Reactive digital printing methods and systems, printed fabric obtained thereby and related clothing items
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Solution Overview
Problem
Existing reactive dye processes face challenges in optimizing high storage stability of ink, color fixation rate, color fastness, and brilliance, while also being inefficient in terms of water and energy consumption.
Innovation Solution
A reactive digital printing method using a low-alkali primer and multi-reactive groups dye, involving steps of priming, printing, steaming, coloring, washing, and shaping, to enhance ink adhesion, reduce consumption, and improve color fixation and fastness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional reactive dye processes are used, then color fixation rate and fastness can be achieved, but water and energy consumption are high
Solution Approach 1:
The patent changes the chemical parameters of the dyeing process by using reactive dyes with multiple reactive groups (such as vinyl sulfone and monochlorotriazine groups) that can form multiple bonds with cellulose fibers. This allows the dyeing process to occur at lower temperatures and with reduced alkali concentration, thereby reducing energy consumption while maintaining high color fixation rates above 60%
Solution Approach 2:
The patent employs composite dye molecules containing multiple types of reactive groups (vinyl sulfone, monochlorotriazine, and difluorotriazine groups) combined in a single dye structure. This composite approach enables the dye to form multiple covalent bonds with the fiber, improving fixation efficiency and reducing the need for excessive water and energy in the dyeing process
2Reliability
If conventional reactive dye processes are used, then color fastness can be achieved, but water consumption is high
Solution Approach 1:
The patent modifies the chemical parameters by using dyes with multiple reactive groups that create stronger and more numerous covalent bonds with cellulose fibers. This enhances color fastness to washing and rubbing while reducing the amount of water needed for rinsing and washing, as the high fixation rate leaves less loose dye to be removed
Solution Approach 2:
The patent extracts and eliminates the need for extensive washing steps by achieving such high color fixation rates (above 60%) that minimal washing is required to remove unfixed dye. This reduces water consumption in the washing step while maintaining color fastness
3Reliability
If multi-reactive groups dye is used, then color fixation rate is improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple reactive groups (vinyl sulfone, monochlorotriazine, difluorotriazine) into a single dye molecule structure, eliminating the need for separate dyeing steps for different dye types. This integration simplifies the overall manufacturing process while achieving high color fixation rates through the synergistic action of multiple reactive groups
Solution Approach 2:
The multi-reactive groups dye serves multiple functions simultaneously: it provides coloration, forms multiple covalent bonds with fibers for high fixation, and maintains solubility in the dyeing bath. This multi-functionality reduces the number of separate processes needed, simplifying manufacturing despite the complex chemistry involved
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 achieves high color fixation rate, good fastness, and bright colors with reduced water and energy consumption, producing environmentally friendly printed fabrics.
Implementation Method 1
contacting the fabric with a primer before printing the fabric by digital printing
Implementation Method 2
uses dyes with reactive groups as colorants in digital printing
Data Source
AI summary
A reactive digital printing method can be performed with the following steps: 1) applying a primer to a fabric to be printed; (2) applying an ink containing a dye with multi-reactive groups to the fabric to be printed in step (1); (3) steaming and coloring, washing, dehydrating and shaping the fabric in step (2), to obtain a printed product. A related system with a combination of primer, a dye with multi-reactive group, printed fabric produced with the reactive digital printing method and items comprising the printed fabric can also be provided.