CN1297705C - Method for printing textile materials and fabrics made therefrom - Google Patents

Abstract

A method of printing textile material is described. The process involves applying to the textile, in a predetermined pattern, a water-soluble chemical substance capable of mechanically inhibiting wetting of the underlying regions of the fabric, and then dyeing the fabric in a conventional manner for uniformly dyeing the fabric, such as by continuous or semi-continuous dyeing. The effect of the chemical substance applied to the fabric is to temporarily mechanically inhibit wetting of the bottom layer region of the fabric so that this bottom layer region is dyed to a lesser extent than its surrounding regions. The resulting fabric has good printing characteristics without a decrease in physical strength or the irregular hand associated with printed fabrics obtained by conventional textile printing processes.

Description

Method for printing textile materials and fabrics made therefrom

field of invention

The present invention generally relates to methods of printing textile materials. More particularly, the present invention relates to a method of manufacturing a patterned textile material using a dyeing method generally used for dyeing plain colored fabrics and a fabric manufactured using the method.

background

Textile manufacturers are striving to obtain products with a unique and different appearance. While designers are superficially able to create infinite fabric looks, fabric manufacturers must consider conditions such as machine efficiency, raw material costs, labor input and processing expenses, the desired performance characteristics of the fabric, and more. Therefore, the creativity of the designer is often limited by the ability of the manufacturer to efficiently manufacture the fabric according to his design.

A traditional way of obtaining patterned fabrics is to create fabrics by interweaving pre-dyed yarns of different colors in different areas. The fabric obtained in this way is called yarn-dyed, and is used to make, for example, woven striped broadloom (such as the variety commonly used in men's suit shirts). While yarn dyed fabrics provide a desirable appearance in many respects, they suffer from certain disadvantages, notably having to be pre-dyed to the desired color in the product. Those of ordinary skill in the art will readily appreciate that this significantly prolongs the development cycle required to manufacture the fabric (since the colors must be determined and the yarns dyed to achieve these colors prior to the fabric forming process), and that small batches of fabrics of particular color combinations can be produced. Products can be expensive.

In addition, fabric weaving equipment, such as looms or knitting machines, must be specially set up to obtain the particular pattern desired. This can lead to long machine downtimes when changing colors and patterns. Furthermore, when the component yarns are exposed to different temperatures and conditions in their dyeing and processing conditions, the yarn-dyed fabric has a tendency to shrink differentially. As a result, after laundering, yarn-dyed fabrics often wrinkle along the transition zone between yarns of one color and yarn of another. All in all, the development cycle of yarn dyed products is unacceptably long, and the weaving is complicated, and the resulting product may have undesirable variation from one side to the other.

Attempts have been made to produce patterned fabrics by methods other than using differently dyed yarns in the weaving process. For example, patterns of various colors are often printed directly on the fabric. In this method, the colors required for the desired design are printed directly onto undyed or pre-dyed fabric. There are two disadvantages of this type of printing. First, when printing colors on pre-dyed fabrics, the color of the pattern is limited by the main ground color. This is due to the fact that the main ground colors show through these colors and some of the colors used in the print will not be visible or shifted. An example would be a blue print on a yellow base colour. After printing, the pattern appears green. In addition, the yellow pattern printed and dyed on the yellow background color is completely invisible. So on very dark bases, few of the printed dyes are visible. This limits designers to using only a few colors for a particular base color, or makes them use undyed base fabrics to use a full color palette.

A second disadvantage of this printing method is encountered when printing with pigments on a primary ground colour. It is generally known that the color limitation problem described above can be overcome by printing with pigments on the surface of the fabric to be printed, as is usually done in plastisol printing. In this way, even white and light-colored patterns can be printed on a very dark background color, and there is no limit to the choice of colors. However, the resulting pattern has a somewhat stiff and/or rubbery feel, with a raised appearance in feel and appearance compared to areas not imprinted with the pattern. In many apparel applications, this is undesirable. Furthermore, after repeated washing and rubbing, the printed design may eventually become brittle, crack and peel off.

Another method commonly used is called discharge printing. In discharge printing, the fabric is dyed (usually piece dyed) and the pattern is printed with a slurry containing chemicals that reduce the dye, thus creating a white pattern on the dyed background. It is also possible to add a colorant to the discharge slurry so that another color is used instead of the discharged color. These discharge chemicals make the portion of the fabric to which they are applied harsh to the touch and often reduce its strength, thereby reducing the overall strength of the fabric. Another disadvantage of this type of processing is that you can only choose dyes that are easy to whiten under the action of chemical reducing agents, otherwise the color will remain in the pattern area. This chemical adds cost and reduces the flexibility of use of the method.

Another method used to create patterned fabrics is called resist printing. In resist printing, a pattern is drawn on a fabric with a substance designed to prevent staining on the fabric. The fabric is then dyed using a batch dyeing method. In the existing resist printing method, the resist is generally a water-insoluble medium. Examples of printing methods using a water-insoluble medium are batik using wax, tie-dye using elastic bands, etc. to suppress fabric dyeing in specific areas. Those of ordinary skill in the art will readily appreciate that use of these media requires additional processing operations to remove these stain-inhibiting media. When the inhibiting dye medium is wax, the method of removal can be difficult and can damage the underlying fabric. In the tie-dye method, removing the elastic bands is labor-intensive. Also, methods such as tie-dyeing are limited in the kinds of designs that can be produced with them, and the waxes used in batik are such that the parts of the fabric that are coated with them cannot be dyed a different color from the rest of the fabric at the same time .

Another type of resist printing involves chemically binding dyed spots of fibers in specific areas of the fabric. Generally speaking, resist chemicals are printed into a specific pattern on the fabric, and then the fabric is dyed. An example of this approach is described in US Patent 5,984,977 to Moore et al., which describes the use of a designed substance to chemically block the stained spots of cellulosic materials in a batch dyeing process. Because the dye spots are bound by the resist chemical, the fabric will not pick up color in the areas where the chemical was applied. While performing well in many applications, this method is somewhat limited in that the resist chemical must be selected for chemical barrier to specific fiber staining points in the fabric, and when the fabric to be printed consists of blended fibers, the There will be problems. Because if one fiber is blocked in the blended fibers and the other fiber is not prevented from being dyed, the printed area cannot be completely protected from dyeing unless the fiber that is not blocked is not dyed. This results in a mottled effect on the main ground color of the fabric, thus limiting design flexibility. Furthermore, the commercially viable chemical resists that are marketed for batch dyeing processes are slower than continuous or semi-continuous processes. Also, these resist chemicals generally impair the strength of the fabric.

Finally, thermal transfer printing is used for patterned fabrics. This method uses calico printed with dye, which sublimes when heated. The paper is placed in direct contact with the fabric and upon heating the dye is transferred from the paper to the fabric by sublimation. Thermal transfer printing is widely used on polyester, which uses disperse dyes, and is generally carried out in a dry state, and the dyes will diffuse into the fibers with heating. The main limitation of this method is disperse dyes which sublime easily. A variation of this method is to perform thermal transfer in the wet state, which enables the use of otherwise dye species that readily transfer from paper to fabric in the vapor phase. The choice of dyes is still limited, and the two-step process of printing on paper and transferring the dye to fabric is still required. Have again, can't realize the effect of anti-dyeing with this method, so the main ground color of fabric before printing has restriction to pattern design.

summary

The method of the invention enables the production of patterned fabrics in an efficient manner while avoiding the additional processing operations required by the methods of the prior art. In addition, this method enables the production of fabrics with the surface appearance of yarn-dyed fabrics, while avoiding the inherent complexities of yarn-dyed manufacturing and the loss of fabric strength caused by other dyeing methods. Furthermore, this method can use continuous or semi-continuous dyeing operations to manufacture patterned fabrics, which has just reached higher manufacturing efficiency than general batch methods. For the purposes of this application, the term "continuous or semi-continuous dyeing operation" refers to those dyeing operations in which the fabric stays in the dye bath for a relatively short period of time, usually due to the continuous movement of the fabric in the process. time. For example, various continuous and semi-continuous dyeing operations in the expectations of the present invention, including hot-melt dyeing, padding/steaming, thermosol/padding/steaming, padding/high-temperature steam operation, jiggering and padding Batch dyeing and other methods. These methods are generally non-exhaustive methods. In contrast, batch dyeing methods involve "batch" dyeing of fabrics where the fabric is left uninterrupted in a dye solution for an extended period of time in order to achieve a uniform dyeing result through exhaustion and equilibration.

The method involves applying to a fabric a chemical substance which temporarily mechanically inhibits wetting of the underlying regions of the fabric, followed by continuous or semi-continuous dyeing of the fabric. Such chemicals desirably include dye pastes. In certain embodiments of the invention, this chemical species may include fluoride. In some cases, the chemicals can include fluorides and dye pastes. In many cases, the chemical is selected so that it mechanically inhibits the wetting of the underlying region of the fabric to which it is applied, without requiring additional removal operations to remove it from the fabric. For this reason, it is desirable that the chemical is water soluble so that it can be removed by chemical and/or mechanical action as desired during subsequent normal dyeing and finishing processes.

The chemical is selected to completely inhibit the wetting of the underlying fabric area, or to only partially inhibit the color pick-up so that the underlying fabric area is less stained than other areas of the fabric not provided with the chemical. In a similar approach, the chemical may be selected corresponding to the particular dyeing process to be used such that the chemical is removed shortly before the dyeing process is complete, with less wetting of the fabric portion underlying the chemical In the basic part of the fabric, there is less chance of the fabric and dye molecules combining in this area. In this way, the portion of the fabric to which the chemical is applied is dyed the same color as the uncovered portion of the fabric, but in a lighter shade. Therefore, it is possible to efficiently manufacture fabrics in which patterns are formed in predetermined regions due to differences in color uptake.

The chemical may also include a dye such that the portion of the fabric printed with the chemical is dyed a different color than it would be in a subsequent continuous dyeing process. The present invention is not limited to the application of a single chemical substance, printing and dyeing different patterns with more different chemical substances is also within the scope of the present invention. For example, applying a chemical that does not include a dye in a first pattern while applying a second, water-soluble chemical designed to inhibit wetting that includes a dye in a second pattern results in a 3-color patterned fabric. In addition, by using two different chemical substances with different anti-dyeing properties and printing two or more patterns, 3 or more color effects can be obtained.

The method of the present invention enables the production of fabrics with a unique yarn-dyed appearance without the disadvantages associated with yarn-dyed products. For example, in one aspect of the invention, the appearance of yarn-dyed fabrics can be obtained by selecting the pattern printed on the fabric to match the yarns of the fabric construction. In addition, the ability to print with this method and the clarity of the printed pattern on the fabric are far superior to yarn-dyed products, especially when complex designs are desired. Furthermore, the fabric retains substantially all of its original strength, has good color fastness, and has excellent aesthetic and functional properties.

Brief description of the drawings

Fig. 1 is a flow chart of one embodiment of the inventive method;

Fig. 2 is the photo (magnifying 40 times) of traditional yarn-dyed product;

Figure 3 is a photograph (40X magnification) of a fabric made in accordance with the present invention.

Detailed description

In the following detailed description of the invention, particularly preferred embodiments of the invention are described so that the invention will be fully and completely understood. It should be recognized that the invention is not intended to be limited to the particular preferred embodiments described, and although specific terminology has been used in describing the invention, these terms are used for purposes of illustration, not limitation.

Referring to accompanying drawing 1, explain according to the method for manufacturing pattern fabric of the present invention. As noted, the steps carried out in this respect are printing resist chemical on fabric, drying this chemical (optional), applying dye, pre-drying dye (if required), fixing dye, cooling The fabric (if previously heated), the desired chemical is applied, the chemical is reacted if necessary, the fabric is washed to remove excess chemical and the fabric is dried and coiled. Those of ordinary skill in the art will appreciate that the specific steps used will vary with the dyeing method used, the type of fabric being printed, the chemicals used, and the pattern desired. These steps are discussed in more detail below.

First get the fabric that will be printed. The fabric can be of any kind, including woven, knitted, nonwoven, and the like. The fabric may be woven from any conventional fiber capable of continuous or semi-continuous dyeing, including but not limited to synthetic fibers such as polyester (including but not limited to polyethylene terephthalate, polypropylene terephthalate ( PTT) and their modified varieties), polyamide, polypropylene, aramid, polyolefin, recycled fibers such as polylactide-based fibers (PLA) and rayon (such as viscose fibers, cupro fibers), natural Fibers such as cotton, flax, ramie, hemp and jute, etc., or combinations thereof. The method according to the invention has been found to work particularly well in the production of 100% polyester, 100% cotton and polyester/cotton blends. Fabrics are selected to provide the weight and performance characteristics desired for the end use of the product.

It is desirable that these fabrics are in prepared form, meaning that they have been washed from oils, impurities, etc., which have been adhering to them during manufacture and/or shipping. Drying of the fabric is preferred as part of the preparation process, which provides a stable product for application of chemicals and dyeing.

A chemical designed to temporarily inhibit wetting of the underlying fabric area is then applied to the fabric in the desired pattern. It is desirable to apply the chemical to the fabric by printing. These printing methods may be, for example, roller bed printing, rotary screen printing, flexographic printing, gravure roll printing, multi-jet printing (such as described in commonly assigned US Patent 4,923,743), and the like. However, other coating methods included within the scope of the present invention include, but are not limited to, brush coating, ultrasonic spraying, foam coating, print head printing, and the like. This chemical can be applied in any desired pattern. In addition, the applied "pattern" may be random dots or the like (such as obtained by brushing). It should be readily understood that the areas where the chemical is applied will define the pattern of undyed or differently colored areas on the final fabric, the type of application pattern being virtually unlimited. As a result, an infinite variety of fabric looks can be obtained in this way.

This chemical is designed to physically inhibit wetting of the underlying area of the fabric over a period of time. In one aspect of the invention, the chemical is designed to prevent wetting of the underlying fabric area for a period of time longer than the contact time of the fabric with the aqueous dye stock solution. In another aspect of the invention, the chemical can be selected for the length of time it inhibits wetting or the degree to which it inhibits wetting to avoid saturation of the underlying region while allowing some wetting. Since downstream processing does not require the removal of these chemicals, the fabric retains wetting inhibiting properties after processing. (In contrast, existing means of mechanically inhibiting fabric wetting, such as waxes, require a separate processing step to remove them, because only after these substances are removed, the fabric has sufficient aesthetics and performance to be useful above features). Therefore, this chemical is desirably water soluble.

To put it another way, the chemical is selected to inhibit wetting of the underlying portion of the fabric, preferably inhibiting wetting entirely. When the chemical is designed to partially inhibit the wetting of the fabric, it can be selected so that the underlying portion of the fabric wets at a significantly slower rate than the untreated portion, or it can be selected to inhibit wetting for a period slightly shorter than the length of the dyeing process . In this way, the chemically printed portion of the fabric will be exposed to a smaller amount of dye and/or for a shorter period of time than an untreated portion of the fabric. As a result, the portion of the fabric treated with the chemical will be stained with the same base color (hue) as the surrounding area of the fabric, but the depth of shade can range from slightly lighter to much lighter than the untreated area.

The chemistry preferably contains a printing paste including a thickener and water. In some forms of the invention, the chemical species includes fluoride. In some forms of the invention, the chemicals include both dye pastes and fluorides. In any event, the chemical is selected such that it inhibits wetting of the underlying regions of the fabric to which it is applied, while not requiring additional removal operations to remove it from the fabric, as will be discussed further.

Examples of chemistries that have been found to work well in the practice of the present invention are alginate based print pastes, xanthan gum based print pastes, synthetic thickener based print pastes, various fluoride compounds, and combinations thereof. The viscosity and rheological properties of these chemistries are selected to optimize wet-out inhibition and achieve the desired design appearance in the finished fabric. Those of ordinary skill in the art will readily appreciate that the precise formulation of the chemical will be selected to suit the coating method used, screen size, desired dosage, etc. These parameters are contemplated within the scope of the present invention and the precise formulation for each fabric can be readily identified without undue experimentation. It has now been found that in the rotary screen printing process (as used in the examples herein), the viscosity of the chemical is from about 8 poise to about 70 poise, preferably from about 10 poise to about 40 poise (depending on the thickener used). Different agent) is fine. The chemical will be applied at a pressure designed to achieve a flat print and allow for proper penetration of the specific chemical and substrate used. For example, a pressure range of about 3 psi to about 10 psi has been found to be good for implementing the above chemistries. In addition, the pressure at which the chemical is applied is selected to optimize the penetration of the chemical into a particular fabric to the extent necessary to obtain the desired design and to obtain a flat printed product. Similarly, the rheology of the chemistry is expected to provide good flow and quick stop properties.

In some forms of the invention, the chemical substance will also include a dye. Thus, the portion of the fabric coated with the chemical will be printed with the first color, while the area around the base fabric which is substantially free of the chemical will be dyed a different color during the dyeing process. Those of ordinary skill in the art will readily appreciate that using different patterns and different chemicals, the chemicals can be applied more than once. Thus, a virtually unlimited number of fabric patterns and looks can be obtained using the present method. For example, the chemical can be applied to the fabric so that it mimics the yarn pattern in the fabric structure, such as by printing stripes in the warp or weft direction to simulate a yarn-dyed striped fabric. Again, the chemicals can include other types of chemicals such as optical brighteners, different types of dyes, copolymers, any type of chemicals that can provide additional benefits without interfering with the performance necessary to practice the invention wait.

In most cases, it is desirable to dry the chemical prior to the subsequent staining step. This drying can be carried out by any conventional method used in fabric drying, such as passing the fabric through an oven. This helps ensure that the chemical stays on the underlying fabric. The temperature and method used are chosen to optimize the properties of the chemistry used and the substrate used.

The fabric is then dyed in a conventional continuous or semi-continuous manner, such as thermosol dyeing. However, other types of dyeing operations such as pad/steam, thermosol/pad/steam, cold pad batch, jigger etc. may be used with different effects within the scope of the present invention. Those of ordinary skill in the art should easily understand that the dyeing method used should be selected according to the type of fabric to be processed and the type of dye to be used. Similarly, the type and amount of chemical is chosen to optimize the appearance of the dyed fabric. In other words, the type of dyeing method and the chemical should be coordinated such that the mechanical inhibition of wetting provided by the chemical can withstand the particular dyeing method used to the extent necessary to achieve the desired pattern by dyeing. Similarly, the dyeing method used is selected to obtain the desired result for the particular fabric being manufactured. For example, in many cases it is desirable to use efficient continuous and semi-continuous dyeing methods; in these cases the yarns forming the fabric are often ring dyed.

When hot sol/pad steam methods are used, these methods generally proceed as follows: The fabric on which the chemical is applied is passed through a dye pad, where the dye will be applied to the fabric except in areas where the chemical prevents the fabric The rest of the fabric is saturated. It is desirable to pre-dry the fabric and then heat it to a temperature sufficient to sublimate the dye into the substrate so that the dye sublimates and penetrates the fibers. This fabric is then desirably steamed, scrubbed and washed in the traditional manner to remove any excess chemicals and dyes that may remain. The fabric is cooled and any desired finishing chemicals may be applied. For example, chemicals designed to facilitate soil removal and wicking, or to reduce static and/or pilling, are available depending on the needs of the fabric. In addition, any desired surface finishing can be applied as desired. The fabric is then dried and packaged for distribution as desired.

The dyes used can also be selected to achieve the type of appearance desired. For example, when the fabric is a polyester/cotton blend and it is desired to have a solid color base, a combination of disperse and vat dyes can be used so that both the polyester and cotton components can be dyed. In this case, using the thermosol/pad/steam method, additional steps of cooking, scrubbing and washing can be added to the method described above after the thermosol oven. Alternatively, the dyebath may contain dyes designed to dye only one constituent fiber, giving the base fabric a variegated appearance. For example, a polyester/cotton blend may be exposed to only a disperse dye which will dye the polyester component while leaving the cotton component substantially undyed, thereby giving the base fabric its unique appearance.

As mentioned above, the chemicals are selected to at least temporarily inhibit the wetting of a portion of the fabric so that patterns can be obtained on the fabric in a continuous or semi-continuous dyeing process. The nature of the chemical is such that subsequent removal is not required. In other words, the dyeing process, drying, finishing and/or scrubbing operations serve to remove any chemicals that would interfere with the final properties of the fabric. For example, where the chemical substance comprises or consists essentially of a printing paste, subsequent processing steps are generally used to remove the printing paste from the fabric. Also, where the chemistry includes or consists essentially of fluorocarbons, it is desirable that some of the fluorocarbons remain on the fabric to render the printed areas water repellent over time. In any event, the chemicals used and the dyeing method can be coordinated so that the amount of chemicals remaining on the fabric after processing is controlled at a desired level.

As shown when comparing the yarn-dyed fabric in Figure 2 with the fabric of the invention represented on Figure 3, the fabrics obtained according to the method of the invention have an excellent appearance, in many cases approaching yarn-dyed fabrics appearance while avoiding the problems associated with that method of manufacture. For example, the problem of differential shrinkage normally associated with yarn-dyed fabrics can be avoided because, if desired, a base fabric with a uniform structure can be obtained. The fabrics of the present invention also have good performance characteristics, such as very uniform physical strength, appearance, color fastness, wash fastness, durability of design, and uniform feel and hand between printed and unprinted areas .

Example

Three commercial yarn-dyed shirting fabrics, described below as samples A, B and C, were obtained.

Sample A was plain poplin fabric with bright blue and dark gray stripes, having a weight of 4.3 oz/sq yd. The finished construction is 102 warp yarns per inch and 57 fill yarns per inch. Both warp and weft are made from a blend of 65% polyester and 35% cotton. The fabric is considered to have been treated with conventional stain release and long-lasting styling chemicals and lightly buffed.

Sample B was plain poplin fabric with thin blue stripes on a white background. The weight of the fabric is 4.3oz/sq yd and the finished construction has 77 ends per inch and 59 wefts per inch. Both warp and weft are made from a blend of 65% polyester and 35% cotton. The fabric is believed to have been treated with conventional stain release and long lasting styling chemicals and lightly buffed.

Sample C is a plain poplin fabric with stripes of various colors. The weight of the fabric is 4.3oz/sq yd and the finished construction is 104 ends per inch and 60 fills. Both the warp and weft are made from a blend of 65% polyester and 35% cotton. The inventors believe that the fabric has been treated with conventional stain release and long-lasting styling chemicals and lightly buffed.

Sample D is a 4.3 oz 65/35 polyester/cotton poplin fabric. The fabric was dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22 (in other words, this fabric was dyed the same primary ground color as Sample E below). This fabric is then finished conventionally, padded over conventional types of finishing chemicals to provide moisture transfer, stain release and durable set properties, conventionally passed through a tenter frame to crosslink the resin, and Make the width of the fabric fixed. The fabric was then mechanically buffed as described in Dischler's commonly assigned U.S. Patent 5,752,300 and treated with high pressure air (creating microcracks in the resin chemistry) as described in Dischler's commonly assigned U.S. Patent 5,822,835 . The finished construction of the fabric was 102 warp yarns and 47 weft yarns per inch.

Sample E is woven to have the same structure as sample D, and after preparation, a 165-mesh screen of the following chemical substances is used to form a double pattern on the fabric: 60g/kg fluoride (APG-85 of Advanced Polymer Company), 11g/kg kg of synthetic backside thickener, 929g/kg of alginate base print paste including 32.5g/kg of low viscosity alginate thickener, chelating agent, defoamer, antimicrobial and water. (Those of ordinary skill in the art can understand that providing a small amount of chelating agent, antifoaming agent and antibacterial agent is to promote the performance of printing equipment). The chemistry also included 1.35g/kg Disperse Red Blend, 0.41g/kg Disperse Blue 60 and 8.2g/kg Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 320°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.36 oz/sq yd, 101 warp yarns and 48 weft yarns per inch.

Sample F was woven to have the same structure as Sample D, and after preparation the fabric was coated with the following chemicals to form a broad stripe pattern: 60 g/kg fluoride (APG-85 from Advanced Polymer Company, Carlstadt, NJ) , 11g/kg of synthetic backside thickener, 929g/kg of alginate base printing paste (which includes 32.5g/kg of low-viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water) . The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 370°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.41 oz/sq yd with a construction of 101 ends per inch and 48 ends per inch.

Sample G was woven in the same manner as Sample D, and after preparation the fabric was coated with the following chemicals to form a broad stripe pattern: 60 g/kg fluoride (APG-85 from Advanced Polymer Company, Carlstadt, NJ) , 11 g/kg of synthetic backside thickener, 929 g/kg of alginate base printing paste (which includes 32.5 g/kg of low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 350°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.36 oz/sq yd, 101 warp yarns and 48 weft yarns per inch.

Sample H is woven in the same manner as sample D, and after preparation, the following chemical substances are coated on the fabric to form a double pattern: 60g/kg fluoride (APG-85 from Advanced Polymer Company), 11g/kg synthetic Backside thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 350°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.31 oz/sq yd with a construction of 101 ends per inch and 48 ends per inch.

Sample I is woven in the same manner as sample D, and after preparation, the following chemical substances are coated on the fabric to form a wide pattern: 60g/kg fluoride (APG-85 of Advanced Polymer Company), 11g/kg synthetic Backside thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antimicrobial and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 320°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.35 oz/sq yd with 102 ends per inch and 48 fills.

Sample J was woven in the same manner as sample D, and after preparation, the following chemicals were coated on the fabric to form a double stripe pattern: 60 g/kg fluoride (APG-85 from Advanced Polymer Company), 11 g/kg synthetic Backside thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antimicrobial and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 370°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.34 oz/sq yd with a construction of 102 warp yarns and 48 weft yarns per inch.

Sample K was woven in the same manner as Sample D, and then the following chemicals were coated on the fabric to form a double stripe pattern: 60 g/kg fluoride (APG-85 from Advanced Polymer Company), 11 g/kg synthetic backside reinforcement Thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 385°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.4 oz/sq yd with 102 ends per inch and 48 fills.

Sample L was woven in the same manner as sample D, and then the following chemicals were coated on the fabric to form a wide stripe pattern: 60 g/kg fluoride (APG-85 from Advanced Polymer Company), 11 g/kg synthetic backside reinforcement Thickener, 929g/kg alginate base dyeing paste (it includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 385°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.42 oz/sq yd, 101 warp yarns and 48 filling yarns per inch.

Sample M was woven in the same manner as sample D, and then the following chemicals were coated on the fabric to form a mesh pattern: 60 g/kg of fluoride (APG-85 from Advanced Polymer Company), 11 g/kg of synthetic backside reinforcement Thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 385°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl Vat Yellow Mixture, 1.811 g/l Cl Vat Red 10 and 3.394 g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.42 oz/sq yd with a construction of 101 ends per inch and 48 ends per inch.

Sample N was woven in the same manner as sample D, and then the following chemicals were coated on the fabric to form a mesh pattern: 60 g/kg of fluoride (APG-85 from Advanced Polymer Company), 11 g/kg of synthetic backside reinforcement Thickener, 929g/kg alginate base printing paste (which includes 32.5g/kg low viscosity alginate thickener, chelating agent, defoamer, antibacterial agent and water). The chemistry also included 1.35g/kg of Disperse Red Blend, 0.41g/kg of Disperse Blue 60 and 8.2g/kg of Disperse Violet 57 dyes. The viscosity of this mixture was 38 poise and it was applied using a 40 mm metal knife with a pressure of approximately 11 psi. The chemical was dried at 385°F. The fabric was then dyed in a thermosol at 425°F for 50 seconds with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729 g/l Cl Disperse Blue 165, 0.700 g/l Cl Disperse Ruby Red Blend, 1.986 g/l Cl mixed Vat Yellow, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then finished in a manner equivalent to that described in Sample D. The weight of the finished fabric was 4.33 oz/sq yd with a construction of 102 warp yarns and 48 weft yarns per inch.

Test Methods

In this test, the term "industrial laundering" means the laundering method as described below.

Industrial Washing Test

Operating procedures:

1. Weigh the sample and take a load of 15±1) lbs.

NOTE: Use a 100% white cotton control if desired to get the proper load weight.

2. Technical specifications for industrial washing methods (Milnor washing machines): process W/L temperature time (min) supply pH value Alkalinity (ppm) available total interrupt retention rinse rinse rinse rinse acidify low low high high high low Add steam to 165140-155120-130110-120100-11090-10090-100 15522225 16.5(±1)oz of Orthosil or 300(±10)mL 2.8(±0.2)oz of IFL#15 or 50(±2)mL None None None None None 0.25(±0.05)oz of Acid or 7±0.5 mL 11.5-12.511.0-12.010.2-10.810.2-10.89.0-10.09.0-10.06.5-7.0 28261880148995012- 3964245929920517346-

3. Put the signal switch in the lower position to start the cycle.

4.W/L means the water surface height. Low = 12 gallons, high = 24 gallons.

5. Remove 4 (±.25) lbs from the 15 (± 1) lb load and place in a Sears Kenmore home dryer (make sure all samples are in the dryer if you have more than 4.25 lbs specimen, please divide it into two loads, each with an even number of specimens. The remainder of each load should consist of the control fabric).

6. Set the dryer's Cotton Sturdy to 30 minutes. Make sure that the sample is completely dry before taking it out of the dryer.

7. Repeat the washing and drying steps above for the specified number of cycles.

Note: Orthosil＝Orthobrite

Tensile Strength: The tensile strength of each fabric specimen was measured in each direction of the warp and weft according to ASTM D-5034-95. Multiple coupons were tested after 10, 25, 50 and 100 industrial washes.

Tear strength: according to ASTM D1424-96, use the Elmendorf tear tester to measure the tear strength of each fabric sample in each direction of warp and weft, after 10 times, 25 times, 50 times and Multiple samples were tested after 100 industrial washes.

Seam slippage: Seam slippage is tested in the warp and weft directions according to ASTM D-434-42.

Bending: The bending of the fabric is tested in both warp and weft directions according to ASTM D3885-99.

Appearance: Fabrics were laundered as described above and graded according to AATCC Test Method 124-1992.

Pilling: Test fabrics for pilling in accordance with ASTM D-3512-99A. For yarn-dyed products, tests are performed upon receipt and after 10, 25 and 50 industrial launderings. Fabrics of the present invention were tested for pilling upon receipt.

Color Data: Primary color data is measured using a 10-grade spherical spectrophotometer with a D65 mirror set at 0% to exclude light sources with a UV filter. Taking the untreated area as the standard and the treated area as the sample, use the following formula to calculate DE, DL, Da and Db:

DL=L ₁ -L ₂ , where L ₁ is unprocessed and L ₂ is processed;

Da=A ₁ -A ₂ , where A ₁ is unprocessed and A ₂ is processed;

Db=B ₁ -B ₂ , where B ₁ is unprocessed and B ₂ is processed;

$\mathrm{<span\; class="notranslate">\; DE</span>}<span\; class="notranslate">\; =</span>\sqrt{{\mathrm{<span\; class="notranslate">\; DL</span>}}^{\mathrm{<span\; class="notranslate">\; 2</span>}}<span\; class="notranslate">\; +</span>{\mathrm{<span\; class="notranslate">\; DB</span>}}^{\mathrm{<span\; class="notranslate">\; 2</span>}}<span\; class="notranslate">\; +</span>{\mathrm{<span\; class="notranslate">\; Da</span>}}^{\mathrm{<span\; class="notranslate">\; 2</span>}}}$

% Intensity = Area under the reflection curve of the treated area/Area under the reflection curve of the untreated area.

DE indicates the total color difference between two areas, while DL indicates the difference in shade depth. For example, a DL of 0 means there is no difference in shade depth between the two regions. Da represents red/green color difference, and Db represents yellow/blue color difference. The grading of intensity indicates the % color difference for the two regions. For samples where the resist chemistry does not include dye, a low intensity value will indicate a high amount of resist.

The results of each test are reported in Tables A and B below.

Table A A B C D. E. f G Width N/A N/A N/A - 64.63 64.63 64.75 Weightoz/sq yd 4.3 4.3 4.3 4.3 4.36 4.41 4.36 Warp 102 77 104 102 101 101 101 weft yarn 57 59 60 47 48 48 48 Tensile strength (after) washing 119 101 117 112 113 111 112 Tensile strength (after) wash 10 times 115 110 96 - 129 121 130 Tensile strength (after) wash 25 times 110 103 97 - 116 115 109 Tensile strength (after) wash 50 times 102 98 71 - 98 110 101 Tensile strength (after) washing 100 times - - - - 99 90 94 Tensile strength (weft) just received 59 78 64 77 80 74 71 Tensile strength (weft) wash 10 times 60 78 66 - 82 79 84 Tensile strength (weft) wash 25 times 51 73 56 - 82 77 79 Tensile strength (weft) wash 50 times 36 64 51 - 74 75 74 Tensile strength (weft) wash 100 times - - - - 77 76 77 Tear resistance (warp) AR 2246 2588 2096 2035 2300 2200 1900 Tear resistance (after) wash 10 times 1958 2166 1833 - 2000 1700 1725 Tear resistance (warp) wash 25 times 1635 1801 1440 - 1750 1650 1575 Tear resistance (after) wash 50 times 1267 1478 1136 - 1750 1800 1700 Tear resistance (after) wash 100 times - - - - 1650 1475 1400 Tear resistance (weft) AR 1401 1715 1264 2100 1950 2100 2250 Tear resistance (weft) wash 10 times 1305 1446 1126 - 1650 1700 1725 Tear resistance (weft) wash 25 times 931 1267 838 - 1600 1650 1650 Tear resistance (weft) wash 50 times 688 976 627 - 1850 2100 1900 Tear resistance (weft) wash 100 times - - - - 1500 1650 1550 seam (warp) 40 40 40 37 33 34 35 Slip (weft) 40 40 40 40 40 40 40 bend (warp) 2000 2000 2000 2000 2000 2000 2000 bending (weft) 2000 2000 2000 2000 2000 2000 2000 Exterior 3 3 3 3.6 3.5 3.5 3.5 Pilling AR 4 4.5 4 - 4 4 4 Pilling wash 10 times 4 4.5 4 3.5 - - - Pilling wash 25 times 4.5 4.5 4.5 - - - - Pilling wash 50 times 4.5 4.5 4.5 - - - -

Form B h I J K L m N Width 64.63 64.75 64.88 64.63 64.75 64.63 64.5 Weightoz/sq yd 4.31 4.35 4.34 4.4 4.42 4.42 4.33 Warp 101 102 102 102 101 101 102 weft yarn 48 48 48 48 48 48 48 Tensile strength (after) washing 109 114 119 108 104 112 101 Tensile strength (after) wash 10 times 124 119 115 110 109 123 105 Tensile strength (after) wash 25 times 113 108 114 113 118 107 105 Tensile strength (after) wash 50 times 107 105 97 95 109 105 107 Tensile strength (after) washing 100 times 99 84 91 73 95 94 95 Tensile strength (weft) average 77 74 74 69 76 73 70 Tensile strength (weft) wash 10 times 82 82 82 76 80 82 77 Tensile strength (weft) wash 25 times 85 78 80 74 84 82 76 Tensile strength (weft) wash 50 times 80 73 72 60 65 82 77 Tensile strength (weft) wash 100 times 78 77 77 68 70 74 74 Tear resistance (warp) AR 1975 1975 2000 1850 2100 1900 2050 Tear resistance (after) wash 10 times 1700 1750 1500 1550 1700 1750 1750 Tear resistance (warp) wash 25 times 1600 1750 1750 1600 1675 1650 1700 Tear resistance (after) wash 50 times 1800 1800 1900 1000 1750 1750 1800 Tear resistance (after) wash 100 times 1400 1450 1500 1250 1400 1500 1450 Tear resistance (weft) AR 2100 2200 2150 1925 2200 2100 2300 Tear resistance (weft) wash 10 times 1700 1575 1450 1750 1600 1675 1750 Tear resistance (weft) wash 25 times 1800 1800 1850 1625 1750 1750 1600 Tear resistance (weft) wash 50 times 2000 2025 1975 1500 1950 1400 1950 Tear resistance (weft) wash 100 times 1750 1550 1600 1500 1550 1650 1575 seam (warp) 31 33 30 36 36 34 34 Slip (weft) 40 40 40 40 40 40 40 bend (warp) 2000 2000 2000 2000 2000 2000 2000 bending (weft) 2000 2000 2000 2000 2000 2000 2000 Exterior 3.5 3.5 3.5 3.5 3.5 3.5 3.5 Pilling AR 4 4 4 4 4 4 4 Pilling wash 10 times - - - - - - - Pilling wash 25 times - - - - - - - Pilling wash 50 times - - - - - - -

Specimens AA through AP were made in the laboratory using laboratory hot sol padding steam. None of the fabrics were finished.

Sample AA was a 4.3 oz 65/35 polyester/cotton poplin fabric. Using alginate-based printing paste containing 11.5g/kg synthetic backside thickener and 988.5g/kg basic printing paste containing alginate thickener, chelating agent, defoamer, antibacterial agent and water in the laboratory Wide-striped patterns are dyed on the fabric on a large-scale dyeing table. (As in the sample above, a small amount of chelating agent, antifoaming agent and antimicrobial agent is included to promote the performance of the printing). The viscosity of the slurry was 25 poise. The chemical was dried on various laboratory infrared belt dryers sold by Glenro, Paterson, New Jersey, set to an output of 65% and a conveyor speed of 1.96 m/min. The temperature is between 220 and 330°. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 5.10 g/l Cl Disperse Orange 30, 11.97 g/l Cl Disperse Blue 165 and 5.65 g/l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AB was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA but also containing 6% of the fluoride APG 5264 from Advanced Polymer Company, Carlstadt, New Jersey. The chemical was dried on a laboratory infrared belt dryer as described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 5.10 g/l Cl Disperse Orange 30, 11.97 g/l Cl Disperse Blue 165 and 5.65 g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AC is the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA, but also containing 6% of the fluoride APG 85 from Advanced Polymer. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 5.10 g/l Cl Disperse Orange 30, 11.97 g/l Cl Disperse Blue 165 and 5.65 g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AD is the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA, but also containing 10% Solopol ZB30, a sugar copolymer from Stockhausen Corporation, Greensboro, North Carolina. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 5.10 g/l Cl Disperse Orange 30, 11.97 g/l Cl Disperse Blue 165 and 5.65 g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Samples AE are the same base fabrics as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AF was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. This slurry also contained 6% of the fluoride APG 5264 from Advanced Polymer. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AG was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The slurry also contained 6% of the fluoride APG 85 from Advanced Polymer. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AH is the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The slurry also contained 10% Solopol ZB30, a sugar copolymer supplied by Stockhausen, Greensboro, North Carolina. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AI was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The slurry also contained 10% Solopol ZB30, a sugar copolymer supplied by Stockhausen, Greensboro, North Carolina, and 1.35 g/kg of a disperse red mixture, 0.41 g/kg of disperse blue 60, and 8.2 g/kg of disperse violet 57 dye. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g/l lCl disperses the ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AJ is the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. This slurry also contained 1.35 g/kg of Disperse Red Mixture, 0.41 g/kg of Disperse Blue 60 and 8.2 g/kg of Disperse Violet 57 dyes. The chemical was dried in the manner described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AK was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The printing paste included 1.35 g/kg of Disperse Red Mixture, 0.41 g/kg of Disperse Blue 60 and 8.2 g/kg of Disperse Violet 57 dyes. The slurry also contained 6% of the fluoride APG 5264 from Advanced Polymer. The chemical was dried on a laboratory infrared belt dryer set to an output of 65% and a conveyor belt speed of 1.96 m/min. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AL was the same base fabric as Sample AA. The fabric was printed with an alginate based print paste as described in Sample AA, further comprising 1.35 g/kg Disperse Red Mixture, 0.41 g/kg Disperse Blue 60 and 8.2 g/kg Disperse Violet 57 dyes Broad pattern. This slurry also contains 6% fluoride APG 85. The chemical was dried in the manner described for Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g/l lCl disperses the ruby red mixture. The fabric was then dried as described in Sample AA.

Sample AM was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described in Sample AA. The print paste also included 1.35 g/kg of disperse red mixture, 0.41 g/kg of disperse blue 60 and 8.2 g/kg of disperse violet 57 dyes. The slurry also contained 10% of Solopol ZB30, a sugar copolymer supplied by the company Stockhausen. The chemical was dried as described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried in the manner described in Sample AA.

Sample AN was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described above in Sample AA. This chemistry also included 1.35g/kg Disperse Red Blend, 0.41g/kg Disperse Blue 60 and 8.2g/kg Disperse Violet 57 dyes. The chemical was dried as described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried as described in Sample AA.

Sample AO was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described above in Sample AA. This paste also included 6% of the fluoride APG5264. This chemistry also included 1.35g/kg Disperse Red Blend, 0.41g/kg Disperse Blue 60 and 8.2g/kg Disperse Violet 57 dyes. The chemical was dried as described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried as described in Sample AA.

Sample AP was the same base fabric as Sample AA. The fabric was printed in broad stripes with an alginate based print paste as described above in Sample AA. This paste also included 6% of the fluoride APG85. This chemistry also included 1.35g/kg Disperse Red Blend, 0.41g/kg Disperse Blue 60 and 8.2g/kg Disperse Violet 57 dyes. The chemical was dried as described in Sample AA. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried as described in Sample AA.

Sample AQ is the same base fabric as Sample AA. Synthetic base print paste containing 17.4 kg water, 12.114 g/kg concentrated synthetic paste (trade name WTA manufactured by Abco Industries, Roebuck, South Carolina) and small amounts of chelating agents, defoamers and antimicrobial agents to facilitate printing performance Print wide stripes on fabric. This slurry was thick so viscosity was not tested. The slurry was dried with various laboratory infrared belt dryers manufactured by Glenro, Paterson, New Jersey, set at 65% output, conveyor speed 1.96 m/min, and temperature 220-330°F. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 5.10 g/l Cl Disperse Orange 30, 11.97 g/l Cl Disperse Blue 165 and 5.65 g/l l Cl dispersed ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300°F.

Sample AR was the same base fabric as Sample AA. The fabrics were printed in broad stripes using various synthetic based printing pastes as described above in Samples AQ. However, the dye paste also included 6 percent of Hipochem FCX fluorocarbon extender sold by High Point Chemical of High Point, North Carolina. The fabric was dried as described in Sample AQ. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l l Cl dispersed ruby red mixture. The fabric is dried in an infrared drying unit at a temperature not exceeding 300<0>F.

Sample AS was the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based print pastes as described in Samples AQ. The fabric was then dried as described in Sample AQ. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g /l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried in the manner described in Sample AQ.

Sample AT was the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based print pastes as described in Samples AQ. This slurry also included 6% HipochemFCX fluorocarbon extender. The fabric was then dried as described in Sample AQ. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g /l Cl Dispersed Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried in the manner described in Sample AQ.

Sample AU was the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based print pastes as described in Samples AQ. Also included in this slurry were 1.35 g/kg Disperse Red Mixture, 0.41 g/kg Disperse Blue 60 and 8.2 g/kg Disperse Violet 57 dyes. The fabric was then dried as described in Sample AQ. The fabric was then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g /l Cl to disperse the ruby red mixture. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AV is the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based printing pastes as described in Samples AQ, which pastes also contained 6% Hipochem FCX fluorocarbon extender and 1.35g/kg Disperse Red blend, 0.41g /kg disperse blue 60 and 8.2g/kg disperse violet 57 dyes. The fabric was then dried as described in Sample AQ and then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469 g/l A mixture of Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165 and 0.700g/l Cl Disperse Ruby Red. The fabric is then dried in an infrared drying unit at a temperature not to exceed 300<0>F.

Sample AW is the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based print pastes as described in Samples AQ. This slurry also included 1.35 g/kg Disperse Red Mixture, 0.41 g/kg Disperse Blue 60 and 8.2 g/kg Disperse Violet 57 dyes. The fabric was then dried as described in Sample AQ and then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mix: 2.469 g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l Cl Disperse Ruby Red Mixture, 1.986g/l Cl Disperse Yellow Mixture, 1.811g/l Cl Disperse Red 10 and 3.394g/l Cl Disperse Black 22 . The fabric was then dried in the manner described in Sample AQ.

Sample AX was the same base fabric as Sample AA. The fabric was dyed in broad stripes with various synthetic based print pastes as described in Samples AQ. The slurry also included 6% Hipochem FCX fluorocarbon extender and 1.35 g/kg Disperse Red Mix, 0.41 g/kg Disperse Blue 60 and 8.2 g/kg Disperse Violet 57 dyes. The fabric was dried as described in Sample AQ and then dyed for 50 seconds at 425°F in a laboratory thermosol/pad/steam unit with the following dye mixture: 2.469 g/l Cl Disperse Orange 30, 0.729g/l Cl Disperse Blue 165, 0.700g/l Cl Disperse Ruby Red Mixture, 1.986g/l Cl Vat Yellow Mixture, 1.811g/l Cl Vat Red 10 and 3.394g/l Cl Vat Black 22. The fabric was then dried as described in Sample AQ.

Test the color data using the methods described above. The relative dE, dL, da, db and strength (portion of fabric with chemical versus non-chemical) were calculated for each sample. The results are listed in Table C below.

Form C E L da db strength(%) AAA 13.858 13.764 0.092 -1.609 39.2 AB 15.391 15.359 0.161 -0.977 35.52 AC 17.106 17.093 0.031 -0.654 31.76 AD 16.026 15.969 0.07 -1.345 33.95 AE 16.37 16.246 1.268 1.556 34.86 AF 17.129 16.983 1.824 1.293 33.01 AG 19.682 19.496 1.95 1.869 28.07 AH 18.319 18.182 1.359 1.755 30.67 AI 14.75 10.127 -6.124 -8.804 50.24 AJ 13.937 8.904 -5.865 -8.976 54.23 AK 16.551 8.624 -7.508 -11.966 55.85 AL 16.87 8.054 -7.872 -12.561 58.2 AM 15.814 8.653 -7.604 -10.834 57.03 AN 15.939 7.56 -7.742 -11.703 61.25 AO 18.173 6.821 -8.024 -14.811 64.18 AP 18.591 5.07 -8.062 -15.966 72.28 AQ 5.681 5.622 -0.091 -0.808 67.8 AR 7.701 7.643 0.041 0.91 60.55 AS 8.6 8.652 0.095 0.35 56.6 AT 10.421 10.353 0.17 1.175 51.13 AU 7.414 2.905 -3.902 -5.595 80.85 AV 7.463 2.752 -4.63 -5.16 82.6 AW 12.73 1.144 -6.616 -10.815 92.22 AX 12.698 0.0601 -6.914 -10.633 95.99

As noted from the examples, both synthetic and alginate print pastes can be used to produce printed fabrics using the continuous dyeing process. However, alginates outperform specific synthetic print pastes based on the specific conditions used (viscosity, pressure, screen mesh, etc.). However, each of the sizings tested provided good pattern while minimizing loss of fabric strength. It is also noted that, using the method of the present invention, the degree of stain resistance can be varied by selection of the type of resist chemical, method of application, substrate and dye used, etc. It is within the contemplation of the present invention to use patterns with high to essentially complete stain resists as well as patterns with lower levels of stain resists which allow only a slight color change.

Fabrics prepared in accordance with the present invention may be used in any end use where printed fabrics are useful, including but not limited to apparel, home furnishings, tablecloths, industrial products, and the like. This fabric has particular utility in the manufacture of garments for the rental laundry market, as evidenced by product durability after industrial laundering.

In this specification the preferred embodiments of the invention have been presented, and although specific terms have been employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

Claims (32)

1. A method for manufacturing a patterned fabric, the method comprising the steps of: Applying water-soluble chemicals designed to inhibit wetting on selected areas of the fabric, thereby identifying treated and untreated areas for pattern formation; Exposing the fabric to an aqueous dye solution for dyeing until the untreated areas are saturated and the treated areas are not sufficiently saturated, thereby forming a patterned fabric. 2. The method of claim 1, wherein the chemical substance comprises a substance selected from the group consisting of alginate printing pastes, synthetic printing pastes, fluorides, and combinations thereof. 3. The method of claim 1, wherein the chemical substance comprises a dye paste. 4. The method of claim 3, wherein the chemical substance consists essentially of a dye paste. 5. The method of claim 1, wherein the chemical species comprises fluoride. 6. The method of claim 1, wherein the chemicals include fluoride and dye paste. 7. The method of claim 1, wherein the chemical substance further comprises a dye. 8. The method of claim 1, wherein the chemical substance comprises an optical brightener. 9. The method of claim 1, wherein the chemicals include dyes and dye pastes. 10. The method of claim 1, wherein the dyeing step is performed by a continuous or semi-continuous dyeing method. 11. The method as claimed in claim 1, wherein said dyeing step is selected from the group consisting of thermosol dyeing, padding/steaming, thermosol/padding/steaming, cold padding in batches, jiggering and method of combining them. 12. The method of claim 11, wherein the step of continuous dyeing is performed using a thermosol dyeing method. 13. The method of claim 11, wherein the step of continuous dyeing is performed using a pad/steam method. 14. The method of claim 1, wherein the fabric comprises fibers selected from the group consisting of polyester, cotton, PLA, PTT, nylon, rayon, and blends thereof. 15. The method of claim 1, wherein the fabric comprises polyester, and the dyeing step is performed using a thermosol or pad/steam dyeing method. 16. The method of claim 1, wherein the dyeing step comprises dyeing the fabric with a dye selected from the group consisting of disperse dyes, reactive dyes, direct dyes, vat dyes, acid dyes, and sulfur dyes. 17. A fabric made by the method of claim 1. 18. The method as claimed in claim 1, wherein the method is selected from flexographic printing, gravure roll coating printing, roller bed printing, rotary screen printing, brush coating method, ultrasonic spray method, multi-nozzle jet printing and printing head printing method. Method The step of coating a chemical substrate is performed. 19. The method of claim 1, wherein the step of applying chemicals defines a first pattern, and further comprises applying a second water-soluble chemical designed to inhibit wetting in a pattern different from that of the first pattern. A step of a second pattern of a pattern, thereby forming a multicolored fabric, wherein the second water-soluble chemical is different from the first water-soluble chemical. 20. The method of claim 19, wherein at least one of the first water-soluble chemical and the second water-soluble chemical designed to inhibit wetting comprises a dye. 21. The method of claim 1, wherein said fabric comprises at least two types of fibers, and said fabric dyeing step comprises dyeing less than all of said at least two types of fibers, thereby forming a heterogeneous colored fabric. 22. A method of manufacturing a patterned fabric, the method comprising the steps of: Applying water-soluble chemicals designed to inhibit wetting to the fabric, thereby defining treated and untreated areas of the fabric; and Expose the fabric to the water-based dye, so that the treated area is less wetted by the water-based dye than the untreated area, and due to the relative difference in the color uptake of the water-based dye, patterns with relatively different colors are formed . 23. The method of claim 22, wherein the chemical species comprises a species selected from the group consisting of alginate print pastes, synthetic print pastes, fluorides, and combinations thereof. 24. The method of claim 22, wherein said step of exposing the fabric to a dye comprises dyeing the fabric by a continuous or semi-continuous dyeing process. 25. The method of claim 22, wherein the water soluble chemical comprises a dye, thereby imparting a different color to the treated area of the fabric than the water-based dye. 26. A fabric made by the method of claim 22. 27. The printed textile produced by the method of claim 1, which has a predetermined color pattern, which is determined by areas with more and less coloring ratios of the same color applied to the same coating, wherein the finished product Areas of fabric with less dye uptake have substantially the same physical strength as said areas with more dye uptake. 28. The fabric of claim 27, wherein the fabric comprises fibers selected from the group consisting of polyester, cotton, PLA, PTT, nylon, rayon, and blends thereof. 29. The fabric of claim 27, wherein the transition between regions of greater and lesser dye uptake is well defined. 30. The fabric of claim 27, wherein the yarns forming the fabric are ring dyed. 31. The fabric of claim 27, wherein the predetermined color pattern mimics the structure of the fabric, thereby providing the appearance of a yarn-dyed fabric. 32. The fabric of claim 27, wherein the fabric is a woven fabric, and the predetermined color pattern includes stripes extending in at least one of a warp direction and a weft direction of the woven fabric.

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