Thin Transfer Layer Pigment Paper for Natural Fiber Textile Printing
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Solution Overview
Problem
Current methods for digital printing on textiles based on natural fibers, such as cotton, face challenges including cumbersome processes, high ink losses, limited scalability, poor hand feel, and inadequate color fastness due to thick transfer layers and complex coating processes, which restrict large-scale applications and image quality.
Innovation Solution
A pigment transfer sheet with a thin transfer layer composed of textile reactive polymers, applied using a method that involves pressure and heat to maintain the original hand feel of the textile while achieving high color fastness, comprising a base layer, a release layer, and a transfer layer with specific additives for improved adhesion and print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick transfer layer is used to ensure adequate color fastness, then color fastness is improved, but hand feel deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the transfer layer by incorporating textile reactive polymers with specific functional groups (isocyanate, carbodiimide, ammonium zirconium carbonate) that can chemically bond to natural fiber substrates. This chemical parameter change enables adequate color fastness with a thinner layer (5-25 g/m2), thereby resolving the contradiction between color fastness and hand feel.
2Reliability
If multiple coating layers are applied to the support layer to achieve desired transfer properties, then transfer performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functional layers into a single integrated transfer layer containing textile reactive polymers, binders, and necessary additives. This consolidation maintains adequate transfer performance while significantly simplifying the manufacturing process by reducing the number of separate coating steps and layers required.
Solution Approach 2:
The transfer layer is designed as a multi-functional material that simultaneously provides adhesion to natural fibers, image transfer capability, and color fastness through the textile reactive polymers. This universal approach eliminates the need for separate specialized layers for each function, reducing manufacturing complexity.
3Manufacturing precision
If a pre-peel step is required to separate the support layer from the transfer layer before application, then transfer precision is improved, but process complexity and scalability deteriorate
Solution Approach 1:
The patent incorporates a release layer between the support layer and the transfer layer that is designed to facilitate easy separation after the transfer process. This preliminary design of the release layer properties allows the transfer layer to remain precisely positioned during printing, then be easily separated post-transfer without requiring complex pre-peel mechanisms, thereby maintaining transfer precision while reducing process complexity.
4Ease of operation
If direct printing with screen printing is used to print images directly onto textiles, then process simplicity is improved, but flexibility and scalability deteriorate
Solution Approach 1:
The patent introduces a transfer sheet as an intermediary carrier that combines the advantages of both direct and indirect printing. The sheet receives the printed image (enabling flexibility and digital printing capabilities), then transfers it to the textile substrate (simplifying the actual application process). This intermediary approach enables flexibility in design and printing methods while maintaining process simplicity during application.
5Reliability
If a thick transfer layer is used to ensure adequate coverage and fastness, then color fastness is improved, but ink usage efficiency deteriorates
Solution Approach 1:
The patent changes the chemical parameters of the transfer layer by using textile reactive polymers that form strong chemical bonds with natural fiber substrates. This chemical bonding mechanism enables adequate color fastness with significantly reduced ink/pigment amounts, improving ink usage efficiency while maintaining color fastness.
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 enables digital printing on natural fibers with improved hand feel, color fastness to rubbing, laundering, and light, while reducing ink usage and process complexity, allowing for large-scale applications with maintained textile properties.
Implementation Method 1
a transfer layer, which is adhesive to said textile substrate when both are at a temperature of T1
Implementation Method 2
The transfer layer comprises textile reactive polymers... wherein said textile reactive polymers comprise at least one group selected from the group consisting of isocyanate, carbodiimide and ammonium zirconium carbonate
Implementation Method 3
applying heat and pressure (for instance with an iron) to melt the transfer layer and adhere the image to the textile
Implementation Method 4
applying pressure and heat to maintain the original hand feel of the textile
Data Source
AI summary
The invention is directed to a pigment transfer sheet (1) suitable for transferring an image to a textile substrate (2), said transfer sheet comprising a base layer and a transfer layer, said transfer layer being present in an amount of 5 to 20 g/m2, preferably in an amount of 8 to 15 g/m2 such as about 12 g/m2. A further aspect of the present invention is a process wherein this transfer sheet is used for transferring an image from a pigment transfer sheet to a textile substrate to provide a textile product carrying said image, said process comprising a transfer step comprising applying a surface pressure of at least 0.4 bar and heat to the superimposed contacted transfer sheet and textile substrate. Yet another aspect of the invention is a textile product (3) obtainable by the sheet and the process, which textile product has favorable properties like good hand and color fastnesses.