Flame-retardant high-color-fastness jacquard full-paving carpet production line and production process thereof

Abstract

The invention provides a flame-retardant high-color-fastness jacquard full-paving blanket production line and a production process, the flame-retardant high-color-fastness jacquard full-paving blanket production line comprises a spinning device, a jacquard device and a compounding device, the spinning device comprises a crystallization drying mechanism, a spiral extrusion mechanism, a spinning forming mechanism and a deformation cooling mechanism; the spiral extrusion mechanism comprises a feeding cavity, a first compression cavity, a second compression cavity, a static mixing cavity, a first metering cavity, a dynamic mixing cavity and a second metering cavity which are sequentially arranged in the material flowing direction. The spiral extrusion mechanism is of a multi-cavity structure, materials are mixed at different temperatures through subareas, and therefore the problem that high-proportion and multi-component functional additives in a polyester matrix are difficult to evenly disperse and stably spin is solved.

Description

Technical Field

[0001] This invention relates to the field of textile technology, specifically to a flame-retardant, high-color-fastness jacquard carpet production line and its production process. Background Technology

[0002] Polyester (PET) fiber is an ideal material for carpet fabrics due to its excellent strength, abrasion resistance, and resilience. However, its inherent flammability and dyeing difficulties limit its application in high-end carpet applications requiring flame retardancy and high color fastness. Current technologies use finishing processes to impart flame retardancy or color to polyester fabrics, but this method suffers from problems such as short-lasting effects, stiffening of the fabric, and environmental pollution. Using melt spinning technology, which blends flame retardant masterbatch and color masterbatch with PET chips before spinning, is the fundamental way to achieve permanent flame retardancy and natural color in the fiber. However, this method faces significant technical challenges: First, it has poor spinnability. The introduction of flame retardants severely damages the rheological properties of the PET melt, leading to decreased melt strength and uneven viscoelasticity, which can easily cause breakage and fuzz during spinning. Second, it has poor dispersion uniformity. Flame retardants and colorants are difficult to disperse evenly in the PET matrix, which can easily lead to uneven flame retardant properties, color differences, and irregular fiber cross-sectional shapes. Third, there are process conflicts. Flame retardant masterbatches and color masterbatches have different decomposition temperatures, particle sizes, and compatibility with PET, which creates contradictions in the requirements for screw temperature, spinning temperature, and cooling conditions. Traditional single process windows cannot accommodate all of these.

[0003] In view of this, the inventor conducted in-depth research on the aforementioned deficiencies in the prior art, which led to the creation of this case. Summary of the Invention

[0004] The purpose of this invention is to address the above-mentioned shortcomings by providing a flame-retardant, high-color-fastness jacquard carpet production line that employs a compartmentalized design during the spinning stage, effectively ensuring uniform mixing and full decomposition of all materials.

[0005] The solution adopted by this invention to solve the technical problem is: a flame-retardant, high-color-fastness jacquard carpet production line, including a spinning device, a jacquard device, and a composite device. The spinning device includes a crystallization and drying mechanism, a spiral extrusion mechanism, a spinning forming mechanism, and a deformation and cooling mechanism. The spiral extrusion mechanism includes a feeding chamber, a first compression chamber, a second compression chamber, a static mixing chamber, a first metering chamber, a dynamic mixing chamber, and a second metering chamber arranged sequentially along the material flow direction. Each of the feeding chamber, the first compression chamber, the second compression chamber, the first metering chamber, the dynamic mixing chamber, and the second metering chamber is provided with a spiral rod for mixing and conveying materials. The wall of the static mixing chamber is provided with several sets of spiral blades, and the spiral directions of adjacent sets of spiral blades are opposite. The spiral rod in the dynamic mixing chamber is provided with spikes for mixing and crushing materials. The inner wall of the dynamic mixing chamber is provided with several radially inwardly extending retaining rings.

[0006] Furthermore, in order to improve the material mixing effect, the diameter of the feeding chamber is larger than the diameter of the first compression chamber and the second compression chamber to accommodate more material. The diameters of the first compression chamber and the second compression chamber gradually decrease along the material flow direction to compress the mixed materials. The diameters of the static mixing chamber, the first metering chamber, the dynamic mixing chamber and the second metering chamber are equal.

[0007] Furthermore, to ensure sufficient melting and mixing of all components, the temperature of the feeding chamber is 265℃-270℃, the temperature of the first compression chamber is 275℃-280℃, the temperature of the second compression chamber is 280℃-285℃, the temperature of the static mixing chamber and the first metering chamber is 285℃-290℃, and the temperature of the dynamic mixing chamber and the second metering chamber is 290℃-295℃.

[0008] Furthermore, for mixing materials, the crystallization and drying mechanism includes a slicing bin for storing PET slices, a masterbatch bin for storing flame retardant masterbatch, a color grain bin for storing color masterbatch, a pre-crystallization chamber, and a drying chamber. The slicing bin, masterbatch bin, and color grain bin are connected to the pre-crystallization chamber via a loss-in-weight scale to transport materials to the pre-crystallization chamber for pre-crystallization to prevent adhesion. The drying chamber is connected to the pre-crystallization chamber to dry the materials.

[0009] Furthermore, in order to filter the melt, the spinning forming mechanism includes a spinning box, and a melt filter is provided inside the spinning box. The melt filter includes a shell, and the shell is provided with a feeding chamber, a first filter layer, a second filter layer, a third filter layer and a discharge chamber from top to bottom. The first filter layer is a metal mesh filter layer, the second filter layer is a metal sand filter layer and the third filter layer is a metal fiber sintered felt filter layer.

[0010] Furthermore, in order to spin the melt into fibers, the spinning box is also equipped with a spinning metering pump located below the melt filter and a spinneret located below the spinning metering pump.

[0011] Furthermore, in order to cool the spinning process in sections, the spinning forming mechanism also includes an annular air window, a first drafting roller, a second drafting roller, and a third drafting roller. The annular air window is arranged around the spinneret, and the top of the annular air window is provided with several top air outlet holes. Several side air blowing holes are evenly distributed on the side wall of the annular air window. The side air blowing window is provided with an upper chamber, a middle chamber, and a lower chamber with independently controllable temperature from top to bottom.

[0012] Furthermore, in order to improve the puffing effect, the deformation cooling mechanism includes a deformer, the deformer includes a body, the body has a spinning channel along the length of the body, and the body also has an air inlet channel intersecting with the spinning channel for introducing high-temperature compressed air and a steam inlet channel for introducing superheated steam.

[0013] Furthermore, for cooling and shaping purposes, the deformation cooling mechanism also includes a cooling drum, which has a cooling channel and a double-helix cooling pipe arranged around the outer periphery of the cooling channel.

[0014] Another objective of this invention is to address the above-mentioned shortcomings by providing a production process for a flame-retardant, high-color-fastness jacquard carpet production line that employs a compartmentalized design during the spinning stage, effectively ensuring uniform mixing and full decomposition of all materials.

[0015] Another solution adopted by the present invention to solve the above-mentioned technical problems is: a production process for a flame-retardant, high-color-fastness jacquard carpet production line, comprising the following steps:

[0016] S1: PET chips, flame retardant masterbatch and color masterbatch are accurately weighed by a loss-in-weight scale and then transported to the pre-crystallization chamber. They are pre-crystallized at 170°C for 30 minutes and then dried at 175°C for 4 hours.

[0017] S2: After the mixture is crystallized and dried, it enters the screw extrusion mechanism. The temperature of each chamber is set as follows: the temperature of the feeding chamber is 265℃-270℃, the temperature of the first compression chamber is 275℃-280℃, the temperature of the second compression chamber is 280℃-285℃, the temperature of the static mixing chamber and the first metering chamber is 285℃-290℃, and the temperature of the dynamic mixing chamber and the second metering chamber is 290℃-295℃.

[0018] S3: The melt is extruded through the spinning forming mechanism at a spinning temperature of 288-295℃, cooled by the annular air window to form nascent fibers, and then undergoes two stages of hot stretching through the first, second and third stretching rollers.

[0019] S4: The stretched filament enters the deformer, where it expands and deforms in a mixed airflow at 235±5℃. It is then cooled and shaped on a cooling drum and finally wound into shape by a winding machine.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] (1) The spiral extrusion mechanism of this invention adopts a multi-chamber structure, and the material is mixed at different temperatures through partitioning to solve the problem that it is difficult to uniformly disperse and stably spin high-proportion, multi-component functional additives in polyester matrix. The produced BCF filament has uniform and reliable flame retardant performance, which can reach GB 8624 B1 level at the highest. The color is body dyeing, and the color fastness (dry / wet rubbing) reaches 4-5 level, and the color difference ΔE≤0.8. The fiber has excellent mechanical properties, with strength ≥3.2 cN / dtex, breaking elongation 30-45%, and stable crimp shrinkage and bulkiness, which fully meet the stringent requirements of high-end carpet yarn.

[0022] (2) The present invention provides at least two sets of multi-head spiral grooves with opposite directions on the inner wall of the screw barrel in the static mixing and homogenization zone, which are used to divide and guide the melt to generate radial flow, thereby effectively ensuring the material mixing effect;

[0023] (3) The present invention directly uses flame retardant masterbatch and color masterbatch for spinning, eliminating the traditional flame retardant finishing and dyeing process of fabrics, eliminating the pollution of related wastewater and chemical auxiliaries from the source, resulting in outstanding environmental benefits. At the same time, it shortens the process flow, reduces the overall energy consumption and production cost, and has high product added value and strong market competitiveness. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0025] Figure 1 This is a schematic diagram of the structure of the present invention;

[0026] Figure 2 This is a schematic diagram of the screw extrusion mechanism;

[0027] Figure 3 This is a schematic diagram of the spinning and forming mechanism;

[0028] Figure 4 This is a schematic diagram of the deformation cooling mechanism.

[0029] In the diagram: 1. Crystallization drying mechanism; 2. Screw extrusion mechanism; 21. Feed chamber; 22. First compression chamber; 23. Second compression chamber; 24. Static mixing chamber; 241. Spiral blade; 25. First metering chamber; 26. Dynamic mixing chamber; 261. Spike tooth; 262. Second metering chamber; 27. Spinning forming mechanism; 3. Melt filter; 31. Spinning metering pump; 33. Spinneret; 34. Annular air window; 341. Top air outlet; 342. Side air outlet; 442. Deformation and cooling mechanism; 41. Spinning channel; 42. Air inlet channel; 43. Steam inlet channel; Cooling drum. Detailed Implementation

[0030] To further explain the technical solution of the present invention, the present invention will be described in detail below through specific embodiments.

[0031] Example 1: As Figure 1-4As shown, this embodiment provides a flame-retardant, high-color-fastness jacquard carpet production line, including a spinning device, a jacquard device, and a composite device. The spinning device includes a crystallization and drying mechanism 1, a spiral extrusion mechanism 2, a spinning and forming mechanism 3, and a deformation and cooling mechanism 4. The spiral extrusion mechanism 2 includes a feeding chamber 21, a first compression chamber 22, a second compression chamber 23, a static mixing chamber 24, a first metering chamber 25, a dynamic mixing chamber 26, and a second metering chamber 27 arranged sequentially along the material flow direction. Each of the feeding chamber 21, the first compression chamber 22, the second compression chamber 23, the first metering chamber 25, the dynamic mixing chamber 26, and the second metering chamber 27 is provided with a spiral rod for mixing and conveying materials. The wall of the static mixing chamber 24 is provided with several sets of spiral blades 241, and the spiral directions of adjacent sets of spiral blades 241 are opposite. The spiral rod in the dynamic mixing chamber 26 is provided with spike teeth 261 for mixing and crushing materials. The inner wall of the dynamic mixing chamber 26 is provided with several radially inwardly extending retaining rings 262.

[0032] In this embodiment, to improve the material mixing effect, the diameter of the feeding chamber 21 is larger than the diameter of the first compression chamber 22 and the second compression chamber 23 to accommodate more material. The diameters of the first compression chamber 22 and the second compression chamber 23 gradually decrease along the material flow direction to compress and mix the materials. The diameters of the static mixing chamber 24, the first metering chamber 25, the dynamic mixing chamber 26, and the second metering chamber 27 are equal. The diameter of the feeding chamber 21 is larger than the diameter of the first compression chamber 22 and the second compression chamber 23. The diameter of the first compression chamber 22 is larger than the diameter of the second compression chamber 23. The diameter of the second compression chamber 23 is larger than the diameters of the static mixing chamber 24, the first metering chamber 25, the dynamic mixing chamber 26, and the second metering chamber 27.

[0033] In this embodiment, to ensure sufficient melting and mixing of the components, the temperature of the feeding chamber 21 is 265℃-270℃, the temperature of the first compression chamber 22 is 275℃-280℃, the temperature of the second compression chamber 23 is 280℃-285℃, the temperature of the static mixing chamber 24 and the first metering chamber 25 is 285℃-290℃, and the temperature of the dynamic mixing chamber 26 and the second metering chamber 27 is 290℃-295℃.

[0034] In this embodiment, for mixing materials, the crystallization drying mechanism 1 includes a slicing bin for storing PET slices, a masterbatch bin for storing flame retardant masterbatch, a color grain bin for storing color masterbatch, a pre-crystallization chamber, and a drying chamber. The slicing bin, masterbatch bin, and color grain bin are connected to the pre-crystallization chamber via a loss-in-weight scale to transport the materials to the pre-crystallization chamber for pre-crystallization to prevent adhesion. The drying chamber is connected to the pre-crystallization chamber to dry the materials.

[0035] In this embodiment, in order to filter the melt, the spinning forming mechanism 3 includes a spinning box, and a melt filter 31 is provided inside the spinning box. The melt filter 31 includes a shell, and the shell is provided with a feeding chamber, a first filter layer, a second filter layer, a third filter layer and a discharge chamber from top to bottom. The first filter layer is a metal mesh filter layer, the second filter layer is a metal sand filter layer and the third filter layer is a metal fiber sintered felt filter layer.

[0036] In this embodiment, in order to spin the melt into fibers, the spinning box is also provided with a spinning metering pump 32 located below the melt filter 31 and a spinneret 33 located below the spinning metering pump 32. A conical guide valve is also provided between the spinning metering pump 32 and the spinneret 33. The small diameter end of the conical guide valve is located on one side of the spinning metering pump 32, and the large diameter end of the conical guide valve is located on one side of the spinneret 33.

[0037] In this embodiment, in order to cool the spinning process in sections, the spinning forming mechanism 3 further includes an annular air window 34, a first drafting roller, a second drafting roller, and a third drafting roller. The annular air window 34 is arranged around the spinneret 33. The top of the annular air window 34 is provided with a plurality of top air outlet holes 341. The side wall of the annular air window 34 is evenly distributed with a plurality of side air blowing holes 342. The side air blowing window is provided with an upper cavity, a middle cavity, and a lower cavity with independently controllable temperature from top to bottom.

[0038] In this embodiment, in order to improve the puffing effect, the deformation cooling mechanism 4 includes a deformer, the deformer includes a body, a spinning channel 41 is provided in the body along the length direction of the body, and the body is also provided with an air inlet channel 42 for introducing high temperature compressed air and a steam inlet channel 43 for introducing superheated steam, which intersect with the spinning channel 41.

[0039] In this embodiment, for cooling and shaping, the deformation cooling mechanism 4 also includes a cooling drum 44, which has a cooling channel and a double-helix cooling pipe arranged around the outer periphery of the cooling channel.

[0040] Example 2: A production process for a flame-retardant, high-color-fastness jacquard carpet production line, comprising the following steps:

[0041] S1: PET chips, flame retardant masterbatch and color masterbatch are transported to the pre-crystallization chamber after being accurately weighed by a loss-in-weight scale in a mass ratio of 92-96: 3-5: 1-3. They are pre-crystallized at 170℃ for 30 minutes, and then dried at 175℃ and -0.095MPa for 4 hours, with a final moisture content of 25ppm.

[0042] S2: After the mixture is crystallized and dried to a moisture content of ≤30ppm, it enters the screw extrusion mechanism 2. The temperature of each chamber is set as follows: the temperature of the feeding chamber 21 is 265℃-270℃, the temperature of the first compression chamber 22 is 275℃-280℃, the temperature of the second compression chamber 23 is 280℃-285℃, the temperature of the static mixing chamber 24 and the first metering chamber 25 is 285℃-290℃, the temperature of the dynamic mixing chamber 26 and the second metering chamber 27 is 290℃-295℃, and the die head pressure is 8-12MPa.

[0043] S3: The melt is extruded through the spinning forming mechanism 3 at a spinning temperature of 288-295℃, cooled by the annular air window 34 to form nascent fibers, and then undergoes two-stage hot stretching through the first stretching roller, the second stretching roller and the third stretching roller.

[0044] S4: The stretched filament enters the deformer, where it expands and deforms in a mixed airflow at 235±5℃. It is then shaped on a cooling drum and finally wound into shape by a winding machine at a speed of 2800-3200 m / min.

[0045] The spiral extrusion mechanism 2 of this invention adopts a multi-chamber structure, which completes the mixing of materials at different temperatures through partitioning, so as to solve the problem that it is difficult to uniformly disperse and stably spin high-proportion, multi-component functional additives in polyester matrix. The produced BCF filament has uniform and reliable flame retardant performance, reaching up to GB 8624 B1 level; the color is body dyed, the color fastness (dry / wet rubbing) reaches 4-5 level, and the color difference ΔE≤0.8; the fiber has excellent mechanical properties, with strength ≥3.2 cN / dtex, breaking elongation 30-45%, and stable crimp shrinkage and bulkiness, which fully meets the stringent requirements of high-end carpet yarn.

[0046] The present invention provides at least two sets of multi-head spiral grooves with opposite directions on the inner wall of the screw barrel in the static mixing and homogenization zone, which are used to divide and guide the melt to generate radial flow, thereby effectively ensuring the material mixing effect.

[0047] This invention directly uses flame-retardant masterbatch and color masterbatch for spinning, eliminating the traditional flame-retardant finishing and dyeing processes for fabrics. It eliminates pollution from related wastewater and chemical auxiliaries at the source, resulting in significant environmental benefits. At the same time, it shortens the process flow, reduces overall energy consumption and production costs, and produces products with high added value and strong market competitiveness.

[0048] The above embodiments and figures are not intended to limit the product form and style of the present invention. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of the present invention.

Claims

1. A flame-retardant, high-color-fastness jacquard whole-cover carpet production line, characterized in that: The device includes a spinning device, a jacquard device, and a compounding device. The spinning device includes a crystallization and drying mechanism, a spiral extrusion mechanism, a spinning and forming mechanism, and a deformation and cooling mechanism. The spiral extrusion mechanism includes a feeding chamber, a first compression chamber, a second compression chamber, a static mixing chamber, a first metering chamber, a dynamic mixing chamber, and a second metering chamber arranged sequentially along the material flow direction. Each of the feeding chamber, the first compression chamber, the second compression chamber, the first metering chamber, the dynamic mixing chamber, and the second metering chamber is equipped with a spiral rod for mixing and conveying materials. The wall of the static mixing chamber is provided with several sets of spiral blades, and the spiral directions of adjacent sets of spiral blades are opposite. The spiral rod in the dynamic mixing chamber is provided with spikes for mixing and crushing materials. The inner wall of the dynamic mixing chamber is provided with several radially inwardly extending retaining rings.

2. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 1, characterized in that: The diameter of the feeding chamber is larger than the diameter of the first compression chamber and the second compression chamber to accommodate more material. The diameters of the first compression chamber and the second compression chamber gradually decrease along the material flow direction to compress the mixed material. The diameters of the static mixing chamber, the first metering chamber, the dynamic mixing chamber, and the second metering chamber are equal.

3. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 1, characterized in that: The temperature of the feeding chamber is 265℃-270℃, the temperature of the first compression chamber is 275℃-280℃, the temperature of the second compression chamber is 280℃-285℃, the temperature of the static mixing chamber and the first metering chamber is 285℃-290℃, and the temperature of the dynamic mixing chamber and the second metering chamber is 290℃-295℃.

4. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 1, characterized in that: The crystallization and drying mechanism includes a slicing bin for storing PET slices, a masterbatch bin for storing flame retardant masterbatch, a color grain bin for storing color masterbatch, a pre-crystallization chamber, and a drying chamber. The slicing bin, masterbatch bin, and color grain bin are connected to the pre-crystallization chamber via a loss-in-weight scale to transport materials to the pre-crystallization chamber for pre-crystallization to prevent adhesion. The drying chamber is connected to the pre-crystallization chamber to dry the materials.

5. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 1, characterized in that: The spinning forming mechanism includes a spinning box, and a melt filter is provided inside the spinning box. The melt filter includes a shell, and from top to bottom, a feeding chamber, a first filter layer, a second filter layer, a third filter layer, and a discharge chamber are provided inside the shell. The first filter layer is a metal mesh filter layer, the second filter layer is a metal sand filter layer, and the third filter layer is a metal fiber sintered felt filter layer.

6. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 5, characterized in that: The spinning box is also equipped with a spinning metering pump located below the melt filter and a spinneret located below the spinning metering pump.

7. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 6, characterized in that: The spinning forming mechanism also includes an annular air window, a first drafting roller, a second drafting roller, and a third drafting roller. The annular air window is arranged around the bottom of the spinneret. The top of the annular air window is provided with several top air outlet holes. Several side air blowing holes are evenly distributed on the side wall of the annular air window. The side air blowing window is provided with an upper cavity, a middle cavity, and a lower cavity with independently controllable temperature from top to bottom.

8. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 1, characterized in that: The deformation cooling mechanism includes a deformer, which includes a body. A spinning channel is provided inside the body along the length of the body. The body is also provided with an air inlet channel intersecting the spinning channel for introducing high-temperature compressed air and a steam inlet channel for introducing superheated steam.

9. The flame-retardant, high-color-fastness jacquard carpet production line according to claim 8, characterized in that: The deformable cooling mechanism also includes a cooling drum, which has a cooling channel and a double-helix cooling pipe arranged around the outer periphery of the cooling channel.

10. A production process for a flame-retardant, high-color-fastness jacquard carpet production line as described in any one of claims 1-9, characterized in that: S1: PET chips, flame retardant masterbatch and color masterbatch are accurately weighed by a loss-in-weight scale and then transported to the pre-crystallization chamber. They are pre-crystallized at 170°C for 30 minutes and then dried at 175°C for 4 hours. S2: After the mixture is crystallized and dried, it enters the screw extrusion mechanism. The temperature of each chamber is set as follows: the temperature of the feeding chamber is 265℃-270℃, the temperature of the first compression chamber is 275℃-280℃, the temperature of the second compression chamber is 280℃-285℃, the temperature of the static mixing chamber and the first metering chamber is 285℃-290℃, and the temperature of the dynamic mixing chamber and the second metering chamber is 290℃-295℃. S3: The melt is extruded through the spinning forming mechanism at a spinning temperature of 288-295℃, cooled by the annular air window to form nascent fibers, and then undergoes two stages of hot stretching through the first, second and third stretching rollers. S4: The stretched filament enters the deformer, where it expands and deforms in a mixed airflow at 235±5℃. It is then cooled and shaped on a cooling drum and finally wound into shape by a winding machine.

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