Acrylic Flocking Carpet Embossed Printing Process (I)

Through the printing, the cationic dye is scraped onto the local surface of the acrylic tufted carpet tuft, and after steaming, the cationic dye penetrates the original paste of the paste in the printing paste to penetrate from the pile head to the bottom of the carpet, from the surface of the fiber to Infiltrate deep inside the fiber. At this time, cationic dyes and acrylic fibers with surface-charged acrylic fibers are combined with ionic bonds to create a partially colorful pattern. In order to produce a pattern with irregularities, we printed a special agent on the contour line of the pattern so that when the acrylic fiber of the part is steamed at high temperature, it will melt and shrink under the action of the agent to form a concave pattern, so that the pattern will have a concave and convex effect.

3 Process Design

Acrylic flocking carpet is a heavy fabric with a high 5mm to 8.5mm fluff. It requires surface villi to be smooth and free of loopholes. The printed pattern has a clear outline, the depth of the recesses is uniform and no color change, and the roughness is strong and has a three-dimensional effect. Bright color, no dew, no positive stain, soft hand, and a certain degree of light fastness and soap fastness. In the case of printing, the positive paste is generally required to have a good penetration effect, but the reverse surface cannot have a print-through phenomenon. To achieve the above requirements, we must choose the appropriate printing methods and dyeing materials.

3.1 The choice of printing method

Because acrylic flocking carpets are heavy fabrics, with varying sizes, varying varieties, irregular batch sizes, and fast pattern changes, lithographic screen printing is used, semi-automatic lithographic screen machines are used, and the printing platen is sized for carpets. Make modifications to suit carpet prints. Due to the large amount of pulp in the flocked carpet, the 60-mesh or 80-mesh screen is selected to match the color paste to ensure a large amount of slurry.

3.2 Selection of dyestuffs

3.2.1 Dyes

The general choice of cationic dye can be, due to a large amount of flocking printing paste, generally do not consider compatibility issues, different types of dyes can be used to prepare different color paste. The original paste is printed or glued.

3.2.2 Additives

(1) Penetrant As the printing is a single-sided feeding, the dye must be penetrated from the pile to the bottom cloth, but it cannot penetrate the bottom cloth. Therefore, a certain amount of non-ionic penetrant is added, and the amount is strictly controlled to prevent Excessive penetration. Different kinds of carpets, according to the customer's color shade height, color tone requirements, the amount is not the same.
(2) pH value The cationic dye is usually dyed with acrylic fiber under the condition of acid hydrazine. The pH value directly affects the dye uptake rate and the dyeing speed.
A certain amount of acid agent should be added in the color paste. After the test, cationic dye pH control in 4 ~ 5 effect is better, you can use acetic acid or acetic acid. The sodium acetate buffer solution acts as an acid agent to stabilize the pH control. However, it should be noted that if the high temperature is too long, acetic acid will volatilize to cause the color change, so for some special varieties, non-volatile acid agents can be used instead.
(3) Leveling agent Because the flock of the flocking carpet is more prone to bleeding during printing, resulting in unclear outline of the pattern and blurred edges of the pattern, an even leveling agent or auxiliary agent for preventing bleeding of the colorant may be added.
(4) Defoamer In the preparation of color paste, in order to prevent the generation of air bubbles, it is necessary to add a defoamer (Ningbo Xingshan Additives Co., Ltd.), and it can also prevent bubbles from squeezing and cause print defects.
(5) The steaming of the soap lotion is completed, and the residual color paste on the carpet must be removed. To ensure that the unprinted parts are not colored or the color of the printed part is to be streaked, a special non-foaming function with anti-fouling function shall be selected for soaping. Soaping agent (Ningbo Xingshan Auxiliary Company) washes to ensure that the product's pattern is clear and bright, and the white surface is clean and white.
(6) Burnt-out auxiliaries The "burnt-out" effect of acrylics on the acrylic fibers causes the fabrics to exhibit certain concave-convex shapes and achieve three-dimensional effects.
(7) Acrylic smooth softener (Ningbo Xingshan Additives Co., Ltd.) Soften the burned fabrics to a smooth, non-rigid effect.

3.3 Color paste preparation

Printing paste recipe (%)
Penetrant 7~14
Leveling agent 4 ~ 5
Defoamer 2
Acetic acid 3
Yuan Mingfen 2.8
Water X
Synthesis 100

The method for preparing the original paste is to put the desired dye in a certain amount according to the formula and put it in a bucket. Add hot water to stir the dye to accelerate the dissolution of the dye, add the original paste to the required amount, and stir until the color paste is uniformly bright. Use, then print. In the entire process, the control of penetrant dosage plays a key role in product quality. The amount of penetrant should be controlled according to factors such as the thickness of the product, the depth of shade, and the ratio of water to the original paste during beating. For products with long fluff, thick bottom cloth, and lighter color, penetrants can be properly increased. Conversely, less. Such as gray fabric villi high 7.5mm, penetrant consumption 8%; fabric villi high 8.5mm, penetrant dosage 10%; if it is dark, the amount of penetrant should be reduced accordingly. If the production of printed carpet products requires a high level of surface sharpness, the amount of leveling agent may be appropriately increased, but the amount of defoamer, pH modifier, etc. does not generally need to change. Different colors of the dye and the original paste are as follows:

Color Dye Paste Light Color 5O% 5O%
Dark 40% 60%
Special thin lines 20% 80%

If there is a requirement for the whiteness of the white part of the finished carpet product, the whitening agent can be stirred with the original paste and squeegeed in a white area. After steaming, a certain whitening effect can be achieved. Burnt pulp preparation method Burnt agent 4.2kg, smooth softener 3.8kg, stir until ready.

Soaping soap lotion 3.5kg, chelating dispersant SX 2 kg.

3.4 T art process design

(1) Non-woven fabrics
(2) Making original paste → Applying color paste → Printing → (pre-baking) → Steam fixing → Washing → Shake drying → Drying → Post-processing of product inspection Note: Pre-baking is mainly used in the process of dye printing with easy color change. The general product may not be pre-baked.

3.5 Printing process

The required screens are arranged in a certain order, usually from light to dark, with large areas and bumps at the end, with the exception of special cases. Acrylic flocking carpet printing, steam fixation, steam temperature of 92% to 98%, insulation 15rain ~ 20rain. Generally, dark fabrics fade slightly, while light colors can meet the requirements. When printing large areas of dark patterns, extend the holding time appropriately. After steam fixing and washing, a certain amount of soaping agent may be added to remove floating color and other residual additives. The light washing time is 4min; dark fabrics are washed three times repeatedly. After the water is thrown, the fabric is put into a 65% oven and baked for 30 minutes. Generally, the fabric should not be over-baked, otherwise it will seriously affect the feel. Drying fabric inspection, authentic punching for post-processing.