaining image definition
Solution Approach 2:
The invention carefully controls the parameters of mechanical compaction, including humidity levels, temperature, and pressure, to achieve optimal fiber stabilization that prevents shrinkage while minimizing fiber displacement, thereby maintaining both elasticity and image definition during subsequent printing
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 process achieves ribbons with considerable elasticity (12-17%) while maintaining excellent image definition, outperforming traditional methods that sacrifice elasticity for image clarity.
Implementation Method 1
a first cold humidification chamber (21), a hot humidification chamber (22)
Implementation Method 2
cold humidification chamber
Implementation Method 3
first compacting unit (23), a second compacting unit (24)
Implementation Method 4
a first braking belt (26a), a second braking belt (26b)
Implementation Method 5
a cooling device (25)
Implementation Method 6
the ink present on the transfer paper passes from the solid state to the gaseous state (sublimation), and is deposited, point by point, on the surface of the ribbon
Data Source
Figure 1
AI summary
A process for the production of a ribbon comprises the steps of subjecting a ribbon (1) woven from polyester fibre to a sanforization treatment (20) wherein the ribbon is compacted at a temperature exceeding 160°C, subjecting the ribbon to sublimation printing (30), and finally subjecting the printed ribbon to a second sanforization treatment (40) wherein the ribbon is compacted at a temperature below 130°C.