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Preparation and characterisation of ink formulations for jet printing on nylon

carpet

Article  in  Pigment and Resin Technology · January 2010

DOI: 10.1108/36994201080000656

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 Preparation and characterisation of ink
formulations for jet printing on nylon carpet
H. Abd El-Wahab
Department of Chemistry, Faculty of Science, Al-azhar University, Cairo, Egypt
M.M. El-Molla
Textile Research Division, National Research Centre, Cairo, Egypt, and
L. Lin
Department of Colour and Polymer Chemistry, School of Chemistry, University of Leeds, Leeds, UK

Abstract
Purpose – The purpose of this paper is to prepare and characterise various ink formulations for inkjet printing on nylon 66 carpet.
Design/methodology/approach – Various ink formulations were prepared using CI Acid Red 57, synthetic thickeners (BYK425 and BYK420),
ethylene glycol, diethylene glycol, isopropanol with auxiliaries. The inks were characterised for their rheological, wetting and storage stability
properties. The inks were jetted using a Printos P16 drop-on-demand jet print-head onto nylon 66 carpet materials. The printed images were
characterised using an ImageXpert system.
Findings – It is found that the inks containing the synthetic thickeners at the optimum ratio give good printing and image properties, such as optical
density, drop size, and depth of penetration into the substrate at pH 4-5. The optimised ink formulation is found to have good storage stability.
Research limitations/implications – The study focuses on ink formulations based on CI Acid Red 57. Ink formulations based on other colorants could
also be studied in order to assess the applicability of the ink formulation system found for other colorants.
Practical implications – The ink formulations developed could find use in industrial scale printing.
Originality/value – Low cost ink formulations for printing of nylon carpets are novel.

Keywords Inks, Inkjet printers, Textile manufacturing processes

Paper type Research paper

Introduction by saturated steam and different processes have been

In recent years, the growth in digital inkjet printing has
stimulated further product development in ink formulations
that suit particular jetting requirements of various type of ink
jet printers used worldwide, textile printing processes use a
wide variety of chemical-based materials to assist textile
printers in achieving fine line definition and appropriate levels
of colour fastness for the intended end use. Research on ink
jet printing has mainly focused on machinery improvement
and optimisation of the physical/chemical properties of ink
formulations. Examples are the machine speed, printing
precision, and ink delivery (Dawson, 2000; Ervine et al.,
2000; Li and Tincher, 1999). However, the physical/chemical
properties and the treatments of the textile substrate before
and after printing are also essential to the success of ink jet
printing technology. Limited research has involved the
understanding and development of textile substrates and
printing processing conditions for better application of ink jet
printing and for better quality of printed goods (Aston et al.,
1993; Dawson, 2001; Smith and Simonson, 1987).
Conventional textile printing can apply dyes that are fixed
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/0369-9420.htm
Pigment & Resin Technology
39/3 (2010) 163– 169
q Emerald Group Publishing Limited [ISSN 0369-9420]
[DOI 10.1108/03699421011040794]
developed for textile printing, depending on the kind of the
fabric used (cellulosic, polyester, acrylic, protein), on the
nature of the dyestuff applied (reactive dye, vat dye) and on
the expected quality of the final product (Saffour et al., 2006).
Water is one of the preferred vehicle for jet inks because of
its viscosity, ionic nature, and conductivity. A water-based ink
has key advantages over an organic-based ink, as it is less
toxic, and does not denature enzymes; this allows for a one-
step printing process which greatly reduces the cost of
production (Crouch et al., 2005). The balance of the inkjet
ink composition may be water, at least 80 per cent of the ink
composition is water. Inkjet inks may also include a pigment.
Generally, the amount of pigment ranges from about 2 wt% to
about 6 wt% (Rolly, 2008). In spite of the superior thickening
properties of kerosene/water emulsion which also contributes
towards a soft hand of the print and good fastness properties,
environmental and economical factors have compelled the
search for a replacement for kerosene (El-Molla and
Schneider, 2006).
Also thickeners and binders play a paramount role in
pigment printing and rheological properties of the printing
pastes during application and to obtain sharp and clean
drawing patterns by preventing dye migration (Zahran et al.,
2007; Baranov et al., 2002; Fijan et al., 2009). The synthesis
and application of thermally stable dyes for ink-jet printed
colour filters was investigated (Kim et al., 2009).
The work reported in this paper was based on the
preparation of various modified ink formulations for inkjet
printing on nylon 66 carpet materials. A comparison between

163
 Preparation and characterisation of ink formulations Pigment & Resin Technology
H. Abd El-Wahab, M.M. El-Molla and L. Lin Volume 39 · Number 3 · 2010 · 163 –169

ink formulations with and without thickeners, in terms of Polyamide fabrics and carpets
jetting properties, storage stability and qualities of the printed Fabrics and carpets made of 100 per cent nylon 66 were
images on nylon 66 carpet materials, such as optical density, obtained from a local supplier.
drop size, and penetration properties.

Preparation of ink formulations

Experimental Water-based inks consisting of the above-mentioned materials
Materials were prepared. The formulations contained 3 per cent
Dye Nylosan Red E-BNL mixed with either BYK425 or BYK
The dye used as CI Acid Dye 57 (Nylosan Red E-BNL) 425/BYK420 mixture (1:1), various other auxiliaries, and
supplied by Clariant, Switzerland, having its structure shown deionised water as a solvent. Each of the formulations was
in Scheme 1. prepared by mixing relevant ingredient under stirring for 2 h.
The ink formulations were designed using Minitab 14
Thickeners
(supplied by Minitab Ltd, Brandon Court, Unit E 1, Progress
Two thickeners were used in the preparation of various ink
Way, Coventry CV3 2TE, UK) following factorial experimental
formulations. There were BYK425 and BYK420, which are
design principle, in order to evaluate the effects of different
briefly described as follows.
binders on the properties of the inks and to obtain optimised
BYK425. The BYK425 used was supplied by BYK-Chemie ink formulations. The ink formulations prepared are shown in
GmbH, Abelstrasse 46483, Wesel, Germany. This was a light Tables I and II.
yellow liquid consisting of a solution (polypropylene glycol
600) of urea modified polyurethane having its structure
shown in Scheme 2. Methods for the characterisation of ink formulations
Rheological analysis
BYK420. The BYK420 used was also supplied by BYK- Rheological properties of the water-based ink formulations
Chemie GmbH. This was modified urea dissolved in N- prepared were analysed (at 258C and different shear rates)
methylpyrrolidone. It was designed for rheology control of using a RFS II (Rheometrics CO 1483) fluid spectrometer.
aqueous and water soluble resin system providing pseudo
plastic flow behaviour. The viscosity increase improves the sag Measurement of surface tension
resistance properties. Surface tension of the inks prepared was measured using a
Auxiliaries TBS Torsion Balance (Torsion Balance Supplies, Malvern
Various other auxiliaries were used to improve the penetration Wells, Worcestershire, UK). Such an instrument determined
of the ink, to reduce the droplet size on fibre and to regulate the force required to detach a platinum ring from the surface
viscosity and wetting characteristics of the inks prepared. of the ink. The measurement procedure was repeated six
These included diethylene glycol (DEG), ethylene glycol times to obtain an average value of the detaching force. Before
(EG), glycerol, BYK800 (an alkoholalkoxylate antifoam), each measurement, the platinum ring was thoroughly rinsed
isopropanol (co-solvent), and acetic acid (AA) (for pH in distilled water and flamed with a Bunsen burner to remove
adjustment to pH 4 , 5), all supplied by Sigma-Aldrich, UK, any residue.
except BYK800 which was supplied by BYK-Chemie GmbH.
In-house made deionised water was used as the main solvent. Table I Ink formulations containing BYK425
Urea supplied by Avocado Research Chemicals Ltd was Compositions (%)
used as a swelling agent for the nylon fibres. Sandogen NH Ink sample code DEG EG IPA Water BYK425 Acid red dye
Liq., an anionic levelling agent supplied by Clariant,
Swaziland, was employed as a levelling agent to achieve A1 10 5 5 27 0 3
level dyeing in textured nylon yarns and fabrics. A2 10 5 5 25 2 3
A3 0 5 0 42 0 3
Scheme 1 Chemical structure of CI Acid Red 57 dye A4 0 5 0 40 2 3
A5 10 0 0 37 0 3
OH A6 10 0 0 35 2 3
A7 0 0 0 47 0 3
N N OSO3Na A8 0 0 0 45 2 3
A9 0 0 5 42 0 3
NaO2SO A10 0 0 5 40 2 3
A11 0 5 5 37 0 3
A12 0 5 5 37 2 3
Scheme 2 Formation and structure of BYK425 A13 10 5 0 32 0 3
A14 10 5 0 30 2 3
PU polymer formed by reacting a diisocyanate with a Urea A15 10 0 5 32 0 3
A16 10 0 0 35 2 3
OC-N-R-R-N-CO + NH2CONH2
Note: Using glycerol (G), levelling agent, antifoam, AA to adjust pH, sodium
–n{HNCOHNOCNHR1-NH-CO-NH-CONH-CONHR2NHCONHCONH–}n– chloride (NaCl), and urea, as 1.78, 0.59, 0.3, 0.59, 0.03, and 2.96 g,
respectively
Notes: R – Benzene ring; N – repeat unit

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 Preparation and characterisation of ink formulations Pigment & Resin Technology
H. Abd El-Wahab, M.M. El-Molla and L. Lin Volume 39 · Number 3 · 2010 · 163 –169

Table II Ink formulations containing BYK425/BYK420 mixture (1:1) Results and discussion
Compositions (%) Two families of ink formulation were prepared namely, Group
BYK A inks containing BYK425 as thickener while Group B inks
Ink 425/BYK420 contained a mixture of BYK425 and BYK420 (1:1) as
sample Acid red mixture thickener. Relevant test results are shown in Tables III-VIII
code DEG EG IPA Water dye (1:1) and Figures 1-11.

B1 10 5 5 27 3 0
B2 10 5 5 22 3 5 Effects of binders on the viscosity of inks
B3 0 5 0 42 3 0
The viscosities of various inks prepared are shown in Tables III
and IV which were limited from 1 to 10 cP. This is suitable
B4 0 5 0 37 3 5
for the piezo jet printing machine used. The effects of the
B5 10 0 0 37 3 0
binders on the viscosity of the inks are shown in Figures 1 and
B6 10 0 0 32 3 5
2. It can be seen from Figure 1 that the viscosity of the inks
B7 0 0 0 47 3 0
increased with the increase of the concentration of BYK425
B8 0 0 0 42 3 5
for Group A inks. The viscosity of the Group B inks also
B9 0 0 5 42 3 0
increased as the concentration of the BYK425/BYK420
B10 0 0 5 37 3 5
mixture in the inks increased (Figure 2). Such effects are
B11 0 5 5 37 3 0
expected, due to the thickening effect of BYK425 and
B12 0 5 5 32 3 5 BYK420 and its viscosity was limited from 1 to 20 cP. This is
B13 10 5 0 32 3 0
B14 10 5 0 27 3 5 Table III Properties of the inks containing BYK425
B15 10 0 5 32 3 0
Ink sample code Viscosity (cP) Surface tension (mN/M)
B16 10 0 0 32 3 5
Note: Using glycerol (G), levelling agent, antifoam, AA to adjust pH, NaCl, A1 5.7 34.1
and urea, as 1.78, 0.59, 0.3, 0.59, 0.03, and 2.96 g, respectively A2 11 33.2
A3 4.3 34.5
A4 7 33.8
Method for inkjet printing onto nylon 66 fabrics and A5 3.2 35.0
carpet materials A6 9 33.5
A Printos P16 drop-on-demand piezo head jet printing A7 3.1 35
machine was used to print the inks prepared onto nylon 66 A8 7 33.5
carpet materials. Samples printed with the prepared inks
A9 3 35.0
containing acid red dye B-NBL and BYK425 and other
A10 7 33.5
inks containing 1:1 mixture of BYK425 and BYK420 were
A11 5 34.7
first air-dried followed by steaming at 1108C for 15 min. at an
A12 8.3 33.8
atmospheric pressure for the fixation of dye onto the fabrics
A13 4 35.0
and carpet materials. These samples were subsequently
A14 11 33.3
subjected to various analyses.
A15 4.5 34.3
A16 11 33.2
Methods for the characterisation of the quality of
printed images
Image qualities Table IV Properties of the inks containing BYK425/BYK420 mixture (1:1)
An ImageXpert Stationary System, supplied by ImageXpert, Ink sample code Viscosity (cP) Surface tension (mN/M)
486 Amherst Street, Nashua, New Hampshire, 03063-1224,
USA, was used in this study to analyse the quality of images B1 5.7 34
inkjet printed on nylon fabrics and carpet materials. The B2 22 31.6
system consisted of CCD cameras and a Power Macintosh G3 B3 4 34.3
Computer, in which the analysis software was integrated. B4 19 32.2
B5 3 34.8
Optical density B6 25 31.0
Optical density of each printed sample was measured using a B7 3 35
GRETAG D183 densitometer. B8 15 32.7
B9 3 35.0
Drop size B10 10 33..0
The diameter of the printed circles on surface of the fabrics/ B11 4.8 34.6
carpet materials was measured using a ruler. B12 12 33..2
B13 4 35.0
Penetration B14 25 31.0
The depth (in percentage) of ink penetration into the printed B15 4.6 34.3
fabrics/carpet materials was measured on the cross section of B16 14 32.5
printed fabrics/carpet materials.

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 Preparation and characterisation of ink formulations Pigment & Resin Technology
H. Abd El-Wahab, M.M. El-Molla and L. Lin Volume 39 · Number 3 · 2010 · 163 –169

Table V Effects of BYK425 on optical density of print at different ratios Table VII Effect of BYK425 on circle size and depth of penetration at
of DEG, EG and IPA different ratios of DEG, EG and IPA
Ink sample Optical density Optical density on Circle size on Depth of penetration
code on fabrics carpet materials Ink sample code fibre (cm) (%)
A1 1.3 1.8 A1 2 100
A2 1.8 2.2 A2 1.5 80
A3 1.7 2.0 A3 2.1 100
A4 2.0 2.2 A4 1.6 100
A5 1.3 2.1 A5 1.9 100
A6 1.9 2.4 A6 1.6 100
A7 1.6 1.8 A7 2.3 60
A8 2.0 2.3 A8 1.8 80
A9 1.3 2.0 A9 2.1 100
A10 2.1 2.3 A10 1.8 80
A11 1.3 1..9 A11 1.6 100
A12 1.9 2.2 A12 1.7 90
A13 1.4 1.9 A13 1.7 100
A14 2.1 2.4 A14 1.5 100
A15 1.3 1.9 A15 1.9 100
A16 1.9 2.3 A16 1.7 90

Table VI Effects of BYK425/BYK420 mixture (1:1) on the optical Table VIII Effects of BYK425/BYK420 mixture (1:1) on circle size and
density of print at different ratios of DEG, EG and IPA depth of penetration at different ratios of DEG, EG and IPA
Ink sample Optical density Optical density Circle size on Depth of penetration
code on fabrics on carpet materials Ink sample code fabrics (cm) (%)
B1 1.3 1.8 B1 2.1 100
B2 2 2.4 B2 1.6 90
B3 1.6 2.0 B3 2.3 100
B4 2.3 2.4 B4 1.9 100
B5 1.3 2.2 B5 2.2 100
B6 2.2 2.6 B6 1.7 100
B7 1.4 1.9 B7 2.4 80
B8 2.3 2.6 B8 2.0 80
B9 1.3 2.1 B9 2.3 100
B10 2.2 2.4 B10 2.2 100
B11 1.3 2.0 B11 2.0 100
B12 2.0 2.5 B12 1.9 80
B13 1.3 1.9 B13 2.2 100
B14 2.4 2.6 B14 1.7 100
B15 1.3 1.9 B15 2.1 100
B16 2.4 2.4 B16 1.9 100

suitable for the piezo jet printing machine used. However, an
interesting observation was that the viscosity of the Group A
inks experienced a peak value before the concentration of the
BYK425 in the ink formulation reached the maximum.
Effects of binders on surface tension of the inks
The surface tension of Group A and Group B inks are shown
in Tables III and IV. The effects of binders on surface tension
of the inks are shown in Figures 3 and 4. It can be seen from
Figure 3 that the surface of Group A inks decreased as the
concentration of BYK425 increased. This was likely due to
the contribution of urea modified polyurethane resin to
improved spreading ability of the resulting inks. There was a
peak value of surface tension experienced by the inks at a low
BYK425 concentration range.
The relationship between surface tension and the binder
concentration of the Group B inks was relatively complex,
possibly due to the opposing effects of the binders and the
various solvents and additives (Figure 4). However, as the
concentration of the binder increased, the surface tension of
the inks generally increased, resulting in reduced spreading
ability of the resulting inks.
Effects of binders on optical density of prints
The optical density of prints on fabrics and carpet materials
are shown in Tables V and VI and Figures 5 and 6. It can be
seen from Figure 5 that the optical density of prints on fabrics
for Group A inks decreased as the content of BYK425 in the
inks increased, possibly due to the dilution effect. However,
such an effect on carpet materials was reversed, which was
possibly due to the reduced extent of ink penetration as

166
 Preparation and characterisation of ink formulations Pigment & Resin Technology
H. Abd El-Wahab, M.M. El-Molla and L. Lin Volume 39 · Number 3 · 2010 · 163 –169

Figure 1 Correlation of viscosity of ink to BYK425, water and DEG Figure 3 Correlation of surface tension to BYK425, water and IPA

45
35

30
DEG 30
Viscosity IPA
22.00
Surface tension 22.00
15
28.00 25
28.00
0.00
0.00
BYK425 (5%) 0 20
22.00 BYK425 (5%) 22.00
0.00
50.00 0.00
Water 50.00
Water
Figure 2 Correlation of viscosity to BYK425/BYK420 mixture (1:1),
Figure 4 Correlation of surface tension to BYK425/BYK420 mixture
water and DEG
(1:1), water and DEG

300
BYK425 (50%) N-me
Viscosity

200

60
100
50 DEG

0 50.00 Surface tension 50.00

50.00 40
0.00
30 0.00
BYK425 (50%) N-methyl pyroli
Water 0.00 0.00 50.00
0.00
50.00
Water
50.00
DEG
Figure 5 Correlation of optical density of print on fabrics to BYK425,
the content of binder increased. Similar effects occurred to water and DEG
Group B inks, as can be seen from Figures 7 and 8.

Effects of binder content on ink spreading

The measured diameters of circles printed on carpet materials
are shown in Tables VII and VIII and Figure 9. It can be seen
from Figure 9 that the diameter of the printed circles 2
decreased as the binder content increased, most likely due to
the reduced spreading of the inks on the carpet materials,
resulting from increased viscosity and surface tension of the DEG
relevant inks. 1
Colour 22.00
Effects of binder content on ink penetration 28.00
The depth of ink penetration on carpet materials is shown in 0
Tables VII and VIII, Figures 10 and 11, and Figures 12 and 13. It 0.00
can be seen from Figures 10 and 11 that the relationship between BYK425 (5%)
the depth of ink penetration and binder content is a complex one. 22.00
This is likely due to the fact that both viscosity and surface tension 0.00
affect the depth of penetration. It is the balance between the 50. 00
opposing effects of viscosity increase and surface tension increase Water

167
 Preparation and characterisation of ink formulations Pigment & Resin Technology
H. Abd El-Wahab, M.M. El-Molla and L. Lin Volume 39 · Number 3 · 2010 · 163 –169

Figure 6 Correlation of optical density of print on carpet materials to Figure 9 Correlation of circle size of print on fabrics to BYK425/BYK420
BYK425, water and EG mixture (1:1), water and EG
EG
50
Drop size
4
< 2.0
2.0 – 2.2
2.2 – 2.4
EG 2.4 – 2.6
3
Op. denistyon carpet 22.00 2.6 – 2.8
2.8 – 3.0
28.00 > 3.0
0 0
0.00
2 Hold values
BYK425 (5%) DEG 0
22.00 IPA 0
0.00
50.00
Water

Figure 7 Correlation of optical density of print on fabrics to BYK425/

BYK420 mixture (1:1), water and DEG 50 0 50
Water BYK425 (50%) N-methyl pyroli

Figure 10 Correlation of depth of penetration of ink on fabrics to

BYK425, water and EG
2

1 DEG
Colour 50.00
0 2.0
0.00
–1 0.00
1.5
BYK425 (50%) EG
N-methyl pyroli 50.00 Panetration on carpet % 22.00
0.00
50.00 1.0
28.00
Water
0.00
Figure 8 Correlation of optical density of print on carpet materials 0.5
BYK425 (5%)
BYK425/BYK420 mixture (1:1), water and EG 22.00 0.00
50.00
EG
Water
50

Op. Figure 11 Correlation of depth of penetration of ink on carpet

denisty materials to BYK425/BYK420 mixture (1:1), water and DEG
carpeton

<2
2–3
3–4 2
0 0 4–5
5–6
>6
1 IPA
Hold values Panetration on carpet % 22.00
DEG 0
IPA 0 28.00
0
0.00
50 0 50
BYK425 (5%)
Water BYK425 (50%) N-methyl pyroli 22.00 0.00
50.00
Water
that determines the depth of penetration, depending on the
structure of the substrate (e.g. porosity).
their viscosity, surface tension and extent of precipitation
Stability of ink observed at regular intervals. It was found that all of the inks
All of the ink formulations prepared were stored in glass prepared had relatively constant viscosity and surface tension
sample bottle for six month at ambient temperature and had and that no precipitation was found.

168
 Preparation and characterisation of ink formulations
H. Abd El-Wahab, M.M. El-Molla and L. Lin
Figure 12 Image of the circles printed on carpet materials
Figure 13 Cross section of printed carpet material showing penetration
of ink
Conclusions
Base on the findings described above, it can be concluded that:
.
The synthetic thickeners BYK425 and BYK425/BYK420
mixture (1:1) could be successfully used to regulate the
viscosity and surface tension of ink formulations for
printing onto nylon carpet materials.
.
All of the fabrics and carpet materials printed with the
inks containing BYK425 and BYK425/BYK420 mixture
(1:1) had higher optical densities than those with inks
containing no binders.
.
Highly reproducible prints could be created by jet-printing
using the inks containing synthetic thickener such as
BYK425 and BYK425/BYK420 mixture (1:1) on
polyamide fabrics and nylon carpet materials giving high
quality prints (Figure 14).
.
All of the ink formulations prepared had good storage
stability.
Figure 14 Images printed on fabrics
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Corresponding author
H. Abd El-Wahab can be contacted at: Hamada19982000@
hotmail.com