U.S. patent application number 16/988445 was filed with the patent office on 2021-02-11 for pretreating natural fiber fabrics for dye sublimation ink printing.
This patent application is currently assigned to Prism Inks, Inc.. The applicant listed for this patent is Prism Inks, Inc.. Invention is credited to Amir A. AJANEE, Travis T. CALHOUN, Graham A. DRACUP, Carlos J. HERNANDEZ.
Application Number | 20210040684 16/988445 |
Document ID | / |
Family ID | 1000005065108 |
Filed Date | 2021-02-11 |
United States Patent
Application |
20210040684 |
Kind Code |
A1 |
AJANEE; Amir A. ; et
al. |
February 11, 2021 |
PRETREATING NATURAL FIBER FABRICS FOR DYE SUBLIMATION INK
PRINTING
Abstract
Provided are pretreatment compositions, pretreated fabrics, and
methods of pretreating fabrics for improved printing quality.
Pretreated fabrics include natural fiber fabric having a polymer
coating. Methods of pretreating fabrics include spraying natural
fiber fabric with a pretreatment composition that comprises one or
more latex polymers, a coalescing agent composition, a surfactant
composition, an ultraviolet stabilizer composition, an antioxidant
composition, and a solvent.
Inventors: |
AJANEE; Amir A.; (Saratoga,
CA) ; DRACUP; Graham A.; (Soquel, CA) ;
HERNANDEZ; Carlos J.; (San Jose, CA) ; CALHOUN;
Travis T.; (San Jose, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Prism Inks, Inc. |
Sunnyvale |
CA |
US |
|
|
Assignee: |
Prism Inks, Inc.
Sunnyvale
CA
|
Family ID: |
1000005065108 |
Appl. No.: |
16/988445 |
Filed: |
August 7, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62884013 |
Aug 7, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06P 1/5257 20130101;
D06P 1/5271 20130101; D06P 5/30 20130101; D06P 5/005 20130101; D06P
5/002 20130101 |
International
Class: |
D06P 5/00 20060101
D06P005/00; D06P 1/52 20060101 D06P001/52; D06P 5/30 20060101
D06P005/30; D06P 5/28 20060101 D06P005/28 |
Claims
1. A pretreatment composition for a natural fiber fabric
comprising: 15 to 35 wt. % one or more latex polymers; 15 to 35 wt.
% one or more humectants; 0.1 to 1 wt. % surfactant composition;
0.1 to 1 wt. % ultraviolet (UV) stabilizer composition; 0.1 to 1
wt. % one or more pH buffers; 0.05 to 0.5 wt. % biocide; and 40 to
60 wt. % solvent.
2. The pretreatment composition of claim 1, wherein the one or more
latex polymers comprise one or more of a polyester, an acrylic
polymer, an aromatic polyamide, a chlorinated polymer, a polyether,
a polyurea, a fluorinated polymer, a polyurethane, a styrene, a
polyvinyl, a thio/ether polymer, a polyolefin, a polystyrene, a
polyacetate, a polyamide, a polyethylene, a polyimide, a
polycarbonate, or a polyvinylalcohol.
3. The pretreatment composition of claim 2, wherein the one or more
latex polymers comprise a polyester.
4. The pretreatment composition of claim 3, wherein the polyester
has a glass transition temperature from -20 to 100.degree. C.
5. The pretreatment composition of claim 4, wherein a latex
dispersion of the polyester has a zeta potential from -60 to -20
mV.
6. The pretreatment composition of claim 2, wherein the one or more
latex polymers comprise an acrylic polymer.
7. The pretreatment composition of claim 6, wherein the acrylic
polymer is self-crosslinking.
8. The pretreatment composition of claim 1, further comprising a
coalescing agent, wherein the coalescing agent composition
comprises one or more compounds comprising an aliphatic
composition, a cycloaliphatic composition, an ether composition, a
glycol composition, an alcohol composition, an ester composition, a
carbonate composition, a lactam composition, or a ketone
composition.
9. The pretreatment composition of claim 8, wherein the coalescing
agent composition comprises ethylene glycol butyl ether.
10. The pretreatment composition of claim 1, wherein the surfactant
composition comprises one or more of an anionic or a nonionic
surfactant.
11. The pretreatment composition of claim 10, wherein the
surfactant composition comprises silicone.
12. The pretreatment composition of claim 1, wherein the UV
stabilizer composition comprises one or more of a sulfonated
benzophenone, a benzotriazole, a salicylate, a cinnamate, a
triazole, or a triazine.
13. The pretreatment composition of claim 12, wherein the UV
stabilizer composition comprises hydroxyphenyl triazine.
14. The pretreatment composition of claim 1, further comprising an
antioxidant composition, wherein the antioxidant composition
comprises one or more of a hydroquinone, an alkoxyphenol, a
dialkoxyphenol, a phenol, an aniline, an amine, an indane, a
chromane, an alkoxyaniline, or a heterocyclic compound.
15. The pretreatment composition of claim 14, wherein the
antioxidant composition comprises a hindered amine light
stabilizer.
16. The pretreatment composition of claim 1, wherein the solvent
comprises one or more of glycol ether, a diol, an ester, ethanol,
or water.
17. The pretreatment composition of claim 16, wherein the solvent
comprises water.
18. A pretreated natural fiber fabric product comprising: natural
fiber fabric; and a polymer coating on the natural fiber fabric,
the polymer coating comprising: 20 to 90 wt. % one or more latex
polymers; 0.4 to 7 wt. % surfactant composition; and 1 to 8 wt. %
ultraviolet (UV) stabilizer composition.
19. The pretreated natural fiber fabric product of claim 18,
wherein the natural fiber fabric comprises one or more of wool,
cotton, silk, linen, leather, hemp, or bamboo.
20. The pretreated natural fiber fabric product of claim 19,
wherein the pretreated natural fiber fabric product comprises a
T-shirt.
21. The pretreated natural fiber fabric product of claim 18,
comprising an image printed using dye sublimation ink.
22. A pretreated natural fiber fabric product comprising: natural
fiber fabric; and a polymer coating on the natural fiber fabric,
wherein the pretreated natural fiber fabric product is produced by
spraying the natural fiber fabric with 8 to 15 grams of a
pretreatment composition per square inch of natural fiber
fabric.
23. The pretreated natural fiber fabric product of claim 22,
wherein the pretreatment composition comprises: 15 to 35 wt. % one
or more latex polymers; 15 to 35 wt. % one or more humectants; 0.1
to 1 wt. % surfactant composition; 0.1 to 1 wt. % ultraviolet (UV)
stabilizer composition; 0.1 to 1 wt. % one or more pH buffers; 0.05
to 0.5 wt. % biocide; and 40 to 60 wt. % solvent.
24. The pretreated natural fiber fabric product of claim 22,
comprising an image printed using dye sublimation ink.
25. The pretreated natural fiber fabric product of claim 22,
wherein the natural fiber fabric comprises one or more of wool,
cotton, silk, linen, leather, hemp, or bamboo.
26. The pretreated natural fiber fabric product of claim 22,
wherein the pretreated natural fiber fabric product is a
T-shirt.
27. A method of pretreating a natural fiber fabric comprising:
spraying a natural fiber fabric with 8 to 15 grams pretreatment
composition per square inch of natural fiber fabric to produce
sprayed natural fiber fabric; and drying the sprayed natural fiber
fabric to form a pretreated natural fiber fabric product.
28. The method of pretreating a natural fiber fabric of claim 27,
wherein the pretreatment composition comprises: 15 to 35 wt. % one
or more latex polymers; 15 to 35 wt. % one or more humectants; 0.1
to 1 wt. % surfactant composition; 0.1 to 1 wt. % ultraviolet (UV)
stabilizer composition; 0.1 to 1 wt. % one or more pH buffers; 0.05
to 0.5 wt. % biocide; and 40 to 60 wt. % solvent.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/884,013, filed Aug. 7, 2019, the entire contents
of which are incorporated herein by reference.
FIELD
[0002] This disclosure relates to processes for pretreating
fabrics. Specifically, this disclosure relates to pretreatment
processes for natural fiber fabrics that may be used for dye
sublimation ink printing.
BACKGROUND
[0003] Printed fabrics are useful for several different products
including, but not limited to, clothing, bedding, window
treatments, signage, upholstery, etc. Printing onto fabrics allows
for a variety of patterns and designs to be used on the fabric.
[0004] Presently, dye sublimation inks are often used for printing
on synthetic fabrics due to their ability to penetrate the fiber,
their color vibrancy, their crock testing results, and their
colorfastness to laundering. However, dye sublimation inks are not
suitable for printing on natural fiber fabrics because the dyes
penetrate and do not adhere to the natural fibers. This lack of
adhesion can cause bleeding during laundering, a reduction in color
density, a decrease in colorfastness to laundering, and a decrease
in crock of the printed fabric.
SUMMARY
[0005] Provided are pretreatment compositions, pretreated natural
fiber fabrics, methods for preparing pretreatment compositions, and
methods for pretreating natural fiber fabrics that can render
fabrics suitable for dye sublimation ink printing by improving the
adhesion of the ink to the natural fiber fabric. In particular,
pretreatment compositions and methods for pretreating provided
herein may be used on natural fiber fabrics such that dye
sublimation ink may be used for printing on the natural fiber
fabric (after pretreatment). Printed natural fiber fabrics that
have been pretreated using the pretreated compositions and/or
methods for pretreating provided herein may have improved crock,
hand, colorfastness to laundering, adhesion, color density, etc.
compared to dye sublimation ink-printed natural fiber fabrics that
have not been pretreated with the pretreatment compositions and/or
methods for pretreating discussed herein.
[0006] Without pretreating natural fiber fabrics according to the
pretreatment compositions and/or methods for pretreating provided
herein, dye sublimation inks cannot sufficiently adhere to natural
fibers of the natural fiber fabrics, as discussed briefly above.
Specifically, natural fiber fabrics are hydrophilic, whereas
synthetic fibers are hydrophobic. The hydrophobicity of synthetic
fibers aid in absorption of dye sublimation. Thus, the
hydrophilicity of natural fiber fabrics inhibit absorption of the
dye sublimation inks. However, pretreatment compositions and
methods of pretreating provided herein provide a synthetic layer
over the natural fibers of the natural fiber fabric to encourage
adhesion and absorption of dye sublimation inks to the natural
fiber fabric. More specifically, pretreatment compositions can
adhere to natural fiber fabric, creating a polymeric, hydrophobic
coating overlying the natural fiber fabric. The dye sublimation ink
then absorbs into the polymeric hydrophobic coating produced by the
pretreatment composition and/or pretreatment method to generate a
printed image that will not penetrate through the fabric.
[0007] Pretreatment compositions, pretreated fabric, and methods
for pretreating fabric provided herein can allow users to apply dye
sublimation ink onto natural fiber fabric to produce a printed
fabric having similar properties that are achieved using dye
sublimation ink on polyester (i.e., synthetic) fabrics.
[0008] In some embodiments, a pretreatment composition for a
natural fiber fabric includes: 15 to 35 wt. % one or more latex
polymers; 15 to 35 wt. % one or more humectants; 0.1 to 1 wt. %
surfactant composition; 0.1 to 1 wt. % ultraviolet (UV) stabilizer
composition; 0.1 to 1 wt. % one or more pH buffers; 0.05 to 0.5 wt.
% biocide; and 40 to 60 wt. % solvent. In some embodiments, the one
or more latex polymers comprise one or more of a polyester, an
acrylic polymer, an aromatic polyamide, a chlorinated polymer, a
polyether, a polyurea, a fluorinated polymer, a polyurethane, a
styrene, a polyvinyl, a thio/ether polymer, a polyolefin, a
polystyrene, a polyacetate, a polyamide, a polyethylene, a
polyimide, a polycarbonate, or a polyvinylalcohol. In some
embodiments, the one or more latex polymers comprise a polyester.
In some embodiments, the polyester has a glass transition
temperature from -20 to 100.degree. C. In some embodiments, a latex
dispersion of the polyester has a zeta potential from -60 to -20
mV. In some embodiments, the one or more latex polymers comprise an
acrylic polymer. In some embodiments, the acrylic polymer is
self-crosslinking. In some embodiments, the coalescing agent
composition comprises one or more compounds comprising an aliphatic
composition, a cycloaliphatic composition, an ether composition, a
glycol composition, an alcohol composition, an ester composition, a
carbonate composition, a lactam composition, or a ketone
composition. In some embodiments, the coalescing agent composition
comprises ethylene glycol butyl ether. In some embodiments, the
surfactant composition comprises one or more of an anionic or a
nonionic surfactant. In some embodiments, the surfactant
composition comprises silicone. In some embodiments, the UV
stabilizer composition comprises one or more of a sulfonated
benzophenone, a benzotriazole, a salicylate, a cinnamate, a
triazole, or a triazine. In some embodiments, the UV stabilizer
composition comprises hydroxyphenyl triazine. In some embodiments,
the antioxidant composition comprises one or more of a
hydroquinone, an alkoxyphenol, a dialkoxyphenol, a phenol, an
aniline, an amine, an indane, a chromane, an alkoxyaniline, or a
heterocyclic compound. In some embodiments, the antioxidant
composition comprises a hindered amine light stabilizer. In some
embodiments, the solvent comprises one or more of glycol ether, a
diol, an ester, ethanol, or water. In some embodiments, the solvent
comprises water.
[0009] In some embodiments, a pretreated natural fiber fabric
product includes a natural fiber fabric and a polymer coating on
the natural fiber fabric, the polymer coating includes: 20 to 90
wt. % one or more latex polymers; 0.4 to 7 wt. % surfactant
composition; and 1 to 8 wt. % ultraviolet (UV) stabilizer
composition. In some embodiments, the natural fiber fabric
comprises one or more of wool, cotton, silk, linen, leather, hemp,
or bamboo. In some embodiments, the pretreated natural fiber fabric
product comprises a T-shirt. In some embodiments, the pretreated
natural fiber fabric includes an image printed using dye
sublimation ink. In some embodiments, the one or more latex
polymers comprise one or more of a polyester, an acrylic polymer,
an aromatic polyamide, a chlorinated polymer, a polyether, a
polyurea, a fluorinated polymer, a polyurethane, a styrene, a
polyvinyl, a thio/ether polymer, a polyolefin, a polystyrene, a
polyacetate, a polyamide, a polyethylene, a polyimide, a
polycarbonate, or a polyvinylalcohol. In some embodiments, the one
or more latex polymers comprise a polyester. In some embodiments,
the polyester has a glass transition temperature from -20 to
100.degree. C. In some embodiments, a latex dispersion of the
polyester has a zeta potential from -60 to -20 mV. In some
embodiments, the one or more latex polymers comprise acrylic
polymer. In some embodiments, the acrylic polymer is
self-crosslinking. In some embodiments, the coalescing agent
composition comprises one or more compounds comprising an aliphatic
composition, a cycloaliphatic composition, an ether composition, a
glycol composition, an alcohol composition, an ester composition, a
carbonate composition, a lactam composition, or a ketone
composition. In some embodiments, the coalescing agent composition
comprises ethylene glycol butyl ether. In some embodiments, the
surfactant composition comprises one or more of an anionic or a
nonionic surfactant. In some embodiments, the surfactant
composition comprises silicone. In some embodiments, the UV
stabilizer composition comprises one or more of a sulfonated
benzophenone, a benzotriazole, a salicylate, a cinnamate, a
triazole, or a triazine. In some embodiments, the UV stabilizer
composition comprises hydroxyphenyl triazine. In some embodiments,
the antioxidant composition comprises one or more of a
hydroquinone, an alkoxyphenol, a dialkoxyphenol, a phenol, an
aniline, an amine, an indane, a chromane, an alkoxyaniline, or a
heterocyclic compound. In some embodiments, the antioxidant
composition comprises a hindered amine light stabilizer.
[0010] In some embodiments, a pretreated natural fiber fabric
product includes natural fiber fabric and a polymer coating on the
natural fiber fabric, wherein the pretreated natural fiber fabric
product is produced by spraying the natural fiber fabric with 8 to
15 grams of a pretreatment composition per square inch of natural
fiber fabric. In some embodiments, the pretreatment composition
includes 15 to 35 wt. % one or more latex polymers; 15 to 35 wt. %
one or more humectants; 0.1 to 1 wt. % surfactant composition; 0.1
to 1 wt. % ultraviolet (UV) stabilizer composition; 0.1 to 1 wt. %
one or more pH buffers; 0.05 to 0.5 wt. % biocide; and 40 to 60 wt.
% solvent. In some embodiments, the pretreated natural fiber
product includes an image printed using dye sublimation ink. In
some embodiments, the natural fiber fabric comprises one or more of
wool, cotton, silk, linen, leather, hemp, or bamboo. In some
embodiments, the pretreated natural fiber fabric product is a
T-shirt. In some embodiments, the one or more latex polymers
comprise one or more of a polyester, an acrylic polymer, an
aromatic polyamide, a chlorinated polymer, a polyether, a polyurea,
a fluorinated polymer, a polyurethane, a styrene, a polyvinyl, a
thio/ether polymer, a polyolefin, a polystyrene, a polyacetate, a
polyamide, a polyethylene, a polyimide, a polycarbonate, or a
polyvinylalcohol. In some embodiments, the one or more latex
polymers comprise a polyester. In some embodiments, the polyester
has a glass transition temperature from 0 to 100.degree. C. In some
embodiments, a latex dispersion of the polyester has a zeta
potential from -60 to -20 mV. In some embodiments, the one or more
latex polymers comprise acrylic polymer. In some embodiments, the
acrylic polymer is self-crosslinking. In some embodiments, the
coalescing agent composition comprises one or more compounds
comprising an aliphatic composition, a cycloaliphatic composition,
an ether composition, a glycol composition, an alcohol composition,
an ester composition, a carbonate composition, a lactam
composition, or a ketone composition. In some embodiments, the
coalescing agent composition comprises ethylene glycol butyl ether.
In some embodiments, the surfactant composition comprises one or
more of an anionic or a nonionic surfactant. In some embodiments,
the surfactant composition comprises silicone. In some embodiments,
the UV stabilizer composition comprises one or more of a sulfonated
benzophenone, a benzotriazole, a salicylate, a cinnamate, a
triazole, or a triazine. In some embodiments, the UV stabilizer
composition comprises hydroxyphenyl triazine. In some embodiments,
the antioxidant composition comprises one or more of a
hydroquinone, an alkoxyphenol, a dialkoxyphenol, a phenol, an
aniline, an amine, an indane, a chromane, an alkoxyaniline, or a
heterocyclic compound. In some embodiments, the antioxidant
composition comprises a hindered amine light stabilizer.
[0011] In some embodiments, a method of pretreating a natural fiber
fabric includes spraying a natural fiber fabric with 8 to 15 grams
pretreatment composition per square inch of natural fiber fabric to
produce sprayed natural fiber fabric; and drying the sprayed
natural fiber fabric to form a pretreated natural fiber fabric
product. In some embodiments, the pretreatment composition includes
15 to 35 wt. % one or more latex polymers; 15 to 35 wt. % one or
more humectants; 0.1 to 1 wt. % surfactant composition; 0.1 to 1
wt. % ultraviolet (UV) stabilizer composition; 0.1 to 1 wt. % one
or more pH buffers; 0.05 to 0.5 wt. % biocide; and 40 to 60 wt. %
solvent. In some embodiments, the pretreated natural fiber product
includes an image printed using dye sublimation ink. In some
embodiments, the natural fiber fabric comprises one or more of
wool, cotton, silk, linen, leather, hemp, or bamboo. In some
embodiments, the pretreated natural fiber fabric product is a
T-shirt. In some embodiments, the one or more latex polymers
comprise one or more of a polyester, an acrylic polymer, an
aromatic polyamide, a chlorinated polymer, a polyether, a polyurea,
a fluorinated polymer, a polyurethane, a styrene, a polyvinyl, a
thio/ether polymer, a polyolefin, a polystyrene, a polyacetate, a
polyamide, a polyethylene, a polyimide, a polycarbonate, or a
polyvinylalcohol. In some embodiments, the one or more latex
polymers comprise a polyester. In some embodiments, the polyester
has a glass transition temperature from 0 to 100.degree. C. In some
embodiments, a latex dispersion of the polyester has a zeta
potential from -60 to -20 mV. In some embodiments, the one or more
latex polymers comprise acrylic polymer. In some embodiments, the
acrylic polymer is self-crosslinking. In some embodiments, the
coalescing agent composition comprises one or more compounds
comprising an aliphatic composition, a cycloaliphatic composition,
an ether composition, a glycol composition, an alcohol composition,
an ester composition, a carbonate composition, a lactam
composition, or a ketone composition. In some embodiments, the
coalescing agent composition comprises ethylene glycol butyl ether.
In some embodiments, the surfactant composition comprises one or
more of an anionic or a nonionic surfactant. In some embodiments,
the surfactant composition comprises silicone. In some embodiments,
the UV stabilizer composition comprises one or more of a sulfonated
benzophenone, a benzotriazole, a salicylate, a cinnamate, a
triazole, or a triazine. In some embodiments, the UV stabilizer
composition comprises hydroxyphenyl triazine. In some embodiments,
the antioxidant composition comprises one or more of a
hydroquinone, an alkoxyphenol, a dialkoxyphenol, a phenol, an
aniline, an amine, an indane, a chromane, an alkoxyaniline, or a
heterocyclic compound. In some embodiments, the antioxidant
composition comprises a hindered amine light stabilizer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will now be described, by way of example only,
with reference to the accompanying drawings, in which:
[0013] FIGS. 1A-1D provide the various stages of pretreating
fabric, according to some embodiments.
DETAILED DESCRIPTION
[0014] Provided are pretreatment compositions, pretreated natural
fiber fabrics, methods for preparing pretreatment compositions, and
methods for pretreating that can be applied to natural fiber
fabrics to make the fabric suitable for dye sublimation ink
printing. By treating natural fiber fabrics with the pretreatment
compositions and/or methods of pretreating provided herein, dye
sublimation inks may adhere more easily to the natural fiber
fabrics. Additionally, pretreating natural fiber fabrics with a
pretreatment composition described herein can improve properties
such as crock, hand, colorfastness to laundering, adhesion, color
density, etc. when printed with dye sublimation ink as compared to
non-treated natural fiber fabrics printed with dye sublimation
inks.
[0015] Dye sublimation inks are sometimes used to print onto a
film. This film can then be transferred to a natural fiber fabric
using a heat press to create a printed natural fiber fabric.
However, this method does not allow for a user to print onto the
fabric. Additionally, this method is limited because only color
images having 100% density can be transferred, the thickness of the
film leads to poor hand (i.e., a subjective characteristic that
includes smoothness, compressibility, and elasticity of the
fabric), the tested colorfastness to laundering is poor, and it
causes a reduction in the elasticity or elongation of the
fabric.
[0016] Accordingly, pretreatment compositions provided herein have
been developed to coat natural fiber fabrics and improve the
adhesion of colorants (e.g., dye sublimation ink) to the fabric.
These pretreatment compositions, in addition to methods for
pretreating disclosed herein, improve the adhesion of dye
sublimation ink to the natural fiber fabric specifically because
natural fiber fabrics are hydrophilic, whereas synthetic fibers are
hydrophobic. The hydrophilicity of the natural fiber fabric impairs
the ability of dye sublimation inks to adhere and absorb into the
natural fibers. Pretreatment compositions and methods of
pretreating provided herein can provide a synthetic, or polymeric
coating on the surface of the natural fibers of a natural fiber
fabric. This synthetic, polymeric coating dries onto the fibers of
the fabric and conforms to the surface of the fabric. Further, the
coating can in turn provide hydrophobic characteristics to the
natural fiber fabric, increasing the affinity of the dye
sublimation ink to the fabric. More specifically, the dye
sublimation ink can adhere and absorb into the synthetic, polymeric
coating of the pretreatment without penetrating the natural fibers
of the natural fiber fabric. Thus, pretreating natural fiber
fabrics can allow for a more permanent printed image, in contrast
to a dye sublimation ink-printed image on a non-pretreated natural
fiber that will penetrate the fibers and fail to withstand
laundering, for example.
[0017] Accordingly, pretreatment compositions provided herein can
provide a coating that adheres to the natural fibers of the natural
fiber fabric and also provides an ink-receptive coating for dye.
Provided below is a discussion of the various components of
pretreatment compositions provided herein. In particular, discussed
below are: (1) pretreatment compositions; (2) methods of preparing
pretreatment compositions; (3) methods of pretreating fabrics; and
(4) pretreated fabrics.
Pretreatment Compositions
[0018] Pretreatment compositions according to embodiments provided
herein may include a polymer, a coalescing agent, a surfactant, an
antioxidant/ultraviolet light absorber, a humectant(s), a pH
buffer(s), a biocide(s), and/or water. A pretreatment composition
comprising each of these components can provide a coating that
adheres to the natural fibers of the natural fiber fabric and also
provides an ink-receptive coating for dye. As described above, the
pretreatment compositions provided herein may be used with natural
fiber fabric, synthetic fabric, or a fabric comprising a
combination of natural and synthetic fibers. Note that the
weight-percents provided with respect to each of these components
refer to pretreatment compositions prior to pretreating fabric,
unless stated otherwise.
[0019] In some embodiments, pretreatment compositions described
herein may include a polymer composition. A polymer provides a
component for the dyes to attach to during the printing process. In
some embodiments, the polymer composition may include a latex
polymer. In some embodiments, the polymer composition may include a
non-latex polymer. Suitable latex polymers may include, but are not
limited to, a polyester, an acrylic polymer, an aromatic polyamide,
a chlorinated polymer, a polyether, a polyurea, a fluorinated
polymer, a polyurethane, a styrene, a polyvinyl, a thio/ether
polymer, a polyolefin, a polystyrene, a polyacetate, a polyamide, a
polyethylene, a polycarbonate, or a polyvinylalcohol and/or any
other suitable dispersed or emulsified natural or synthetic
polymers. The polymer(s) may be in an aqueous- or a solvent-based
environment. In some embodiments, the polymer(s) may be soluble in
the pretreatment composition. In some embodiments, the polymer(s)
may be dispersed as particulates in the pretreatment composition.
In some embodiments, a pretreatment composition provided herein may
comprise 10 to 40 wt. %, 15 to 35 wt. %, 20 to 30 wt. %, 25 to 30
wt. % or 26.6 wt. % polymer composition. In some embodiments, a
pretreatment composition may comprise less than 40 wt. %, less than
35 wt. %, less than 30 wt. %, less than 25 wt. %, less than 20 wt.
%, less than 15 wt. %, less than 10 wt. %, or less than 5 wt. %
polymer composition. In some embodiments, a pretreatment
composition may include more than 1 wt. %, more than 5 wt. %, more
than 10 wt. %, more than 15 wt. %, more than 20 wt. %, more than 25
wt. %, more than 30 wt. %, more than 35 wt. %, or more than 40 wt.
% polymer composition.
[0020] In some embodiments, the polymer may be a polyester latex.
Polyester latex provides a dye receptor (i.e., coating) that can
accept the diffusion of the dye (e.g., sublimating dye). A dye
receptor can increase the color density and can improve the
colorfastness to laundering of the printed image. Additionally, a
polyester latex can adhere to natural fibers. Thus, pretreatment
compositions comprising polyester latex can adhere to the natural
fibers of a natural fiber fabric, forming a coating over the
natural fiber fabric. Once the coating is formed over the natural
fiber fabric, it can act as an adhesive between the dye sublimation
ink and natural fiber fabric. Polyester latex in pretreatment
compositions provided herein may be in dispersed form. Dispersed
polyester may be formed from one or more of diols, diacids, and/or
anhydrides through a step-growth (condensation) synthesis
process.
[0021] In some embodiments, a polyester that may be used for a
polyester latex may have a relatively high glass transition
temperature. A relatively high glass transition temperature can
improve the abrasion resistance and colorfastness to laundering. If
the glass transition temperature of the polyester is too low, the
abrasion resistance and colorfastness to laundering may be
compromised. For instance, the glass transition temperature of a
polyester may be from -30.degree. C. to 50.degree. C., from
-20.degree. C. to 40.degree. C., from -20.degree. C. to 100.degree.
C., or 0.degree. C. to 100.degree. C. from 0.degree. C. to
30.degree. C. In some embodiments, the glass transition temperature
of the polyester may be less than 110.degree. C., less than
100.degree. C., less than 90.degree. C., less than 80.degree. C.,
less than 70.degree. C., less than 60.degree. C., less than
50.degree. C., less than 40.degree. C., less than 30.degree. C.,
less than 20.degree. C., less than 10.degree. C., less than
0.degree. C., less than -10.degree. C., or less than -20.degree. C.
In some embodiments, the glass transition temperature of the
polyester may be greater than -30.degree. C., greater than
-20.degree. C., greater than -10.degree. C., greater than 0.degree.
C., greater than 10.degree. C., greater than 20.degree. C., greater
than 30.degree. C., greater than 40.degree. C., greater than
50.degree. C., greater than 60.degree. C., greater than 70.degree.
C., greater than 80.degree. C., greater than 90.degree. C., greater
than 100.degree. C., or greater than 110.degree. C.
[0022] Pretreatment compositions comprising polyester latex may
also improve abrasion resistance and colorfastness to laundering.
In particular, the surface charge density of a polyester latex may
impact the abrasion resistance and colorfastness to laundering. In
some embodiments, the polyester latex of a pretreatment composition
may have a surface charge density from 0.1 to 1 milliequivalent per
gram (meq/g), from 0.2 to 0.9 meq/g, or from 0.3 to 0.8 meq/g. In
some embodiments, the surface charge density of a polyester latex
may be less than 1 meq/g, less than 0.9 meq/g, less than 0.8 meq/g,
less than 0.7 meq/g, less than 0.6 meq/g, less than 0.5 meq/g, less
than 0.4 meq/g, or less than 0.3 meq/g. In some embodiments, the
surface charge density of a polyester latex may be greater than 0.1
meq/g, greater than 0.2 meq/g, greater than 0.3 meq/g, greater than
0.4 meq/g, greater than 0.5 meq/g, greater than 0.6 meq/g, greater
than 0.7 meq/g, or greater than 0.8 meq/g.
[0023] Zeta potential is the electrokinetic potential of a
colloidal dispersion. The zeta potential of a latex dispersion
(e.g., polyester latex, acrylic latex) may be from -100 to -10,
from -80 to -20, from -60 to -20, or from -60 to -30 mV. In some
embodiments, the zeta potential of a latex dispersion of a
pretreatment composition provided herein may be less than -10, less
than -20, less than -30, less than -40, less than -50, less than
-60, less than -70, less than -80, or less than -90 mV. In some
embodiments, the seta potential of a latex dispersion of a
pretreatment composition provided herein may be more than -100,
more than -90, more than -80, more than -70, more than -60, more
than -50, more than -40, more than -30, or more than -20 mV.
[0024] In some embodiments, a pretreatment composition provided
herein may comprise 1 to 40 wt. %, 5 to 30 wt. %, 10 to 20 wt. %,
15 to 20 wt. % or 16.6 wt. % polyester. In some embodiments, a
pretreatment composition may comprise less than 40 wt. %, less than
35 wt. %, less than 30 wt. %, less than 25 wt. %, less than 20 wt.
%, less than 15 wt. %, less than 10 wt. %, or less than 5 wt. %
polyester. In some embodiments, a pretreatment composition may
include more than 1 wt. %, more than 5 wt. %, more than 10 wt. %,
more than 15 wt. %, more than 20 wt. %, more than 25 wt. %, more
than 30 wt. %, or more than 35 wt. % polyester. Suitable
commercially-available polyesters may include Eastek 1200
(Eastman), Eastek 1400 (Eastman), Vylonol.RTM. MD-100 (Toyobo),
Vylonol.RTM. MD-1480 (Toyobo), Vylonol.RTM. MD-1335 (Toyobo), and
Vylonol.RTM. MD-1930 (Toyobo).
[0025] In some embodiments, a pretreatment composition according to
embodiments provided herein may comprise an acrylic latex. An
acrylic latex may be included in addition to, or in lieu of, the
polyester latex described above. The acrylic latex may include a
self-crosslinking acrylic polymer or a non-self-crosslinking
acrylic polymer. A self-crosslinking acrylic polymer may reduce the
solubility and improve the adhesion of the pretreatment coating on
a pretreated fabric ensuring further improvement in washability. In
some embodiments, a pretreatment composition provided herein may
comprise 1 to 30 wt. %, 1 to 20 wt. %, 5 to 15 wt. %, 8 to 12 wt. %
or 10 wt. % acrylic polymer. In some embodiments, a pretreatment
composition may comprise less than 40 wt. %, less than 35 wt. %,
less than 30 wt. %, less than 25 wt. %, less than 20 wt. %, less
than 15 wt. %, less than 10 wt. %, or less than 5 wt. % acrylic
polymer. In some embodiments, a pretreatment composition may
include more than 1 wt. %, more than 5 wt. %, more than 10 wt. %,
more than 15 wt. %, more than 20 wt. %, more than 25 wt. %, more
than 30 wt. %, or more than 35 wt. % acrylic polymer. Acrylic
polymers used in pretreatment compositions disclosed herein may be
produced by chain polymerization using one or more of alkyl
(cyclo)alkyl (meth)acrylate, (meth)acrylic acid, hydroxyalkyl
(meth)acrylates, glycidyl group-containing addition polymerizable
monomer, n-methylol(meth)acrylamide, and/or monovinyl aromatic
compounds. For example, commercially-available acrylic polymers
include Acrygen 61192 (OMNOVA Solutions) and Mowinyl 6760.
[0026] Pretreatment compositions including too much acrylic latex
may cause poor color density in a printed image. Pretreatment
compositions including too little acrylic latex may not reduce the
solubility to the necessary extent to improve the washability of
the printed image. In some embodiments, a pretreatment composition
provided herein may comprise 1 to 40 wt. %, 5 to 30 wt. %, or 8 to
20 wt. % acrylic latex. In some embodiments, a pretreatment
composition may comprise less than 40 wt. %, less than 35 wt. %,
less than 30 wt. %, less than 25 wt. %, less than 20 wt. %, less
than 15 wt. %, less than 10 wt. %, less than 8 wt. %, or less than
5 wt. % acrylic latex. In some embodiments, a pretreatment
composition may include more than 1 wt. %, more than 5 wt. %, more
than 8 wt. %, more than 10 wt. %, more than 15 wt. %, more than 20
wt. %, more than 25 wt. %, more than 30 wt. %, or more than 35 wt.
% acrylic latex.
[0027] Pretreatment compositions described herein may include more
than one type of latex. For example, a pretreatment composition may
include both polyester latex and acrylic latex. In some
embodiments, the total amount of latex in a pretreatment
composition may be 2 to 80 wt. %, 10 to 60 wt. %, 10 to 40 wt. %,
15 to 35 wt. %, 20 to 30 wt. %, 25 to 30 wt. %, or 26.6 wt. %. In
some embodiments, the total amount of latex in a pretreatment
composition may be less than 80 wt. %, less than 70 wt. %, less
than 60 wt. %, less than 50 wt. %, less than 40 wt. %, less than 30
wt. %, less than 25 wt. %, less than 18 wt. %, or less than 10 wt.
%. In some embodiments, the total amount of latex in a pretreatment
composition may be more than 2 wt. %, more than 10 wt. %, more than
18 wt. %, more than 20 wt. %, more than 25 wt. %, more than 30 wt.
%, more than 40 wt. %, more than 50 wt. %, more than 60 wt. %, or
more than 70 wt. %.
[0028] In some embodiments, a pretreatment composition may include
a coalescing agent composition. A coalescing agent can help a
pretreatment composition form a more uniform coating. In some
embodiments, a coalescing agent can help reduce the minimum film
formation temperature of the latex polymer(s), allowing the
pretreatment coating to dry faster at room temperature. Reducing
the minimum film formation temperature can create a more uniform
saturation level of the dye, as well as improved crock and
colorfastness. A lower minimum film formation temperature can also
increase the range of temperatures that the pretreatment
composition may be applied to a natural fiber fabric without
adversely affecting the performance characteristics of the coated
natural fiber fabric. Examples of suitable coalescing agents
include, but are not limited to, an aliphatic composition, a
cycloaliphatic composition, an ether composition, a glycol
composition, an alcohol composition, an ester composition, a
carbonate composition, a lactam composition, or a ketone
composition.
[0029] In some embodiments, the type of coalescing agent
composition may be dependent upon the type of latex used. The
coalescing agent of a pretreatment composition according to
embodiments provided herein may include ethylene glycol butyl
ether. Ethylene glycol butyl ether can lower the minimum film
formation temperature (MFFT) of the latex(es). Ethylene glycol
butyl ether also has a relatively high evaporation rate, which help
achieve the final film properties of the polymeric pretreatment
composition on the natural fiber fabric in a shorter period of
time. Pretreatment compositions comprising too little coalescing
agent may not sufficiently lower the MFFT. Pretreatment
compositions comprising too much of a coalescing agent composition
may alter the ratio of other components in the composition and the
properties of the composition. In some embodiments, a pretreatment
composition may include from 0.1 to 10 wt. %, from 0.3 to 8 wt. %,
or from 0.5 to 5 wt. % coalescing agent. In some embodiments, a
pretreatment composition may include less than 10 wt. %, less than
8 wt. %, less than 5 wt. %, less than 3 wt. %, or less than 1 wt. %
coalescing agent. In some embodiments, a pretreatment composition
may include more than 0.1 wt. %, more than 0.3 wt. %, more than 0.5
wt. %, more than 1 wt. %, more than 3 wt. %, or more than 5 wt. %
coalescing agent.
[0030] In some embodiments, a pretreatment composition may include
a surfactant composition. Surfactants in pretreatment compositions
provided herein can help increase the setting of the pretreatment
composition on various fabrics (e.g., synthetic, natural).
Specifically, a surfactant can improve the wetting of the
pretreatment composition onto the fabric. A surfactant can also
improve the hand, or feel, of the fabric by reducing the thickness
of the pretreatment coating on the fabric. Suitable surfactants
include, but are not limited to, anionic, cationic, nonionic,
and/or amphoteric surfactants. Specific examples of suitable
surfactants include BYK.RTM.-348 (BYK), Surfynol.RTM. 104 (Evonik
Industries), Surfynol.RTM. 504 (Evonik Industries), and Dynol.TM.
360 (Evonik Industries). Too much surfactant composition in a
pretreatment composition may not provide a sufficient polymer
coating on the fabric. Too little surfactant and the pretreatment
composition may not sufficiently spread to create a thin layer on
the fabric and/or may not provide desirable hand of the fabric. In
some embodiments, a pretreatment composition may include from 0.01
to 5 wt %, from 0.05 to 4 wt. %, from 0.1 to 3 wt. %, 0.1-2 wt. %,
0.1-1 wt. %, or 0.5 wt. % surfactant composition. In some
embodiments, a pretreatment composition may include less than 5 wt.
%, less than 4 wt. %, less than 3 wt. %, less than 2 wt. %, less
than 1 wt. %, less than 0.5 wt. %, less than 0.1 wt. %, or less
than 0.05 wt. % surfactant composition. In some embodiments, a
pretreatment composition may include more than 0.01 wt. %, more
than 0.05 wt. %, more than 0.1 wt. %, more than 0.5 wt. %, more
than 1 wt. %, or more than 3 wt. % surfactant composition.
[0031] Pretreatment compositions according to embodiments described
herein may also include an ultraviolet (UV) stabilizer composition.
A UV stabilizer composition in the pretreatment composition may
help increase the weatherfastness of the printed inks on the
pretreated fabric. Suitable UV stabilizer compositions include, but
are not limited to, sulfonated benzophenones, benzotriazoles,
salicylates, cinnamates, triazoles, and triazines. Specific
examples of commercially-available UV stabilizers that may be
suitable for pretreatment compositions provided herein may include
Tinuvin.RTM. 400 (BASF), Tinuvin.RTM. 477DW, or Chiguard.RTM. 5400
(Chitec). Both Tinuvin.RTM. 400 (BASF) and Chiguard.RTM. 5400
(Chitec) are hydroxyphenyl triazines. Pretreatment compositions
including too little UV stabilizer composition may not provide
enough protection against weather damage. Pretreatment compositions
including too much UV stabilizer composition may compromise the
beneficial effects of other components in the pretreatment
composition. In some embodiments, a pretreatment composition may
include from 0.01-1 wt. %, 0.1 to 1 wt. %, 0.25 wt. %, 0.1-0.5 wt.
%, 0.3 to 8 wt. %, 0.5 to 5 wt. % UV stabilizer composition. In
some embodiments, a pretreatment composition may include less than
10 wt. %, less than 8 wt. %, less than 5 wt. %, less than 3 wt. %,
less than 1 wt. %, less than 0.5 wt. %, less than 0.3 wt. %, or
less than 0.25 wt. % UV stabilizer composition. In some
embodiments, a pretreatment composition may include more than 0.01
wt. %, more than 0.05, more than 0.1 wt. %, more than 0.2 wt %,
more than 0.25 wt. % more than 0.3 wt. %, more than 0.5 wt. %, more
than 1 wt. %, more than 3 wt. %, more than 5 wt. %, or more than 8
wt. % UV stabilizer composition.
[0032] Pretreatment compositions provided herein may also include
an antioxidant composition. Like UV absorbers, described above,
antioxidants may help increase the weatherfastness of the printed
inks on the pretreated fabric. Suitable antioxidants include, but
are not limited to, hydroquinones, alkoxyphenols, dialkoxyphenols,
phenols, anilines, amines, indanes, chromanes, alkoxyanilines, and
heterocyclic compounds. Specific examples of antioxidants that may
be suitable for pretreatment compositions provided herein may
include Chiguard.RTM. 101WB (Chitec) or Tinuvin.RTM. 123 DW (BASF).
In some embodiments, a pretreatment composition may include from
0.01-1 wt. %, 0.1 to 1 wt. %, 0.25 wt. %, 0.1-0.5 wt. %, 0.3 to 8
wt. %, 0.5 to 5 wt. % antioxidant. In some embodiments, a
pretreatment composition may include less than 10 wt. %, less than
8 wt. %, less than 5 wt. %, less than 3 wt. %, less than 1 wt. %,
less than 0.5 wt. %, less than 0.3 wt. %, or less than 0.25 wt. %
antioxidant. In some embodiments, a pretreatment composition may
include more than 0.01 wt. %, more than 0.05, more than 0.1 wt. %,
more than 0.2 wt %, more than 0.25 wt. % more than 0.3 wt. %, more
than 0.5 wt. %, more than 1 wt. %, more than 3 wt. %, more than 5
wt. %, or more than 8 wt. % antioxidant.
[0033] Pretreatment compositions provided herein may also include
at least one humectant. Humectants can help ensure that the
pretreatment composition does not prematurely dry. Suitable types
of humectants that can be used are alcohols, glycols, polyols,
glycol ethers, ketones, esters, carbonates, lactams and/or
lactones. More specifically, suitable humectants include, but are
not limited to, glycerine and dipropylene glycol. In some
embodiments, a pretreatment composition may include 10-40 wt. %,
15-35 wt. %, 20-30 wt. %, or 25 wt. % humectant(s). In some
embodiments, a pretreatment composition may include less than 50 wt
%, less than 45 wt. %, less than 40 wt. %, less than 35 wt. %, less
than 30 wt. %, less than 27 wt. %, less than 25 wt. %, less than 20
wt. %, or less than 15 wt. % humectant(s). In some embodiments, a
pretreatment composition may include more than 5 wt. %, more than
10 wt. %, more than 15 wt. %, more than 20 wt. %, more than 23 wt.
%, more than 25 wt. %, more than 30 wt. %, or more than 35 wt. %
humectant.
[0034] Pretreatment compositions provided herein may also include
at least one pH buffer. Suitable classes of compounds are the
following: amines, organic and inorganic buffers. Specific examples
of amines include but are not limited to alkylamines, ammonia (in
equilibrium with ammonium hydroxide), ethanolamine derivatives,
pyridine derivatives, and/or amino acids. Specific examples of
organic and inorganic buffers include, but are not limited to,
Trizma ((tris)hydroxymethylaminomethane), MOPS
(4-morpholinopro-panesulfonic acid), MES
(4-morpholinoethanesulfonic acid), sodium acetate, sodium
bicarbonate, sodium dihydrogen phosphate, phosphonates and organic
phosphates. In some embodiments, the pH of the pretreatment
composition is between about 6 and 10. Suitable pH buffers include,
but are not limited to, triethanolamine. In some embodiments, a
pretreatment composition may include from 0.1 to 2 wt. %, from 0.1
to 1 wt. %, from 0.3 to 0.7 wt. %, or 0.5 wt. % pH buffer(s). In
some embodiments, a pretreatment composition may include less than
5 wt. %, less than 3 wt. %, less than 2 wt. %, less than 1 wt. %,
less than 0.75 wt. %, less than 0.5 wt. %, or less than 0.25 wt. %
pH buffer(s). In some embodiments, a pretreatment composition may
include more than 0.1 wt. %, more than 0.3 wt. %, more than 0.4 wt.
%, more than 0.5 wt. %, more than 0.75 wt. %, more than 1 wt. %,
more than 2 wt. %, or more than 3 wt. % pH buffer(s).
[0035] Pretreatment compositions provided herein may also include
at least one biocide. Biocides can help prevent the formation of
bacteria and/or fungus (e.g., mold) in the pretreatment
composition. Suitable types of biocides include, but are not
limited to, 1,2-Benzisothiazolin-3-one (BIT),
methylchloroisothizolinone (CMIT), methylisothiazolinone (MIT),
2-Bromo-2-nitro-propane-1,3 diol (Bronopol), Formaldehyde releasing
biocides (FA-R), and/or dodecylguanidine hydrochloride (DGH).
Suitable biocides include, but are not limited to, Proxel GXL. In
some embodiments, a pretreatment composition may include from 0.01
to 1 wt. %, from 0.05 to 0.5 wt. %, from 0.1 to 0.2 wt. %, or 0.15
wt. % biocide(s). In some embodiments, a pretreatment composition
may include less than 2 wt. %, less than 1 wt. %, less than 0.75
wt. %, less than 0.5 wt. %, less than 0.25 wt. %, less than 0.2 wt.
%, or less than 0.15 wt. % biocide(s). In some embodiments, a
pretreatment composition may include more than 0.01 wt. %, more
than 0.05 wt. %, more than 0.075 wt. %, more than 0.1 wt. %, more
than 0.15 wt. %, more than 0.2 wt. %, or more than 0.5 wt. %
biocide(s).
[0036] In some embodiments, pretreatment compositions described
herein include a solvent. Suitable solvents may include glycol
ether, diols, esters, ethanol and/or water. For example, a
pretreatment composition may include from 10 to 80 wt. % solvent,
from 20 to 70 wt. % solvent, from 30-60 wt. %, from 40-50 wt. %,
from 45-50 wt. %, 47 wt. % solvent. In some embodiments, a
pretreatment composition may include less than 80 wt. %, less than
75 wt. %, less than 70 wt. %, less than 60 wt. %, less than 50 wt.
%, less than 45 wt. %, less than 40 wt. %, or less than 30 wt. %
solvent. In some embodiments, a pretreatment composition may
include more than 20 wt. %, more than 30 wt. %, more than 40 wt. %,
more than 45 wt. %, more than 50 wt. %, more than 60 wt. %, more
than 70 wt. %, or more than 75 wt. % solvent.
[0037] In some embodiments, after pretreatment and drying of the
pretreatment composition, the pretreatment coating may comprise 20
to 90 wt. % latex polymer, 2 to 8 wt. % coalescing agent
composition, 0.4 to 7 wt. % surfactant composition, 1 to 8 wt. %
ultraviolet (UV) stabilizer composition, 1 to 8 wt. % antioxidant
composition, 20 to 90 wt. % humectant(s), 0.01-1 wt. % pH
buffer(s), and/or 0.01-1 wt. % biocide(s).
Preparing Pretreatment Compositions
[0038] Provided below are methods of preparing pretreatment
compositions.
[0039] Each of the components are measured/weighed in a suitable
container (e.g., neoprene beaker) using a microbalance. The solvent
and humectant(s) can be added first, and then the latex with the
lowest pH. The components can be mixed together using a suitable
mixing device, such as a magnetic stirrer or a mechanical stirrer.
Once the solvent and latex are mixed, the pH of the mixture is
adjusted using a basic solution until the pH of the mixture reaches
a value close to the pH of the next latex to be added. The next
latex is added to the solution while the mixture is being
stirred.
[0040] The coalescing agent composition can be diluted and added to
the solution slowly. The rest of the components may be added to the
solution and mixed in any order.
Methods of Pretreating Natural Fiber Fabric
[0041] Provided below are methods of pretreating fabrics according
to some embodiments provided herein. In some embodiments, methods
may be used to pretreat natural fiber fabrics. Methods may also be
used to treat synthetic fabrics. In some embodiments, methods may
be used to treat fabrics that have both natural and synthetic
fibers.
[0042] FIGS. 1A-1C provide various phases of a method of
pretreating fabric.
[0043] FIG. 1A includes fabric 102 and pretreatment composition
104. Fabric 102 may comprise a natural fiber fabrics including, but
not limited to, wool, hemp, jute, cotton, silk, linen, leather,
hemp, or bamboo. In some embodiments, fabric 102 may comprise a
synthetic fiber fabric including, but not limited to, nylon,
Kevlar, spandex, polyester, polyvinyl chloride, or rayon. In some
embodiments, fabric 102 may comprise a combination of natural fiber
fabric and synthetic fiber fabric. In some embodiments, methods may
use pretreatment compositions discussed above to treat fabrics.
[0044] Pretreatment composition 104 is shown in droplet form in
FIG. 1A. Specifically, pretreatment composition 104 has been
applied to fabric 102, but has not yet formed a dry coating.
Pretreatment composition 104 may be applied to fabric 102 using
various methods including, but not limited to, ink-jetting,
spraying, dip-coating, and/or roll-to-roll processes. For example,
fabric 102 (such as a T-shirt) may be pretreated by using a
spraying process.
[0045] If too much pretreatment composition is applied to the
fabric, it may take away from the benefits of the natural fiber
fabric (e.g., sustainability, durability, biodegradability, etc.).
If too little pretreatment composition is applied to the fabric,
the pretreated product won't lend itself to a high-quality printed
image (particularly with dye sublimation ink) The size of the
fabric area to be printed on is measure and the amount of
pretreatment composition is calculated based on the desired amount
of pretreatment composition per square inch of fabric.
[0046] In some embodiments, 0.001 to 1 grams of pretreatment
composition per square inch (g/in.sup.2) of fabric surface area
applied. In some embodiments, 0.01 to 0.8 or 0.05 to 0.5 g/in.sup.2
pretreatment composition is applied. In some embodiments, less than
1 g/in.sup.2, less than 0.8 g/in.sup.2, less than 0.5 g/in.sup.2,
less than 0.3 g/in.sup.2, less than 0.2 g/in.sup.2, less than 0.1
g/in.sup.2, less than 0.05 g/in.sup.2, or less than 0.01 g/in.sup.2
pretreatment composition is applied. In some embodiments, more than
0.001 g/in.sup.2, more than 0.01 g/in.sup.2, more than 0.05
g/in.sup.2, more than 0.1 g/in.sup.2, more than 0.2 g/in.sup.2,
more than 0.3 g/in.sup.2, more than 0.5 g/in.sup.2, or more than
0.8 g/in.sup.2 pretreatment composition is applied.
[0047] FIG. 1B shows heat press or calender 106 being applied to
pretreatment composition 104 on fabric 102. In some embodiments,
the heat press or calender can apply uniform pressure during the
pretreatment application for improved color and washability. In
some embodiments, pretreatment composition 104 may air dry without
the application of a heat press. Heat press 106 may apply heat from
40 to 250.degree. C., from 50 to 150.degree. C., or from 60 to
100.degree. C. In some embodiments, heat press 106 may apply heat
that is less than 250.degree. C., less than 200.degree. C., less
than 150.degree. C., less than 120.degree. C., less than
100.degree. C., less than 90.degree. C., less than 80.degree. C.,
less than 70.degree. C., less than 60.degree. C., or less than
50.degree. C. In some embodiments, heat press may apply heat that
is more than 40.degree. C., more than 50.degree. C., more than
60.degree. C., more than 70.degree. C., more than 80.degree. C.,
more than 90.degree. C., more than 100.degree. C., more than
120.degree. C., more than 150.degree. C., or more than 200.degree.
C.
[0048] In some embodiments, heat press 106 may be applied to the
pretreated fabric for 1 to 120 seconds, for 5 to 90 seconds, or for
10 to 60 seconds. In some embodiments, heat press 106 may be
applied for less than 120 seconds, less than 90 seconds, less than
60 seconds, less than 50 seconds, less than 40 seconds, less than
30 seconds, less than 20 seconds, or less than 10 seconds. In some
embodiments, heat press 106 may be applied for more than 1 second,
more than 10 seconds, more than 20 seconds, more than 30 seconds,
more than 40 seconds, more than 50 seconds, more than 60 seconds,
or more than 90 seconds.
[0049] In some embodiments, instead of heat press 106, the
pretreated fabric may be placed in an oven to dry. In some
embodiments, an oven may heat the pretreated fabric from 40 to
250.degree. C., from 50 to 150.degree. C., or from 60 to
100.degree. C. In some embodiments, an oven may heat the pretreated
fabric less than 250.degree. C., less than 200.degree. C., less
than 150.degree. C., less than 120.degree. C., less than
100.degree. C., less than 90.degree. C., less than 80.degree. C.,
less than 70.degree. C., less than 60.degree. C., or less than
50.degree. C. In some embodiments, an oven may heat the pretreated
fabric more than 40.degree. C., more than 50.degree. C., more than
60.degree. C., more than 70.degree. C., more than 80.degree. C.,
more than 90.degree. C., more than 100.degree. C., more than
120.degree. C., more than 150.degree. C., or more than 200.degree.
C.
[0050] In some embodiments, an oven may heat the pretreated fabric
from 1 to 60, from 5 to 50, or from 10 to 40 minutes. In some
embodiments, the pretreated fabric may be heated in an oven for
less than 60 minutes, less than 50 minutes, less than 40 minutes,
less than 30 minutes, less than 20 minutes, less than 10 minutes,
or less than 5 minutes. In some embodiments, the pretreated fabric
may be heated in an oven for more than 1 minute, more than 5
minutes, more than 10 minutes, more than 20 minutes, more than 30
minutes, more than 40 minutes, or more than 50 minutes.
[0051] FIG. 1C shows a dry pretreatment coating 108 on fabric 102.
In some embodiments, after pretreatment and drying of the
pretreatment composition, the pretreatment coating may comprise 20
to 90 wt. % latex polymer, 2 to 8 wt. % coalescing agent
composition, 0.4 to 7 wt. % surfactant composition, 1 to 8 wt. %
ultraviolet (UV) stabilizer composition, 1 to 8 wt. % antioxidant
composition, 20 to 90 wt. % humectant(s), 0.01-1 wt. % pH
buffer(s), and/or 0.01-1 wt. % biocide(s). Once dry, colorants
including dye sublimation ink may be printed onto pretreated fabric
110.
[0052] FIG. 1D shows a pretreated fabric product 114 that includes
a printed image. Product 114 includes fabric 102 and colorant from
the printed image absorbed into the pretreatment coating (i.e.,
item 112). In some embodiments, the printed image may be applied
using dye sublimation ink. In some embodiments, the printed image
may be printed onto the pretreated natural fiber fabric product. In
some embodiments, the printed image may be printed onto a film and
then transferred onto the pretreated natural fiber fabric product.
For example, an image may be printed onto a standard transfer sheet
using a drop-on-demand printer, which can then be transferred onto
the dried pretreated natural fiber fabric using a heat press, for
example. In some embodiments, an image can be transferred using
heat press at about 300-500.degree. F., about 350-450.degree. F.,
about 350-400.degree. F., about 375-395.degree. F., about
380-390.degree. F., or about 385.degree. F. for about 10-200
seconds, about 30-150 seconds, about 35-125 seconds, about 75-125
seconds, about 80-100 seconds, about 85-95 seconds, or about 90
seconds.
Pretreated Fabrics
[0053] The pretreatment compositions described above may be used to
prepare various articles or products for printing. For example, a
pretreatment composition may be applied to an article of clothing
(e.g., T-shirt, sweater, dress), bedding, window treatment (e.g.,
curtains), and other types of fabrics that a consumer may wish to
print onto.
[0054] As described above, a coating provided by a pretreatment
composition can adhere to the fabric and allow the colorant (e.g.,
dye sublimation ink) to absorb and stay onto the pretreated fabric.
Various properties may be used to characterize the pretreated
fabric such as colorfastness to laundering, hand, crock,
weatherfastness, and color uniformity. These properties, in
addition to other properties that may be used to characterize the
pretreatment composition, are described in more detail below.
Testing Methods
[0055] Various chemical and physical properties may be used to
characterize the sufficiency of a pretreated natural fiber fabric.
In some embodiments, the pretreated natural fiber fabric may be
printed with an ink or dye (e.g., dye sublimation ink) prior to
characterization. Discussed below are properties used for
characterizing fabrics and the testing methods used for each.
[0056] Pretreatment Application: The pretreatment application of
the various examples can be applied using Method 1, Method 2,
and/or Method 3, described below.
[0057] Method 1: 0.11 g/in.sup.2 of pretreatment was added to each
cotton substrate. The pretreatment can be applied using either a
handheld sprayer or an automatic pretreatment machine. A piece of
parchment paper can placed on top of the treated fabric followed by
a piece of polyester fabric. The substrate can then be pressed
using a heat press at 385.degree. F. for 15 seconds.
[0058] Method 2: The cotton substrate can be dip coated at 75% wet
pickup (+/-5%) and then dried using an oven at 100.degree. C. at 5
meters/min.
[0059] Method 3: The amount of pretreatment added to each cotton
substrate can be 0.1 g/in.sup.2. The pretreatment can be applied
using a handheld sprayer onto a cotton t-shirt. The cotton t-shirt
can be setup with a section of aluminum of the same size as the
printed image inside the shirt and a plastic cut out of the print
image outside to ensure that no pretreatment is applied outside the
area where the print image will be transferred. Once the
pretreatment was applied, the shirt can be slipped onto the bottom
half of the heat press and the same aluminum substrate can be
placed inside. This can ensure that the area covered with
pretreatment will be the only area pressed. The shirt can be
pressed for 325 F for 10 seconds. This can reduce the level of
oxidation that the cotton undergoes and thus can reduce the
yellowing of the fabric. In some embodiments, the pretreatment
application of the pretreatment composition can be applied in an
amount of 0.01-5 g/in.sup.2, 0.5-1.5 g/in.sup.2, or 0.1 g/in.sup.2
and pressed at 200-400.degree. F., 250-400.degree. F.,
300-350.degree. F., or 325.degree. F. for 1-60 seconds, 1-30
seconds, 1-20 seconds, or 10 seconds.
[0060] Colorfastness to Laundering: A printed fabric's
colorfastness determines its ability to retain its depth and shade
throughout the life of the product, and in particular, throughout
laundering of the product. Ideally, a printed image on a fabric can
withstand the lifetime of the product without significantly
compromising the quality (e.g., depth, shade) of the printed image.
The colorfastness of a printed natural fiber fabric may be tested
using Method 1, Method 2, and/or Method 3, described below.
[0061] Method 1: Colorfastness to laundering may be tested by
placing a printed fabric sample measuring 4.5 inches by 5.5 inches
in a consumer washing machine and washed for 15 minutes with room
temperature water and 0.5 g of Tide.RTM. detergent per 0.5 L of
water. A standard wash cycle was used (cotton/medium) with a
standard spin cycle. (The sample was washed with 9-14 other printed
fabric samples). The printed fabric sample was rinsed with 0.5 L
water per sample for six minutes. The sample(s) was then spin-dried
for five minutes and placed in an oven at 60.degree. C. until
dry.
[0062] The washed and dried samples were analyzed using a Gretag
spectrophotometer for optical density, L, a*, and b* values. The
ink used was drawn down using a 2 Krod at speed 10 on a K Control
Coater (RKPrint) onto Wing Wing Hybrid transfer paper. The image
was transferred at 392.degree. F. for 40 seconds.
[0063] Method 2: Colorfastness to laundering may be tested by
placing a printed fabric sample measuring 9 inches by 5 inches was
placed in a consumer washing machine and washed for 15 minutes with
room temperature water and 0.5 g of Woolite.RTM. Delicate detergent
per 0.5 L of water. A standard wash cycle was used (cotton/medium)
with a standard spin cycle. (The sample was washed with 4-7 other
printed fabric samples). The printed fabric sample was rinsed with
0.5 L water per sample for six minutes. The sample(s) was then
spin-dried for five minutes and hung to air dry.
[0064] The washed and dried samples were analyzed using a Gretag
spectrophotometer for optical density, L, a*, and b* values. The
image was printed using a standard DOD inkjet printer (Mutoh 901x)
using standard dye sublimation inks onto Wing Wing Hybrid transfer
paper. The image was transferred at 385.degree. F. for 35
seconds.
[0065] Method 3: Colorfastness to laundering may be tested by
placing a printed fabric sample measuring 9 inches by 5 inches was
placed in a consumer washing machine and washed for 15 minutes with
room temperature water and 0.5 g of Woolite.RTM. Delicate detergent
per 0.5 L of water. A standard wash cycle was used (cotton/medium)
with a standard spin cycle. (The sample was washed with 4-7 other
printed fabric samples). The printed fabric sample was rinsed with
0.5 L water per sample for six minutes. The sample(s) was then
spin-dried for five minutes and hung to air dry.
[0066] The washed and dried samples were analyzed using a Gretag
spectrophotometer for optical density, L, a*, and b* values. The
image was printed using a standard DOD inkjet printer (Mutoh 901x)
using standard dye sublimation inks onto Jacquard pretreated
cotton. The image was heat pressed at 385.degree. F. for 35
seconds.
[0067] Particle Size and Polydispersity Index: The particle size
and polydispersity of a pretreatment compostion was measured using
ASTM E2490 (referring to the American Society for Testing and
Materials standards) Standard Guide for Measurement of Particle
Size Distribution of Nanomaterials in Suspension by Photon
Correlation Spectroscopy (PCS).
[0068] Zeta Potential: Zeta potential is the electrokinetic
potential of a colloidal dispersion. The zeta potential of a latex
dispersion (e.g., polyester latex, acrylic latex) and/or
pretreatment composition may be measured using ASTM E2865 Standard
Guide for Measurement of Electrophoretic Mobility and Zeta
Potential of Nanosized Biological Materials.
[0069] Fabric Hand: The hand of a fabric measures the "feel" of the
fabric against skin. The hand of a fabric can change with the
printing of an image on the fabric. However, it is generally not
desirable for the printed image to significantly impact the hand of
the fabric, particularly for wearable products. The hand of a
fabric was measured using standard AATCC EP 5 (referring to the
American Association of Fabric Chemists and Colorists standards)
Guidelines to the Subjective Evaluation of Fabric Hand. This
standard uses a scale of 1-5 to characterize the hand of the
fabric, where 1 is worst and 5 is best.
[0070] Crock Testing: Crock refers to the transfer of ink/dye from
the fabric to another. For example, if the ink/dye of a printed
image does not sufficiently adhere to the fabric, it may transfer
to another substrate that it contacts. Ideally, the ink/dye of a
printed image sufficiently adheres to the fabric to minimize any
tendency for the ink/dye to crock. Crock may be tested using
standard AATCC 8 Colorfastness to Crock: Crockmeter Method and a
scale of 1 to 5, 5 being the best, and 1 being the worst. AATCC 8
includes testing methods for wet crock and dry crock as well.
[0071] Weatherfastness: Weatherfastness may refer to the ability of
a printed image on a fabric to withstand extended periods of
weathering. For example, weatherfastness may refer to a printed
image's ability to resist fading when exposed to ultraviolet light.
A high quality printed image will have a higher tolerance to
weather and will be able to resist fading due to ultraviolet light
exposure. Weatherfastness may be tested using ASTM G154 Standard
Practice for Operating Fluorescent Light Apparatus for UV Exposure
of Nonmetallic Materials.
[0072] Color Measurement: The color uniformity of a printed image
may be tested. In many cases, a higher quality printed image will
have a higher uniformity. The color may be tested using ASTM
D2244-16 Standard Practice for Calculation of Color Tolerances and
Color Differences from Instrumentally Measured Color
Coordinates.
EXAMPLES
[0073] Provided below are several examples that highlight different
characteristics of specific components of a pretreatment
composition and/or the pretreatment compositions provided
herein.
Testing Different Latexes for Pretreatment Composition
[0074] Table 1 and 2 shows pretreatment compositions with different
types of latexes. Specifically, pretreatment compositions were
prepared and tested using seven different latex polymers: Acrygen
61192 (50%) (Omnova Solutions), Eastek 1200 (30%) (Eastman),
Vylonel MD-1100 (30%) (Toyobo), Eastek 1400 (30%) (Eastman),
Vylonel MD-1480 (25%) (Toyobo), Vylonel MD-1335 (30%) (Toyobo), and
Vylonel MD-1930 (31%) (Toyobo).
[0075] Table 1, below, shows the properties of each latex polymer
used in this trial.
TABLE-US-00001 TABLE 1 Properties of each of latex polymer tested.
Acrygen Eastek Eastek 61192 1200 MD-1100 1400 MD-1480 MD-1335
MD-1930 Tg (.degree. C.) -12 63 40 29 20 4 -10 Viscosity (cps) 30
100 2.0-7.0 15 <1.0 0.1-1.1 <1.0 pH 5 6.6 4.0-6.0 6 4.0-7.0
4.0-6.0 4.0-7.0 MFFT (deg C.) 27 <5 Solids % 43 30 30 30 25 30
31 Acid Value <3 <3 <3 <3 Ionic Character Non-Ionic
Anionic Anionic Chemistry Self Sulfo- Co-polyester Sulfo-
Co-polyester Co-polyester Co-polyester Crosslinking Polyester Resin
Polyester Resin Resin Resin Acrylic
[0076] Table 2, below, provides the type and amount of latex in
each of the seven different samples, in addition to a control.
TABLE-US-00002 TABLE 2 Amount of latex for each sample. Component:
Control Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6
Sample 7 DI Water 90.00 83.40 83.40 83.40 80.00 83.40 83.40 Acrygen
10.00 61192 (50%) Eastek 16.60 1200 (30%) Vylonal 16.60 MD-1100
(30%) Eastek 16.60 1400 (30%) Vylonal 20.00 MD-1480 (25%) Vylonal
16.60 MD-1335 (30%) Vylonal 16.60 MD-1930 (31%) TOTAL 0.00 100.00
100.00 100.00 100.00 100.00 100.00 100.00
[0077] Each latex composition was applied to a 100% cotton natural
fiber fabric by spraying using a consumer spray bottle with spray
trigger such that 0.11 g/in.sup.2 composition was applied (i.e.,
Method of Pretreatment 1). An image was printed on the treated
natural fiber fabric by printing the image using dye sublimation
ink onto a standard transfer sheet with a drop-on-demand printer
and transferring the image onto the dried natural fiber fabric
using a heat press at 370.degree. F. for 60 seconds. Table 3,
below, provides the charge density, particle size, polydispersity
index, zeta potential, fabric hand, crock wet, and crock dry of
each sample, tested using the methods provided above.
TABLE-US-00003 TABLE 3 Test results for each of the seven samples
(in addition to the control) treated with a different latex and
printed with dye sublimation ink. Testing Control Sample 1 Sample 2
Sample 3 Sample 4 Sample 5 Sample 6 Sample 7 Method Charge Density
(meq/g) 0.33 0.45 Particle Size (nm) 18.28 24.83 33.03 59.85 52.68
97.05 ASTM E2490 Polydispersity Index 0.227 0.154 0.265 0.196 0.177
0.115 ASTM E2490 Zeta Potential (mV) -56.72 -44.57 -58.26 -59.74
-56.56 -50.35 ASTM E2865 Fabric Hand 5 3 2 1 2.5 2.5 3.5 3.5 AATC 5
Crock Wet 3.5 3 2 3.5 3 3 2.5 2.5 AATC 8 Crock Dry 5 5 3 4 5 4 3.5
3 AATC 8
[0078] The particle size can indicate a composition's ability to
create a smoother and more uniform film. In particular, a
composition having a smaller particle size indicates better
film-forming properties than a larger particle size. As shown in
Table 3, the particle size may vary from about 15 to about 100 nm.
In some embodiments, the particle size may be from about 20 to
about 80 nm or from about 25 to about 60 nm. In some embodiments,
depending on the latex used, the particle size may be less than 100
nm, less than 90 nm, less than 80 nm, less than 70 nm, less than 60
nm, less than 50 nm, less than 40 nm, less than 30 nm, less than 25
nm, or less than 20 nm. In some embodiments, depending on the
latex, the particle size may be more than 15 nm, more than 20 nm,
more than 25 nm, more than 30 nm, more than 40 nm, more than 50 nm,
more than 60 nm, more than 70 nm, more than 80 nm, or more than 90
nm.
[0079] The polydispersity index may also vary depending on the type
of latex used. In some embodiments, depending on the latex, the
polydispersity index used may be from about 0.1 to about 0.3. In
some embodiments, the polydispersity index may be from about 0.15
to 0.25. Depending on the latex used, the polydispersity index may
be less than 0.3, less than 0.25, less than 0.2, or less than 0.15.
In some embodiments, the polydispersity index may be more than 0.1,
more than 0.15, more than 0.2, or more than 0.25.
[0080] As shown in Table 3, pretreating and printing a natural
fiber fabric can compromise the fabric hand to an extent.
Specifically, the control (an untreated sample) was tested at
having the "best" hand, with a value of 5. The samples pretreated
with a latex composition each exhibited a hand value from 1 to 3.5.
In some samples, the hand was less than 3.5, less than 3, less than
2.5, less than 2, or less than 1.5. In some samples, the hand value
was more than 1, more than 1.5, more than 2, more than 2.5, or more
than 3.
[0081] Pretreating and printing a natural fiber fabric can also
compromise the crock wet and the crock dry results. In particular,
the control sample tested a crock wet value of 3.5. However, the
crock wet values of the samples pretreated with the various latex
compositions tested a crock wet value of 2 to 3.5. For some types
of latex, the crock wet value was less than 3.5, less than 3, or
less than 2.5. For some types of latex, the crock wet value was
more than 2, more than 2.5, or more than 3. Additionally, the crock
dry value for the control sample was 5. However, the crock dry
measurements for the pretreated samples were from 3 to 5. Some
samples had a crock dry value of less than 5, less than 4.5, less
than 4, or less than 3.5. Some samples had a crock dry value of
more than 3, more than 3.5, more than 4, or more than 4.5.
[0082] Table 4, provided below, shows the testing results of color
density and colorfastness for each sample (i.e., the same samples
provided in Table 2). Color was tested using ASTM D2244-16, and
colorfastness was tested using Method 1.
TABLE-US-00004 TABLE 4 Color and colorfastness results for each
sample. Control Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample
6 Sample 7 Color Black 59.7 45.7 40.1 42.9 50.9 39.8 38 46.1
Measurement Yellow 87.8 83.7 82.4 82.7 88.2 81.7 80.6 83.1 After
Transfer Magenta 71.3 58.7 53.4 57 65.7 57.7 51.6 59.6 392.degree.
F. 40 s Cyan 74.9 67.4 62.9 66.8 78.6 66.3 64.2 70 (L value)
Colorfastness .DELTA.E Black 20.9 19.5 11.4 12.4 27.1 12.6 13.2
20.1 Method 1 .DELTA.E Yellow 20.7 16.9 20.1 20.5 32.2 22.6 23 24.7
after 5 washes .DELTA.E Magenta 32.3 22.8 12.6 15.8 31.2 18 11.4
25.4 .DELTA.E Cyan 16.4 11.3 8.2 7.2 26.5 12.1 12.1 14.4 Average
22.575 17.625 13.075 13.975 29.25 16.325 14.925 21.15
[0083] As described above, the color measurement of a printed image
is the measurement of the color density, or amount of dye transfer.
A smaller number (L value) indicates a darker shade and more dye
transfer, whereas a larger L value indicates a lighter shade and
less dye transfer. As shown in Table 4, the color measurements for
each color tested--black, yellow, magenta, and cyan, were all lower
in the pretreated samples than they were for the non-pretreated
control sample. The control sample tested a 59.7 color measurement
value for black dye, compared to the color measurement values from
about 35 to about 55 for the pretreated samples, depending on the
latex. The color measurement of some pretreated samples for black
dye was less than 55, less than 50, less than 45, or less than 40.
The color measurement of some pretreated samples for black dye was
more than 35, more than 40, more than 45, or more than 50. The
control sample tested a color measurement of 87.8 for yellow dye.
However, the pretreated samples tested a color measurement value
for yellow dye of about 80 to about 90.
[0084] The color measurement of the control sample tested a value
of 71.3 for magenta dye. The pretreated samples tested color
measurement values of about 50 to about 70 for magenta dye.
Depending on the latex, the pretreated samples tested a color
measurement value of less than 70, less than 65, less than 60, or
less than 55 for magenta dye. Depending on the latex, the
pretreated samples tested a color measurement value of more than
50, more than 55, more than 60, or more than 65 for magenta dye.
For cyan dye, the color measurement of the control sample was 74.9.
The pretreated samples tested a color measurement of about 60 to 70
for cyan dye. For some pretreated samples, the color measurement of
cyan dye was less than 70 or less than 65. For some pretreated
samples, the color measurement of cyan dye was more than 60 or more
than 65.
[0085] The colorfastness test results show that the pretreated
samples exhibited a smaller color change and thus, better
colorfastness results. The results are reported as delta E
(.DELTA.E) values, which is the color difference between the
original L a* b* values measured before laundering and after the
five washes. The non-pretreated control sample exhibited a change
in color for black dye of 20.9. The pretreated samples tested a
black dye .DELTA.E value of about 10 to about 30. Each of the
pretreated samples tested a black dye .DELTA.E of less than 30,
less than 25, less than 20, or less than 15. Each of the pretreated
samples tested a black dye .DELTA.E of greater than 10, greater
than 15, greater than 20, or greater than 25.
[0086] The non-pretreated control sample tested a yellow dye
.DELTA.E of 20.7. Pretreated samples tested a yellow dye .DELTA.E
of 15 to 25. Each of the pretreated samples tested a yellow dye
.DELTA.E of less than 25 or less than 20, and more than 15 or more
than 20.
[0087] The non-pretreated control sample tested a magenta dye
.DELTA.E of 32.3. In contrast, most of the pretreated samples
tested a magenta dye .DELTA.E of less than 32.3. In particular, the
pretreated samples tested a magenta dye .DELTA.E of 10 to 35. Each
of the pretreated samples tested a magenta dye .DELTA.E of less
than 35, less than 30, less than 25, less than 20, or less than 15.
Each of the pretreated samples tested a magenta dye .DELTA.E of
more than 10, more than 15, more than 20, more than 25, or more
than 30.
[0088] For the cyan dye, the non-pretreated control sample tested a
.DELTA.E value of 16.4. The pretreated samples tested from about 5
to about 30. Each of the pretreated samples tested a cyan dye
.DELTA.E of less than 30, less than 25, less than 20, less than 15,
or less than 10. Each of the pretreated samples tested a cyan dye
.DELTA.E of more than 5, more than 10, more than 15, more than 20,
or more than 25.
Testing the Effects of Various Light Stabilizers on
Weatherfastness
[0089] Provided below is a description of testing that was
performed to test different light stabilizers. In particular, the
light stabilizers Tinuvin 123 DW HAL (BASF), Tinuvin 400 DW UVA
(BASF), Tinuvin 477 DW UVA (BASF), Tinuvin 479 DW UVA (BASF),
Tinuvin 5333 DW UVA/HAL (BASF), Chiguard 5400 UVA (Chitec), and
Chiguard 101 WB HAL (Chitec) were tested. Table 5 provides the
amounts used in each of nine different samples (including the
control sample).
TABLE-US-00005 TABLE 5 Samples of different light stabilizers.
Control Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6
Sample 7 Sample 8 Sample 9 DI Water 90.00 88.00 88.00 88.00 88.00
88.00 88.00 88.00 88.00 Acrygen 5.00 5.00 5.00 5.00 5.00 5.00 5.00
5.00 5.00 61192 (50%) Eastek 5.00 5.00 5.00 5.00 5.00 5.00 5.00
5.00 5.00 1200 (30%) Tinuvin 2.00 123 DW HAL Tinuvin 2.00 1.00 400
DW UVA Tinuvin 2.00 477 DW UVA Tinuvin 2.00 1.00 479 DW UVA Tinuvin
2.00 5333 DW UVA/HAL Chiguard 2.00 5400 UVA Chiguard 2.00 101 WB
HAL TOTAL 0.00 100.00 100.00 100.00 100.00 100.00 100.00 100.00
100.00 100.00
[0090] Each composition was applied to a 100% cotton natural fiber
fabric by spraying using a consumer spray bottle with spray trigger
such that 0.11 g/in.sup.2 composition was applied (i.e., Method of
Pretreatment 1). An image was printed on the treated natural fiber
fabric by printing the image using dye sublimation ink onto a
standard transfer sheet with a drop-on-demand printer and
transferring the image onto the dried natural fiber fabric using a
heat press at 370.degree. F. for 60 seconds. Table 6, below,
provides the weatherfastness results for each sample, tested using
ASTM G154 (described above) And QLAB's QUV Accelerated Weathering
Tester.
TABLE-US-00006 TABLE 6 Weatherfastness results for natural fiber
fabric samples pretreated with different types and amounts of light
stabilizers, according to Table 5. Note that "S" stands for
"Sample." .DELTA.E Control S1 S2 S3 S4 S5 S6 S7 S8 S9 QUV (Hours)
Cyan 25 7.39 8.85 13.95 9.08 7.50 7.90 13.94 7.55 7.50 15.94 69
16.61 15.26 20.08 15.10 13.66 14.88 20.42 13.24 13.07 21.84 162
25.47 22.99 25.20 20.90 19.02 23.17 24.25 19.00 18.43 26.92 185
26.37 24.76 26.29 22.54 20.30 25.39 25.71 20.66 19.51 27.81 210
27.38 26.69 27.60 24.05 21.63 27.47 26.79 22.54 21.42 29.31 234
28.01 28.10 28.41 25.60 23.01 29.03 28.61 24.07 22.88 30.06 262
29.04 29.40 29.87 27.04 24.26 30.88 29.48 25.55 24.49 31.76 291
29.75 30.80 30.43 28.87 24.58 32.65 29.91 27.17 25.02 32.26 312
30.42 32.46 30.94 29.34 24.83 33.50 31.21 28.11 25.95 32.58 387
31.49 35.22 32.38 33.08 27.53 36.50 33.15 31.25 30.16 34.65 QUV
(Hours) Magenta 25 7.9 5.5 3.4 2.2 2.3 2.5 2.0 2.1 2.2 2.3 69 15.2
9.6 6.9 4.4 4.3 4.9 4.0 4.8 4.7 4.9 162 25.8 17.1 11.4 8.8 8.7 11.3
8.0 9.8 8.5 10.8 185 27.2 18.3 11.7 8.9 8.3 13.4 8.2 10.1 9.1 11.4
210 29.0 19.2 12.6 10.2 10.0 12.8 8.7 11.7 10.2 12.8 234 31.5 21.8
13.6 12.2 10.9 14.4 10.6 13.1 12.1 13.7 262 33.9 24.7 16.3 13.7
11.7 17.4 11.0 14.5 12.9 14.3 291 35.9 28.3 16.1 15.2 15.5 18.1
12.5 15.6 15.1 17.1 312 37.8 30.5 16.6 15.1 15.3 21.6 12.9 16.6
16.4 16.7 387 41.8 39.3 19.1 21.0 16.5 27.9 14.1 20.9 20.1 19.5 QUV
(Hours) Yellow 25 4.7 9.9 8.6 10.7 10.7 9.6 10.3 10.0 9.4 6.6 69
12.0 11.6 10.1 11.4 12.8 11.1 11.9 11.5 10.8 7.7 162 21.5 20.8 13.3
15.3 15.2 14.7 14.2 14.0 13.4 10.3 185 22.0 23.4 12.9 14.7 15.2
13.7 13.8 13.2 13.4 9.9 210 23.8 28.4 14.2 14.8 16.2 15.1 14.3 14.1
14.6 11.1 234 25.8 35.9 15.3 16.3 17.4 16.1 15.3 15.1 15.4 12.7 262
27.5 42.3 17.2 18.2 17.8 17.8 16.4 16.3 17.0 14.0 291 29.0 48.5
19.0 18.8 19.1 18.4 16.7 17.7 18.0 14.8 312 30.0 52.0 20.3 20.0
19.0 18.8 17.7 17.5 17.9 15.7 387 33.1 60.2 24.9 24.9 21.5 22.8
18.8 20.7 21.7 20.7 QUV (Hours) Black 25 8.9 12.7 11.5 12.6 10.7
9.4 12.7 11.5 11.6 13.2 69 9.3 16.2 14.1 16.2 14.6 14.2 15.9 15.0
15.0 16.8 162 9.2 20.2 15.7 20.5 18.4 20.6 19.3 19.4 19.6 20.6 185
9.7 20.5 15.7 21.2 19.1 21.9 20.3 20.7 19.8 21.6 210 10.4 22.0 15.9
22.2 19.8 22.8 20.6 21.0 21.0 21.9 234 10.6 23.0 15.4 23.3 20.5
23.5 20.8 22.5 21.4 22.9 262 11.7 24.2 15.5 24.8 20.9 25.1 22.2
23.5 22.5 24.2 291 11.8 25.3 14.0 25.6 20.8 26.3 21.6 24.6 22.2
23.7 312 12.8 27.1 14.9 25.5 22.0 27.0 22.8 25.5 23.4 25.0 387 13.8
34.1 13.1 31.5 24.2 31.0 23.8 28.6 26.9 26.3
[0091] As shown, the color change for cyan dye (as indicated by
.DELTA.E) varied from 7.5 to almost 40. At 25 hours, the color
change for cyan dye measured from 7.5 to about 16. At 69 hours, the
color change was from about 13 to about 24; at 162 hours, from
about 18 to about 27; at 185 hours, from about 19 to about 28; at
210 hours, from about 21 to about 30; at 234 hours, from about 23
to about 30; at 262 hours, from about 24 to about 32; at 291 hours,
from about 24 to about 33; at 312 hours, from about 25 to about 34;
and at 387 hours, the color change was from about 27 to about 37,
depending on the light stabilizer.
[0092] The color change for magenta dye varied from 2 to about 40.
At 25 hours, the color change was from 2 to about 6; at 69 hours,
from 4 to about 10; at 162 hours, from 8 to about 17; at 185 hours,
from about 8 to about 19; at 210 hours, from about 8 to about 20;
at 234 hours, from about 10 to about 22; at 262 hours, from about
11 to about 25, at 291 hours, from about 15 to about 29; at 312
hours, from about 12 to about 31; and at 387 hours, the color
change was from about 14 to about 40, depending on the light
stabilizer.
[0093] The color change for yellow dye varied from about 6 to about
60, depending on the light stabilizer. At 25 hours, the color
change was from about 6 to about 11; at 69 hours, from about 8 to
about 13; at 162 hours, from about 10 to about 21; at 185 hours,
from about 10 to about 24; at 210 hours, from about 11 to about 28;
at 234 hours, from about 13 to about 36; at 262 hours, from about
14 to about 42; at 291 hours, from about 15 to about 49; at 312
hours, from about 16 to about 52; and at 387 hours, the color
change was from about 21 to about 60, depending on the light
stabilizer.
[0094] The color change for black dye varied from about 9 to about
34, depending on the light stabilizer. At 25 hours, the color
change was from about 9 to about 13; at 69 hours, from about 14 to
about 17; at 162 hours, from about 18 to about 21; at 185 hours,
from about 16 to about 22; at 210 hours, from about 16 to about 23;
at 234 hours, from about 15 to about 24; at 262 hours, from about
16 to about 25; at 291 hours, from about 14 to about 26; at 312
hours, from about 15 to about 26; and at 387 hours, the color
change was from about 13 to about 32, depending on the light
stabilizer.
Market Comparison
[0095] Provided below is a description of testing that was
performed to test a pretreatment composition disclosed herein and
commercially available products that are related to the
pretreatment compositions provided herein. In particular, the
commercially available products used in this analysis were Forever
Sublilight, Hanrun, and Shockline TopCut (and a control sample).
Table 7 provides the amounts used of the pretreatment sample.
TABLE-US-00007 TABLE 7 Pretreatment Composition Used in Market
Analysis. Pretreatment COMPONENT Composition (wt. %) DI Water 47
Glycerine 15 Dipropylene Glycol 10 Acrygen 61192 (50%) 10 Eastek
1200 (30%) 16.6 Tinuvin 477DW 0.25 Proxel GXL 0.15 BYK 348 0.5
Triethanolamine 0.5 TOTAL 100
[0096] The pretreatment method used for each of the compositions
tested in the market analysis was Pretreatment Method 2. Table 8,
provided below, shows the testing results of fabric hand, color
density, and colorfastness for each sample. Color was tested using
ASTM D2244-16, and colorfastness was tested using Method 2 for
samples with images transferred and Method 3 for direct print
samples.
TABLE-US-00008 TABLE 8 Color and colorfastness results for each
sample. No Treatment Forever Shockline Pretreatment (Control)
Sublilight Hanrun TopCut Composition Fabric Hand 5 1 1 1 3 Color
Black 51.16 31.3 36.3 29.04 32.83 Measurement Yellow 91.58 85.94
87.84 88.06 88.22 After Transfer Magenta 60.79 53.77 55.45 50.8
50.65 392.degree. F. 40 s Cyan 68.2 38.92 46.07 55.77 45.35 (L
value) Colorfastness .DELTA.E Black 30.5 13.8 10.9 17.8 14 Method 2
.DELTA.E Yellow 34.2 26 31.3 39.8 33.1 after 5 washes .DELTA.E
Magenta 48.1 10.8 27.3 30.4 16.8 .DELTA.E Cyan 30.1 22.3 24.8 17.5
17 Color Black 44.87 31.3 36.3 29.04 35.98 Measurement Yellow 87.49
85.94 87.84 88.06 82.2 After Direct Magenta 52.67 53.77 55.45 50.8
51.01 to Textile Cyan 52.73 38.92 46.07 55.77 44.81 385.degree. F.
30 s (L value) Colorfastness .DELTA.E Black 25.9 13.8 10.9 17.8
11.7 Method 3 .DELTA.E Yellow 34.7 26 31.3 39.8 25.9 after 5 washes
.DELTA.E Magenta 41.5 10.8 27.3 30.4 17.6 .DELTA.E Cyan 22 22.3
24.8 17.5 12.1
[0097] As described above, the color measurement of a printed image
is the measurement of the color density, or amount of dye transfer.
A smaller number (L value) indicates a darker shade and more dye
transfer, whereas a larger L value indicates a lighter shade and
less dye transfer. As shown in Table 8, the color measurements for
each color tested--black, yellow, magenta, and cyan, were all lower
in the pretreated samples than they were for the non-pretreated
control sample. In some embodiments, the color measurement of a
pretreated sample with a pretreatment composition disclosed herein
for black dye was less than 45, less than 40, less than 38, or less
than 35. In some embodiments, the color measurement of a pretreated
sample with a pretreatment composition disclosed herein for black
dye was more than 25, more than 30, more than 32, or more than 35.
In some embodiments, the color measurement of a pretreated sample
with a pretreatment composition disclosed herein for yellow dye was
less than 95, less than 90, less than 85, or less than 83. In some
embodiments, the color measurement of a pretreated sample with a
pretreatment composition disclosed herein for yellow dye was more
than 70, more than 75, more than 80, or more than 82. In some
embodiments, the color measurement of a pretreated sample with a
pretreatment composition disclosed herein for magenta dye was less
than 65, less than 60, less than 55, or less than 52. In some
embodiments, the color measurement of a pretreated sample with a
pretreatment composition disclosed herein for magenta dye was more
than 35, more than 40, more than 45, or more than 50. In some
embodiments, the color measurement of a pretreated sample with a
pretreatment composition disclosed herein for cyan dye was less
than 60, less than 55, less than 50, or less than 46. In some
embodiments, the color measurement of a pretreated sample with a
pretreatment composition disclosed herein for cyan dye was more
than 30, more than 35, more than 40, or more than 44.
[0098] The colorfastness test results show that the pretreated
sample exhibited a smaller color change and thus, better
colorfastness results. The results are reported as delta E
(.DELTA.E) values, which is the color difference between the
original L a* b* values measured before laundering and after the
five washes. In some embodiments, a pretreated sample with the
pretreatment composition disclosed herein tested a black dye
.DELTA.E of less than 25, less than 20, or less than 15. In some
embodiments, a pretreated sample with the pretreatment composition
disclosed herein tested a black dye .DELTA.E of greater than 1,
greater than 5, or greater than 10. In some embodiments, a
pretreated sample with the pretreatment composition disclosed
herein tested a yellow dye .DELTA.E of less than 45, less than 40,
less than 35, or less than 30. In some embodiments, a pretreated
sample with the pretreatment composition disclosed herein tested a
yellow dye .DELTA.E of greater than 15, greater than 20, or greater
than 25. In some embodiments, a pretreated sample with the
pretreatment composition disclosed herein tested a magenta dye
.DELTA.E of less than 30, less than 25, or less than 20. In some
embodiments, a pretreated sample with the pretreatment composition
disclosed herein tested a magenta dye .DELTA.E of greater than 5,
greater than 10, or greater than 15. In some embodiments, a
pretreated sample with the pretreatment composition disclosed
herein tested a cyan dye .DELTA.E of less than 25, less than 20, or
less than 15. In some embodiments, a pretreated sample with the
pretreatment composition disclosed herein tested a cyan dye
.DELTA.E of greater than 1, greater than 5, or greater than 10.
[0099] The preceding description sets forth exemplary methods,
parameters and the like. It should be recognized, however, that
such description is not intended as a limitation on the scope of
the present disclosure but is instead provided as a description of
exemplary embodiments. The illustrative embodiments described above
are not meant to be exhaustive or to limit the disclosure to the
precise forms disclosed. Many modifications and variations are
possible in view of the above teachings. The embodiments were
chosen and described to best explain the principles of the
disclosed techniques and their practical applications. Others
skilled in the art are thereby enabled to best utilize the
techniques, and various embodiments with various modifications as
are suited to the particular use contemplated.
[0100] Although the disclosure and examples have been thoroughly
described with reference to the accompanying figures, it is to be
noted that various changes and modifications will become apparent
to those skilled in the art. Such changes and modifications are to
be understood as being included within the scope of the disclosure
and examples as defined by the claims. In the preceding description
of the disclosure and embodiments, reference is made to the
accompanying drawings, in which are shown, by way of illustration,
specific embodiments that can be practiced. It is to be understood
that other embodiments and examples can be practiced, and changes
can be made without departing from the scope of the present
disclosure.
[0101] Although the preceding description uses terms first, second,
etc. to describe various elements, these elements should not be
limited by the terms. These terms are only used to distinguish one
element from another.
[0102] Also, it is also to be understood that the singular forms
"a," "an," and "the" used in the preceding description are intended
to include the plural forms as well unless the context indicates
otherwise. It is also to be understood that the term "and/or" as
used herein refers to and encompasses any and all possible
combinations of one or more of the associated listed items. It is
further to be understood that the terms "includes, "including,"
"comprises," and/or "comprising," when used herein, specify the
presence of stated features, integers, steps, operations, elements,
components, and/or units but do not preclude the presence or
addition of one or more other features, integers, steps,
operations, elements, components, units, and/or groups thereof.
[0103] The term "if" may be construed to mean "when" or "upon" or
"in response to determining" or "in response to detecting,"
depending on the context.
[0104] Although the disclosure and examples have been fully
described with reference to the accompanying figures, it is to be
noted that various changes and modifications will become apparent
to those skilled in the art. Such changes and modifications are to
be understood as being included within the scope of the disclosure
and examples as defined by the claims.
* * * * *