METHOD FOR PRODUCING DENIM-EFFECT GARMENTS

Abstract

A method is disclosed for producing denim-effect garments by the following steps: 1) printing a reactive dye ink onto a PET film to form a pattern thereby obtaining a transfer printed PET film; 2) transfer printing a base pulp-treated fabric by attaching the transfer printed PET film thereby obtaining a denim-effect fabric; 3) cutting, sewing, washing to soften, and drying the denim-effect fabric and thereby obtaining a denim-effect garment. The method has the advantages of simple production, being environmentally friendly, having high efficiency, and being suitable for flexible fabrics, and the produced denim-effect garment of the invention has the advantages of having a good color fastness to rubbing, washing resistance, and having a diversity of patterns, and are suitable for large-scale production and application.

Claims

1. A method for producing a denim-effect garment, the method comprising: 1) printing a reactive dye ink onto a PET film to form a pattern thereby obtaining a transfer printed PET film; 2) transfer printing a base pulp-treated fabric by attaching the transfer printed PET film thereby obtaining a denim-effect fabric; 3) cutting, sewing, washing to soften, and drying the denim-effect fabric, thereby obtaining a denim-effect garment.

2. The method according to claim 1, wherein a dye of the reactive dye ink comprises one or more of K-type dye, M-type dye, KN-type dye and P-type dye; and a mass fraction of the dye of the reactive dye ink is 5% to 20%.

3. The method according to claim 1, wherein, a thickness of the PET film is 5 μm to 30 μm.

4. The method according to claim 1, wherein the base pulp comprises a hygroscopic agent, an alkali agent, an anti-reducing agent and a thickening agent.

5. The method according to claim 4, wherein the hygroscopic agent is urea; the thickening agent is one or more of sodium alginate, modified starch and modified cellulose; the alkali agent is one or more of sodium hydroxide, sodium carbonate, sodium bicarbonate and sodium silicate; and the anti-reducing agent is 3-nitrobenzenesulfonic acid sodium salt.

6. The method according to claim 1, wherein the base pulp-treated fabric is woven from at least one of cellulose fiber and regenerated cellulose fiber; a temperature of the transfer printing in step 2) is 10° C. to 40° C., a pressure of the transfer printing in step 2) is 0.1 MPa to 0.8 MPa, and a speed of the transfer printing in step 2) is 2 m/min to 25 m/min.

7. The method according to claim 1, wherein, the washing to soften in step 3) uses a softener to treat the fabric; and the washing to soften in step 3) is performed at 20° C. to 60° C. with a treatment time of 5 min-30 min.

8. The method according to claim 1, wherein step 3) further comprises steaming, washing, and shaping the denim-effect fabric.

9. The method according to claim 8, wherein the steaming is performed at a pressure of 0.1 MPa to 0.5 MPa; the steaming is performed at a temperature of 95° C. to 110° C.; and of the steaming is performed for a duration of 3 min to 15 min.

10. The method according to claim 8, wherein the shaping is performed by adding a shaping additive to the denim-effect fabric and then performing a stiffening treatment on said denim-effect fabric; the shaping additive comprising one or more of natural starch, cellulose, modified starch, and guar gum.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0059] FIG. 1 is an example flow chart of producing denim-effect garments according to embodiments herein.

[0060] FIG. 2 is an example material diagram obtained by scanning sample clothes according to embodiments herein.

[0061] FIG. 3 is an example front side effect diagram of a garment according to embodiments herein.

[0062] FIG. 4 is an example back side effect diagram of a garment according to embodiments herein.

[0063] FIG. 5 is an example material diagram obtained by scanning sample clothes according to embodiments herein.

[0064] FIG. 6 is an example front side effect diagram of a garment according to embodiments herein.

[0065] FIG. 7 is an example back side effect diagram of a garment according to embodiments herein.

[0066] FIG. 8 is an example material diagram according to embodiments herein.

[0067] FIG. 9 is an example front side effect diagram of a garment according to embodiments herein.

[0068] FIG. 10 is an example material diagram according to embodiments herein.

[0069] FIG. 11 is an example front side effect diagram of a garment according to embodiments herein.

[0070] FIG. 12 is an example front side effect diagram of a garment according to embodiments herein.

[0071] FIG. 13 is an example front side effect diagram of a garment according to embodiments herein.

[0072] FIG. 14 is an example front side effect diagram of a garment according to embodiments herein.

[0073] FIG. 15 is an example test result diagram of color fastness to rubbing of denim-effect garments according to embodiments herein.

DETAILED DESCRIPTION

[0074] The technical solutions in the example embodiments herein are clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments described herein. Based on the disclosure herein, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the claims provided.

Example Embodiment 1

[0075] Specifications of the fabric to be printed: 10S/1×10S/1, 100% cotton twill woven fabric, semi-bleaching, gram weight 270 g/m.sup.2, width 150 cm.

[0076] The composition of the base pulp: urea 10%, sodium bicarbonate 3%, 3-nitrobenzenesulfonic acid sodium salt 1%, sodium alginate 2%, the rest is water (by mass percentage).

[0077] A method for producing denim-effect garments comprises following steps: (see FIG. 1):

[0078] 1) Extracting printing materials (105): scanning the sample clothes or images to obtain the image materials to be printed;

[0079] 2) Nesting paper patterns (110) and generating printing files (115): nesting the image materials to be printed on the paper patterns and generating image files, as shown e.g., in FIG. 2;

[0080] 3) Printing transfer printing substrate (120): setting the shrinkage rate of reserved printing and clothing general washing and softening, and using an active ink to print the image files on the transfer printing substrate (coating PET film with the thickness of 14 μm) to obtain transfer printing film;

[0081] 4) Cold transfer printing film (125): immersing the fabric to be printed in the base pulp, and then pad-batching the fabric to be printed by the uniform padder (a pressure of the padder is 0.51 MPa, after pad-batching, the application amount of the base pulp of the fabric to be printed is about 80%); after pad-batching, attaching the front side of the fabric to be printed with the printing surface of the transfer printing film, and sending them to a cold transfer printing roller (applying pressure of 0.3 MPa, transfer printing speed of 5 m/min). After drying (drying in the oven, drying temperature is 80° C.), the printed fabric (130) is obtained.

[0082] 5) Steaming (135): feeding the printed fabric into a steaming process (steaming temperature is 102° C., steam pressure is 0.3 MPa, steaming time is 10 mins).

[0083] 6) Post-processing: the steamed fabric is washed (140), shaped (145), cut (150), sewn (155), washed and dried (160), and ironed (165) to obtain the denim-effect garment (for example, twill jeans with front and back side effects as shown in FIG. 3 and FIG. 4 respectively);

[0084] in this example, the shaping composition is 20 g/L corn starch; washing and drying includes the first washing (0.5 g/L α-amylase, bath ratio: 1:20, processing at 40° C. for 20 minutes), the second washing (2 g/L softener CWS-5™ of NANFENG DAXIN TECHNOLOGY CO., LTD, bath ratio: 1:20, processing at 40° C. for 20 minutes), draining, dehydrating and drying (drying temperature is 70° C.).

Example Embodiment 2

[0085] Specifications of the fabric to be printed: 10S/1×7S/1 cotton twill, gram weight 310 g/m.sup.2, width 150 cm.

[0086] The composition of the base pulp: urea 12%, sodium bicarbonate 2%, 3-nitrobenzenesulfonic acid sodium salt 1%, sodium alginate 3%, the rest is water (by mass percentage).

[0087] A method for producing denim-effect garments comprises following steps (the process is basically the same as shown for Example Embodiment 1, see FIG. 1):

[0088] 1) Extracting printing materials: scanning the sample clothes or images to obtain the image materials to be printed;

[0089] 2) Nesting paper patterns and generating printing files: nesting the image materials to be printed on the paper patterns and generating image files, as shown in FIG. 5;

[0090] 3) Printing transfer printing substrate: setting the shrinkage rate of reserved printing and clothing general washing and softening, and using an active ink to print the image files on the transfer printing substrate (coating PET film with the thickness of 12 μm) to obtain transfer printing film;

[0091] 4) Cold transfer printing film: immersing the fabric to be printed in the base pulp, and then pad-batching the fabric to be printed by the uniform padder (a pressure of the padder is 0.6 MPa, after pad-batching, the application amount of the base pulp of the fabric to be printed is about 85%); after pad-batching, attaching the front side of the fabric to be printed with the printing surface of the transfer printing film, and sending them to a cold transfer printing roller (applying pressure of 0.4 MPa, transfer printing speed of 4 m/min). After drying (drying in the oven, drying temperature is 100° C.), the printed fabric is obtained.

[0092] 5) Steaming: feeding the printed fabric into a steaming process;

[0093] 6) Post-processing: the steamed fabric is washed, shaped, cut, sewn, washed, dried and ironed to obtain the denim-effect garment (namely, twill jeans with front and back side effects as shown in FIG. 6 and FIG. 7 respectively);

[0094] in this case, the shaping composition is 20 g/L corn starch; washing and drying includes the first washing (0.5 g/L α-amylase, bath ratio: 1:20, processing at 40° C. for 20 minutes), the second washing (2 g/L amino silicone oil, bath ratio: 1:20, processing at 40° C. for 20 minutes), draining, dehydrating and drying (drying temperature is 80° C.).

Example Embodiment 3

[0095] Specifications of the fabric to be printed: 7S/1×7S/1, 100% cotton, gram weight 320 g/m.sup.2, width 150 cm.

[0096] The composition of the base pulp: urea 10%, sodium bicarbonate 3%, 3-nitrobenzenesulfonic acid sodium salt 1%, sodium alginate 2%, and the rest is water (by mass percentage).

[0097] In some embodiments, a method for producing denim-effect garments comprises following steps (the difference between this process and the method of Example Embodiment 1 is that there is no need for nesting image pattern, but rather it is directly cyclically connected to the whole image):

[0098] 1) Extracting printing materials: scanning the sample clothes or images to obtain the image materials to be printed;

[0099] 2) Generating printing files: directly cyclically connecting the images to be printed to the whole image and generating image files, as shown in FIG. 8;

[0100] 3) Printing transfer printing substrate: setting the shrinkage rate of reserved printing and clothing general washing and softening, and using an active ink to print the image files on the transfer printing substrate (coating PET film with the thickness of 14 μm) to obtain transfer printing film;

[0101] 4) Cold transfer printing film: immersing the fabric to be printed in the base pulp, and then pad-batching the fabric to be printed by the uniform padder (a pressure of the padder is 0.5 MPa, after pad-batching, the application amount of the base pulp of the fabric to be printed is about 80%); after pad-batching, attaching the front side of the fabric to be printed with the printing surface of the transfer printing film, and sending them to a cold transfer printing roller (applying pressure of 0.3 MPa, transfer printing speed of 5 m/min). After drying (drying in the oven, drying temperature is 90° C.), the printed fabric is obtained.

[0102] 5) Steaming: feeding the printed fabric into a steaming process;

[0103] 6) Post-processing: the steamed fabric is washed, shaped, cut, sewn, washed, dried and ironed to obtain the denim-effect garment (namely, jeans with jacquard effect, and its front and back side effects are shown in FIG. 9 respectively);

[0104] in this case, the shaping composition is 10 g/L corn starch; washing and drying includes the first washing (0.3 g/L α-amylase, bath ratio: 1:20, processing at 40° C. for 20 minutes), the second washing (2 g/L amino silicone oil, bath ratio: 1:20, processing at 40° C. for 20 minutes), draining, dehydrating and drying (drying temperature is 80° C.).

Example Embodiment 4

[0105] Specifications of the fabric to be printed: 32S/1 cotton yarn+20 D spandex elastic wool circle knitted semi-bleaching fabric, gram weight 230 g/m.sup.2, width 180 cm.

[0106] The composition of the base pulp: urea 12%, sodium bicarbonate 2%, 3-nitrobenzenesulfonic acid sodium salt 1%, sodium alginate 3%, the rest is water (by mass percentage).

[0107] A method for producing denim-effect garments comprises following steps (similar to Example Embodiment 3, no nesting pattern is required):

[0108] 1) Extracting printing materials: scanning the sample clothes or images to obtain the image materials to be printed;

[0109] 2) Generating printing files: directly cyclically connecting the images to be printed to the whole image and generating image files, as shown in FIG. 10;

[0110] 3) Printing transfer printing substrate: setting the shrinkage rate of reserved printing and clothing general washing and softening, and using an active ink to print the image files on the transfer printing substrate (coating PET film with the thickness of 12 μm) to obtain transfer printing film;

[0111] 4) Cold transfer printing film: immersing the fabric to be printed in the base pulp, and then pad-batching the fabric to be printed by the uniform padder (a pressure of the padder is 0.6 MPa, after pad-batching, the application amount of the base pulp of the fabric to be printed is about 90%); after pad-batching, attaching the front side of the fabric to be printed with the printing surface of the transfer printing film, and sending them to a cold transfer printing roller (applying pressure of 0.35 MPa, transfer printing speed of 4 m/min). After drying (drying in the oven, drying temperature is 100° C.), the printed fabric is obtained.

[0112] 5) Steaming: feeding the printed fabric into a steaming process;

[0113] 6) Post-processing: the steamed fabric is washed, shaped, cut, sewn, washed, dried and ironed to obtain the denim-effect garment (namely, hooded denim sweater, and its front and back side effects are shown in FIG. 11 respectively);

[0114] in this case, the shaping composition is 1% amino silicone oil; washing and drying includes general washing and softening (1 g/L soft oil for CWS-5™, bath ratio: 1:20, processing at 40° C. for 20 minutes), draining, dehydrating and drying (drying temperature is 80° C.).

[0115] Unless otherwise specified, the accuracy of the scanner used in the manufacturing method of embodiments 1 to 4 should be above 300 dpi; the steaming temperature is 102° C., the steam pressure is 0.3 MPa, the steaming time is 10 mins; the step of washing uses an open-width washing machine, including pre-washing, washing with warm water, washing with hot water, soaping, washing with clean water, etc.; a setting machine is used to complete shaping, wherein the shaping temperature is 150° C., the shaping time is 90 seconds; the washing with water and the drying use a rotary cage washing machine and a drum dryer, respectively.

Comparative Embodiment 1

[0116] The method for producing denim-effect garments in Comparative Embodiment 1 (that is, denim pants, as shown in FIG. 12) and the method in Example Embodiment 1 differs in that: the Comparative Embodiment 1 uses the denim-effect garment produced by a washing method with indigo dye, the method includes: using VAT dyes to dye after warp yarn and weaving, sewing, denim-effect garment washing.

Comparative Embodiment 2

[0117] The method for producing denim-effect garments in Comparative Embodiment 2 (that is, denim pants, as shown in FIG. 13) and the method in Example Embodiment 1 differs in that: the Comparative Embodiment 2 uses the denim-effect garment produced by a washing method with indigo dye, the method includes: using VAT dyes to dye after warp yarn and weaving, sewing, denim-effect garment washing.

Comparative Embodiment 3

[0118] The method for producing denim-effect garments in Comparative Embodiment 3 (that is, denim pants, as shown in FIG. 14) and the method in Example Embodiment 1 differs in that: the Comparative Embodiment 3 uses the denim-effect garment produced by a washing method with indigo dye, the method includes: using VAT dyes to dye after warp yarn and weaving, sewing, denim-effect garment washing.

[0119] Color Fastness to Rubbing Test

[0120] Samples to be tested: denim-effect garments of Comparative Embodiments 1-3 and Example Embodiments 1-4.

[0121] Testing method for color fastness to rubbing: results are measured and rated in accordance with the ISO 105-X12:2016 standard “Textiles—Tests for color fastness—Part X12: Color fastness to rubbing”. In other words, a white cotton is used to rub against samples to be tested, and the staining of the white cotton is observed, so as to determine the color fastness of colored fabrics; wherein, the color fastness to rubbing increases sequentially from 1 to 5, where 1 represents the worst color fastness to rubbing, while 5 represents the best color fastness to rubbing.

[0122] The dyed denim-effect garments similar in color to indigo in Comparative Embodiments 1-3 are purchased in the market. The color fastness to rubbing test for denim-effect garments is carried out for Example Embodiments 1-4 and Comparative Embodiments 1-3. The results are shown in FIG. 15.

[0123] As shown in FIG. 15, the color fastness to rubbing test shows that: the color fastness to rubbing in both dry rubbing and wet rubbing of denim-effect garments in Example Embodiments 1-4 (1500) is better than that in Comparative Embodiments 1-3 (1510). The above test results demonstrate that the method in this invention can be used for different fabrics and it has following advantages of strong adhesive fastness, simple processes, environmental protection, safety, and garment washing resistance and no color fading, which is suitable for large-scale production.

[0124] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited by the above embodiments. Any other changes, modifications, substitutions, combinations, and simplifications that do not deviate from the spirit and principle of the present invention should be regarded as equivalent alternatives and are included in the protection scope of the present invention.