A dyeing and finishing method for basalt yarn knitted fabric

Abstract

This invention provides a dyeing and finishing method for basalt fiber core knitted fabric. The basalt fiber core knitted fabric includes a basalt fiber core and a polyester covering layer surrounding the basalt fiber core. The dyeing and finishing method includes the following steps: performing a preliminary setting treatment on the greige fabric, controlling the preliminary setting temperature at 180-200℃; dyeing the pre-set fabric, the dyeing including staged temperature increases: first, increasing the temperature to 90℃ at 1.5-2.0℃ / min, then increasing the temperature to 130℃ at 0.5-1.0℃ / min and holding at that temperature; after dyeing, using a rubber... The rubber blanket pre-shrinking machine pre-shrinks the fabric, controlling the wet-feed liquid ratio at 15%-20%, the heating roller temperature at 110-120℃, the rubber blanket pressure at 1.2-1.5MPa, and the pre-shrinking overfeed at 6%-12%. After pre-shrinking, the fabric undergoes finishing, with a warp overfeed of 8%-12% and a weft tension of 0.1-0.2N / cm. At the end of the finishing process, cold air at 20-25℃ and a wind speed of 8-10m / s is used for cooling, and the finishing process is repeated 2-3 times. Compared to conventional dyeing and finishing methods for basalt yarn knitted fabrics, this dyeing and finishing method can improve the problems of poor fabric smoothness and itchy feeling after dyeing and finishing.

Description

Technical Field

[0001] This invention relates to the field of dyeing and finishing technology for knitted fabrics, specifically to a dyeing and finishing method for basalt yarn knitted fabrics. Background Technology

[0002] Basalt fiber possesses characteristics such as heat resistance, corrosion resistance, and high rigidity, making it a promising candidate for application in functional textile materials. However, basalt fiber itself is quite brittle. If used directly in apparel or footwear fabrics, it is prone to breakage and burr formation during weaving, finishing, and subsequent wear and friction, affecting fabric integrity and comfort. To improve the textile processing performance of basalt fiber, current technologies typically use it as a core material, wrapping it with organic fibers such as polyester to form a core-loaded yarn. This type of core-loaded yarn can, to some extent, balance the functionality of basalt fiber with the weaveability and softness of the outer coating fibers, thus enabling its use in the preparation of knitted shoe uppers, functional mesh fabrics, and other similar materials. However, for core-loaded yarn knitted fabrics with a polyester outer coating, current dyeing and finishing methods result in poor fabric smoothness and an itchy feel after dyeing and finishing. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned defects or problems in the background art and to disclose a dyeing and finishing method for basalt yarn knitted fabric. Compared with conventional dyeing and finishing methods for basalt yarn knitted fabric, this method can improve the problems of poor fabric smoothness and itchy feeling after dyeing and finishing.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: In at least one embodiment, a dyeing and finishing method for basalt fiber yarn knitted fabric is disclosed. The basalt fiber yarn includes a basalt fiber core and a polyester covering layer covering the outer periphery of the basalt fiber core. The dyeing and finishing method includes the following steps: performing a preliminary setting treatment on the greige fabric, controlling the preliminary setting temperature at 180-200℃; and dyeing the fabric after preliminary setting, wherein the dyeing includes staged temperature increase: first, increasing the temperature to 90℃ at 1.5-2.0℃ / min, and then increasing the temperature to 130℃ at 0.5-1.0℃ / min and holding at that temperature. After dyeing, the fabric is pre-shrinked using a rubber blanket pre-shrinking machine. The wet supply liquid rate is controlled at 15%-20%, the heating roller temperature is 110-120℃, the rubber blanket pressure is 1.2-1.5MPa, and the pre-shrinking overfeed is 6%-12%. After pre-shrinking, the fabric is finished and shaped. The warp overfeed of the finished shaping is 8%-12%, the weft tension is 0.1-0.2N / cm, and the finished shaping is cooled with cold air at 20-25℃ and wind speed of 8-10m / s at the end of the shaping process. The finished shaping is repeated 2-3 times.

[0005] The applicant discovered that the shrinkage behavior of the basalt fiber core material and the polyester overlay in basalt yarn knitted fabrics differs significantly under high-temperature and humid conditions. Existing dyeing and finishing processes typically still use the conventional high-temperature and high-pressure dyeing process for polyester packaged yarns, with process design primarily focused on dyeing uniformity, dye uptake, and color fastness. However, the polyester overlay undergoes some thermal shrinkage and recovery under high-temperature and humid conditions, while the basalt core material exhibits virtually no corresponding thermal shrinkage.

[0006] In the above design, by establishing a continuous process control chain before, during and after dyeing, and by quantitatively constraining the key parameters in pre-shrinking and finished product shaping, the stress release, heat shrinkage and final structural stabilization of the fabric in the whole dyeing and finishing process can be synergistically regulated, thereby improving the problems of poor smoothness and itchy feeling of the fabric after dyeing and finishing.

[0007] In the above design, the pre-conditioning treatment of the greige fabric before dyeing allows the polyester overlay to release some of its residual internal stress before entering the high-temperature dyeing process. This reduces the tendency of the overlay to shrink suddenly during the subsequent high-temperature treatment, allowing the fabric to obtain a more stable initial state before entering the dyeing process, thus providing a basis for the size and structure control in the subsequent dyeing process.

[0008] In the above design, the dyeing process adopts a segmented heating method, especially the first heating to 90°C and then heating to 130°C at a slower rate and holding it at that temperature. Compared with the conventional single heating or faster heating method, this is more conducive to controlling the shrinkage behavior of the polyester coating layer in the critical thermal response range. It avoids the coating layer shrinking too quickly, which would cause a sudden increase in the core-sheath length difference. This reduces the risk of basalt fiber core material being exposed on the fabric surface and subsequently breaking and forming burrs.

[0009] The applicant also discovered that even after dyeing, the residual internal stress and poor structure recovery accumulated during the high-temperature treatment of the basalt yarn knitted fabric in the prior art may continue to be released during subsequent drying, pre-shrinking, shaping and even actual wear. This causes the polyester covering layer that was originally attached to the outer periphery of the basalt fiber core material to recover or shift again, thereby causing the basalt fiber core material to re-outward. This not only affects the smoothness of the fabric, but also easily causes itching in the wearer.

[0010] In the above design, the pre-shrinking treatment using a rubber blanket pre-shrinking machine after dyeing, with the wet-feed liquid ratio controlled at 15%-20%, the heating roller temperature controlled at 110-120℃, the rubber blanket pressure controlled at 1.2-1.5MPa, and the pre-shrinking overfeed controlled at 6%-12%, can further digest and rebuild the length difference and tissue recovery difference formed during the dyeing stage, making the fabric structure tend to rebalance and reducing the possibility of the basalt fiber core material continuously protruding or being exposed again in subsequent processes. Furthermore, since the warp overfeed is 8%-12% and the weft tension is 0.1-0.2N / cm after pre-shrinking, and the finished product is cooled by cold air at 20-25℃ and wind speed of 8-10m / s at the end of the setting process, and the finished product setting process is repeated 2-3 times, the reconstructed structural state can be further locked, thereby suppressing the secondary exposure caused by heat recovery and internal stress redistribution after the first heat finishing, so that the fabric maintains a more stable surface state during subsequent use.

[0011] In the above design, the warp overfeed is controlled at 8%-12% and the weft tension is controlled at 0.1-0.2 N / cm during the finishing process. At the end of the finishing process, cold air at 20-25℃ and wind speed of 8-10 m / s is used for cooling, and this process is repeated 2-3 times. Compared with a single ordinary finishing process, this is more conducive to gradually solidifying the relative positional relationship between the polyester overlay layer and the basalt fiber core material without applying excessive tension to the fabric. This reduces local stacking and reverse rebound of the fabric, which not only helps to improve the smoothness of the fabric, but also helps to reduce the itching caused by the exposed core material and rough surface.

[0012] The applicant also discovered that existing technologies, which improve fabric smoothness solely by increasing setting temperature, setting tension, or simply extending the heat preservation time, while achieving short-term appearance improvements in localized situations, are more likely to cause the fabric to feel stiff, experience uneven stress in certain areas, and create new imbalances in the core-sheath structure, making it difficult to simultaneously achieve both smoothness and comfort. In the aforementioned design, this invention does not rely on a single forced finishing method, but rather uses a combination of initial setting, segmented temperature-increasing dyeing, pre-shrinking, and repeated setting with specific warp overfeed, weft tension, and end-of-line cold air cooling conditions to gradually digest and disperse stress along the process chain. Therefore, it can improve smoothness while simultaneously ensuring the fabric's wearing comfort.

[0013] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in the initial treatment, the machine speed is 7-10 m / min, the hot air speed is 15-25 m / s, the warp stretching ratio is 5%-10%, and the overfeed is 10%-12%.

[0014] In the above design, by simultaneously controlling the conveying speed, hot air action, warp stretching and overfeeding degree in the initial stage, the residual internal stress in the fabric is released in advance without introducing new tensile imbalance, thereby reducing local wrinkling and core-sheath misalignment caused by sudden shrinkage of the coating layer during subsequent high-temperature dyeing, which is conducive to maintaining the flatness of the fabric surface.

[0015] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the dyeing is carried out using a high-temperature and high-pressure dyeing device and a disperse dye, the initial temperature of the dyeing solution is 50-60°C, the pH of the bath solution is 4.5-5.0, and the bath ratio is 1:8-1:12.

[0016] In the above design, by adopting a high-temperature and high-pressure dispersion dyeing system that matches the polyester coating layer, and keeping the starting temperature, bath pH and bath ratio within a relatively stable range, the heat transfer, dye transfer and coating layer thermal response can be more synchronized, reducing the shrinkage difference and color difference caused by inconsistent heating and dyeing rhythm in different parts, thereby improving the fabric appearance stability and dyeing uniformity.

[0017] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in the dyeing step, the dye liquor circulation flow rate is 80-100 L / min during the heating to 90°C stage, the dye liquor circulation flow rate is 60-80 L / min during the 130°C holding stage, the 130°C holding time is 20-60 min, and after dyeing, the temperature is lowered to 60°C at a rate of 0.5-1.5°C / min.

[0018] In the above design, by controlling the liquid flow and thermal history during the heating, heat preservation and cooling stages within a relatively gentle rhythm, it ensures that the covering layer can be fully heated and dyed, while reducing the disturbance of the yarn surface caused by liquid flow impact and rapid temperature change, and preventing the core-sheath length difference from being rapidly amplified in the critical temperature zone, thereby making the fabric surface smoother.

[0019] In the dyeing and finishing method disclosed in at least one embodiment, preferably, after the initial treatment and before dyeing, an oil removal step is further included. In the oil removal step, the water temperature is 30-50°C, the roller speed is 15-25 m / min, the working pressure is 1.0-1.5 bar, and a neutral oil remover is used for treatment for 10-20 min.

[0020] In the above design, by removing oil and impurities from the fabric surface before dyeing, the wettability, heat transfer and dye adsorption conditions of each part are more consistent, reducing dyeing and finishing deviations caused by local surface condition differences, thereby improving the uniformity of subsequent processing and improving the appearance of the fabric.

[0021] In the dyeing and finishing method disclosed in at least one embodiment, preferably, a reduction cleaning step is further included after dyeing. In the reduction cleaning step, the temperature is 80-90℃, the heating and cooling rate is 1-2℃ / min, and the holding time is 20-30 min. After reduction cleaning, acid neutralization is performed at 35-45℃ and the pH is adjusted to neutral.

[0022] In the above design, by removing floating dye and residual dye after dyeing and adjusting the fabric surface environment to a more stable neutral state, the residual chemical components can be reduced from continuing to affect the fiber surface state and subsequent heat finishing behavior, thereby making the subsequent pre-shrinking and setting processes more stable and improving the appearance and feel of the finished product.

[0023] In the dyeing and finishing method disclosed in at least one embodiment, preferably, a loose drying step is included before the pre-shrinking treatment, wherein the drying temperature is 60-80°C, the drying time is 3-5 min, the overfeed rate is 15%-20%, and the air velocity is 8-12 m / s.

[0024] In the above design, by completing the post-dyeing moisture migration and additional stress release in a relatively relaxed state, it is possible to avoid the formation and retention of temporary deformation in the fabric under stretching conditions, and reduce the continued transmission of this deformation into the subsequent structural correction stage. Therefore, it is beneficial to reduce residual deformation and unevenness in the finished product.

[0025] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the pre-shrinking treatment is carried out using a three-roller rubber blanket pre-shrinking machine with a machine speed of 8-15 m / min and a drying temperature of 100-110℃.

[0026] In the above design, by using a three-roller rubber blanket pre-shrinking machine and controlling the pre-shrinking machine speed and drying temperature within the above range, it is possible to ensure the stable realization of compression and recovery while avoiding excessive mechanical disturbance or excessively fast drying and heat setting on the fabric surface. This allows the length difference, recovery difference, and tightness difference that have formed after dyeing to be released more smoothly and become more consistent again, thereby reducing the tendency of basalt fibers to push outward, improving the smoothness of the fabric surface, and reducing itching.

[0027] In the dyeing and finishing method disclosed in at least one embodiment, preferably, in the finished product setting step, the liquid carry-over rate is not higher than 8%, the setting temperature is 130-160℃, and the machine speed is 8-10m / min.

[0028] In the above design, by controlling the liquid content, setting temperature and machine speed within the above range, the fabric can be finally cured under relatively stable hot air and running rhythm. In combination with the aforementioned warp overfeed, weft tension and end cold air cooling conditions, the heat recovery and stress rebound after leaving the machine will further reduce the damage to the relative position of the core and sheath. Therefore, the flatness of the finished fabric surface is maintained more stably.

[0029] In the dyeing and finishing method disclosed in at least one embodiment, preferably, the knitted fabric is a circular knitted mesh fabric with a fabric weight of 300-400 g and a basalt content of 35%-45%, the polyester coating layer is a polyester filament coating layer, and the dyeing adopts a dark disperse dye route.

[0030] In the above design, by ensuring that the fabric structure, weight, basalt content, coating layer form, and dyeing route are within a mutually matching range, the thermal response difference between the basalt core material and the coating layer can be controlled within a more easily adjustable range. This avoids amplifying structural imbalance due to excessively high core material ratio, loose structure, or insufficient coating continuity, and thus is more conducive to stably demonstrating the improvement effect of this invention on smoothness and comfort. Attached Figure Description

[0031] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments are briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is a flowchart of the dyeing and finishing method for basalt yarn knitted fabrics according to an embodiment of the present invention. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are preferred embodiments of the present invention and should not be considered as excluding other embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0034] In the claims, description and accompanying drawings of this invention, the terms "comprising," "having," and variations thereof are used to mean "including but not limited to."

[0035] This invention relates to a dyeing and finishing method for basalt fiber yarn knitted fabric, wherein the basalt fiber yarn comprises a basalt fiber core and a polyester covering layer covering the outer periphery of the basalt fiber core. (Refer to...) Figure 1The dyeing and finishing method mainly includes the following steps: S10: Perform initial setting treatment on the greige fabric, controlling the initial setting temperature to 180-200℃; S20: Perform the degreasing step, in which the water temperature is 30-50℃, the drum speed is 15-25m / min, the working pressure is 1.0-1.5bar, and a neutral degreasing agent is used for treatment for 10-20min; S30: Dye the fabric after initial determination. The dyeing includes staged heating: first, heating to 90℃ at 1.5-2.0℃ / min, then heating to 130℃ at 0.5-1.0℃ / min and holding at that temperature. S40: After dyeing, the fabric is pre-shrinked using a rubber blanket pre-shrinking machine. The wet-feed liquid ratio is controlled at 15%-20%, the heating roller temperature is 110-120℃, the rubber blanket pressure is 1.2-1.5MPa, and the pre-shrinking overfeed is 6%-12%. S50: After pre-shrinking, the fabric is finished and shaped. The warp overfeed of the finished product is 8%-12%, the weft tension is 0.1-0.2 N / cm, and the finished product is cooled with cold air at 20-25℃ and wind speed of 8-10m / s at the end of the shaping process. The finished product shaping is repeated 2-3 times.

[0036] The following is a detailed explanation of each of the above steps.

[0037] The dyeing and finishing method provided by this invention is applicable to knitted fabrics woven from basalt core yarn and dyed and finished using a continuous flat-width method. The basalt core yarn consists of a basalt fiber core and a polyester covering layer surrounding the basalt fiber core. The fabric can be a circular knitted mesh, with a fabric weight of 300g to 400g and a basalt content of 35% to 45%. The covering layer can be a polyester filament covering layer. Before entering the dyeing and finishing process, the fabric is first unfolded into a flat-width state and fed into the initial determination process using a continuous feeding method.

[0038] Preliminary setting refers to a hot air setting treatment of the fabric before dyeing. Step S10 uses a hot air setting machine for preliminary setting. The hot air setting machine is equipped with a hot air circulation system, a machine speed adjustment system, a tension adjustment system, and an overfeed adjustment system. After starting the machine, preheating is performed first. After the temperature of each hot air chamber stabilizes, the internal temperature is controlled between 180℃ and 200℃. When using a multi-chamber setting machine, the set temperature of each hot air chamber is controlled between 180℃ and 200℃. The machine speed is controlled between 7m / min and 10m / min, and the hot air speed is controlled between 15m / s and 25m / s.

[0039] When the fabric enters the stenter, it is flattened along its width and then fed into the chain area or clamping area by the feeding device, maintaining continuous and stable operation. The warp stretch ratio is controlled at 5% to 10%. The warp stretch ratio can be set by adjusting the difference between the feed roller speed and the stenter chain speed, or it can be calibrated according to the percentage change in the warp reference length of the fabric before and after entering the machine. Overfeed is controlled at 10% to 12%. Overfeed can be set by adjusting the difference between the overfeed roller speed and the chain speed, and it remains stable during continuous operation.

[0040] After initial setting, the fabric is continuously exited from the output end of the machine to obtain the initially set fabric, which is then directly sent to the degreasing process. In one specific embodiment, the initial setting temperature is controlled at 200℃, the machine speed is controlled at 8m / min, the hot air speed is controlled at 20m / s, the warp stretch ratio is controlled at 5%, and the overfeed is controlled at 10%.

[0041] Step S20 uses the pre-determined fabric obtained in the previous step as the treatment object. The degreasing treatment is carried out using a flat-width washing device. The flat-width washing device may include a feed roller, a guide roller, a washing tank, rollers, and a fabric exit device. Before starting the treatment, treatment water is added to the device, and the water temperature is controlled between 30℃ and 50℃. Then, a neutral degreasing agent is added and circulated for mixing, ensuring that the degreasing agent is evenly dispersed in the treatment liquid.

[0042] After initial fabric preparation, the fabric is continuously fed into the flat-width washing device in a flat-width manner. The roller speed is controlled at 15 m / min to 25 m / min, and the working pressure is controlled at 1.0 bar to 1.5 bar. The fabric is in continuous contact with the treatment solution within the device, and the treatment time is controlled at 10 min to 20 min. During the treatment process, the temperature of the treatment solution, the roller speed, and the working pressure are kept stable.

[0043] After the degreasing treatment is completed, the fabric is continuously discharged from the flat-width washing device and transferred to the dyeing process. In one specific embodiment, the treatment water temperature is controlled at 50°C, the roller speed is controlled at 20 m / min, the working pressure is controlled at 1.5 bar, and the treatment time with the neutral degreasing agent is controlled at 10 to 20 minutes.

[0044] Step S30 uses the degreased fabric obtained in the previous step as the treatment object. Dyeing is carried out using a high-temperature, high-pressure dyeing machine, employing disperse dyes suitable for polyester overlays. Before starting dyeing, dyeing water is added to the dyeing machine, and the initial temperature of the dyeing solution is controlled at 50℃ to 60℃. Then, disperse dyes and matching auxiliaries are added, and the pH of the bath is adjusted to 4.5 to 5.0, with a liquor ratio controlled at 1:8 to 1:12. After the dyeing solution has circulated evenly, the degreased fabric is loaded into the dyeing machine.

[0045] After installation, the dyeing process begins with staged temperature increases. In the first stage, the temperature is increased to 90℃ at a rate of 1.5℃ / min to 2.0℃ / min, with the dye liquor circulation flow rate controlled at 80L / min to 100L / min during this stage. After reaching 90℃, the temperature continues to increase. In the second stage, the temperature is increased to 130℃ at a rate of 0.5℃ / min to 1.0℃ / min. During the temperature increase from 90℃ to 130℃, the dye liquor circulation flow rate is maintained at 80L / min to 100L / min. After reaching 130℃, the temperature is held for 20 to 60 minutes, with the dye liquor circulation flow rate controlled at 60L / min to 80L / min during this holding period.

[0046] After the heat preservation period, the temperature is lowered to 60℃ at a rate of 0.5℃ / min to 1.5℃ / min, with the dye liquor circulation flow rate controlled at 80L / min to 100L / min during the cooling phase. The dye liquor is then discharged after cooling to 60℃. The dyeing machine can continue reduction cleaning in the same equipment after draining the dye.

[0047] During reduction cleaning, first add reduction cleaning solution to the dyeing machine, then control the treatment temperature at 80℃ to 90℃, with both the heating and cooling rates controlled at 1℃ / min to 2℃ / min, the dye liquor circulation flow rate controlled at 80L / min to 100L / min, and the holding time controlled at 20min to 30min. After reduction cleaning, drain the treatment solution and add acid neutralization solution at 35℃ to 45℃ to neutralize the solution before removing it from the bath.

[0048] In one specific embodiment, the initial temperature of the staining solution is controlled at 60°C, and the pH of the bath solution is controlled at 4.5. The temperature is first increased to 90°C at a rate of 1.5°C / min, then increased to 130°C at a rate of 0.5°C / min, with a circulation flow rate of 80 L / min during the heating phase. After holding at 130°C for 60 min, the temperature is decreased to 60°C at a rate of 1°C / min. Subsequently, reduction cleaning is performed in the same equipment, with the reduction cleaning temperature controlled at 90°C and a circulation flow rate of 100 L / min. After holding at this temperature for 30 min, the temperature is decreased, and the solution is neutralized to neutral at approximately 40°C.

[0049] Step S40 uses the fabric obtained and neutralized in the previous step as the processing object. After the fabric leaves the vat, it is first dehydrated, and then sent to a loose drying combined machine for loose drying. During loose drying, the drying temperature is controlled at 60℃ to 80℃, the drying time is controlled at 3 min to 5 min, the overfeed rate is controlled at 15% to 20%, and the air velocity is controlled at 8 m / s to 12 m / s.

[0050] After the loose drying process, the fabric is fed into a rubber blanket pre-shrinking machine for pre-shrinking treatment. A three-roller rubber blanket pre-shrinking machine can be used. Before entering the pre-shrinking zone, the fabric is first moistened to control the liquid content at 15% to 20%. The liquid content can be controlled by coordinating the moistening device and the liquid-pinching device, and adjusted according to the difference between the wet weight and dry weight of the fabric after moistening.

[0051] After the fabric enters the pre-shrinking zone, it continuously passes through the working area formed by the rubber blanket and the heated rollers. The temperature of the heated rollers is controlled at 110℃ to 120℃, the pressure of the rubber blanket is controlled at 1.2MPa to 1.5MPa, the pre-shrinking overfeed is controlled at 6% to 12%, the machine speed is controlled at 8m / min to 15m / min, and the drying temperature after pre-shrinking is controlled at 100℃ to 110℃. The pre-shrinking overfeed can be set by adjusting the difference between the fabric feeding speed of the pre-shrinking machine and the running speed of the rubber blanket.

[0052] After pre-shrinking, the fabric is continuously discharged from the machine and sent to the finished product setting process. In one specific embodiment, after dehydration, the fabric is first loosely dried at 60°C for 5 minutes, with the overfeed rate controlled at 15% and the air velocity controlled at 10 m / s. Subsequently, a three-roller rubber blanket pre-shrinking machine is used for pre-shrinking, with the wet-feed liquid ratio controlled at 15%, the heating roller temperature controlled at 110°C, the rubber blanket pressure controlled at 1.2 MPa, the pre-shrinking overfeed controlled at 8%, and the drying temperature after pre-shrinking controlled at 100°C and the machine speed controlled at 10 m / min.

[0053] Step S50 uses the pre-shrinked fabric obtained in the previous step as the processing object. The finished product is set using a setting machine. Before the fabric enters the setting machine, the liquid content is checked and controlled to be no higher than 8%. Then, the fabric is fed into the setting machine in a flat, continuous manner.

[0054] During finished product setting, the setting temperature is controlled at 130℃ to 160℃, the machine speed is controlled at 8m / min to 10m / min, the warp overfeed is controlled at 8% to 12%, and the weft tension is controlled at 0.1N / cm to 0.2N / cm. The warp overfeed can be set by adjusting the difference between the fabric feed speed and the setting machine chain speed. The weft tension can be controlled through the setting machine width control and the tension setting of the spreading device.

[0055] After the fabric passes through the setting zone, it is cooled at the end of the setting machine with cold air at 20°C to 25°C and a wind speed of 8m / s to 10m / s. After cooling, the fabric is exited and rolled up. The finishing process is repeated 2 to 3 times. During repeated setting, the fabric from the previous setting is fed back into the setting machine, and in each setting, the liquid content, setting temperature, machine speed, warp overfeed, weft tension, and end-of-line cold air conditions are maintained within the above-mentioned ranges.

[0056] In one specific embodiment, the liquid carryover rate is controlled to be no higher than 8%, the setting temperature is controlled to 150℃, the machine speed is controlled to 8m / min, the warp overfeed is controlled to 10%, the weft tension is controlled to 0.15N / cm, the end cold air temperature is controlled to 20℃ to 25℃, the cold air velocity is controlled to 10m / s, and the setting process is repeated twice. The above description of the specification and embodiments is used to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the above embodiments, should all be included within the scope of protection of this invention.

[0057] To further illustrate the beneficial effects of the dyeing and finishing method for basalt yarn knitted fabrics disclosed in this invention, the following embodiments and comparative examples are provided in this specification.

[0058] The fabric used for implementing this invention is a basalt core yarn knitted fabric. The basalt core yarn comprises a basalt fiber core and a polyester covering layer surrounding the basalt fiber core. The fabric is preferably a circular knitted mesh fabric with a weight of 300 g / m² to 400 g / m², a basalt content of 35% to 45%, and a polyester filament covering layer. Disperse dyes suitable for the polyester covering layer are used during dyeing. Pretreatment may employ a neutral degreasing agent, and post-dyeing treatment may employ a reducing cleaning agent and an acid neutralizing agent.

[0059] The main equipment may include a hot air setting machine, a flat-width washing device, a high-temperature and high-pressure dyeing machine, a loose drying combined machine, a three-roll rubber blanket pre-shrinking machine, and a finished product setting machine. All of the above equipment can be conventionally available in this field, and should be set and operated according to the process parameters given in this manual.

[0060] Example 1 Example 1 uses circularly woven basalt core yarn mesh as the greige fabric, with a fabric weight of 350 g / m², a basalt content of 40%, and a polyester filament covering layer on the outer layer of the core yarn. The finished product color is black. The greige fabric is first unfolded into a flat state and fed into a hot air setting machine for initial setting using a continuous feeding method. The initial setting temperature is controlled at 200℃, the machine speed at 8 m / min, the hot air speed at 20 m / s, the warp stretch ratio at 5%, and the overfeed at 10%. The pre-set fabric is obtained after the initial setting is completed.

[0061] After initial determination, the fabric is sent to a flat-width washing device for degreasing treatment. The degreasing water temperature is controlled at 50℃, the roller speed is controlled at 20 m / min, the working pressure is controlled at 1.5 bar, and a neutral degreasing agent is added for 15 min of treatment. After the treatment, the degreased fabric is obtained.

[0062] After degreasing, the fabric is placed into a high-temperature, high-pressure dyeing machine for dyeing. First, dyeing water at 60℃ and disperse dye are added to the dyeing machine, and the pH of the bath is adjusted to 4.5, with a bath ratio controlled at 1:10. Then, the temperature is increased to 90℃ at 1.5℃ / min, and then increased to 130℃ at 0.5℃ / min. During the heating stage, the circulation flow rate is controlled at 80 L / min. The temperature is held at 130℃ for 60 min, and then the temperature is decreased to 60℃ at 1℃ / min and the bath is drained.

[0063] After dyeing, reduction cleaning is performed in the same equipment. First, reduction cleaning solution is added, then the temperature is increased to 90°C at 1°C / min, the circulation flow rate is controlled at 100 L / min, and the temperature is maintained for 30 min. Then, the temperature is decreased to 60°C at 1°C / min. After draining the treatment solution, a neutralizing solution at about 40°C is added for acid neutralization, and the pH of the bath solution is adjusted to neutral before being discharged from the tank.

[0064] After exiting the drying drum, the fabric is first dehydrated and then sent to a loose drying combined machine for loose drying. The drying temperature is controlled at 60℃, the drying time is controlled at 5 min, the overfeed rate is controlled at 15%, and the air velocity is controlled at 10 m / s. After loose drying, a three-roller rubber blanket pre-shrinking machine is used for pre-shrinking treatment. The wet-feeding liquid ratio is controlled at 15%, the heating roller temperature is controlled at 110℃, the rubber blanket pressure is controlled at 1.2 MPa, the pre-shrinking overfeed is controlled at 8%, the drying temperature after pre-shrinking is controlled at 100℃, and the machine speed is controlled at 10 m / min.

[0065] After pre-shrinking, the finished product is set. The liquid content of the fabric before entering the machine is controlled to be no higher than 8%, the setting temperature is controlled at 150℃, the machine speed is controlled at 8 m / min, the warp overfeed is controlled at 10%, and the weft tension is controlled at 0.15 N / cm. At the end of the setting machine, cold air at 20℃ to 25℃ and a wind speed of 10 m / s is used for cooling. The finished product setting is repeated twice to obtain the finished fabric.

[0066] Example 2 Example 2 uses circularly woven basalt core yarn mesh as the greige fabric. The fabric weight is 340 g / m², the basalt content is 38%, and the outer layer of the core yarn is a polyester filament covering layer. The finished product color is black. The greige fabric first enters a hot air setting machine for initial setting. The initial setting temperature is controlled at 190℃, the machine speed is controlled at 9 m / min, the hot air speed is controlled at 18 m / s, the warp stretch ratio is controlled at 7%, and the overfeed is controlled at 11%.

[0067] After initial setup, the fabric enters a flat-width washing unit for degreasing. The treatment water temperature is controlled at 40℃, the roller speed at 18 m / min, and the working pressure at 1.2 bar. A neutral degreasing agent is added, and the treatment lasts for 15 minutes. After degreasing, the fabric is sent to a high-temperature, high-pressure dyeing machine. The initial temperature of the dyeing liquor is controlled at 55℃, the pH of the bath is controlled at 4.8, and the liquor ratio is controlled at 1:9. The temperature is first increased to 90℃ at a rate of 1.8℃ / min, with a first-stage circulation flow rate controlled at 90 L / min. Then, the temperature is increased to 130℃ at a rate of 0.8℃ / min, with a second-stage circulation flow rate controlled at 90 L / min. The fabric is then held at 130℃ for 40 minutes, with a circulation flow rate controlled at 70 L / min during the holding stage. Finally, the temperature is decreased to 60℃ at a rate of 1℃ / min, and the liquor is drained.

[0068] After draining, the solution undergoes reduction cleaning in the same equipment. The reduction cleaning temperature is controlled at 85℃, with both the heating and cooling rates controlled at 1.5℃ / min, the circulation flow rate controlled at 90 L / min, and the temperature held for 25 min. After reduction cleaning, acid neutralization is performed at 40℃, and the pH of the bath solution is adjusted to neutral before being discharged from the tank.

[0069] After being dehydrated, the fabric is sent to a loose drying machine for loose drying. The drying temperature is controlled at 70℃, the drying time is controlled at 4 min, the overfeed rate is controlled at 18%, and the air velocity is controlled at 9 m / s. Subsequently, a three-roller rubber blanket pre-shrinking machine is used for pre-shrinking treatment. The wet-feed liquid ratio is controlled at 18%, the heating roller temperature is controlled at 115℃, the rubber blanket pressure is controlled at 1.35MPa, the pre-shrinking overfeed is controlled at 10%, and the drying temperature after pre-shrinking is controlled at 105℃, with the machine speed controlled at 12 m / min.

[0070] After pre-shrinking, the finished product is set. The liquid content of the fabric before entering the machine is controlled to be no higher than 8%, the setting temperature is controlled at 145℃, the machine speed is controlled at 9 m / min, the warp overfeed is controlled at 9%, and the weft tension is controlled at 0.12 N / cm. At the end of the setting machine, cold air at 22℃ and a wind speed of 9 m / s is used for cooling. The finished product setting is repeated twice to obtain the finished fabric.

[0071] Example 3 Example 3 uses circularly woven basalt core yarn mesh as the greige fabric. The fabric weight is 380 g / m², the basalt content is 42%, and the outer layer of the core yarn is a polyester filament covering layer. The finished product color is black. The greige fabric is first fed into a hot air setting machine for initial setting. The initial setting temperature is controlled at 180℃, the machine speed is controlled at 10 m / min, the hot air speed is controlled at 25 m / s, the warp stretch ratio is controlled at 10%, and the overfeed is controlled at 12%.

[0072] After initial setup, the fabric enters a flat-width washing unit for degreasing. The treatment water temperature is controlled at 30℃, the roller speed at 25 m / min, and the working pressure at 1.0 bar. A neutral degreasing agent is added, and the treatment lasts for 20 minutes. After degreasing, the fabric is sent to a high-temperature, high-pressure dyeing machine. The initial temperature of the dyeing liquor is controlled at 50℃, the pH of the bath is controlled at 5.0, and the liquor ratio is controlled at 1:12. The temperature is first increased to 90℃ at a rate of 2.0℃ / min, with a first-stage circulation flow rate controlled at 100 L / min. Then, the temperature is increased to 130℃ at a rate of 1.0℃ / min, with a second-stage circulation flow rate controlled at 100 L / min. The fabric is held at 130℃ for 20 minutes, with a circulation flow rate controlled at 60 L / min during the holding stage. Finally, the temperature is decreased to 60℃ at a rate of 1.5℃ / min, and the liquor is drained.

[0073] After draining, the solution undergoes reduction cleaning in the same equipment. The reduction cleaning temperature is controlled at 80℃, with both the heating and cooling rates controlled at 2℃ / min, the circulation flow rate controlled at 80 L / min, and the temperature held for 20 min. After reduction cleaning, acid neutralization is performed at 35℃, and the pH of the bath solution is adjusted to neutral before being discharged from the tank.

[0074] After being dehydrated, the fabric is sent to a loose drying machine for loose drying. The drying temperature is controlled at 80℃, the drying time is controlled at 3 min, the overfeed rate is controlled at 20%, and the air velocity is controlled at 12 m / s. Subsequently, a three-roller rubber blanket pre-shrinking machine is used for pre-shrinking treatment. The wet-feed liquid ratio is controlled at 20%, the heating roller temperature is controlled at 120℃, the rubber blanket pressure is controlled at 1.5MPa, the pre-shrinking overfeed is controlled at 12%, and the drying temperature after pre-shrinking is controlled at 110℃, with the machine speed controlled at 8 m / min.

[0075] After pre-shrinking, the finished product is set. The liquid content of the fabric before entering the machine is controlled to be no more than 8%, the setting temperature is controlled to 160℃, the machine speed is controlled to 10 m / min, the warp overfeed is controlled to 12%, and the weft tension is controlled to 0.10 N / cm. At the end of the setting machine, cold air at 25℃ and a wind speed of 8 m / s is used for cooling. The finished product setting is repeated 3 times to obtain the finished fabric.

[0076] Comparative Example 1 Comparative Example 1 used the same greige fabric and dyeing route as Example 1, without initial setting treatment; the greige fabric went directly into the degreasing process. Degreasing, dyeing, reduction cleaning, acid neutralization, loose drying, pre-shrinking, and finished product setting were all carried out according to the steps and parameters of Example 1.

[0077] Comparative Example 2 Comparative Example 2 used the same greige fabric and pretreatment route as Example 1, performing initial setting and degreasing before entering the dyeing process. During dyeing, instead of a segmented heating method, the initial temperature of the dyeing liquor was controlled at 60°C, then directly increased to 130°C at a rate of 1.5°C / min, with a circulation flow rate controlled at 80 L / min. It was held at 130°C for 60 min, then cooled to 60°C at a rate of 1°C / min and drained. Reduction washing, acid neutralization, loose drying, pre-shrinking, and finished product setting were all performed according to the steps and parameters of Example 1.

[0078] Comparative Example 3 Comparative Example 3 used the same route as Example 1 for greige fabric, initial setting, degreasing, dyeing, reduction cleaning, and acid neutralization. After the fabric was dehydrated from the vat, it was first loosely dried according to Example 1, without the rubber blanket pre-shrinking treatment. The loosely dried fabric directly entered the finished product setting process. The finished product setting steps and parameters were the same as in Example 1.

[0079] Comparative Example 4 Comparative Example 4 used the same route as Example 1 for greige fabric, initial setting, degreasing, dyeing, reduction cleaning, acid neutralization, loose drying, and pre-shrinking. After pre-shrinking, only one finishing process was performed. The finishing temperature was controlled at 150°C, the machine speed was controlled at 8 m / min, the warp overfeed was controlled at 3%, and the weft tension was controlled at 0.35 N / cm. No cold air cooling was provided at the end of the finishing machine. All other conditions were the same as in Example 1.

[0080] The samples prepared in the above embodiments and comparative examples were tested. All samples used basalt yarn knitted fabrics from the same batch or within the same specification range, and were processed under the same equipment conditions according to their respective corresponding processes. At least three independent sample fabrics were prepared as parallel samples for each group of samples, with each sample fabric having an effective test area of ​​not less than 0.5 m².

[0081] To ensure comparability among the various tests, all samples were placed in a standard environment with a temperature of 20℃ to 22℃ and a relative humidity of 65% to 70% for at least 24 hours before testing. For tests requiring pre-treatment by washing, all samples underwent the same washing procedure, drying method, and humidification conditions.

[0082] The test items include fabric smoothness, core material exposure and burrs, and itching sensation upon contact.

[0083] Fabric smoothness was evaluated using a standardized manual observation method. Three samples were cut from each group of samples, each measuring 20 cm by 20 cm. The samples were placed in an environment with a temperature of 20℃ to 22℃ and a relative humidity of 65% to 70% for 24 hours before evaluation. During evaluation, the samples were laid flat on a smooth background board, and the fabric surface undulation, localized stacking, wrinkling, and surface smoothness were observed under standard white light conditions. The evaluation results were categorized into five levels: smooth, relatively smooth, fair, poor, and very poor.

[0084] The condition of exposed core material and burrs was evaluated using a standardized method combining manual observation and tactile confirmation. Three 20 cm x 20 cm samples were cut from each group and observed under conditioned conditions identical to those used for fabric surface flatness. During evaluation, the fabric surface was first observed under standard white light to check for protruding, exposed, or locally burred basalt core material. Then, the fabric surface was gently touched with a finger to confirm the presence of obvious protrusions, sharp edges, or localized burrs. Evaluation results were categorized into five levels: very little, few, moderate, many, and obvious.

[0085] The sensation of itching upon contact was evaluated using a standardized manual contact evaluation method. At least three 10 cm x 10 cm specimens were cut from each sample group, numbered, and then blind-sampled for evaluation. Evaluators were preferably five or more adults with normal skin sensation, and the evaluation site was uniformly the inner forearm. During evaluation, the specimen was gently touched and rubbed several times in the same direction on the evaluation site, and the evaluation was based on subjective contact sensation. Evaluation results were categorized into five levels: no obvious itching, slight itching, some itching, obvious itching, and severe itching.

[0086] The following results table uses manual evaluation to illustrate the relative differences between the examples and the comparative examples.

[0087]

[0088] As can be seen from the results table, the fabrics prepared in Examples 1 to 3 are generally better than those in Comparative Examples 1 to 4 in terms of fabric smoothness. This indicates that after processing according to the process route of the present invention, the surface state of the fabric is more stable, and there are fewer fabric undulations, local stacking and unevenness.

[0089] Regarding the exposure of the core material and burrs, Examples 1 to 3 showed very little or no burrs, while Comparative Examples 1 to 4 showed moderate, significant, or obvious burrs. This indicates that the continuous process control route adopted in this invention can effectively reduce the problems of basalt core material exposure and the resulting local burrs. Comparative Example 1 eliminated the initial setting treatment, Comparative Example 2 changed the dyeing heating path, Comparative Example 3 omitted the pre-shrinking step, and Comparative Example 4 weakened the final shaping control; all showed varying degrees of increased exposure and burrs, indicating that the above steps are interconnected in the entire process chain.

[0090] Regarding the tingling sensation upon contact, Examples 1 to 3 all exhibited mild tingling, while Comparative Examples 1 and 2 showed some tingling, and Comparative Examples 3 and 4 showed significant tingling. This indicates that when the fabric surface smoothness decreases and the core material is exposed and the burrs are aggravated, the fabric is more likely to cause tingling upon contact. It can be seen that the present invention does not achieve improvement through a single finishing step, but rather through the continuous coordination of initial setting, segmented temperature dyeing, pre-shrinking, and finished product setting, resulting in an overall stable fabric surface condition.

[0091] The foregoing description of the specifications and embodiments is intended to explain the scope of protection of this invention, but does not constitute a limitation on the scope of protection of this invention. Modifications, equivalent substitutions, or other improvements to the embodiments of this invention or a portion thereof that can be obtained by those skilled in the art through logical analysis, reasoning, or limited experimentation, based on the teachings of this invention or the foregoing embodiments, in conjunction with common knowledge, general technical knowledge, and / or existing technology, should all be included within the scope of protection of this invention.

Claims

1. A dyeing and finishing method for basalt yarn knitted fabric, characterized in that, The basalt fiber core yarn comprises a basalt fiber core material and a polyester covering layer surrounding the basalt fiber core material. The dyeing and finishing method includes the following steps: Perform initial conditioning on the greige fabric, controlling the initial conditioning temperature at 180-200℃; The fabric after initial determination is dyed, and the dyeing includes staged heating: first, the temperature is increased to 90℃ at 1.5-2.0℃ / min, and then increased to 130℃ at 0.5-1.0℃ / min and held at that temperature; After dyeing, the fabric is pre-shrinked using a rubber blanket pre-shrinking machine. The wet-feed liquid ratio is controlled at 15%-20%, the heating roller temperature is 110-120℃, the rubber blanket pressure is 1.2-1.5MPa, and the pre-shrinking overfeed is 6%-12%. After pre-shrinking, the fabric is subjected to finished product shaping. The warp overfeed of the finished product shaping is 8%-12%, the weft tension is 0.1-0.2 N / cm, and the fabric is cooled with cold air at 20-25℃ and wind speed of 8-10 m / s at the end of the shaping process. The finished product shaping is repeated 2-3 times.

2. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, In the initial treatment, the machine speed is 7-10 m / min, the hot air speed is 15-25 m / s, the radial stretching ratio is 5%-10%, and the overfeed is 10%-12%.

3. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, The dyeing is carried out using high-temperature and high-pressure dyeing equipment and disperse dyes. The initial temperature of the dyeing solution is 50-60℃, the pH of the bath solution is 4.5-5.0, and the bath ratio is 1:8-1:

12.

4. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, In the dyeing process, the dye solution circulation flow rate is 80-100 L / min during the heating to 90℃ stage, the dye solution circulation flow rate is 60-80 L / min during the 130℃ holding stage, the 130℃ holding time is 20-60 min, and after dyeing, the temperature is reduced to 60℃ at a rate of 0.5-1.5℃ / min.

5. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, After the initial treatment and before dyeing, an oil removal step is also included. In the oil removal step, the water temperature is 30-50℃, the drum speed is 15-25m / min, the working pressure is 1.0-1.5bar, and a neutral oil removal agent is used for treatment for 10-20min.

6. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, The process after staining also includes a reduction and cleaning step, in which the temperature is 80-90℃, the heating and cooling rate is 1-2℃ / min, and the holding time is 20-30min; after reduction and cleaning, acid neutralization is carried out at 35-45℃ and the pH is adjusted to neutral.

7. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, The process includes a loose drying step before the pre-shrinking treatment. In the loose drying step, the drying temperature is 60-80℃, the drying time is 3-5 minutes, the overfeed rate is 15%-20%, and the air velocity is 8-12 m / s.

8. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, The pre-shrinking process is carried out using a three-roller rubber blanket pre-shrinking machine with a machine speed of 8-15 m / min and a drying temperature of 100-110℃.

9. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, In the finished product shaping step, the liquid content is no higher than 8%, the shaping temperature is 130-160℃, and the machine speed is 8-10m / min.

10. The dyeing and finishing method for basalt yarn knitted fabric according to claim 1, characterized in that, The knitted fabric is a circular knitted mesh with a weight of 300-400g and a basalt content of 35%-45%. The polyester coating layer is a polyester filament coating layer, and the dyeing process uses a dark disperse dye route.

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