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高温热转移印花纸印刷色彩管理及评价的研究
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摘要
随着人们物质生活水平的不断提高,追求舒适高雅的家居环境已经成为一种时尚。家庭装饰的日趋多样化、个性化需要更多色彩鲜艳的装饰面料,热转移印花产品正好能满足这种需求。将印刷方式引入到纺织行业,热转移印花起到了非常重要的作用。热转移印花是印刷技术在纺织行业应用的延伸,织物表面凹凸不平有无数孔隙,跟纸张印刷效果相比,很难获得精细度很高的图案。因此热转移印花是将油墨通过印刷的方式制成印花纸,然后将织物处于一定温度和压力条件下,印花纸上的染料通过加压、加热升华、将印花纸上的图案转移到织物上。这是纺织行业的一次革命性变化,可以降低成本、节约能源、实现绿色低碳环保的生产工艺过程。
     本论文以高温热转移印花纸为研究对象,以热转移印花产品生产工艺流程为主线,按照工艺流程将热转移印花过程中的相关制版、印刷等核心技术及机理进行深入研究,旨在为热转移印花在纺织行业中的应用提供一定的理论依据及技术支持。在传统印刷基础上,以热转移印花最常用的凹版印刷方式为主线,研究了热转移印花纸印前制版雕刻网穴的优化选择、电雕分色曲线的设置;工艺流程中的色彩管理、色空间转换、印花专色印花浆调配,最后构建了热转移印花纸印刷质量评价模型;进而对所构建的热转移印花纸的印刷质量等进行了评价及表征。扩大了热转移印花技术在纺织工业中的应用范围及用量。
     进行了高温热转移印花纸凹版印刷网穴再现半色调机理研究。优化了网穴结构、网穴参数,进而对网穴再现半色调过程中释墨量计算进行了分析。研究表明:网穴作为凹版印刷中再现层次和传递油墨的最基本单元,在热转移印花凹版印刷中,雕刻图文的铜面层亮调部分网穴的网值在30~42μm左右,暗调部分的网值在155~170μm左右。为提高印刷品暗调部分网穴的传墨量,在暗调部分需要做通沟,通沟尺寸在26~32μm。常用的加网角度为:对于开口压偏的网穴采用38°,对于开口拉长的网穴采用60°。在凹版印刷中为了提高图文边缘的清晰度,黑版的加网线数为90线/cm,网穴角度为38°;品红版加网线数为70线/cm,网穴角度为60°;青版加网线数为70线/cm,网穴角度为30°;黄版的加网线数为60线/cm,网穴角度为45°。
     基于高温热转移印花纸分色制版电雕曲线的研究。从灰平衡入手,通过设置雕刻线数,雕刻网穴的形状及雕刻角度等要素建立一条适合热转移印花的电雕曲线,利用电雕曲线,通过设置印刷测试版,输出数码样张。对雕刻版的雕刻网穴利用网穴测量仪测试,对输出的数码样张的印刷密度、印刷相对反差分析,均达到国标要求,进而最终确定了适合凹版印刷的热转移印花电雕分色曲线。通过线性化处理之后,将转移印花的细微层次从8%~10%提高到了5%,优化了网穴的结构,降低了暗调部分糊版的印刷故障。
     高温热转移印花纸色彩空间转换方法的研究。采用动态子空间划分的BP神经网络理论,将热转移印花制版分色系统的色空间进行划分,分别选择与输入点X(r,g,b)距离最小的采样点15、20、30等,最多取120个点建模,通过对模型精度进行分析,结果表明:平均转换精度可达1.65个色差单位,属于小色差范围,可以满足大多数实际应用的要求。将色空间转换的模型嵌入到色彩管理的ICC文件中,并且将ICC文件应用在某知名制版公司的电脑分色制版中,对公司常用电脑的CRT进行了色空间转换,根据色差的计算公式ΔE=4.9NBS,属于精细产品。动态子空间划分的BP神经网络的色空间转换方法适合热转移印花纸的分色制版及色空间转换,对于提高热转移印花纸印刷的色彩管理提供了一种有效的方法。
     热转移印花纸印刷适性的研究。选取了热转移印花行业常用的国产和进口的打样纸和印刷纸输出样张。结果表明,热转移印花纸张印刷的实地密度控制在Y:0.5~0.7;M:0.8~0.95;C:0.8~0.9;K:1.15~1.25范围。热转移印花纸印刷反差一般在Y:0.2~0.25;M:0.25~0.3;C:0.2~0.25;K:0.2~0.25范围;热转移印花转移后织物的颜色再现色域范围基本能达到传统四色印刷的色域范围。为热转移印花行业提供质量评价的参考依据。
     高温热转移印花纸印刷色浆专色调配的研究。利用蒙版方程的机理,采集标准色谱上的数据作为建模样本,利用线性回归法求出各项线性回归系数。确定好各项回归系数后,利用C++程序,求出Dr、Dg、Db三滤色片密度值就能得到所需的配色方案。探索了一种热转移印花浆调配的方法,并建立基于蒙版方程的印花浆配色模型。对配色模型进行精度分析,平均色差范围为19.85。与目标配色块相比,配色精度偏低。在研究中分析了影响配墨精度的因素;提出了修正配墨模型的建议。建立了高温热转移印花纸印刷质量评价模型。利用CIE1976L*a*b*均匀颜色空间的特点,应用X-RITE530测试热转移印花纸样张的L,a,b值,建立三维CIE L*a*b*的颜色评价模型。该颜色评价模型符合人眼的观察习惯,能直观分析出待评价颜色点在CIE L*a*b*颜色空间中的偏色趋势,符合人们评价转移印花产品颜色的心理习惯。利用matlab构建了热转移印花纸中间媒介和纺织品色差之间的色差评价拟合函数:y=-0.0575x~4+0.1508x~3+3.5082x~2-10.5732x~+43.4983,并对拟合函数进行了验证,平均色差E=8.02,函数拟合精度较高。结果表明:作为中间媒介的热转移印花纸的印刷,平均色差可以控制在61.32NBS,可以大大降低热转移印花产品的生产成本,也为热转移印花纸印刷品色差评价提供了重要的参考依据。基于莫尔条纹的形成机理,通过设置印刷加网线数,加网角度,输出点数,建立了基于莫尔条纹的图像分析方法,并制作形成了印刷网线尺。对印刷品加网线数和角度进行量化测试。并从网点光学透射原理对设计的印刷网线尺给予机理说明。用网线尺评价印刷品质量在生产实践中也得到了验证,提高了工作效率和工作精度,对于印刷实际生产有很重要的指导意义。上述基础研究和应用研究为热转移印花纸生产中的制版确定了合理的网穴、电雕曲线;明确了印刷工艺过程中色彩管理、色空间转换、彩色印花浆调配的方法;最终构建了颜色评价方法并解释了工作机理。为进一步全面提高热转移印花纸印刷质量打下了良好的基础、积累了研究经验。
With the improvement of living conditions, It has been turned intoa kind of fashion for People to demand residential environment ofhigher quality. More bright colorful decorative materials have beento meet with the diversification and personalized trends. The productsof heat transfer printing can meet the need. The printing technology isintroduced into the textile industry. The heat transfer printing plays animportant role in textile industry. The heat transfer printing technologyextended the application of the printing technology on the textileproducts. The surface of the fabrics is uneven.There arenumerous porous on the surfaces. It is difficult to obtain the finelyproducts to compared with the paper. In the procedure of heat transferprinting, the ink is coated on the heat transfer printing paper against theprocess. Therefore the printed paper is obtained. Under the certainpressure and temperature, the printed graph and article on the paper istransferred to the fabrics. This technology brought about therevolutionary changes on the textile industry. It can reduce the cost andsave energy to realize the low carbon and environmental protection.
     The heat transfer printing paper is investigated in this paper. Theresearch of technological process lined with heat transfer printing paper.The principle and core technology of plate making and printing aremade thorough research during the heat transfer printing. For thepurpose of affording certain technical supports and theory, this canexpand the application scope and usage in textile industry for heattransfer printing. On the basis of conversional printing, the research ofthe heat transfer printing lined with the gravure printing. In the process of heat transfer printing, firstly the technology of engraving the cellshapes of gravure is optimized, the engraved curve is established, thenthe color management, the color space conversion and t he spot colorInk matching are researched. Finally, the color appraisement model ofthe heat transfer printing paper is set up. Furthermore, the printingqualities of heat transfer printing paper are evaluated and characterizedIt is lending an impetus of the development for production andapplication of the technology of heat transfer printing. This can expandthe application scope and usage in textile industry for heat transferprinting.
     The principle of the cell shapes of gravure how to take on thehalftone image on the heat transfer printing paper was investigated.Shapes and parameters of cell were optimized, then, the release inkquantity of cell during the reproduced half tone were analysed. Resultsindicated that: the cell shapes of gravure were the most minimum unit toreproduce the tone and transfer the ink. In the process gravure of heattransfer printing, the value of cell on the highlight is about30~42μm,the value of cell on the shadow is about155~170μm.The gap is set uprange of the shadow in order to improve amount of transferring ink. Thevalue of gaps is about26~32μm. The common screen angle is38°or60°when the shapes of cell is flattened or elongated. In order to improvethe sharpness of printed image in the process gravure, in general case,the screen line and screen angle of the black gravure cylinder are90L/cm and38°, the screen line and screen angle of the magentagravure cylinder are70L/cm and60°, the screen line and screen angle ofthe cyan gravure cylinder are70L/cm and30°, the screen line andscreen angle of the yellow gravure cylinder are60L/cm and45°。
     The engraved curve of heat transferring printing paper wasresearched. According to the grey balance equation, the engraved lines,the engraved shapes of cell and the engraved angle were set,the adaptive engraved curve is established. On the basis of the curve,the printing test plates are made and the digital proofs are output.Analysis of the engraved cell, printing density and the printing contract K could well meet the Chinese national standards. Through thehe linearization of gravure heat transfer printing, the final detail of heattransfer printed imaging improved from10%to5%and the structure ofthe cells are optimized. At the same time, it reduced printing fault suchas tinting on the shadow area.
     Color space conversion technology was studied. On the basis ofdynamic subspace divided BP identification theory and the input value,the color space of heat transfer printing was divided. These samplingpoints such as15,20,30, and so on till120were used asmodeling points. The minimum distance between the sampling pointsand the input point (x, y) must be kept. The model and the thresholdwere tested using new samples. The result shows color difference was1.65NBS, it belonged to the range of minimized color difference. Itcould meet the demand of practical printing. The model was embeddedin the profile of color management system. The profiles were applied onthe famous gravure plate company, the color space of CRT experimentswere designed and calculated the color difference. The color error was4.9NBS, it could get the finely products. It was shown that: an effectivemethod of color management for heat transfer printing could be putforward.
     Important printing parameters of heat transfer printing paperwere researched. The imported and domestic paper was selected toproof. The result shows that the solid density were controlled range atY:0.5~0.7;M:0.8~0.95;C;0.8~0.9; K:1.15~1.2and the printingcontract K was range at Y:0.2~0.25;M:0.25~0.3;C:0.2~0.25;K:0.2~0.25. The gamut of heat transfer printing was got the range ofconventional printing. The reliable guidance for the heat transferprinting industry.
     Ink matching of the heat transfer printing paper was researched.Based on the principle of masking equation, the sampling points werecollected on the standard chromatography.Based on the linearregression algorithm, linear regression coefficients were obtained. Thedensity value of Dr,Dg,Db were calculated to got the matching scheme. A new method of ink matching was probed and established ink matchingmodel.
     The model and the threshold were tested using new samples. Theresult shows the average color difference was19.85NBS. In comparisonwith the target color patches, the accuracy was low. The factors thateffected the ink matching were analyzed. At last, the suggestion was putforward to correct the ink matching model.
     According to the even characteristic of color space CIE1976L*a*b*, the value of L, a, b were measured with X-RITE on the proofsof heat transfer printing. Then, thethree-dimensional color space were established. The quality evaluationmodels according with the characters of human vision could analyzeand evaluate the trend of color deviation directly.
     Fitting functions of color error are constructed according to thedifference between the media heat transfer printing paper and textileproducts. The fitting function was:y=-0.0575x4+0.1508x3+3.5082x2-10.5732x+43.4983.
     The model was tested using new samples. The result shows theaverage color error of media heat transfer printing paper was about8.02NBS. Fitting precision of the model was high. The result showed thatthe average color error could be controlled range at61.32NBS. Theheat transfer printing industry could reduce production cost enormously.It provided important basis for practical production.
     The image analysis methods based on tollennar equation studied.The scale for screen lines and screen angle was invented by setting upthe screen lines, screen angle, the output points and so on. The scalecould be used to finish quantitative measurement. In the basis of the dotoptical transmission theory, the scale for screen lines and screen anglemodel was explained. It was more well-grounded and reliable than the method of evaluation before. The model was used to evaluate thequalities of the prints had gotten degree of some enterprises. It couldalso improve work efficiency and precision. The scale wascertain guiding significance for practical printing.
     The present basic and application research confirms the reasonablecells and engraved line for the platingmaking of the heat transferprinting. It makes clear the method of color management, color spaceconversion and the ink matching model for the printing process. Finally,the color evaluation is constructed and the mechanism has beenexplained.It is a good foundation and has accumulated practicalexperience for the further development of Heat transfer printing paper.
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