Methods to improve the quality reproducibility of small-batch yarn-dyed fabrics and mass production

Abstract

This invention relates to a method for improving the quality reproducibility of small-batch yarn-dyed fabrics compared to mass production, belonging to the field of yarn-dyed fabric technology in the textile industry. The production process for small-batch yarn-dyed fabrics in the warp direction employs a process of warping the raw yarn – dyeing the warp beam – dehydration – sizing the yarn onto the small beam – sizing machine assembly, achieving consistency with the mass production process. This results in consistent dyeing reproducibility, yarn elasticity, and sizing effect. Comparative tests show a color reproducibility level of 4 or higher, a yarn elongation deviation within 3%, and a sizing rate deviation within 1%. This avoids the differences in color, elasticity, and yarn absorbency between the warp-dyed yarn in small-batch yarn-dyed fabrics and the warp beams in mass production, which can lead to differences in sizing rates.

Description

Technical Field

[0001] This invention relates to a method for improving the quality reproducibility of small-batch yarn-dyed fabrics and mass production, belonging to the field of yarn-dyed fabric technology in the textile industry. Background Technology

[0002] Yarn-dyed fabric refers to fabric woven from dyed yarn. Compared with printed fabric, yarn-dyed fabric has the characteristics of rich colors, strong three-dimensional effect, high color fastness, and small minimum order quantity. However, the dyeing, weaving, and finishing processes have greater losses, and the output is not as high as that of greige fabric. Therefore, the input cost is high and the technical requirements are high.

[0003] For yarn-dyed fabrics, the weft direction is generally dyed using cone yarns. After dyeing, the yarn is dehydrated, dried, and rolled into tight yarns for weaving. For the warp direction, depending on the batch size and pattern of the order, the production method can be divided into two types: raw yarn warping - warp beam dyeing - dehydration - sizing (hereinafter referred to as the raw yarn finishing method) and loose winding - cone yarn dyeing - dehydration and drying - tight winding - colored yarn warping - sizing (hereinafter referred to as the color finishing method). For polyester-cotton four-way stretch orders or orders requiring a warp elasticity elongation rate higher than 10%, to ensure warp elasticity, the yarn is generally dyed using a spring tube + bread yarn method before color finishing. The raw yarn finishing method is generally used for batches and initial portions that meet the warp beam dyeing conditions and do not require warp pattern arrangement. The color finishing method is generally used for small batches (batch length ≤ 500 meters) or orders requiring warp pattern arrangement. Due to the differences in production processes and dyeing techniques between the raw yarn finishing method and the color finishing method, the reproducibility between small batches (batch length ≤ 500 meters) and large batch production is poor, mainly in the following aspects:

[0004] 1. Dyeing reproducibility: Small-batch orders use cone dyeing for the warp direction, which requires smoothing and drying the yarn after dyeing. Large-scale production uses beam dyeing, which does not require smoothing or drying the yarn. The difference in dyeing methods and post-processing of the yarn leads to differences in color reproducibility between the two methods, making color matching between the two more difficult.

[0005] 2. In terms of elasticity reproducibility: For small-batch orders of elastic fabrics, the warp direction is dyed using cone yarn or spring tube + bread yarn, while large-scale production uses warp beam dyeing. The different dyeing methods result in different tensions, causing a large elasticity deviation between the two. In particular, the elasticity deviation between the spring tube + bread yarn dyeing method and the warp beam dyeing method is as high as 20% or more after dyeing the same yarn, making it difficult to ensure that the elasticity of the fabrics produced by the two methods is consistent.

[0006] 3. Regarding the sizing effect: Due to the smoothing and drying process of the yarn, the yarn absorbs less sizing during sizing in the color finishing method than in the original finishing method, resulting in a lower sizing rate. In contrast, the yarn sizing rate in the original finishing method is higher, which leads to deviations in color rendering and fabric feel after desizing, thus affecting fabric quality.

[0007] In the actual production of yarn-dyed fabrics, there are many situations where large-scale production meets the standards of small-batch orders, or vice versa. Differences in color, elasticity, and sizing effects between the finishing and dyeing processes lead to deviations in fabric quality, affecting its reproducibility. Therefore, ensuring consistency between the warp direction of small-batch yarn-dyed fabrics and the production process of large-scale production is a key challenge in its application. Summary of the Invention

[0008] The purpose of this invention is to provide a method for improving the quality reproducibility of small-batch yarn-dyed fabrics (batch length ≤ 500 meters) compared to large-scale production, without increasing equipment investment or modification. This is achieved by redesigning the warp production process for small-batch yarn-dyed fabrics from loose winding – yarn dyeing – dehydration and drying – tight winding – yarn warping – sizing and warping onto the warp beam to: raw yarn warping – warp beam dyeing – dehydration – sizing and warping onto the small warp beam – sizing machine warping. This improves the consistency of the warp production process between small-batch and large-scale production, thereby enhancing the quality reproducibility of small-batch yarn-dyed fabrics compared to large-scale production. Simultaneously, it shortens the production process flow and reduces raw material input and energy consumption.

[0009] The technical solution adopted in this invention is:

[0010] The method for improving the quality reproducibility of small-batch yarn-dyed fabrics and large-scale production includes the following steps:

[0011] (1) Production process design:

[0012] The warp direction of the variety is produced according to the production process of raw yarn warping - warp beam dyeing - dehydration - sizing and placing on small beams - sizing machine beam assembly. The warping head count of a single warp beam = total number of warp heads ÷ number of sizing small beams ÷ number of warp heads. The warping length of a single warp beam = sizing small beam length * number of sizing small beams + 35 meters * 2. The sizing small beam length = warp beam length + 40 meters. The number of warp heads is 3, 4, 5 or 6, and the number of sizing small beams is 2, 3 or 4.

[0013] (2) Warping of raw yarn:

[0014] Based on the process design, select either a small or medium warp beam for warping. Adjust the machine speed to 300-500 m / min according to the yarn type, with a pressure of 0-20 cN, tension of 0-8 mm, and a warp beam density of 0.42-0.50 g / cm³. 3 The density deviation of a single batch of warp beams is within 0.02 g / cm³. 3 Within;

[0015] (3) Axial staining:

[0016] The warp beam is suspended into the dyeing vat and pre-treated according to the dyeing process of the corresponding type of warp beam: enzyme washing or water washing, dyeing, soap washing, water washing, and color fixing. Whether color fixing is required depends on the type and concentration of dye.

[0017] (4) Dehydration:

[0018] The dyed warp beams are placed on a vacuum dehydrator for dehydration until the moisture content is 60%-70%.

[0019] (5) Sizing and dropping onto the small beam:

[0020] After dyeing, the warp beams are placed on the warp beam frame. The sizing formula is selected according to the type of yarn, and the process parameters are adjusted to sizing the yarn. The sized yarn is then placed on the empty warp beams for dyeing according to the length and number of small warp beams designed in the process. The empty warp beams are 1600mm high and 160-226mm in diameter. Connecting shaft heads are installed at both ends of the warp beams and fixed with screws. One end of the connecting shaft head matches the warp beam disc for dyeing, and the other end matches the warp beam fixing device in the crimping part of the sizing machine.

[0021] (6) Sizing machine shaft connection:

[0022] Place the prepared small shaft onto the warp beam frame, adjust the process parameters, pull the sized yarn sheet out from the shaft and separate it into layers, guide the yarn, and after auxiliary pre-drying, sizing in the sizing tank, drying in the cylinder, and separating the yarn, wind it onto the warp beam through the telescopic reed.

[0023] The tension of the warping machine is controlled by tension bars, which are adjusted by the distance between the two tension bars.

[0024] The number of warp heads per single warp beam is between 600 and 780.

[0025] The height of both the small warp beam and the medium warp beam is 1600mm, the diameter of the small warp beam is 100mm, the diameter of the medium warp beam is 120mm, and the total warping weight ranges from 4-11kg / shaft for the small warp beam and 11-19kg / shaft for the medium warp beam.

[0026] The slurry formulation consists of 3-5 of the following: modified starch, PVA, polyacrylate, phosphate starch, solid propylene, and wax flakes.

[0027] The crimping tension setting during sizing is 2%-5% lower than that of similar mass-produced dyeing and sizing yarn on the weaving beam. The sizing elongation and drying elongation are 0.1%-0.2% lower than those of similar mass-produced dyeing and sizing yarn on the weaving beam. The moisture regain setting is 0.5%-1% higher than that of similar mass-produced dyeing and sizing yarn on the weaving beam. The remaining parameters are set the same as those of similar mass-produced dyeing and sizing yarn on the weaving beam.

[0028] In step (6), the sizing rate is controlled between 6% and 12% according to different varieties, the reinforcement rate is ≥10%, the elongation reduction rate is ≤25%, the hair reduction rate is ≥70%, the wear resistance improvement rate is ≥200%, the sizing rate deviation between each small shaft is ≤1%, and the elongation reduction rate deviation is ≤2%.

[0029] Before the sizing machine is closed, the sizing tank liquid is recovered, the drying cylinder temperature is reduced to below 100℃, the crimping tension during sizing is set 2%-5% lower than that of similar mass-produced dyeing and sizing yarn on the weaving beam, the sizing elongation and drying elongation are set 0.1%-0.2% lower than those of similar mass-produced dyeing and sizing yarn on the weaving beam, and the other parameters are set the same as those of similar mass-produced dyeing and sizing yarn on the weaving beam.

[0030] The small batch of yarn-dyed fabrics refers to fabrics with a batch length of ≤500 meters.

[0031] The parameter data for dyeing and sizing yarn-docking beams produced in large quantities within the same product category are as follows:

[0032] (1) Winding tension:

[0033] For natural fibers and blends of 50 count and below (including 50 count): Take-up tension = Total warp ends / Yarn count * Constant * 10 Constant = 1.1

[0034] For natural fibers and blends of 60 count and above (including 60 count): Take-up tension = Total warp ends / Yarn count * Constant * 10 Constant = 1.0

[0035] Regenerated cellulose and its blends: Take-up tension = Total warp ends / Yarn count * Constant * 10 Constant = 0.9

[0036] Polyester / cellulose fiber blended varieties: Take-up tension = Total warp ends / Yarn count * Constant * 10 Constant = 1.2

[0037] Elastic varieties: Take-up tension = Total warp ends / Yarn count * Constant * 10 Constant = 0.8

[0038] (2) Sizing elongation: 0-0.5% for natural fibers and their blends;

[0039] Regenerated cellulose and its blends: 0-0.4%;

[0040] Elastic varieties: 0-0.3%;

[0041] (3) Dry elongation: 0.1-0.7% for natural fibers and their blends;

[0042] Regenerated cellulose and its blends: 0.1-0.5%;

[0043] Elastic varieties: 0.1-0.3%;

[0044] (4) Set moisture regain: standard moisture regain of fiber.

[0045] The yarn type is either short-fiber blended yarn or short-fiber pure yarn other than flax.

[0046] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0047] (1) The production process of warp yarn of small batch yarn-dyed fabric adopts the process of warp yarn preparation, warp beam dyeing, dehydration, sizing and small beam, and sizing machine beam assembly. This process is consistent with the large production process and has consistent dyeing reproducibility, yarn elasticity and sizing effect. According to comparative tests, the color reproducibility level is above 4, the yarn elastic elongation deviation is within 3%, and the sizing rate deviation is within 1%. This avoids the difference in sizing rate caused by the color and elasticity difference between the warp yarn dyed in small batch yarn-dyed fabric and the warp beam dyed in large production, as well as the difference in yarn water absorption.

[0048] (2) The production process of small-batch yarn-dyed fabrics is shortened. Compared with the production method of loose winding-yarn dyeing-dehydration and drying-tight yarn splitting-dyed yarn warping-sizing and weaving beam, the loose winding, drying and tight yarn splitting processes are reduced, and the efficiency is increased by more than 30%.

[0049] (3) The input of raw materials for small-batch yarn-dyed fabric production is reduced. According to calculations, the input of raw yarn can be reduced by 5%-6%, and the input of smoothing agent can be reduced by 3.5% of the yarn weight.

[0050] (4) In terms of energy consumption, it reduces the water and electricity consumption caused by drying the yarn package. At the same time, for medium and light-colored varieties, it can save a batch of water for yarn smoothing treatment during the dyeing process.

[0051] (5) This invention was completed without increasing equipment investment and equipment modification, thus avoiding a large amount of capital investment and helping enterprises reduce costs and increase efficiency. Detailed Implementation

[0052] The present invention will be further described below with reference to specific embodiments, so that those skilled in the art can better understand the present invention, but this does not limit the present invention.

[0053] Test method:

[0054] (1) Yarn elasticity: Take a yarn bundle with a circumference of 1 meter and 50 turns, with a tension of about 0.1 GPD, put it in boiling water at 100℃ for 10 minutes under free tension, then dry it and let it stand for 16 hours. The length tested when the load is 0.01 kg is L0, and the length tested when the load is 0.25 kg and stretched for 1 minute is recorded as L1. Potential elasticity YPS% = (L1 – L0) / L0 * 100%;

[0055] (2) Yarn sizing rate: Randomly cut yarn bundles about 20 cm long before and after sizing, weigh 10 g each, tie them with 3-4 yarns, put the sample in an oven (105-110℃) and dry for 1.5 hours until constant weight, weigh the dry weight W1 (g), put the sample in the test desizing solution, boil for 15 minutes, take it out, rinse it with clean water, squeeze out the water, put it in an oven and dry it until constant weight, weigh the dry weight W2 (g), sizing rate (%) = (W1-W2) / W2*100%;

[0056] (3) Yarn color difference and whiteness: The color difference and whiteness of the yarn samples were tested using a DATACOLOR D650 colorimeter.

[0057] Example 1

[0058] Fabric code: CK1E091-2300002-5-V, contract quantity: 50 meters, total warp count: 8616, required warp beam length: 87 meters, finished product specifications: 53 / 54*BAM / POLY50(40D)*P50D(SPANDEX20), specific steps are as follows:

[0059] 1) Production process design:

[0060] The production process for the warp direction of the variety is designed according to the following steps: warping of raw yarn - dyeing of warp beams - dehydration - sizing and placement on small beams - sizing machine beam assembly. The warping head count per warp beam is 8616 ÷ 4 ÷ 3 = 718, the sizing placement length on small beams is 87 + 40 = 127 meters, the warping length of a single warp beam is 127 * 4 + 35 * 2 = 578 meters, the number of warping heads is 3, the number of sizing placements on small beams is 4, and the designed warp yarn consumption is 15.04 kg.

[0061] 2) Warping of raw yarn:

[0062] Based on the process design, the warping head count, length, and raw yarn specifications of a single warp beam, the warping weight of a single warp beam is 5.66 kg. A small warp beam (1600 mm high, 100 mm diameter) is selected for warping. The warping speed is 300 m / min, the pressure is 0 cN, the tension is 0 mm, and 3 warp beams are warped. The densities of the three warp beams are 0.428 g / cm³. 3 0.426 g / cm 3 0.423 g / cm 3 ;

[0063] 3) Axial staining:

[0064] The warp beam is suspended into the dyeing vat and pre-treated, washed, dyed, soaped, and washed according to the dyeing process for bamboo-polyester core-wrapped varieties.

[0065] 4) Dehydration:

[0066] The dyed warp beams were placed on a vacuum dehydrator for dehydration until the moisture content reached 62%.

[0067] 5) Sizing and placing the yarn onto the small beam:

[0068] After dyeing, the warp beams are placed on the warp beam frame. The sizing formula is selected: 75kg modified starch, 30kg PVA, 30kg solid propylene, and 3kg wax flakes. The crimping tension is adjusted to 1300N, and the sizing elongation and drying elongation are 0.1% and 0.2% respectively. The moisture regain is set to 7.5% for sizing, and the sizing rate is controlled at 12%. The sized yarn is then laid on the empty warp beam for dyeing in 127-meter lengths. The empty warp beam has a beam height of 1600mm and a beam diameter of 226mm.

[0069] 6) Sizing machine shaft alignment:

[0070] Place the prepared small shaft onto the warp beam frame, recover the sizing liquid in the sizing tank, and lower the temperature of the drying cylinder to 90℃. Adjust the process parameters, set the crimping tension to 1300N, the sizing elongation and drying elongation to 0.1% and 0.2% respectively, and set the moisture regain to 6.5%. Pull the sized yarn from the beam and layer it, guide the yarn, and after auxiliary pre-drying, sizing in the sizing tank, drying in the drying cylinder, and yarn separation, wind it onto the warp beam through the telescopic reed.

[0071] Comparative Example 1

[0072] The small-batch color finishing process steps are as follows:

[0073] 1) Production process design:

[0074] The production process for the warp direction of the yarn variety is designed according to the loose winding - yarn dyeing - dehydration and drying - tight winding - colored yarn warping - sizing. The colored yarn warping length is 131 meters, and the number of warp ends is 10 warp beams with a first portion of 666 and 2 warp beams with a first portion of 665, for a total of 12 warp ends. The required warp yarn amount is 15.02 kg, the warp yarn surplus is 1.72 kg, and the total warp yarn amount is 16.74 kg.

[0075] 2) Loose winding:

[0076] The raw yarn was weighed at (0.6±0.05) kg and had a density of (0.18±0.01) g / cm³. 3 After being woven into bread yarn, it is fitted onto a spring tube that is wrapped with a stocking.

[0077] 3) Dyeing of yarn packages:

[0078] After the spring tube containing the bread yarn is installed on the yarn frame and pressed and fixed, it is hoisted into the dyeing vat. The process of dyeing the core yarn of bamboo polyester is carried out according to the process of pretreatment-washing-dyeing-soap washing-washing-softening. After completion, the yarn is dehydrated, dried and re-moistened before being sent to the tight winding for use.

[0079] 4) Tight-fitting splitter:

[0080] After picking out defects from the yarn package according to the internal and external differences, 667 tight yarns with a weight of 0.02kg each (calculated based on the warping length) were wound together. The tube type used was a plastic parallel tube with a tube stroke of 150mm and a diameter of 67mm.

[0081] 5) Warping of colored yarn:

[0082] Hang the wound yarn onto the warping machine back frame as required, and align the warp beams according to the designed head portion, warping length, and number of warp ends. After completion, feed the sizing yarn.

[0083] 6) Sizing:

[0084] After coloring and finishing, place the warp beam on the warp beam frame, adjust the process parameters, and then sizing the yarn and placing it onto the weaving beam.

[0085] Comparative Example 2

[0086] The large-scale production process steps are as follows (taking a contract quantity of 3300 meters as an example):

[0087] 1) Production process design:

[0088] The warp direction of the variety is designed according to the production process of warping the raw yarn - dyeing the warp beams - dehydration - sizing. The warping length is 2196 meters, the production batch is 2 batches, the number of warp ends is 10 warp beams of 666 first batch and 2 warp beams of 665 first batch, for a total of 12 ends, and the required warp yarn weight is 478.56 kg.

[0089] 2) Warping of raw yarn:

[0090] Warping is performed according to the warping head portion, length, and number of warp beams designed in the process;

[0091] 3) Axial staining:

[0092] After the warp beam is fixed on the beam frame, it is hoisted into the dyeing vat and pre-treated, washed, dyed, soaped and washed again according to the dyeing process of bamboo-polyester core-spun warp beam. After that, the warp beam is dehydrated and sent to sizing.

[0093] 4) Sizing:

[0094] After dyeing, the warp beams are placed on the warp beam frame, and the sizing and yarn are then dropped onto the warp beams after adjusting the process parameters.

[0095] The elastic elongation, color reproducibility (using the color obtained by the large-scale original finishing process as the standard sample), sizing rate, and color deviation before and after sizing (using the color before sizing as the standard sample) of the yarn produced by the process method described in this invention, the large-scale original finishing process, and the small-batch color finishing process were tested respectively. The test results are shown in Table 1.

[0096] Table 1

[0097]

[0098]

[0099] Example 2

[0100] Fabric code: CJK12101-2200049-2-V, contract quantity: 107 meters, total warp count: 7976, required warp beam length: 144 meters, finished product specifications: 53 / 54*TENCELCPT50*NYLON40D (SPANDEX20D), specific steps are as follows:

[0101] 1) Production process design:

[0102] The warp direction of the product is designed according to the production process of raw yarn warping - warp beam dyeing - dehydration - sizing and placing on the small beam - sizing machine beam assembly. The warping head count of a single warp beam = 7976 ÷ 3 ÷ 4 = 665, the sizing and placing length on the small beam = 144 + 40 = 184 meters, the warping length of a single warp beam = 184 * 3 + 35 * 2 = 622 meters, the number of warping heads = 4, the number of sizing and placing on the small beam = 3, and the designed warp yarn consumption is 17.64 kg.

[0103] 2) Warping of raw yarn:

[0104] Based on the process design, the warping head count, length, and raw yarn specifications of a single warp beam, the warping weight of a single warp beam is 4.41 kg. A small warp beam (1600 mm high, 100 mm diameter) is selected for warping. The warping speed is 400 m / min, the pressure is 15 cN, the tension is 4 mm, and 4 warp beams are warped. The density of the 4 warp beams is 0.464 g / cm³. 3 0.465g / cm 3 0.465g / cm 3 0.462 g / cm 3 ;

[0105] 3) Axial staining:

[0106] The warp beam is suspended into the dyeing vat and pre-treated, washed, dyed, soaped, and washed according to the Tencel dyeing process.

[0107] 4) Dehydration:

[0108] The dyed warp beams were placed on a vacuum dehydrator for dehydration until the moisture content reached 65%.

[0109] 5) Sizing and placing the yarn onto the small beam:

[0110] After dyeing, the warp beams are placed on the warp beam frame. The sizing formula is selected: 100 kg of modified starch, 50 kg of solid propylene, and 3 kg of wax flakes. The crimping tension is adjusted to 1400 N, and the sizing elongation and drying elongation are 0.2% and 0.4% respectively. The moisture regain is set to 12.5% ​​for sizing. The sized yarn is then laid on the empty warp beam for dyeing in a length of 184 meters. The empty warp beam has a height of 1600 mm and a diameter of 226 mm.

[0111] 6) Sizing machine shaft alignment:

[0112] Place the prepared small shaft onto the warp beam frame, recover the sizing liquid in the sizing tank, and lower the temperature of the drying cylinder to 98°C. Adjust the process parameters, set the crimping tension to 1400N, the sizing elongation and drying elongation to 0.2% and 0.4% respectively, and set the moisture regain to 12.5%. Pull the sized yarn from the shaft and layer it, guide the yarn, and after auxiliary pre-drying, sizing in the sizing tank, drying in the drying cylinder, and yarn separation, wind it onto the warp beam through the telescopic reed.

[0113] Comparative Example 3

[0114] The small-batch color finishing process steps are as follows:

[0115] 1) Production process design:

[0116] The production process for the warp direction of the yarn is designed according to the loose winding - yarn dyeing - dehydration and drying - tight winding - colored yarn warping - sizing. The colored yarn warping length is 187 meters, and the number of warp ends is 8 warp beams with a first portion of 665 and 4 warp beams with a first portion of 664, for a total of 12 ends. The required warp yarn amount is 17.62 kg, the warp yarn surplus is 1.41 kg, and the total warp yarn amount is 19.03 kg.

[0117] 2) Loose winding:

[0118] The raw yarn was weighed at (1.0±0.05) kg and had a density of (0.36±0.01) g / cm³. 3 The yarn is wound on a loose bobbin, with a bobbin stroke of 136mm, a bobbin diameter of 56mm, and 19 bobbins.

[0119] 3) Dyeing of yarn packages:

[0120] After the loose yarn is fixed on the yarn rack, it is hoisted into the dyeing vat and pre-treated, washed, dyed, soaped, washed, softened, and then dehydrated, dried and re-moistened before being sent to the tight winding machine for later use.

[0121] 4) Tight-fitting splitter:

[0122] After picking out defects from the yarn package according to the internal and external differences, 665 tight yarns with a weight of 0.039kg each (calculated based on the warping length) were wound together. The tube type used was a plastic parallel tube with a tube stroke of 150mm and a diameter of 67mm.

[0123] 5) Warping of colored yarn:

[0124] Hang the wound yarn onto the warping machine back frame as required, and align the warp beams according to the designed head portion, warping length, and number of warp ends. After completion, feed the sizing yarn.

[0125] 6) Sizing:

[0126] After coloring and finishing, place the warp beam on the warp beam frame, adjust the process parameters, and then sizing the yarn and placing it onto the weaving beam.

[0127] Comparative Example 4

[0128] The large-scale production process steps are as follows (taking a contract quantity of 914 meters as an example):

[0129] 1) Production process design:

[0130] The warp direction of the variety is designed according to the production process of warping the raw yarn - dyeing the warp beam - dehydration - sizing. The warping length is 1102 meters, the production batch is 1 batch, the number of warp ends is 1 warp beam of 726 first batch and 10 warp beams of 725 first batch, for a total of 11 ends, and the required warp yarn amount is 103.84 kg.

[0131] 2) Warping of raw yarn:

[0132] Warping is performed according to the warping head portion, length, and number of warp beams designed in the process;

[0133] 3) Axial staining:

[0134] After the warp beam is fixed on the beam frame, it is hoisted into the dyeing vat. The process of dyeing warp beams for Tencel varieties is carried out as follows: pretreatment - washing - dyeing - soaping - washing. After completion, the warp beam is dehydrated and then sent to sizing.

[0135] 4) Sizing:

[0136] After dyeing, the warp beams are placed on the warp beam frame, and the sizing and yarn are then dropped onto the warp beams after adjusting the process parameters.

[0137] The color reproducibility (using the color obtained by the large-scale original finishing process as the standard sample), sizing rate, and color deviation before and after sizing (using the color before sizing as the standard sample) of the yarn produced by the process method described in this invention, the large-scale original finishing process, and the small-batch color finishing process were tested respectively. The test results are shown in Table 2.

[0138] Table 2

[0139]

[0140] Example 3

[0141] Fabric code: CW0G0G1-2300114-1, contract quantity: 500 meters, total warp count: 11475, required warp beam length: 574 meters, finished product specifications: 57 / 58*LYOCELL SIROCPT120 / 2*LYOCELL SIROCPT120 / 2, specific steps are as follows:

[0142] 1) Production process design:

[0143] The production process for the warp direction of the variety is designed according to the following steps: warping of raw yarn - dyeing of warp beams - dehydration - sizing and placement on small beams - sizing machine beam assembly. The warping head count per warp beam = 11475 ÷ 3 ÷ 5 = 765, the length of sizing and placement on small beams = 574 + 40 = 614 meters, the warping length of a single warp beam = 614 * 3 + 35 * 2 = 1912 meters, the number of warping heads = 5, the number of sizing and placement on small beams = 3, and the designed warp yarn consumption is 70.25 kg.

[0144] 2) Warping of raw yarn:

[0145] Based on the process design, including the warping head count, length, and raw yarn specifications for each warp beam, the warping weight of a single warp beam is 14.2 kg. A center warp beam (1600 mm high, 120 mm diameter) is selected for warping. The warping speed is 400 m / min, the pressure is 15 cN, the tension is 4 mm, and 5 warp beams are warped. The density of the three warp beams is 0.458 g / cm³. 3 0.461 g / cm 3 0.455g / cm 3 0.453 g / cm 3 0.465g / cm 3 ;

[0146] 3) Axial staining:

[0147] The warp beam is suspended into the dyeing vat and pre-treated, washed, dyed, soaped, and washed according to the Tencel dyeing process.

[0148] 4) Dehydration:

[0149] The dyed warp beams were placed on a vacuum dehydrator for dehydration until the moisture content reached 67%.

[0150] 5) Sizing and placing the yarn onto the small beam:

[0151] After dyeing, the warp beams are placed on the warp beam frame. The sizing formula is selected: 100 kg of modified starch, 50 kg of solid propylene, and 3 kg of wax flakes. The crimping tension is adjusted to 1700 N, and the sizing elongation and drying elongation are 0.2% and 0.4% respectively. The moisture regain is set to 11.4% for sizing. The sized yarn is then laid on the empty warp beam for dyeing in a length of 614 meters. The height of the empty warp beam is 1600 mm and the diameter is 226 mm.

[0152] 6) Sizing machine shaft alignment:

[0153] Place the prepared small shaft onto the warp beam frame, recover the sizing liquid in the sizing tank, and lower the temperature of the drying cylinder to 98°C. Adjust the process parameters, set the crimping tension to 1700N, the sizing elongation and drying elongation to 0.2% and 0.4% respectively, and set the moisture regain to 11.4%. Pull the sized yarn from the shaft and layer it, guide the yarn, and after auxiliary pre-drying, sizing in the sizing tank, drying in the drying cylinder, and yarn separation, wind it onto the warp beam through the telescopic reed.

[0154] Comparative Example 5

[0155] The small-batch color finishing process steps are as follows:

[0156] 1) Production process design:

[0157] The production process for the warp direction of the variety is designed according to the loose winding - yarn dyeing - dehydration and drying - tight winding - colored yarn warping - sizing. The colored yarn warping length is 619 meters, the number of warping heads is 765 heads and 15 warp beams, the required warp yarn amount is 70.82 kg, the warp yarn surplus is 2.13 kg, and the total warp yarn amount is 72.95 kg.

[0158] 2) Loose winding:

[0159] The raw yarn was weighed at (1.0±0.05) kg and had a density of (0.36±0.01) g / cm³. 3 The yarn is wound on a loose bobbin, with a bobbin stroke of 136mm, a bobbin diameter of 56mm, and 73 bobbins.

[0160] 3) Dyeing of yarn packages:

[0161] After the loose yarn is fixed on the yarn rack, it is hoisted into the dyeing vat and pre-treated, washed, dyed, soaped, washed, softened, and then dehydrated, dried and re-moistened before being sent to the tight winding machine for later use.

[0162] 4) Tight-fitting splitter:

[0163] After picking out defects from the yarn package according to the internal and external differences, 765 tight yarns with a weight of 0.0926kg each (calculated based on the warping length) were wound together. The tube type used was a plastic parallel tube with a tube stroke of 150mm and a diameter of 67mm.

[0164] 5) Warping of colored yarn:

[0165] Hang the wound yarn onto the warping machine back frame as required, and align the warp beams according to the designed head portion, warping length, and number of warp ends. After completion, feed the sizing yarn.

[0166] 6) Sizing:

[0167] After coloring and finishing, place the warp beam on the warp beam frame, adjust the process parameters, and then sizing the yarn and placing it onto the weaving beam.

[0168] Comparative Example 6

[0169] The production process steps are as follows (taking a contract quantity of 1000 meters as an example):

[0170] 1) Production process design:

[0171] The warp direction of the variety is designed according to the production process of warping the raw yarn - dyeing the warp beam - dehydration - sizing. The warping length is 1254 meters, the production batch is 1 batch, the number of warping ends is 765 warp beams with 15 ends, and the required amount of warp yarn is 144.97 kg.

[0172] 2) Warping of raw yarn:

[0173] Warping is performed according to the warping head portion, length, and number of warp beams designed in the process;

[0174] 3) Axial staining:

[0175] After the warp beam is fixed on the beam frame, it is hoisted into the dyeing vat. The process of dyeing warp beams for Tencel varieties is carried out as follows: pretreatment - washing - dyeing - soaping - washing. After completion, the warp beam is dehydrated and then sent to sizing.

[0176] 4) Sizing:

[0177] After dyeing, the warp beams are placed on the warp beam frame, and the sizing and yarn are then dropped onto the warp beams after adjusting the process parameters.

[0178] The color reproducibility (using the color obtained by the large-scale original finishing process as the standard sample), sizing rate, and color deviation before and after sizing (using the color before sizing as the standard sample) of the yarn produced by the process method described in this invention, the large-scale original finishing process, and the small-batch color finishing process were tested respectively. The test results are shown in Table 3.

[0179] Table 3

[0180]

[0181] Example 4

[0182] Fabric code: CADJK15451-2300075-2, contract quantity: 465 meters, total warp count: 9204, required warp beam length: 535 meters, finished product specifications: 54 / 55*C / TENCEL CPT60XFFT50 (40D), specific steps are as follows:

[0183] 1) Production process design:

[0184] The production process for the warp direction of the variety is designed according to the following steps: warping of raw yarn - dyeing of warp beams - dehydration - sizing and placement on small beams - sizing machine beam assembly. The warping head count per warp beam = 9204 ÷ 2 ÷ 6 = 767, the sizing placement length on small beams = 535 + 40 = 575 meters, the warping length of a single warp beam = 575 * 2 + 35 * 2 = 1220 meters, the number of warping heads = 6, the number of sizing placements on small beams = 2, and the designed warp yarn consumption is 54.18 kg.

[0185] 2) Warping of raw yarn:

[0186] Based on the process design, the warping head count, length, and raw yarn specifications of a single warp beam, the warping weight of a single warp beam is 9.03 kg. A small warp beam (1600 mm high, 100 mm diameter) is selected for warping. The warping speed is 500 m / min, the pressure is 20 cN, the tension is 8 mm, and the number of warp beams is 6. The density of the 6 warp beams is 0.485 g / cm³. 3 0.496 g / cm 3 0.493 g / cm 3 0.493 g / cm 3 0.489 g / cm 3 0.497g / cm 3 ;

[0187] 3) Axial staining:

[0188] The warp beam is suspended into the dyeing vat and pre-treated, washed, dyed, soaped, and washed according to the Tencel dyeing process.

[0189] 4) Dehydration:

[0190] The dyed warp beams were placed on a vacuum dehydrator for dehydration until the moisture content reached 61%.

[0191] 5) Sizing and placing the yarn onto the small beam:

[0192] After dyeing, the warp beams are placed on the warp beam frame. The sizing formula is selected: 100 kg of modified starch, 50 kg of solid propylene, and 3 kg of wax flakes. The crimping tension is adjusted to 1500 N, and the sizing elongation and drying elongation are 0.3% and 0.5% respectively. The moisture regain is set to 10% for sizing. The sized yarn is then laid on the empty warp beam for dyeing in a length of 575 meters. The height of the empty warp beam is 1600 mm and the diameter is 226 mm.

[0193] 6) Sizing machine shaft alignment:

[0194] Place the prepared small shaft onto the warp beam frame, recover the sizing liquid in the sizing tank, and lower the temperature of the drying cylinder to 95℃. Adjust the process parameters, set the crimping tension to 1500N, the sizing elongation and drying elongation to 0.3% and 0.5% respectively, and set the moisture regain to 10%. Pull the sized yarn from the shaft and layer it, guide the yarn, and after auxiliary pre-drying, sizing in the sizing tank, drying in the drying cylinder, and yarn separation, wind it onto the warp beam through the telescopic reed.

[0195] Comparative Example 7

[0196] The small-batch color finishing process steps are as follows:

[0197] 1) Production process design:

[0198] The production process for the warp direction of the variety is designed according to the loose winding - yarn dyeing - dehydration and drying - tight winding - colored yarn warping - sizing. The colored yarn warping length is 585 meters, the number of warping heads is 767 heads and 12 warp beams, the required warp yarn amount is 53.00 kg, the warp yarn surplus is 2.12 kg, and the total warp yarn amount is 55.12 kg.

[0199] 2) Loose winding:

[0200] The raw yarn was weighed at (1.0±0.05) kg and had a density of (0.36±0.01) g / cm³. 3 The yarn is wound on a loose bobbin, with a bobbin stroke of 136mm, a bobbin diameter of 56mm, and 55 bobbins.

[0201] 3) Dyeing of yarn packages:

[0202] After the loose yarn is fixed on the yarn rack, it is hoisted into the dyeing vat and pre-treated, washed, dyed, soaped, washed, softened, and then dehydrated, dried and re-moistened before being sent to the tight winding machine for later use.

[0203] 4) Tight-fitting splitter:

[0204] After picking out defects from the yarn package according to the internal and external differences, 767 tight yarns with a weight of 0.0691kg (calculated based on the warping length) were wound together. The tube type used was a plastic parallel tube with a tube stroke of 150mm and a diameter of 67mm.

[0205] 5) Warping of colored yarn:

[0206] Hang the wound yarn onto the warping machine back frame as required, and align the warp beams according to the designed head portion, warping length, and number of warp ends. After completion, feed the sizing yarn.

[0207] 6) Sizing:

[0208] After coloring and finishing, place the warp beam on the warp beam frame, adjust the process parameters, and then sizing the yarn and placing it onto the weaving beam.

[0209] Comparative Example 8

[0210] The production process steps are as follows (taking a contract quantity of 1600 meters as an example):

[0211] 1) Production process design:

[0212] The warp direction of the variety is designed according to the production process of warping the raw yarn - dyeing the warp beams - dehydration - sizing. The warping length is 1999 meters, the production batch is 1 batch, the number of warp ends is 767 heads and 12 warp beams, and the required amount of warp yarn is 225.29 kg.

[0213] 2) Warping of raw yarn:

[0214] Warping is performed according to the warping head portion, length, and number of warp beams designed in the process;

[0215] 3) Axial staining:

[0216] After the warp beam is fixed on the beam frame, it is hoisted into the dyeing vat. The process of dyeing warp beams for Tencel varieties is carried out as follows: pretreatment - washing - dyeing - soaping - washing. After completion, the warp beam is dehydrated and then sent to sizing.

[0217] 4) Sizing

[0218] After dyeing, the warp beams are placed on the warp beam frame, and the sizing and yarn are then dropped onto the warp beams after adjusting the process parameters.

[0219] The color reproducibility (using the color obtained by the large-scale original finishing process as the standard sample), sizing rate, and color deviation before and after sizing (using the color before sizing as the standard sample) of the yarn produced by the process method described in this invention, the large-scale original finishing process, and the small-batch color finishing process were tested respectively. The test results are shown in Table 4.

[0220] Table 4

[0221]

Claims

1. A method for improving the quality reproducibility of small batch yarn-dyed fabric and large production, characterized in that, It comprises the following steps: (1) production process design: The production process of the warp direction is as follows: original warp winding-dyeing on warp beam-dehydration-sizing and falling on small beam-sizing beam production process, single warp beam winding head = total warp number ÷ sizing fall small beam number ÷ winding number, single warp beam winding length = sizing fall small beam length * sizing fall small beam number + 35 meters * 2, sizing fall small beam length = beam length + 40 meters, winding number is 3, 4, 5 or 6, sizing fall small beam number is 2, 3 or 4; (2) original warp winding: According to the process design, the single-axis weight selection small warp beam or medium warp beam is used for warping, the speed is adjusted to 300-500 m / min according to the yarn type, the pressure is 0-20 cN, the warp beam density is 0.42-0.50 g / cm 3 , and the single batch warp beam density deviation is within 0.02 g / cm 3 . (3) warp beam dyeing: The warp beam is hung into the dyeing vat, and the corresponding variety dyeing beam process is carried out, including pretreatment-enzyme washing or water washing-dyeing-soaping-water washing-fixing, whether fixing is needed is determined according to the type and concentration of dye; (4) dehydration: The dyed warp beam is placed in a vacuum dehydrator to dehydrate the warp beam to a moisture content of 60%-70%; (5) sizing and falling on small beam: The dyed warp beam is placed on the warp beam frame, the sizing formula is selected according to the type of yarn and the process parameters are adjusted for sizing, and the sized yarn is fallen on the empty warp beam according to the process design of the length and number of the small beam, the empty warp beam is 1600mm high, the beam diameter is 160-226mm, the two ends of the warp beam are equipped with connecting shaft heads and fixed with screws, one end of the connecting shaft head matches the dyeing warp beam disc, and the other end matches the beam fixing device of the crimping part of the sizing machine; (6) sizing beam: The fallen small beam is placed on the warp beam frame, the process parameters are adjusted, the sized yarn sheet is pulled out of the beam and layered, the auxiliary pre-drying, sizing tank sizing, tin drum drying and yarn separation are carried out, and the yarn is wound on the beam through the telescopic reed; The single warp beam winding head is between 600-780; The small warp beam and the medium warp beam are both 1600mm high, the small warp beam diameter is 100mm, the medium warp beam diameter is 120mm, the winding weight range is 4-11kg / beam for small warp beam and 11-19kg / beam for medium warp beam; The sizing tension is set to be 2%-5% lower than that of the same variety of large production dyeing beam and sizing beam falling beam variety, the sizing elongation and drying elongation is adjusted to be 0.1%-0.2% lower than that of the same variety of large production dyeing beam and sizing beam falling beam variety, the moisture regain is set to be 0.5%-1% higher than that of the same variety of large production dyeing beam and sizing beam falling beam variety, and the rest of the parameters are the same as those of the same variety of large production dyeing beam and sizing beam falling beam variety; The sizing rate in step (6) is controlled between 6%-12% for different varieties, the strengthening rate is ≥10%, the elongation reduction rate is ≤25%, the hairiness reduction rate is ≥70%, the wear resistance improvement rate is ≥200%, the sizing rate deviation between each small beam is ≤1%, and the elongation reduction rate deviation is ≤2%.

2. The method for improving quality reproducibility of small batch yarn-dyed fabric with mass production according to claim 1, characterized in that, The sizing formula is 3-5 kinds of modified starch, PVA, polyacrylate, phosphate starch, solid propylene and wax sheet.

3. The method of improving quality reproducibility of small batch yarn-dyed fabric with mass production according to claim 1, characterized in that, The sizing tank liquid is recycled before the sizing beam, and the drying cylinder temperature is reduced to within 100℃.

4. The method of improving quality reproducibility of small batch yarn-dyed fabric with mass production according to claim 1, characterized in that, The small batch color woven fabric is less than 500 meters in length.

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