Brief introduction to disperse printing dyeing process

Disperse printing is an efficient dyeing process for synthetic fibers such as polyester, especially suitable for textile processing with bright colors and complex patterns. This process is based on disperse dyes, combined with heat transfer, high-temperature fixation and other technologies, and is widely used in the fields of clothing, home textiles and industrial textiles.

I. Technical principles and core advantages of disperse printing

1. Technical basis

Dye characteristics: Disperse dyes are hydrophobic non-ionic dyes with small molecular weight (200-500 Da), which sublimate and diffuse into the fiber at high temperature.

Fiber adaptability: Designed for synthetic fibers with high crystallinity and glass transition temperature (Tg≈80℃) such as polyester and acetate.

Color fixation mechanism: Through high temperature (180-220℃), the dye is sublimated → adsorbed → penetrated → crystallized to form stable color fastness.

2. Process advantages

High color fastness: dry/wet friction fastness can reach 4-5 levels, and sunlight fastness is above 6 levels (better than traditional paint printing).

Fine pattern: It can achieve high-precision printing of more than 1200 dpi, suitable for gradient colors and complex geometric patterns.

Environmental protection and energy saving: Waterless printing and dyeing process (thermal sublimation method) reduces wastewater discharge and reduces energy consumption by 30% compared with traditional dyeing.

2. Detailed explanation of mainstream process types and processes of disperse printing；

1.Pattern printing: Print the pattern on transfer paper (PET coated paper) with disperse dye ink.

Hot pressing transfer: The transfer paper is bonded to the polyester fabric, and the dye sublimation transfer is completed by the hot pressing roller (200℃, 20-30 seconds).

Post-processing: Cooling and setting, no need for washing.

Application scenarios: sportswear, flags, personalized customized fabrics.

2. Direct-injection digital printing

Technology upgrade: Use piezoelectric nozzles to directly spray disperse dye ink onto the fabric surface.

Fix the color through infrared pre-baking (100℃) → high-temperature baking (210℃, 2-3 minutes).

Advantages: small batch fast production, support gradient colorless printing.

3. Traditional screen printing (hot melt color fixation method)

Process characteristics:

Color paste preparation: disperse dye + thickener (sodium alginate) + urea (dyeing promoter).

Printing: rotary screen/flat screen printing.

Pre-baking (100℃, 2 minutes) → high temperature baking (200℃, 5-8 minutes).

Applicable fields: large-scale curtain and sofa fabric production.