MXPA06009124A - Method for the precision saturation of substrates in preparation for digital printing, and the substrates produced therefrom - Google Patents

Abstract

A method for precisely applying a premetered amount of a composition into a textile substrate includes the steps of feeding a textile substrate into an application station, wherein the application station is desirably a reverse (indirect) rotogravure roll arrangement, applying a metered amount of a saturating solution to the textile substrate, while controlling the rate of speed of the substrate relative to the application station, monitoring the concentration of the solute in the textile substrate to assure a uniform level of saturation, desirably by use of an NIR evaluation, adjusting the application station to the extent necessary to assure uniform concentration of the solute on the textile substrate, and then drying the textile substrate.

Description

METHOD FOR THE PREPARATION OF PRECISION SATURATION OF SUBSTRATES IN THE PREPARATION FOR DIGITAL PRINTING, AND THE SUBSTRATES PRODUCED THEREOF In accordance with documents 35 U.S.C. § 120 and / or 35 U.S.C. 119 (e), the applicants claim priority of the copending provisional patent application of the United States of America number 60 / 544,228 filed on February 12, 2004.

Field of the Invention This invention relates to the field of printing on substrates, including cloth substrates. More specifically it relates to methods for previously treating substrates to impart printing capability to a digital printing operation.

Background of the Invention Substrates such as fabrics and paper, which are used for digital printing, for example, inkjet printing using either thermal or piezo type printheads, require the addition of certain pretreatment chemicals to their surfaces or interstices to order to allow for a high quality in image printing. For the purposes of this application, the terms "fabrics" and "textiles" shall be used interchangeably and shall refer to woven, woven and non-woven substrate materials. The level of concentration of the chemical additives in a substrate, and in particular a cloth substrate, must be carefully controlled so as to maximize the performance properties of the image that can be achieved by using an accurate ink jet output from the various heads of ink. Print. It has been found that there is a narrow window of concentration that exists in which these chemicals can impart their optimum performance characteristics.

In the past, the previous treatment of the fabric has been achieved using saturation processes of the "dip and squeeze" type. For example, it has been common to use a method that immerses a cloth in a saucer containing a saturation solution (supply solution). The excess solution is then squeezed in a pressure point roller assembly, which is located above the submerging plate. However, the saturation method of submerging and squeezing has proven inadequate, since it inefficiently uses a large amount of chemicals from previous treatment, resulting in wasted resources. In particular, it requires a significant volume of fastening of the saturation solution to "prepare" the system, with the excess solution being squeezed back into the submerging pan. The requirement that the clamping volume be greater means that an excessive amount of saturation solution must be formulated. For short runs of saturation production, this method is inefficient, often resulting in waste of the solution. In addition, the method requires considerable cleaning time when switching from a production run that has a saturation solution to another. For the purposes of this application, the term "production run" describes the saturation process as much as several hundred yards of a fabric with a specific solution, and then quickly switch to another solution / fabric system.

Another problem associated with the saturation method of "dip and squeeze" is that relative to the excess saturation solution being squeezed back (squeezed) into the supply solution can be of a different composition than the start solution, since it can Include substrate materials, or it may be of another concentration than the start solution. This is not unusual since substrates often-preferably attract certain components of the saturation solutions. This can result in a variable composition of the saturation solution as a function of processing time, ultimately leading to less optimal performance for textiles that are used in a printer. For these textiles, it is particularly important that the correct collection of the solution is highly controlled and maintained throughout the saturation process. This is necessary since the concentration of dissolved substances in the textile has a direct behavior on the textile printing performance. Variable concentrations can result in printing and poor stability attributes.

Other processes to precisely deposit the. compositions on textile substrates are known. However, such processes are now to be used mainly as coating applications. For example, engraving and quilting roller systems have been used to treat textiles, typically followed by a drying step. For example, US Pat. No. 3,844,813 issued to Leonard et al. Describes a precision deposition on coating compositions of a textile substrate by various engraving roller systems. This process fails to ensure that the solution is predictably and uniformly dispersed throughout the textile fabric, or at least over the target area (eg, saturation). In addition, the processes described in the Leonard reference are used to treat one side of a cloth substrate with a highly viscous coating. The patent indicates that such a system sometimes requires physical "night media", such as a measuring blade in close proximity to the application rolls, to ensure complete coverage of the substrate evenly and uniformly.

Finally, the application roll processes have been used to impregnate the fabrics with viscous fluids. "For example, such methods are described in United States of America No. 1,558,271 issued to Newell." However, such processes have failed to include mechanisms to ensure uniform penetration of such fluids through an entire fabric, or into a target region of a fabric, despite including fluid guides to physically direct the fluid to specific locations on A fabric.

Therefore, there is a need in the area of printing to both reduce the volume of the solution that is required to "prepare" the saturation process as well as the flexibility to be able to change production runs quickly. In addition, there is a need in the printing area for a saturation method that demonstrates the predictable and uniform distribution of dissolved substances in a substrate, or a region of a substrate.

Synthesis of the Invention Generally speaking, the process of the present invention involves a method for precisely applying a pre-measured amount of a composition to a substrate, such as a paper or textile substrate, including the steps of supplying a substrate in an application station, wherein the application station is desirably a reverse (indirect) rotogravure roll arrangement, applying a measured amount of a saturation solution to the substrate, while controlling the velocity rate of the substrate relative to the application station, monitoring, the concentration of the dissolved substances in the substrate to ensure a uniform level of saturation, desirably by the use of a near infrared evaluation, by adjusting the application station to an extent necessary to ensure the uniform concentration of the dissolved substances in the substrate, and then drying of the substrate. In an alternative embodiment, the substrate can be laminated to a backing material before storing. In another embodiment of the present invention, the method includes a post-treatment step to increase transmission in the material before monitoring. Such a step may be a subsequent measured vacuum or squeeze step. In still another embodiment of the method of the present invention, the pre-treatment method includes a moistened pre-step, before previously measuring the substrate with the saturation solution. In yet another embodiment of the present invention, the method includes a second application of a saturation solution from the previously untreated side of the substrate. This second application can be from the same saturation solution as the first treated side, or from a different saturation solution.

Brief Description of the Drawings Figure 1 illustrates a schematic view of a double inverse rotogravure roller system, illustrating a slide-engraving process with reverse roller transfer, to previously treat a substrate with a saturation solution and monitor the level of the dissolved substances in a pretreated textile fabric, in accordance with the present invention.

Figure 2 is an alternative embodiment of the method of Figure 1, illustrating an inverse rotogravure roller system for applying dissolved substances on both sides of a textile substrate, in accordance with the present invention.

Figure 3 is a graph illustrating viscosity data against percent solids for the cotton poplin saturation solution used in the method of the present invention.

Figure 4 is a graph illustrating the viscosity data against the percentage of solids for the polyester poplin saturation solution used in the method of the present invention.

Figure 5 is a graph illustrating the differences in total absorption of near infrared energy (NIR) in the spectral region for the sides treated against those not treated for the maximum frequency (peak) region about 4300 centimeters "1 a 4290 centimeters "1 minus the minimum region about 4550 centimeters" 1 on cotton.

Figure 6 is a graph illustrating the Spectral analysis of the saturated Cotton Poplin fabric, using the near infrared energy (NIR) scanners showing the chemically treated front side as contrasted to the back side. The untreated control Cotton Poplin is the bottom curve.

Figure 7 is a graph illustrating the Spectral analysis of the saturated Polyester Poplin fabric, using the near infrared energy (NIR) scanners showing the chemically treated front side as contrasted to the back side. The untreated Polyester Poplin is the bottom curve.

Figure 8 is a graph illustrating the correlation of the dry weight aggregate with the near infrared energy absorbance (NIR) data for the treated front side of the Polyester Poplin fabric.

Figure 9 is a diagram illustrating the position of several near infrared energy (NIR) sensors as part of the method of the invention.

Detailed description of the invention A method of saturated substrates includes supplying a substrate such as a cloth or paper in an application station containing a saturation solution, pre-measured from the saturation solution in the substrate, monitored for the concentration of the saturant on the substrate and then the drying of the substrate. The measured pre-saturation solution, as opposed to the subsequent measurement, it is possible to minimize and possibly eliminate the subsequent waste and concentration variations associated with the "squeezing" of a submerging and squeezing method. The pre-measured method can be achieved using a variety of methods including rotogravure (offset engraving) techniques. Such rotogravure techniques may be a pan or capped delivery supply. Alternatively, they can be supplied by a saturated pressure point, rotary grid, cascade, curtain matrix or slot applications. The slot die application can be configured to have the die touching the substrate or without touching the substrate (eg space) and the die can be located on the side of the substrate immediately opposite a roll or between two rolls. Desirably, the pre-measured approach uses an offset rotogravure roll arrangement, with reverse roll transfer.

Once the saturation solution has been previously measured in the respective substrate, it is monitored to determine / verify the appropriate amount of deposition of dissolved substances in the substrate. It is determined that a non-optimal amount of such solution has been deposited on the substrate, adjustments are made to the pre-measure mechanism at the saturation solution application station. Following the monitoring step, the substrate is dried in a drying station.

This method is generally illustrated in Figure 1, the scheme includes a dual offset rotogravure roller arrangement with dual transfer roller, generally shown as application stations 10 and 20. It should be appreciated that while two application stations are shown in opposite sides of a moving substrate, the invention may include one or multiple application stations on the same or opposite sides of a substrate. For example, several application stations may appear in sequence or in series on the same side of the substrate to place the same or different treatments on the substrate. For the purposes of the examples that follow, only one application station was used.

A second embodiment, shown in the Figure 2, illustrates an alternative configuration having two application stations on opposite sides of a fabric, without the use of backup rollers (as will be explained later). However, the arrangement as illustrated, includes enclosed head applicators 12 and 22 as part of an engraving roller arrangement.

Again, with reference to Figure 1, the offset engraving roller with enclosed head applicator is a standard roller such as that available from Southern Graphics. Such engraving rolls can be made from a variety of constructions, including ceramic and metallic materials. Desirably, such an engraving roll is of a metallic construction including cells of a volume of about 1 and 200 billion cubic microns (BCM). Such cells can be of a variety of shapes, such as, quadrangle, Z-flow, grooved, hexagonal and pyramidal. The reverse transfer rollers 14 and 24 are located adjacent said rotogravure roller and operated to desirably rotate in the direction opposite to the rotogravure roller (reverse transfer mode). Desirably, such a transfer roll is comprised of a metal including an outer rubber cover, desirably 55 Shore A rubber. Such rubber transfer rolls help to allow the saturation solution to soften prior to impregnation into the substrate. The backing rolls 16 and 26 are located adjacent said transfer rollers 14 and 24 and serve to carry the substrate, eg, textile, through the system.

In such a system, a substrate 50 is unwound from a wire feeder (not shown) and passes around a guide roller 60 before being supplied to the backing roller 16. The substrate is typically under tension as to avoid uneven saturation of the substrate in the substrate. process. Such tension is achieved by dancers or pressure point pressure. The fabric substrates may require a separate accessory to hold the substrate in proper alignment and with proper stretching in the transverse direction, to be carried to the engraving roller application station. If a textile wrinkle exists at the point of application, a non-uniform print image may result. For the purposes of this application, the term "transverse direction" should refer to the direction perpendicular to the direction of the substrate through the process.

Alternatively, in such a system, a pressure point of the fabric cleaning rollers may replace the guide roller, or may be included in addition to the guide roller, in order to clean the substrate before being saturated with the solution. Such fabric cleaning rollers will help to remove lint or other waste substrate that may be present on the substrate as to avoid inefficient operation of the engraving roller system. If present, the fabric cleaning rollers can be of a special polymer construction that seizes surface waste and loose yarns, such as those available from Teknek. Such fabric cleaning rolls are typically operated at the same speed as the line speed (speed of unwinding of the fabric).

The saturation solution is pumped to the head engraving application rollers enclosed in the. application stations, by way of standard pumps 70 and 75, such as a centrifugal, progressive cavity or gear pump. An energy source energizes pump 70, but it is not shown. The excess fluid is drained from the application roller to a container for supporting the saturation solution 80, 82. The backing rolls 16 and 26 are chromium backing rolls. Desirably, both the transfer and back-up rolls are operated at the on-line speed of the substrate and in directions of opposite rotation. For the method, the speed in line, for example, the speed of the fabric through the arrangement can be between about 5 and 3000 feet per minute. Desirably, the online speed is between 20 and 500 feet per minute. The speed of the rotogravure roller is normally operated between about +/- 50 percent of the line speed. The speed of the transfer roller is desirably the same as the line speed of the fabric.

A monitoring device 90, desirably a near infrared monitor including a sensor (hereinafter NIR) is placed between the backing roller and the dryer 100, to monitor the levels of dissolved substances on the fabric. It is placed to monitor dissolved substances on the side facing the transfer roller. While the arrangement in Figure 1 only shows a monitoring device, it is contemplated that a separate monitoring device can be placed if desired, on both sides of the substrate, depending on the proficiency of the analysis / observation by the near infrared energy (NIR). ). While a near infrared energy (NIR) system is desired, other systems for monitoring dissolved substances include ultraviolet, visible, near infrared, infrared, Raman, and X-ray fluorescent spectrometry. These techniques can be combined with photometry, scattering , gray scale image, reflectance, transmission, and interaction to obtain equivalent results. A variety of geometric sampling configurations may be acceptable, however, 30 degrees of a normal specular reflection technique is desirable because of its unique surface sensitivity characteristic, as compared to diffuse reflectance and diffuse transmission. The near infrared technique is optimal in that the instrumentation can be made unequal for industrial use due to the use of simple optical designs and robust optical materials, quartz or glass.

There is a variety of nearby infrared sensor manufacturers. These include, but are not limited to, AM Tech Services Inc., Analyti Chem Corp., Boston Piezo-Optics, Bran & Luebbe Inc., Brimrose Corp. Of America, Chemicon Inc., Electro Optical Products Corp., Encoré Lab & Analytical, - Infrared Fiber Systems, Isomet Corp., ABB Bomem Inc., Bio-Rad, - Bloick Engineering, Bruker Optics Inc., Galileo Corp., Amattson Instruments Inc., Nicolet Instruments Corp., Ocean Optics.

The information obtained by the monitoring system can be read manually from the system, or electronically sent to the application station of the saturation solution as illustrated by the electronic communication systems 95 and 97. The saturation solution application station (arrangement of offset engraving roller) can then be adjusted manually to compensate for the desired level of dissolved substances in the fabric, or electronically directed to compensate for the desired concentration of dissolved substances in the fabric.

While other monitoring means can be used with the method of the invention, it has been found that the near infrared energy (NIR) method has proven to be particularly effective. In this regard, a near-infrared test method was developed to quantify the organic material added to polyester poplin and cotton poplin fabrics since the analytical method is sensitive to the level of material added on the surface of the fabrics. ' The practice of standard spectroscopic measurement uses diffuse reflectance or diffuse transmission. These optical measurement geometries are sensitive to the total chemical composition of a coarse sample but are not sensitive on the surface.

Attenuated total reflectance is also commonly used for surface spectroscopic analysis, but this technique requires that the sample be in direct physical contact with the measurement glass and therefore this technique is not suitable for online analysis.

The selected measurement technique specifies an incidence of 30 degrees and a specular reflectance collection technique. The technique has been found to provide sensitive surface measurements for diffuse reflection samples. Specular reflectance is typically used for specular reflection surfaces, such as mirrors or metal objects in a laboratory installation, to determine the surface properties of highly reflective surfaces.

The near infrared energy (NIR) sensor can therefore be successfully used as an online monitor. When the degree of saturation of the fabric begins to deviate from a desired range, the sensor can detect this change and send a signal to an operator, or the application station (saturation), to make an adjustment in the process. As noted, this can be done by either manual or automatic interface for a control in process.

The near infrared sensors used can be of the single-point sampling type (as described and tested), where either the sensor is the same spatially moved on the surface of the treated substrate; or the treated substrate is moved relative to the sensor. The measurements thus obtained can be reconstructed in data indicative of the amount or efficacy of the treatment. Alternatively, the sensors employed can also be of the in-line scanning type, using a two-dimensional assembly detector. These types of joint sensors can be used to build real-time images of the treatment chemistry. The advantages of the chemical images of the surface formed using the ensemble detectors are that they allow the operator to make adjustments of the treatment process manually or automatically based on more detailed and faster information. This greater detail of the surface information provides clues more quickly for further improvement of the treatment process given by a faster response time to make adjustments in the treatment process.

The near infrared energy (NIR) sensor is desirably located immediately after the saturation application station for a faster response time compared to the monitoring of the cloth after oven drying, although this position may also achieve the purpose monitoring. The near infrared energy (NIR) sensor can be adjusted in such a way that the presence of water does not interfere with the detection of the constituents of the printing coating in the saturation solution. Additionally, in a subsequent alternative incorporation another near infrared energy sensor (NIR) can be located immediately following the drying station as to monitor the degree of dryness in the textiles, making them sensitive to the presence of water. Such is illustrated in Figure 9, which also illustrates the substrate exiting the winder and passing through two cleaning rollers, before entering the application station 10.

Following monitoring to determine the level of dissolved substances in the fabric, the fabric is passed to dryer 100. The dryer can comprise a standard oven or frame frame dryer, and typically dries to the substrate at temperatures between 100 and 400 degrees. Fahrenheit, depending on the types of substrate to be dried.

It has been found that the process of the invention can be used to previously measure the saturation solution on a variety of substrates including for example, fabrics, paper, nonwovens and films. Such fabrics include, for example, cotton based poplin substrates, polyester poplin, Chiffon, Georgette, Nylon / lycra, silk, and cellulose. Desirably, the viscosity of the solution that is applied to the substrates is greater than 100 centipoise, and more desirably between 100 and 1000 centipoise. It is clear that this may depend on the rheological characteristics of the specific saturation solution. In the examples that follow, the saturation solutions were run at viscosities of about 600 centipoise for cotton poplin and 450 centipoise for polyester poplin. Once the substrate has been dried, it can be rolled up for storage on a storage roller for further on-line processing (not shown). Alternatively, it can be laminated to a backing, such as a paper backing to facilitate printing, when the substrate must run through an inkjet printer.

In an alternative embodiment of the method of the invention of Figure 1, as illustrated in Figure 2, a second offset rotogravure with reverse transfer process can be used with the arrangement of Figure 1. In this embodiment, a second rotogravure roller offset with enclosed application head 20 ', similar to the rotogravure roller 20, receives the saturation solution of a second pump 75' and the source of the saturation solution 80 '. A second reverse transfer roller 24 'of a construction similar to the first transfer roller 24 receives the saturation solution of the rotogravure roller and applies it to the opposite side of the substrate 50 thus applied by the first rotogravure roller arrangement. The substrate then continues on the dryer as previously described. When using two rotogravure rolls, the method can be used to apply the same or different saturation solution on each side of a cloth material.

Alternatively, the second offset rotogravure arrangement can be used to apply the saturation solution to the same side of the substrate that has been previously treated if it is desired that multiple applications of the saturation solution be made. It should be appreciated that a series of rollers can be placed on either side of the substrate or on the same side.

In other embodiments of the method of the invention, other optional process steps may be added to aid in the processing of a textile substrate. Such additions include a step of subsequent squeezing treatment to help increase the transmission of the saturant in the treated fabric. It may be desirable to squeeze the solution into the textile, as opposed to outside the textile. This squeezing action can be achieved by either a pressure point roll arrangement or by applying a vacuum to the coated substrate to pull the solution onto the substrate. This vacuum and / or pressure point increases the transmission action of the substrate in addition to producing a more uniform concentration of the saturation solution across the width of the substrate. In addition, since substances dissolved in the saturation solution can be located primarily on the outer surface of the textile fibers in a substrate, these subsequent spreading steps help to amplify the ability of the substrate to demonstrate an improved printing surface.

Additionally, a moistened pre-step can be added to the process to wet a cloth substrate prior to saturation. By adding a predetermined amount of moisture to the textile, the ability of the solution to penetrate the substrate can be increased, leading to a more controlled and predictable process. Moisture can be added through a process of immersion, atomization of water in the fabric, or by having the fabric exposed to a controlled moisture before having to apply the saturation solution to the fabric. Further additions of processing steps may include a Corona treater and an ultraviolet light station to create a surface on the substrate, which is more polar (to result in better wetting of the impregnated dissolved substances) and to use in the photo-cured the impregnated solution. Still, other additional steps of the process may include infrared heating and exposure to microwaves. In yet another embodiment of the method of the invention, a rolling step can be added to the process for laminating the substrate to a backing layer. If such a laminate step is added, it may include unwinding the backing material, such as paper, available from American Biltrite. The backing material is supplied at the pressure point of the rolling rolls. Desirably, the backing material is constructed of paper with either heat activated or pressure activated adhesive. Both the treated and backing fabric can then be pressed together under the pressure / heat pressure point to create a laminate. The rolled product can then be rolled onto a roller for storage. By laminating the fabric to a backing layer, the material can then be easily supplied in the ink jet printers.

Finally, the present invention also includes pre-treated substrates made in accordance with previously described methods.

The present invention is further described by the following examples. Such examples, however, are not construed as limiting in any way, to any spirit of the scope of the present invention. Unless otherwise noted, all percentages are in the hundreds by weight.

Eg Test plots The performance and adequacy properties of the reverse rotogravure offset transfer process were evaluated by the precision saturation of cotton and polyester poplin fabrics. Various modes and settings of the engraving application were evaluated. In addition, the quantitative collection of the saturation solution in these treated fabrics was determined along with their digital image performances. Finally, the gradient concentration of the chemicals applied through the fabrics was also quantified.

The cotton poplin was purchased from Sorber Industries, under the code number / style 9680, which has a simple wave construction. The cotton poplin sample has a measured basis weight of 124 grams per square meter (gsm). It was wound on a 2-inch core, and the cloth is about 15 inches wide. The polyester poplin fabric was purchased from Fisher Textiles, under the code number / style PP6248, which has a simple waved construction. It has been measured by basis weight of 175 grams per square meter. It was rolled into a 2-inch core and the fabric has a width of approximately 11.5 inches.

The method used in the offset rotogravure arrangement with reverse transfer roller containing an enclosed head applicator similar to that shown in Figure 1, except that the treatment was only applied to one side of the substrate. Specifically, the system includes an enclosed head applicator with a transfer roller composed of an outer rubber jacket of 55 Shore A hardness. The engraving and transfer rollers were operated in the transfer mode in the reverse direction. However, both the transfer and back-up roller were operated at tissue line speed of 25 feet per minute. The specific engraving roller that was used was made by Southern Graphic System, and has a designation of H2. It was of the design of three helices and has a theoretical cell volume of 69.5 billion cubic microns (BCM) per square inch with a depth of 190 microns. The specifications of Southern Graphic Systems show that it has 24 lines per inch at a 35 degree angle.

The engraving roller was filled with the saturation solution through the enclosed head applicator. For a fabric 60 inches wide, the applicator can have a support volume of approximately 5 gallons. This is not a significant amount of solution and can easily be accommodated for the formulation step. When using the reverse transfer mode, the supply rate of the saturation solution to the transfer roller at the interface of the pressure point can be easily varied, by increasing the speed of the engraving roller, more solution is available to the unit area by tissue. This allows for adjustments in the process when the fabric is being saturated at a specific level.

The rubber transfer roller and the chrome backing roller were operated at the line speed of the fabric 25 feet per minute) and in opposite directions. The reverse transfer roll at this point in the process can result in damage to the fibers in the fibrous fabric. If the engraving roller has been in direct contact with the fabric, this may have required it to be operated at the line speed since tissue damage may otherwise result. Therefore, keeping the tissue and the engraving roller at a synchronized peripheral speed may not give the advantage of being able to adjust the delivery rate of the solution as can be obtained with the reverse transfer mode.

The rubber transfer roller also allows the saturation solution to "soften" before impregnating into the fabric. In addition, the design of the engraving roller used for these examples may not result in uniform placement of the solution to the fabric, if a direct transfer has been used. This is the result of a rough three-helix cell in the engraving roll, which can generate in an irregular saturation pattern in the textile, and thus produce a non-uniform printed image. It should be noted that the backing roller was plated in chrome to allow for the effective transfer of the solution to the textile being processed.

For the purposes of this application, the terms "front side" and "treated side" of the saturated textile should have the same meaning and should describe the side of the textile that comes into contact with the rubber transfer roller and therefore comes into contact direct with the applied solution. The "back side" or the "untreated side" should have the same meaning and should refer to the side of the textile that comes into contact with the chrome backing roller.

Subsequent to the saturation of a specific cloth, the cloth was first dried in a 60 foot air force oven. Hot air at 150 degrees Fahrenheit was used with direct impregnated on top of the fabric with air bars in the bottom. A constant line speed of 25 feet per minute was used for all tests. The fabric was not supported in any way through the dryer section except by vacuum rollers.

Two reserve solutions were prepared for saturation of the fabrics, one for cotton poplin and the other for polyester poplin. These solutions were made in concentrated form, giving it flexibility to adjust the viscosity of the solution to select the appropriate concentration for the processing conditions. The concentrated solution for the saturated solution of cotton poplin is synthesized in the following Table I: Table I; Saturated Solution of Concentrated Cotton Poplin Each ingredient was added, with stirring, to a 50-gallon drum in the order of the sequence listed in the table. The water was added first followed by the other components. The saturation solution including water as a carrier, a cationic polymer, for example, CP 7091RV, available from Calgon Corp., a fabric softener, for example Varisoft 222 LM, available from Witco, a binder, eg, PrintRite 591 , available from BF Goodrich and a binder, for example, Air Flex 540, available from Air Products. This was determined by the evaporation of the liquids to determine a dry amount. The parts of the previous solution were diluted with water for several solid contents. The viscosity of these solutions was then determined by using the Brookfield viscometer model RVF using operating procedures provided in the user's manual. Spindle number 3 was used for all measurements. These data were synthesized in the graph of Figure 3.

The concentrated solution for Polyester Poplin is summarized in the following Table II: Table II: Polyester Poplin Saturation Solution The order of addition for the ingredients was as sequenced in Table II with continued agitation. The solids determined analytically in the solution were 44.4%. Portions of the above solution were diluted with water to various solids contents. The viscosity of these solutions was then determined using the same procedure as described above. This is summarized in the Graph of Figure 4.

A saturation test in which a fire retardant was added to the Polyester Poplin was also carried out. The specific fire retardant used was from BF Goodrich and had a trade name of Pyrosan SYN and was composed of dialkyl alkyl phosphonate esters.

For each of the examples, the monitoring of the solution concentration on the fabric samples was carried out using the NIR method, and in particular, with the use of a FTS-66 FT-NIR Broker Model, available from Bruker Optics. Inc., 19 Fortune Drive, Manning Park, Billerica, Massachussets 01821. Measurements were made at a resolution of 16 centimeters "1 and 3 minutes of scanning time.A 30-degree specular reflectance accessory available from Pike Technologies, of 2919 Commerce Park Drive, Madison, Wisconsin 53719 was used with a gold coated mirror for a background reference and as the background for a single layer thickness measurement.

The analysis of the fabric saturated by near infrared (NIR) allowed the quantification of printing layer chemists on both front and back surfaces of saturated textiles. The measured conditions were as described in the following Table III: Table III: Measurement Conditions Using the NIR Test Method It should be noted that it is possible to exhibit the printing coating chemicals in terms of images or data in the direction of the machine or transverse direction !; which can be properly processed into digital output data or map images for precise control of the saturation process. The output information regarding the coating coating chemical can be tied to a DCS (distributive control system) capable of a control of! : i manual or automated process.

Sample Measurement The gold mirror was measured as the reference material before the measurement of all the test samples. The samples were then placed on the reflectance fitting and each side was measured separately and reported as Absorbency = -logmReflectance The measurements were taken using the. special operating procedures for using the surface signal and signal-to-noise of the coating coating chemical in the outer plane of the substrate. The unique combination of measurement and geometry conditions allows quantitative data of a high quality to be measured in relation to chemical surface addition. The; 16-wave number resolution provides a sufficient resolution1 with an improved signal to optimize the overall quality of the data for quantitative use.

The absorbance differences for the sides treated against the untreated ones are reported for the region of maximum frequency (peak) about 4300 centimeters "1 to 4290 centimeters" 1 minus the minimum region about 4550 centimeters "1. was carried out for the test sample and the control sample.The difference of final deaeration signal was reported as ? A Front Side = (Front side of test sample less control)? A Rear Side = (Rear side of test sample less control) The difference in overall absorbency was found to be proportional to the concentration of aggregate material. The NIR spectral region of 4300 centimeters "1 corresponds to the presence of the CH / CH stretching of the chemical treatment near the surface.The global absorbency of NIR energy in the spectral region indicates the increased presence of the CH bonds of the chemical treatments at, or near the surface as shown in Figure 5, which demonstrates an absorbance of a treated side (upper curve) against an untreated side (lower curve).

The use of a 30-degree specular reflectance measurement geometry combined with infrared energy allowed the coating properties of this process to be determined. The aspects of the division of the chemical aggregates was measurable using the detection geometry, while the conventional on-line techniques (meaning online processing) were not sensitive to the surface deposit aspects of this printing process.

The system therefore allows a real-time measurement of the aggregate process during manufacturing.

This will allow the properties of the manufacturing process to be controlled during manufacturing.

After the saturation tests were completed, the respective fabrics were printed using either Encad GS or GO inks, stocked from a Pro-E printer on Tyvek collocations. These inks were composed of a mixture of acid, direct, and reactive dyes available from Encada. The GS inks were made from liquid dyes and were used to evaluate the printing coat on both the Polyester and Cotton Poplin textiles, while the GO inks are formulated of pigments and used to characterize the effect that a Fire retardant has on the performance of the printing coating.

The color properties on the textiles with images were measured using an X-Rite 938 spectrodensitometer instrument. The standard operating procedures of the instrument were followed. The illuminant was D65 at an angle of 2 degrees. The C.I.E. L *, a *, b * determined (1,2) describe the location of the color on a three-dimensional diagram. The CIÉ is the International De L'eclairage Commission (such as the International Commission on Enlightenment, and the Beleuchtungskommission Internationale). The main publications that cover the use of measurements include: (1) CIÉ Publication No. 15.2 (1982), Central Office of the ICD, A-1033 Vienna, PO Box 169 - Austria and (2) ASTM E 308-90, Standard Test Method to Compute Object Colors by Using the CIÉ System, from the American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania, 19428-2959 United States of America. The data is represented by the CIÉ LAB values in the tables.

COTTON POPLIN FABRIC RESEARCH Cotton poplin was the first fabric processed using this method. A solids concentration of 21.6% was used in the operation. This resulted in a viscosity of 600 centipoise (cp) in the saturation solution. The resulting dry weight intake for this run was nominally 11 percent (%). This varied by no more than + 0.1% over the full length of the run, which was around 200 feet. For the purposes of this application the dry weight intake is calculated using the following equation: (100) Dry Weight of Saturated Fabric-Dry Weight of Unsaturated Fabric Dry Weight of Unsaturated Fabric The level of control will help achieve the optimum image quality that will result from the precise ink jet output. Using the dry weight aggregate of 11% for this cloth, the following calculations gave the total weight of the saturation solution that was impregnated in one square meter of the fabric.

The fabric had a basis weight of 124 gsm (grams per square meter). 0. 11 x 124 gsm = 13.6 grams of solids were impregnated in one square meter of textile. 13. 6 / 0.216 = 63 grams of saturation solution (21.6% total solids) was delivered to one square meter of Cotton Poplin.

That is, the conditions that were used for this test resulted in a gravure roll that delivered 63 grams per square meter of saturation solution to the Cotton Poplin fabric. As previously mentioned, the gravure roll used for this study had a theoretical cell volume of 69.5 BCM per square inch. Converting this volume per unit area to grams of solution, using a solution density of 1.0 grams / cubic centimeter, per square meter results in 108 grams per square meter. This conversion is shown below.

CONVERSION FROM BCM TO GSM The specific gravure roll used in this study had a rating of 69.5 BCM per square inch. 1 BCM = 1 trillion cubic microns = 1 trillion cubic micron = IxlO9 mieras3.

Assuming that the solution that occupies the cells in the gravure roll had a density of 1.0 grams / cubic centimeter, the following conversion applies: (1 micron / lxlO "6 M) 3 x (1 M / 100 cm) 3 x (1 cm3 / gram) = 1 miera3 / lxlO" 12 grams The above conversion states that 1 cubic meter of cell volume will contain 1x10-12 grams of saturation solution. 1 BCM = IxlO9 mieras3 So : 1 BCM = (1x10 microns) x (lxlO "12 grams / miera) = 1x103 grams The above conversion declares that 1 BCM of cell volume will contain 1x10-3 grams of solution.

The conversion of square inches to square meters: 1 square inch x (2.54 centimeters / inch) 2 x (1 M / 100 cm) 2 = 6.45xl0"4 M2 Therefore: 1 BCM / square inch = lxlO "3 grams / 6.45xl0" 4 M2 = 1.55 GSM Therefore: 69.5 BCM / square inch converts to 108 GSM Based on the values reported in the literature, the gravure rolls can integrate from between 33 to 60% of the cell volume to the fabric. If the surface velocity of the gravure roll is the same as the speed of the fabric, this will theoretically result in the specific roll delivering from 36 to 65 grams per square meter. The peripheral speed of the off-center gravure roller was operating at a speed slightly higher than that of the fabric speed, about 30% faster. However, it can go up to around 50% faster. However, even with this difference in speed, the theoretically determined range approaches 63 grams per square meter calculated for the Cotton Poplin test. This fabric then had a textile strip onyx pattern printed on it using the GS inks stocked from a Pro-E printer. The LAB color values were obtained at the beginning, the middle and the end of the 200-foot test. This was measured on both surfaces of the fabric. As previously defined, the "front side" is the side of the fabric that was in contact with the rubber transfer roller. The "back side" is the side that was in contact with the chrome backing roller. The following Tables IV, V and VI summarize the results of the color evaluation using the LAB measurements.

Table IV: CIÉ LAB Results for Cotton Poplin Test (START OF ASSAY) Table V: CIÉ LAB Results for Cotton Poplin Test (HALF OF THE TEST) Table VI: CIÉ LAB Results for Cotton Poplin Test (END OF TEST) As the data demonstrate, there was little change in the LAB results from the beginning to the end of the trial run. This correlates with the dry weight intake of the Cotton Poplin which varied by no more than + 0.1% points. This small color difference is insignificant to the human visual perception, and is within the measurements of § error of the instrument. In addition, there is very little difference in the 1: | LAB measurements on the opposite side of the Popelina í%!;! of cotton. I The spectral results, as obtained from the near-infrared (NIR) scans show that there is a little difference between the unsaturated and saturated Cotton Poplin fabric of this test using the off-center gravure method. These results are summarized in the graph of Figure 6. Near the infrared sensors aided in the; process control and in the measurement of surface chemistry i: on cellulose and polymeric materials. For Figure 6, the untreated fabric is represented by the background curve with the upper curve representing the treated side and the middle curve representing the untreated side. After saturation, the fabric shows superior optical absorbency.

More specifically, the absorbance values around the wave numbers from 4400 centimeters "1 to 3900; centimeters" 1 are of particular interest. This range is the "location of the various functional groups in the chemicals": printing layer that were added to the fabric that would be absorbed.

Also, as illustrated in Figure 6, there is a subtle difference in the concentration of the printed layer chemistries on the opposite side of the Cotton Poplin (represented by the two upper curves respectively). The front side, being slightly more concentrated than the back. The NIR results indicate that-, the treatments produce similar results on both:. surfaces of Cotton Poplin, even when the treated side has a slightly higher concentration of the chemical added. Note that the absorbance signal to this wave number region is proportional to the amount of chemical treatment.

Table VII, which follows, summarizes the change in absorbency, at a wave number of 4300 centimeters-1, for the specific treated side against the Cotton Poplin fabric (control), as obtained from the Figure 6 Table VII: Change in Absorbency for Run of Cotton Poplin Test It should be noted that the fabric had a dry weight aggregate of 11% and that "Abs (change in absorbency) was determined at a wave number of 4300 centimeters" 1 and that is the absorbency of the specific treated surface minus the fabric of Poplin. of untreated cotton (control) Even though it is a small NIR optical difference between the front and back side of the fabric (0.009 of Absorbency Units), as will be seen, this difference becomes more pronounced with the Polyester Poplin.

POLYESTER POPELIN INVESTIGATION The next fabric that was investigated was Polyester Poplin. A series of different sequences for the saturation of the fabric were simulated on the placement of a gravure roll. However, the same concentration- of the saturation solution was used for all the tests. The solution had 36.1% solids and a resulting viscosity of 450 centipoise. The first roller sequence consisted of the use of a single textile step through the photogravure configuration as previously shown in Figure 1 (but for a single application station). The nominal dry weight on the fabric was 12%. Again, this varied by no more + 0.1% over the 200-foot length of the run. This reproduced the degree of precision that was observed in the Cotton Poplin test.

Taking a mass balance gave the delivery of grams per square meter of the saturation solution to the fabric, which had a basis weight of 175 grams per square meter. The mathematics is as follows: 0. 12 x 175 gsm = 21 grams of solids were impregnated in one square meter of the fabric. 21 / 0.361 = 58 grams of the saturation solution (36.1% of total solids) were delivered to one square meter of Polyester Poplin.

Therefore, for this test, the gravure roll was delivering 58 grams per square meter of the saturation solution to Polyester Poplin, which again is in the range of a theoretically calculated value.

The fabric then had a textile strip onyx pattern printed on it using GS inks stocked from a Pro-E printer.

As with the previously discussed Cotton Poplin Test, the CIÉ LAB color measurements were obtained at the beginning, middle and end of the 200-foot pilot test. This is summarized on the following Tables VIII, IX and X.

Table VIII: CIÉ LAB Results for Polyester Poplin (START OF ASSAY) Table IX: CIÉ LAB Results for Polyester Poplin (HALF OF THE TEST) Table X: CIÉ LAB Results for Polyester Poplin (END OF ASSAY) As in the Cotton Poplin trial, the data show that there was very little change in the CIÉ LAB results from the beginning to the end of the run for a -; specific side. However, the significant difference in the CIÉ LAB data was observed when comparing the two .4 polyester textile surfaces. The values indicate that there were fewer chemical layer constituents on the backside of the Polyester Poplin fabric compared to the front side. .i The front side of the textile produced a sharp and intense image. In contrast, the printed back side was dull and faded, having the appearance of the fabric without the addition of the printed coating formulation. This is consistent with the CIÉ LAB results.

The spectral analysis of the saturated fabric, using the NIR scans are presented on Figure 7 showing the front side chemically treated as contrasted with the back side. The untreated control Polyester Poplin is the background curve as in the previous Figure 6. After the chemical treatment of the polyester, the data; they reflect a higher level of NIR absorbency indicating that more-chemical has been present on the treated side of the material. The NIR wave number region with the highest optical absorbance is indicated between 4450 cm "1 and 3950 cm" 1. This region corresponds to where the chemical groups represented by the treatment absorbed NIR energy.

As also shown in Figure 7, there is much less chemical treatment on the untreated side than on the treated side, indicating that there is very little migration of the chemicals through the polyester. Most chemicals remain 'on the treated surface. The absorbance signal to this wave number region is proportional to the amount of chemical treatment.

Table XI below summarizes the change in absorbency at a wave number of 4300 cm "1 for one side, specific against the Polyester Poplin fabric no. treated (control), as obtained from Figure 7.

Table XI: Change in Absorbency for the Test Run of Polyester Poplin It should be noted that the fabric had an aggregate of 12% by dry weight. The -? Abs (change in absorbency) was determined at a wave number of 4300 cm "1 and is the absorbance of the specific treated surface minus the untreated Polyester Poplin fabric (control).

The data in Table XI show that there is a significant NIR optical difference between the front side and. i after the Polyester Poplin (difference of 0.075 '; Absorbency Units). The back side appeared having very little of the solutions melted in the saturation solution. Again, as for Cotton Poplin samples, the NIR spectral results correlate with the CIÉ LAB data and the visual quality of the printed image.

In the second set of test examples, the additive effect on the dry weight intake was evaluated. During this test, Polyester Poplin was passed through the gravure arrangement twice. A series of gravure applicators was simulated by conducting two discrete passes on the same side of the textile substrate.

The aggregate of dry weight on the NIR absorbency values is summarized in Table XII below.

Table XII: Additive Effect of Two Saturations on the Polyester Poplin Fabric It should be noted that the? Abs (change in absorbency) was determined at a wave number of 4300 cm "1 and is the absorbance of the treated front surface less than that of the untreated Polyester Poplin fabric. (control) . As the data in Table XII demonstrate, the use of multiple passes through the decentering gravure configuration will allow an added weight again. The aggregate can be the same side of the textile or the opposite side. Additionally, the weight gain will be in direct proportion to the number of passes on the textile through the process. There were no observed processing issues associated with the accumulation of solution on the transfer or backing roller. Additionally, the fabric retained its structural integrity through the entire test.

The correlation of the dry weight aggregate with the NIR absorbance data (? Abs) for the treated front side of the fabric, as summarized in Tables XI and XII, is shown in Figure 8. As seen, a straight line results . Additionally, the best notch line goes through the origin (0,0) which shows that the dry weight gain is in direct proportion to the absorbency value (? Abs). ? Abs = 0.00822 x (Percent of Dry Weight Aggregate). It should be noted that the absorbance values on the y-axis were determined at 4300 cm "1. It is the absorbance of the treated front surface minus that of the untreated Polyester Poplin fabric (control) .The values were obtained from the Tables XI and XII This is designated as? Abs in these tables.

The review of the absorbency data as summarized in Table XII shows that the front side of the treated fabric (? Abs of 0.100) had 4 times the concentration of the coated coating chemicals when compared to the back side (? 0.025). This would imply that less than the saturation chemicals should be taken to give the same surface impression as compared to the total saturation of the fabric that could result in cost savings in chemicals. The ability to maintain these more localized surface solutions can result in a textile fabric with a "better feel". The printed coating chemicals impart a certain degree of rigidity to the fabric, which is undesirable and which can be reduced by not allowing these chemicals to penetrate.

As previously discussed, Polyester Poplin produces a two-sided fabric. The back side of the fabric contained very little of the printed layer coatings while the front side retained most of these. Again, this shows that through the CIÉ LAB results, the visual observation of the quality of the image and also of the NIR spectral analysis. This phenomenon can be advantageously used for the addition of a fire retardant (FR) to the textile material in an alternate embodiment of the present method.

It is not common for a lower printed image to result when an FR is added to a saturation solution of the print coat. It has been found that if the fire retardant was applied to one side of the fabric followed by the printing layer on the other side, this problem can be avoided.

A test example was carried out on the Polyester Poplin using the fire retardant in addition to the saturation solution. The test consisted of adding the Pyrosan SYN fire retardant to the aqueous printing layer solution. The fire retardant composed of 20% of the total solids in the solution. The remaining 80% of the solids comprised the constituents in the printed coating.

After application of the fire retardant / printing coating solution by the offset gravure method of Figure 1 (one application station), the fabric was dried using a forced air dryer. This was followed with the application of the printing coating solution, without the fire retardant on the untreated side of the textile and drying. The impregnation conditions were controlled so that the dry weight aggregate was 9.0% for the printed coating and 11.1% for the fire retardant / printed coating ingredients. This resulted in both sides receiving approximately the same amount of printing coating chemicals.

Then an onyx image of textile strip was printed on both sides of the fabric using the GO inks of a Pro-E printer. One can visually observe the difference in the quality of the print when the colors are observed.

The side that contained the fire retardant produced a "sandy" appearance. One way to rate this observation is to calculate the color saturation of the Polyester Poplin. This was obtained from the "a" and "b" data from the Laboratory tests. Equation (1) quantifies this interaction. + b (1) The term "S" represents the color situation of the fabric. The larger this value, the higher the color intensity. Tables XIII and XIV below summarize the CIÉ LAB values for green, yellow and red that were collected for the two surfaces of the saturated Polyester Poplin. The calculated "S" value was also presented by comparison.

Table XIII: Polyester Poplin Surface with Applied Print Coating Table XIV: Polyester Poplin Surface with Fire Retardant and Applied Printed Coating As indicated by the results in both Tables XIII and XIV, the level of color saturation (S) has been measurably reduced with the presence of the fire retardant in the printing layer. This correlates with the visual examination of the fabrics with images. The surface of the Polyester Poplin which contained the fire retardant and the printing coating chemicals produced an unacceptable printed image. Nevertheless, the side with only the printed coating resulted in an acceptable printed image. This incorporation of the method of the invention therefore allows the application of different saturation solutions to the respective surfaces of a specific textile without having to interfere with each other.

This can be achieved with the use of two offset gravure rolls with reverse roller transfer applicators in series. As shown in Figure 2, a station will apply the first saturation solution. The textile will then immediately go to the second station where a different solution will be applied to the opposite side of the fabric. The use of the saturation modes delineated in Figure 2 allows independent control of the aggregate on each side of the fabric, since the gravure rolls are offset from the fabric by means of the transfer roller. The gravure rolls can operate at a different peripheral speed compared to the fabric and therefore have variable solution delivery rates. This is a result of the opposite direction to which the transfer and gravure rollers are operating in the pressure point interconnection. With this configuration, the saturation solutions of both identical and different compositions can be applied to opposite sides of the fabric.

It is therefore apparent that the methods of the invention require a small volume of solution to "print" the system. For example, for a fabric 60 inches wide, it will be around 5 gallons. In particular, the decentralized gravure application model lends itself to "short" production runs where the system must be easily cleaned and changed to another fabric and saturation solution. By pre-measuring the saturation solution on the cloth through the gravure roll, there is very little or no excess solution to squeeze back into the system stream. This ensures that the concentration of the solutions melted in the solution remains constant through a production run. The high level of saturation accuracy for textiles can be achieved and corroborated by the dry weight intake (result in a variation of +0.1 percent around the nominal), minimum variations in the measurements on CIÉ LAB on a textile with image, and perceive the difference of color.

In addition, the method provides a means of monitoring and controlling the degree of saturation through the use of an almost infrared sensor. Finally, a two-sided textile can be produced as a result of the chemical concentration gradient. That is, both surfaces can be saturated with two different solutions and each side will retain its specific and independent attributes.

Although the invention has been described in detail with particular reference to the preferred embodiments thereof, it should be understood that many modifications and additions can be made thereto, in addition to those expressly recited, without departing from the spirit and scope of the invention as it is established in the following claims.

Claims (19)

1. A saturation method with precision of a substrate comprising the steps of: to. supply a substrate to an application station, b. apply a dosed amount of a melting solution to the substrate, while controlling the velocity rate of the substrate in relation to the application station, c. monitor the concentration of the solution on the substrate, d. adjusting the application station to the extent necessary to ensure an essentially uniform concentration of the melted solution on the substrate; and e. Dry the substrate.

2. The method as claimed in clause 1, characterized in that said application is achieved by a method selected from the group consisting of rotogravure application, saturated pressure point application, rotating screen application, cascade application, curtain application , and slot matrix application.

3. The method as claimed in clause 2, characterized in that said application is achieved by an offset rotogravure arrangement with a reverse transfer roller.

4. The method as claimed in clause 2, characterized in that said application is achieved by a rotogravure application with a gravure roller made of ceramic or metal materials.

5. The method as claimed in clause 4, characterized in that the roll is made of metallic materials and has cells in a shape selected from the group consisting of quadrangle, z-flow, grooved, hexagonal and pyramidal and combinations of the same.

6. The method as claimed in clause 3, characterized in that the reverse transfer roller has an outer surface made of rubber.

7. The method as claimed in clause 1, further characterized in that it comprises cleaning the substrate before applying this solution to said substrate.

8. The method as claimed in clause 7, characterized in that said cleaning is achieved with cleaning rollers.

9. The method as claimed in clause 1, characterized in that said speed rate relative to the application station is between 20 and 500 feet per minute.

10. The method as claimed in clause 1, characterized in that said monitoring is achieved by a method selected from the group consisting of near-infrared surveillance, ultraviolet surveillance, visible light monitoring, infrared surveillance, Raman monitoring, and spectrometry monitoring of X-ray fluorescence.

11. The method as claimed in clause 10, characterized in that said monitoring is carried out at 30 degrees from the normal specular reflectance technique.

12. The method as claimed in clause 10, characterized in that said monitoring is achieved by an almost infrared monitoring and said monitoring occurs immediately after said application.

13. The method as claimed in clause 12, further characterized in that it comprises the step of monitoring said substrate immediately after said drying.

1 . The method as claimed in clause 1, characterized in that said substrate is selected from the group consisting of woven fabrics, non-woven fabrics, papers and films.

15. A precision saturation method of both sides of a substrate comprising the steps of: to. supplying a substrate to a first application station, b. applying a measured quantity of a first solution to a first side of the substrate, while controlling the velocity rate of the substrate in relation to the first application station, c. monitor the concentration of the first solution on the substrate, d. adjust the first application station to the extent necessary to ensure an essentially uniform concentration of the first solution on the first side of the substrate, e. supplying the substrate to a second application station, f. applying a measured amount of a second solution to a second side of the substrate, while controlling the velocity rate of the substrate relative to the second application station, g. monitor the concentration of the second solution on the substrate, h. adjust the application station to the extent necessary to ensure an essentially uniform concentration of the second solution on the second side of the substrate; and i. Dry the substrate.

16. The method as claimed in clause 15, characterized in that said application is achieved by a method selected from the group consisting of rotogravure application, saturated pressure point application, rotating screen application, cascade application, curtain application , and slot matrix application.

17. The method as claimed in clause 15, further characterized in that it comprises the step of squeezing said substrate prior to drying, by a method selected from the group consisting of a pressure point roll arrangement or by the application of a vacuum .

18. The method as claimed in clause 15, further characterized in that it comprises the step of wetting said substrate before the supply of said substrate inside said first application station by a method selected from the group consisting of embedding said substrate in water, applying water to said substrate by atomization or by exposing said substrate to a controlled humidity.

19. The method as claimed in clause 15, further characterized in that it comprises the step of laminating said substrate to a backing layer. SUMMARY A method for applying precisely a pre-measured amount of a composition to a textile substrate includes the steps of supplying a textile substrate in an application station, wherein the application station is desirably a reversed rotogravure roller arrangement (indirect), applying a measured amount of saturation solution to the textile substrate, while controlling the velocity rate of the substrate in relation to the application station, monitoring the concentration of the solution in the textile substrate to assume a uniform level of saturation, desirably by the use of a NIR evaluation, adjusting the application station to the extent necessary to ensure a uniform concentration of the solution on the textile substrate, and then drying the textile substrate.