Process of printing polyester
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Solution Overview
Problem
Direct-To-Garment (DTG) printing on polyester fabrics faces issues with poor adhesion, vibrancy, dye migration, and discoloration, particularly when using non-black fabrics, resulting in images that are not wash-resistant and may alter the fabric's appearance.
Innovation Solution
A process involving pretreatment of polyester fabrics with an aqueous solution containing 5% to 35% multivalent cationic salt, 0.1% to 5% blocked polyisocyanate crosslinking agent, and 3% to 40% waterborne resin, followed by drying and digital printing with water-based textile ink, enhances adhesion and vibrancy while minimizing dye migration and discoloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional DTG printing is used on polyester fabrics, then the printing process is simple, but adhesion is poor and wash resistance is low
Solution Approach 1:
The patent applies preliminary action by implementing a pretreatment step before printing where polyester fabrics are contacted with an aqueous solution containing multivalent cationic salt, blocked polyisocyanate crosslinking agent, and waterborne resin. This pretreatment creates a receptive surface that improves ink adhesion and wash resistance before the actual printing occurs.
Solution Approach 2:
The patent changes chemical parameters by introducing specific concentrations of multivalent cationic salt (5-35%), blocked polyisocyanate crosslinking agent (0.1-5%), and waterborne resin (3-40%) in the aqueous pretreatment solution. These parameter changes transform the fabric surface properties to enable better ink bonding and wash resistance.
2Illumination intensity
If conventional DTG printing is used on polyester fabrics, then the process is straightforward, but vibrancy is poor
Solution Approach 1:
The pretreatment step is performed in advance to prepare the polyester fabric surface, ensuring optimal conditions for vibrant color deposition during printing. The multivalent cationic salt and crosslinking agent create a surface that enhances color saturation and prevents dye migration.
Solution Approach 2:
The chemical composition of the pretreatment solution is carefully controlled with specific ranges of multivalent cationic salt (5-35%), blocked polyisocyanate crosslinking agent (0.1-5%), and waterborne resin (3-40%). These parameter optimizations ensure maximum color vibrancy while maintaining fabric integrity.
3Object-affected harmful factors
If conventional DTG printing is used on non-black polyester fabrics, then the process is simple, but dye migration and discoloration occur
Solution Approach 1:
The patent introduces an intermediary substance - the aqueous pretreatment solution containing multivalent cationic salt, blocked polyisocyanate crosslinking agent, and waterborne resin - that acts as a mediator between the ink and polyester fabric. This intermediary prevents direct harmful interaction between dye and fabric, eliminating dye migration and discoloration issues.
Solution Approach 2:
The patent converts the inherently problematic interaction between conventional inks and polyester fabrics into a beneficial process by using the pretreatment solution to create controlled bonding. The multivalent cationic salt and crosslinking agent transform potential harmful dye migration into controlled, stable color fixation.
4Stability of the object's composition
If conventional DTG printing is used on polyester fabrics, then the process is straightforward, but the fabric appearance is altered (stiffer and discolored)
Solution Approach 1:
The patent carefully controls the parameters of the pretreatment solution, using specific concentrations of multivalent cationic salt (5-35%), blocked polyisocyanate crosslinking agent (0.1-5%), and waterborne resin (3-40%). These optimized parameters ensure that the chemical treatment improves printability without excessively altering fabric hand or causing discoloration.
Solution Approach 2:
The pretreatment solution applies different functional components to different aspects of fabric treatment: multivalent cationic salt for surface charge modification, blocked polyisocyanate crosslinking agent for controlled bonding, and waterborne resin for flexibility maintenance. This localized quality approach ensures improved adhesion while preserving fabric appearance and hand.
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 achieves lasting, wash-resistant images on polyester fabrics without significantly altering their appearance, with improved adhesion and vibrancy, and minimal staining or discoloration, even on non-black fabrics.
Implementation Method 1
contacting polyester fabric with an aqueous solution comprising (A) 5% to 35% by weight of at least one multivalent cationic salt
Implementation Method 2
contacting polyester fabric with an aqueous solution comprising (A) 5% to 35% by weight of at least one multivalent cationic salt
Implementation Method 3
0.1% to 5% by weight of a blocked polyisocyanate crosslinking agent
Implementation Method 4
3% to 40% by weight of a waterborne resin
Implementation Method 5
drying the polyester fabric to remove the water from the polyester fabric
Data Source
AI summary
Disclosed is a process for printing on polyester fabric comprising (1) contacting polyester fabric with an aqueous solution comprising (A) 5% to 35% by weight of at least one multivalent cationic salt; (B) 0.1% to 5% by weight of a blocked polyisocyanate crosslinking agent, and (C) 3% to 40% by weight of a waterborne resin, all percentages based on the weight of the aqueous solution; (2) drying the polyester fabric to remove the water from the polyester fabric; and (3) digitally printing the pretreated and coated polyester fabric with a water-based textile ink.